ARMY TM 9-2320-366-20-3

AIR FORCE T.O. 36A12-1C-1102-3

TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
UNIT MAINTENANCE
M1083 SERIES, 5-TON, 6 X 6,
MEDIUM TACTICAL VEHICLES (MTV)
VOLUME NO. 3 OF 5
HOW TO USE THIS MANUAL
MODEL NSN EIC PAGE v

TRK, CAR., MTV, M1083 CENTRAL TIRE INFLATION (CTIS)

W/WN 2320-01-360-1895 BT3 SYSTEM TROUBLESHOOTING
W/O WN 2320-01-354-3386 BR2 PAGE 2-2007

TRK, CAR., MTV, W/MATL

HDLG EQPT (MHE), M1084 2320-01-354-3387 BR3 STEERING HYDRAULIC SYSTEM
TROUBLESHOOTING
TRK, CAR., MTV, LWB, M1085 PAGE 2-2213
W/WN 2320-01-360-1897 BT5
W/O WN 2320-01-354-4530 BR7
A I R T R A N S P O R T
TRK, CAR., MTV, LWB, W/MATL TROUBLESHOOTING
HDLG EQPT (MHE), M1086 2320-01-354-4531 BR8 PAGE 2-2219

TRK, TRACTOR, MTV, M1088 CAB TILT AND SPARE TIRE

W/WN 2320-01-360-1892 BTY RETAINER
W/O WN 2320-01-355-4332 BTJ TROUBLESHOOTING
PAGE 2-2413
TRK, WKR, MTV, M1089 2320-01-354-4528 BR4

FRAME TROUBLESHOOTING
TRK, DUMP, MTV, M1090 PAGE 2-2435
W/WN 2320-01-360-1893 BTZ
W/O WN 2320-01-354-4529 BR5
ENGINE MAINTENANCE
TRK, CHAS, MTV, M1092 2320-01-354-3382 BRZ PAGE 3-1

TRK, CAR., MTV, AIR DROP, M1093

W/WN 2320-01-360-1896 BT4 FUEL SYSTEM MAINTENANCE
W/O WN 2320-01-355-3063 BR9 PAGE 4-1

TRK, DUMP, MTV, AIR DROP, M1094

W/WN 2320-01-360-1984 BT2 EXHAUST SYSTEM MAINTENANCE
W/O WN 2320-01-355-3062 BTK PAGE 5-1

TRK, CHAS, MTV, LWB, M1096 2320-01-354-4527 BR6

COOLING SYSTEM MAINTENANCE
PAGE 6-1

E L E C T R I C A L S Y S T E M
MAINTENANCE
DISTRIBUTION STATEMENT A. Approved for public release; distribution is PAGE 7-1
unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE

SEPTEMBER 1998
 TM 9-2320-366-20-3

WARNING SUMMARY

WARNING

EXHAUST GASES CAN KILL

1. DO NOT operate your vehicle engine in an enclosed area.

2. DO NOT idle vehicle engine with cab windows closed.

3. DO NOT drive vehicle with inspection plates or covers removed.

4. BE ALERT at all times for exhaust odors.

5. BE ALERT for exhaust poisoning symptoms, they are:

Headache

Dizziness

Sleepiness

Loss of Muscular Control

6. IF YOU SEE another person with exhaust poisoning symptoms:

Remove person from area.

Expose to open air.

Keep person warm.

Do not permit person to move.

Administer cardiopulmonary resuscitation, if

necessary.*

* For cardiopulmonary resuscitation, refer to FM 21-11.

WARNING

Remove rings, bracelets, watches, necklaces, and any other jewelry before
working around vehicle. Jewelry can catch on equipment and cause injury or
short across electrical circuit and cause severe burns or electrical shock.
Batteries can explode from a spark. Battery acid is harmful to skin and eyes.
Always wear eye protection and rubber gloves when working with batteries.
Failure to comply may result in injury to personnel.

WARNING

Do not work on fuel system when engine is hot; fuel can be ignited by a hot
engine.

a
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and
rubber gloves, and do not smoke when performing maintenance on batteries.
Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent
clothing being damaged. Failure to comply may result in injury to personnel.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, 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, solvent, or sealing compound gets
on skin or clothing, wash immediately with soap and water. Failure to comply
may result in injury to personnel.

WARNING

Dry Cleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective

goggles and gloves; use only in well ventilated area; avoid contact with skin,
eyes, and clothes, and do not breathe vapors. Keep away from heat or flame.
Never smoke when using solvent; the flashpoint for Type I Dry Cleaning Solvent
is 100°F (38°C) and for Type II is 130°F (50°C). Failure to comply may result
in serious injury or death to personnel.

If personnel become dizzy while using Dry Cleaning Solvent, immediately get
fresh air and medical help. If Dry Cleaning Solvent contacts skin or clothes,
flush with cold water. If Dry Cleaning Solvent contacts eyes, immediately flush
eyes with water and get immediate medical attention. Failure to comply may
result in injury to personnel.

WARNING

Diesel fuel is flammable. If fuel is spilled, clean it up immediately. Failure to

comply may result in serious injury or death to personnel.

WARNING

Diesel fuel is flammable. Do not fill fuel tank with engine running, while
smoking, or when near an open flame. Never overfill the tank or spill fuel. If
fuel is spilled, clean it up immediately. Failure to comply may result in serious
injury or death to personnel.

WARNING

Use care when removing/installing springs. Springs are under tension and can
act as projectiles when being removed. Failure to comply can cause injury to
personnel.

b
 TM 9-2320-366-20-3

WARNING

Adhesive sealant MIL-S-46163 can damage your eyes. Wear safety

goggles/glasses when using; avoid contact with eyes. If sealant contacts eyes,
flush eyes with water and get immediate medical attention. Failure to comply
may result in injury to personnel.

WARNING

After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters
shall be handled with extreme caution. Unprotected personnel may experience
serious injury or death if residual toxic agents or radioactive material are
present. If vehicle is exposed to chemical or biological agents, servicing
personnel shall wear protective mask, hood, protective overgarments, and
chemical protective gloves and boots in accordance with FM-3-4. All
contaminated air filters shall be placed in double-lined plastic bags and moved
swiftly to a segregation area away from the worksite. The same procedure
applies for radioactive dust contamination. The Company NBC team should
measure radiation prior to filter removal to determine extent of safety
procedures required per the NBC Annex to the unit Standard Operating
Procedures (SOP). The segregation area in which the contaminated air filters
are temporarily stored shall be marked with appropriate NBC placards. Final
disposal of contaminated air filters shall be in accordance with local SOP.
Decontamination operation shall be in accordance with FM-3-5 and local SOP.
Failure to comply may result in serious injury or death to personnel.

WARNING

Ensure exhaust system is cool before performing maintenance. Failure to

comply may result in injury to personnel.

WARNING

Wear appropriate eye protection when working under vehicle due to the
possibility of falling debris. Failure to comply may result in injury to personnel.

WARNING

Post signs that read "NO SMOKING WITHIN 50 FEET" when working with open
fuel, fuel lines or fuel tanks. Failure to comply may result in injury to personnel
or damage to equipment.

WARNING

Do not operate vehicle with muffler removed. Toxic exhaust fumes may enter
cab, resulting in serious injury or death to personnel.

c
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Exhaust pipe, transmission oil lines, and transmission scavenge pump hose may
be hot to the touch. Extreme care should be taken when checking exhaust pipe,
transmission oil lines, and transmission scavenge pump hose for leaks. Failure
to comply may result in injury to personnel.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc). Failure to comply may result in injury to personnel.

WARNING

Wheel drum weighs approximately 90 lbs (41 kgs). Use the aid of an assistant
to help remove wheel drum. Failure to comply may result in injury to personnel.

WARNING

Wheel drum weighs approximately 90 lbs (41 kgs). Use the aid of an assistant
to help install wheel drum. Failure to comply may result in injury to personnel.

WARNING

Brake shoes may be covered with dust. Breathing this dust may be harmful to
your health. Do not use compressed air to clean brake shoes. Wear a filter
mask approved for use against brake dust. Failure to comply may result in
injury to personnel.

WARNING

Cage spring brake before air chamber is removed or severe injury to personnel
will occur.

WARNING

Ensure air chamber is caged prior to installation. Failure to comply may result
in injury to personnel.

WARNING

Ensure that tire is totally deflated before removing self-locking nuts. Failure to
comply may result in serious injury or death to personnel.

d
 TM 9-2320-366-20-3

WARNING

Spring brakes must be caged before attempting replacement of a rear axle wheel
stud. Failure to comply may result in severe injury to personnel.

WARNING

Wear protective goggles to protect against possible injury from release of high
pressure air. Failure to comply may result in injury to personnel.

WARNING

Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin
and clothing that come in contact with lubricating oil should be thoroughly
washed immediately. Saturated clothing should be removed immediately. Areas
in which lubricating oil is used should be well ventilated to keep fumes to a
minimum. Failure to comply may result in injury to personnel.

WARNING

Hydraulic fluid (MIL-H-5606) is TOXIC. Wear protective goggles and gloves; use
only in well ventilated area; avoid contact with skin, eyes, and clothes. Skin and
clothing that come in contact with hydraulic oil should be washed immediately.
Saturated clothing should be removed immediately. Failure to comply may result
in injury to personnel.

WARNING

Never let moving wire rope slide through hands, even when wearing gloves. A
broken wire could cut through gloves and cut hands. Failure to comply may
result in injury to personnel.

WARNING

Wear appropriate eye protection when removing rivets. Failure to comply may
result in injury to personnel.

WARNING

Wear appropriate eye protection when drilling holes. Failure to comply may
result in injury to personnel.

WARNING

Wear leather gloves at all times when handling winch cable. Do not allow cable
to slide through hands even with gloves on. Broken wires may cause injury.

e
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Use extreme caution when working around moving cable. Failure to do so may
result in serious injury to personnel.

WARNING

Caution must be exercised while cab is raised. Ensure that locking mechanism
is functioning properly before proceeding. Failure to comply may result in death
or serious injury to personnel and damage to equipment.

WARNING

Coolant may be very hot and under pressure from engine operation. Ensure
engine is cool before performing maintenance. Failure to comply may result in
injury to personnel.

WARNING

Light Material Handling Crane (LMHC) weighs approximately 250 lbs (114 kgs).
Attach a suitable lifting device prior to removal. Failure to comply may result in
injury to personnel.

WARNING

Light Material Handling Crane (LMHC) mast weighs approximately 110 lbs (50
kgs). Attach a suitable lifting device prior to installation. Failure to comply may
result in injury to personnel or damage to equipment.

WARNING

Light Material Handling Crane (LMHC) boom assembly weighs approximately

150 lbs (68 kgs). Use an assistant when removing boom assembly. Failure to
comply may result in injury to personnel.

f Change 2
 TM 9-2320-366-20-3

WARNING

Light Material Handling Crane (LMHC) boom weighs approximately 60 lbs (27
kgs). Attach a suitable lifting device prior to installation. Failure to comply may
result in injury to personnel or damage to equipment.

WARNING

Machine gun ring assembly weighs approximately 350 pounds (159 kgs). Attach
a suitable lifting device prior to removal. Failure to comply may result in injury
to personnel or damage to equipment.

WARNING

Ensure vehicle is on level ground prior to installation/removal of collapsible

drums. Failure to comply may result in serious injury or death to personnel or
damage to equipment.

WARNING

Ensure cargo bed is free of equipment and debris and not warped or damaged
in any way. Failure to comply may result in serious injury or death to personnel
or damage to equipment.

WARNING

Both collapsible drums weigh approximately 235 lbs (107 kgs) empty and 3800
lbs (1725 kgs) full. Attach a suitable lifting device prior to installation. Failure
to comply may result in serious injury or death to personnel or damage to
equipment.

WARNING

S-280 shelter weighs approximately 1500 lbs (680 kgs) empty. Attach a suitable
lifting device prior to installation. Failure to comply may result in serious injury
or death to personnel or damage to equipment.

WARNING

Ensure vehicle is on level ground prior to installation or removal of tank and

pump unit. Failure to comply may result in serious injury or death to personnel
or damage to equipment.

WARNING

Tank weighs approximately 500 lbs (227 kgs) empty or 4000 lbs (1816 kgs) full.
Attach a suitable lifting device prior to installation. Failure to comply may result
in serious injury or death to personnel or damage to equipment.

g
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Pump unit weighs approximately 870 lbs (395 kgs). Attach a suitable lifting
device prior to installation. Failure to comply may result in serious injury or
death to personnel or damage to equipment.

WARNING

Do not remove oil filter while engine is hot. Failure to comply may result in
injury to personnel.

WARNING

Starting fluid is toxic and highly flammable. Container is pressurized. NEVER

heat container and NEVER discharge starting fluid in confined areas or near
open flame. Failure to comply may cause serious injury or death to personnel.

WARNING

Tab of HAND THROTTLE lever must be positioned above throttle pivot bar.
Failure to comply may result in injury to personnel or damage to equipment.

WARNING

Use extreme care when opening cab door with cab raised. Failure to comply
may result in injury to personnel or damage to equipment.

WARNING

Do not operate vehicle with exhaust pipe removed. Toxic exhaust fumes may
enter cab, resulting in serious injury or death to personnel.

WARNING

Radiator and charge air cooler assembly weigh approximately 160 lbs (73 kgs).
Attach a suitable lifting device prior to removal. Failure to comply may result
in injury to personnel or damage to equipment.

WARNING

Cargo sling must be placed under charge air cooler inlet and outlet ports.
Failure to comply may result in injury to personnel or damage to equipment.

h
 TM 9-2320-366-20-3

WARNING

Alternator weighs approximately 50 lbs (23 kgs). The aid of an assistant is

required to remove alternator. Failure to comply may result in injury to
personnel.

WARNING

Starting motor weighs approximately 60 lbs (27 kgs). Attach a suitable lifting
device prior to removal. Failure to comply may result in injury to personnel or
damage to equipment.

WARNING

Negative battery terminals must be connected last. Failure to comply may result
in serious injury or death to personnel.

WARNING

Negative battery terminals and battery tester negative terminal lug must be
disconnected first. Failure to comply may result in serious injury or death to
personnel.

WARNING

Battery box weighs approximately 70 lbs (32 kgs). The aid of two assistants is
required to remove battery box from vehicle frame. Failure to comply may result
in injury to personnel.

WARNING

Battery box weighs approximately 70 lbs (32 kgs). The aid of two assistants is
required to position battery box on vehicle frame. Failure to comply may result
in injury to personnel.

WARNING

Ensure WTEC III cab transmission harness does not interfere with throttle
linkage. Failure to comply may result in injury to personnel.

WARNING

Self-adjusting brakes will not self-adjust without applying brake pedal. Failure
to comply may result in injury to personnel.

i
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Ensure air hoses are connected to correct fittings. Failure to comply may result
in serious injury or death to personnel.

WARNING

Proper adjustment of load sensing valve may only be accomplished with vehicle
unloaded. Failure to comply may result in injury to personnel or damage to
equipment.

WARNING

Always use an inflation safety cage to inflate tires mounted on multipiece rims,
and tire/rim assemblies not mounted on a tire changing machine that has a
positive lock down device designed to hold the assembly during inflation (TM
9-2610-200-14). When using a tire changing machine, always follow
manufacturer’s mounting and safety instructions. Failure to comply may result
in serious injury or death to personnel. Always inflate tires that are mounted on
rims with demountable side ring flanges or lockrings in an inflation safety cage
or serious injury or death may result.

WARNING

Tire weighs approximately 350 lbs (159 kgs). Use extreme care when handling
tire. Failure to comply may result in injury to personnel.

WARNING

Wheel drum weighs approximately 92 lbs (42 kgs). Use the aid of an assistant
to help remove wheel drum from axle. Failure to comply may result in injury to
personnel.

WARNING

The sudden release of high pressure air can cause damage to eyes. Wear
appropriate eye protection when working near pressurized air. Failure to comply
may result in injury to personnel.

WARNING

Leave shackles installed in front bumper to support front bumper until ready to
remove. Failure to comply may result in injury to personnel.

j
 TM 9-2320-366-20-3

WARNING

Front bumper weighs approximately 100 lbs (45 kgs). Use the aid of an
assistant to remove front bumper. Failure to comply may result in injury to
personnel.

WARNING

Tractor platform weighs approximately 550 lbs (250 kgs). Attach a suitable
lifting device prior to removal. Failure to comply may result in injury to
personnel or damage to equipment.

WARNING

Spare tire retainer weighs approximately 150 lbs (68 kgs). The aid of two
assistants is required to remove spare tire retainer from vehicle. Failure to
comply may result in injury to personnel.

WARNING

Rear stabilizer bar weighs approximately 50 lbs (22 kgs). Attach a suitable lifting
device prior to removal. Failure to comply may result in injury to personnel or
damage to equipment.

WARNING

Cab roof weighs approximately 110 lbs (50 kgs). Attach a suitable lifting device
prior to removal. Failure to comply may result in injury to personnel.

WARNING

Use care when removing/installing window. Do not force window, or window may
shatter. Failure to comply may result in injury to personnel or damage to
equipment.

WARNING

Tailgate assembly weighs approximately 130 lbs (59 kgs). Attach a suitable
lifting device prior to removal. Failure to comply may result in injury to
personnel or damage to equipment.

WARNING

Tow bar weighs approximately 150 lbs (68 kgs). Attach a suitable lifting device
prior to removal. Failure to comply may result in injury to personnel or damage
to equipment.

k
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Rear tool box weighs approximately 75 lbs (34 Kgs) empty. Attach a suitable
lifting device prior to removal. Failure to comply may result in injury to
personnel or damage to equipment.

WARNING

Cable can become frayed or contain broken wires. Wear heavy leather-palmed
gloves when handling cable. Frayed or broken wires can injure hands. Failure
to comply may result in injury to personnel.

WARNING

Remote control must be used to operate 30K winch while breaking in cables.
Failure to comply may result in injury to personnel.

WARNING

Cab weighs approximately 3000 lbs (1362 kgs) attach a suitable lifting device
prior to raising cab. Failure to comply may result in injury to personnel.

WARNING

Hydraulic tank weighs approximately 190 lbs (86 kgs). Attach a suitable lifting
device prior to removal. Failure to comply may result in injury to personnel or
damage to equipment.

WARNING

Extreme care must be taken when lowering gravel deflector. Coolant hoses
could be pulled loose. Failure to comply could result in serious eye injury.

WARNING

Retaining rings are under tension and can act as projectiles when released
causing severe eye injury. Use care when installing retaining rings. Failure to
comply may result in injury to personnel.

WARNING

Do not open coolant fill cap if temperature reads above 110 degrees F (43
degrees C). Steam or hot coolant is under pressure. Failure to comply may
result in injury to personnel.

l
 TM 9-2320-366-20-3

WARNING

Pressure in reservoir tank must be released before removing cap. Failure to

comply may result in injury to personnel.

WARNING

200 amp alternator weighs approximately 72 lbs (33 kgs). The aid of an
assistant is required to install 200 amp alternator. Failure to comply may result
in injury to personnel.

WARNING

100 amp alternator weighs approximately 70 lbs (32 kgs). Attach a suitable
lifting device prior to removal. Failure to comply may result in injury to
personnel.

WARNING

Both collapsible drums weigh approximately 235 lbs (107 kgs) empty and 3800
lbs (1725 kgs ) full each. Attach a suitable lifting device prior to removal.
Failure to comply may result in serious injury or death to personnel or damage
to equipment.

WARNING

Air dryer may contain air pressure. Loosen input air hose connector slowly to
vent off air pressure. Failure to comply may result in injury to personnel.

WARNING

Radiator and charge air cooler assembly weigh approximately 160 lbs (73 Kgs).
Attach a suitable lifting device prior to installation. Failure to comply may result
in injury to personnel or damage to equipment.

WARNING

Tractor platform weighs approximately 550 lbs (250 kgs). Attach a suitable
lifting device prior to installation. Failure to comply may result in injury to
personnel or damage to equipment.

Change 1 m
TM 9-2320-366-20-3

WARNING SUMMARY (CONT)

WARNING

Spare tire retainer weighs approximately 150 lbs (68 kgs). The aid of two
assistants is required to install spare tire retainer on vehicle. Failure to comply
may result in injury to personnel.

WARNING

Rear stabilizer bar weighs approximately 50 lbs (22 kgs). Attach a suitable lifting
device prior to installation. Failure to comply may result in injury to personnel
or damage to equipment.

WARNING

Cab roof weighs approximately 110 lbs (50 kgs). Attach a suitable lifting device
prior to installation. Failure to comply may result in injury to personnel.

WARNING

Do not remove radiator cap when the engine is hot; steam and hot coolant can
escape and burn skin. Failure to comply may result in injury to personnel.

WARNING

Wear appropriate eye protection when removing spring rings. Spring rings are
under tension and can act as projectiles when being removed. Failure to comply
may result in injury to personnel.

WARNING

Wear appropriate eye protection when installing spring rings. Spring rings are
under tension and can act as projectiles when being installed. Failure to comply
may result in injury to personnel.

n Change 1
 ARMY TM 9-2320-366-20-3
AIR FORCE T.O. 36A12-1C-1102-3

CHANGE HEADQUARTERS
NO. 3 DEPARTMENTS OF THE ARMY
AND THE AIR FORCE
Washington, D.C., 10 February 2006

TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
UNIT MAINTENANCE
M1083 SERIES, 5-TON, 6x6,
MEDIUM TACTICAL VEHICLE
(MTV)

VOLUME NO. 3 OF 5

TM 9-2320-366-20-3, 15 September 1998, is changed as follows:

1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the out margin of the page.
3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration.

Remove Pages Insert Pages

None Change 3 Transmittal/ Change 3 Authentication

A thru D A thru D
B1 thru B-29/(B-30 Blank) B-1 thru B-30

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

1 of 1
By Order of the Secretary of the Army:

PETER J. SCHOOMAKER
General, United States Army
Chief of Staff

Official:

SANDRA R. RILEY
Administrative Assistant to the
Secretary of the Army
0601915

By Order of the Secretary of the Air Force:

JOHN P. JUMPER
General, United States Air Force
Chief of Staff

Official:

GREGORY S. MARTIN
General, United States Air Force
Commander, Air Force Materiel Command

Distribution:

To be distributed in accordance with the initial distribution number (IDN) 380940,

requirements for Family of Medium Tactical Vehicles TM 9-2320-366-20-3.
 ARMY TM 9-2320-366-20-3
AIR FORCE T.O. 36A12-1C-1102-3

CHANGE HEADQUARTERS
NO. 2 DEPARTMENTS OF THE ARMY
AND THE AIR FORCE
Washington, D.C., 20 AUGUST 2005

TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
UNIT MAINTENANCE
M1083 SERIES, 5-TON, 6x6,
MEDIUM TACTICAL VEHICLE
(MTV)

VOLUME NO. 3 OF 5

TM 9-2320-366-20-3, 15 September 1998, is changed as follows:

1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the out margin of the page.
3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration.

Remove Pages Insert Pages Remove Pages Insert Pages

e and f e and f B-5 thru B-8 B-5 thru B-8

A thru D A thru D B-27 thru B-29/ B-27 thru B-29
none Change 2 Authentication Sheet (B-30 Blank) (B-30 Blank)
2-2069 thru 2-2078 2-2069 thru 2-2078 C-1 thru C-4 C-1 thru C-4
(2-2101 Blank)/2-2102 (2-2101 Blank)/2-2102 D-1 thru D-6 D-1 thru D-6
2-2237/(2-2238 Blank) 2-2237 and 2-2238 G-1 thru G-12 G-1 thru G-12
none 2-2239 thru 2-2241/(2-2242 Blank) H-1 thru H-32 H-1 thru H-32
2-2253 thru 2-2254.2 2-2253 thru 2-2254.2 K-1 thru K-4 K-1 thru K-4
2-2263 thru 2-2264.2 2-2263 thru 2-2264.2 INDEX-3 thru INDEX-12 INDEX-3 thru INDEX-12
2-2271/(2-2272 Blank) 2-2271 and 2-2272 FO-1 FP-69/(FP-70 Blank) FO-1 FP-69/(FP-70 Blank)
none 2-2273 thru 2-2307/(2308 Blank) Metric Conversion Chart Metric Conversion Chart
3-9 and 3-10 3-9 and 3-10 /PIN /PIN
6-45 and 6-46 6-45 and 6-46
6-63 and 6-64 6-63 and 6-64
6-69 and 6-70 6-69 and 6-70
7-3 thru 7-6 7-3 thru 7-6
7-9 and 7-10 7-9 and 7-10
7-19 thru 7-22 7-19 thru 7-22
7-33 and 7-34 7-33 and 7-34
none 7-34.1/(7-34.2 Blank)
7-35 thru 7-38 7-35 thru 7-38
7-41 and 7-42 7-41 and 7-42
7-61 and 7-62 7-61 and 7-62
7-65 and 7-66 7-65 and 7-66
7-85 and 7-86 7-85 and 7-86
7-91 thru 7-94 7-91 thru 7-94
7-109 and 7-110 7-109 and 7-110
7-113 and 7-114 7-113 and 7-114
7-150.1/(7-150.2 Blank) 7-150.1/(7-150.2 Blank)
7-171 and 7-172 7-171 and 7-172
7-243 thru 7-246 7-243 and 7-246
7-255 and 7-256 7-255 and 7-256
7-269 thru 7-274 7-269 thru 7-274
7-331 thru 7-334 7-331 thru 7-334
Place this change sheet in the front of the publication for reference purposes.

1 of 1
By Order of the Secretary of the Army:

PETER J. SCHOOMAKER
General, United States Army
Chief of Staff

Official:

SANDRA R. RILEY
Administrative Assistant to the
Secretary of the Army
0401515

By Order of the Secretary of the Air Force:

JOHN P. JUMPER
General, United States Air Force
Chief of Staff

Official:

GREGORY S. MARTIN
General, United States Air Force
Commander, Air Force Materiel Command

Distribution:

To be distributed in accordance with the initial distribution number (IDN) 380940,

requirements for TM 9-2320-366-20-3.
 ARMY TM 9-2320-366-20-3
AIR FORCE T.O. 36A12-1C-1102-3

CHANGE HEADQUARTERS
NO. 1 DEPARTMENTS OF THE ARMY
AND THE AIR FORCE

Washington, D.C., 1 July 2003

TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
UNIT MAINTENANCE
M1083 SERIES, 5-TON, 6x6,
MEDIUM TACTICAL VEHICLE
(MTV)

VOLUME NO. 3 OF 5

TM 9-2320-366-20-3, 15 September 1998, is changed as follows:

1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the out margin of the page.
3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration.

Remove Pages Insert Pages Remove Pages Insert Pages

m and n m and n 2-2417/(2-2418 Blank) thru 2-2417/(2-2418 Blank) thru

none A thru D 2-2426 2-2426
i thru v/(vi Blank) i thru vi none 2-2426.1 and 2-2426.2
none 2-2006.1/(2-2006.2 Blank) 2-2427 and 2-2428 2-2427 and 2-2428
2-2007 thru 2-2010 2-2007 thru 2-2010 none 2-2428.1 thru 2-2428.8
2-2069 thru 2-2080 2-2069 thru 2-2079/(2-2080 Blank) 2-2429 and 2-2430 2-2429 and 2-2430
2-2081 thru 2-2100 none none 2-2430.1 thru 2-2430.8
2-2101 thru 2-2104 (2-2101 Blank)/2-2102 thru 2-2104 2-2431 and 2-2432 2-2431 and 2-2432
2-2109 thru 2-2122 2-2109 thru 2-2122 none 2-2432.1 and 2-2432.2
2-2143 thru 2-2143 thru 2-2433/(2-2434 Blank) 2-2433/(2-2434 Blank)
2-2149/(2-2150 Blank) 2-2149/(2-2150 Blank) none 2-2446.1/(2-2446.2 Blank)
2-2219 thru 2-2228 2-2219 thru 2-2228 2-2447 and 2-2448 2-2447 and 2-2448
none 2-2228.1 thru 2-2228.18 3-1 and 3-2 3-1 and 3-2
2-2229 and 2-2230 2-2229 and 2-2230 3-15 thru 3-21/(3-22 Blank) 3-15 thru 3-21/(3-22 Blank)
none 2-2230.1 thru 2-2230.14 4-1 and 4-2 4-1 and 4-2
2-2231 thru 2-2234 2-2231 thru 2-2234 4-5 and 4-6 4-5 and 4-6
none 2-2234.1 thru 2-2234.22 4-9 and 4-10 4-9 and 4-10
2-2235/(2-2236 Blank) thru 2-2235/(2-2236 Blank) thru none 4-10.1 and 4-10.2
2-2238 2-2237/(2-2238 Blank) 4-11 thru 4-18 4-11 thru 4-18
2-2239 thru 2-2241/(2-2242 Blank) none 4-41 thru 4-48 4-41 thru 4-48
2-2253 and 2-2254 2-2253 and 2-2254 4-59 and 4-60 4-59 and 4-60
none 2-2254.1 and 2-2254.2 4-63 and 4-64 4-63 and 4-64
2-2255 and 2-2256 2-2255 and 2-2256 4-69 and 4-70 4-69 and 4-70
2-2263 and 2-2264 2-2263 and 2-2264 4-81 thru 4-84 4-81 thru 4-84
none 2-2264.1 and 2-2264.2 5-1 and 5-2 5-1 and 5-2
2-2265 and 2-2266 2-2265 and 2-2266 5-7 thru 5-15/(5-16 Blank) 5-7 thru 5-15/(5-16 Blank)
2-2271 and 2-2272 2-2271/(2-2272 Blank) 6-1 thru 6-4 6-1 thru 6-4
2-2273 thru 2-2370 none none 6-4.1 and 6-4.2
2-2371 and 2-2372 (2-2371 Blank)/2-2372 6-5 thru 6-24 6-5 thru 6-24
2-2413 and 2-2414 2-2413 and 2-2414 none 6-24.1/(6-24.2 Blank)
none 2-2414.1/(2-2414.2 Blank) thru 2-2414.12 6-25 thru 6-28 6-25 thru 6-28
2-2415 and 2-2416 2-2415 and 2-2416 6-33 and 6-34 6-33 and 6-34
none 2-2416.1/(2-2416.2Blank) thru 2-2416.10 6-39 and 6-40 6-39 and 6-40
Place this change sheet in the front of the publication for reference purposes.

1 of 2
Remove Pages Insert Pages Remove Pages Insert Pages

6-49 and 6-50 6-49 and 6-50 None D-7/(D-8 Blank)

6-53 and 6-54 6-53 and 6-54 E-1 thru E-6 E-1 thru E-6
6-67 thru 6-72 6-67 thru 6-72 E-15 and E-16 E-15 and E-16
none 6-72.1/(6-72.2 Blank) none E-27 thru E-31/(E-32 Blank)
6-73 thru 6-78 6-73 thru 6-78 G-1 thru G-11/(G-12 Blank) G-1 thru G-12
7-1 thru 7-6 7-1 thru 7-6 H-1 thru H-12 H-1 thru H-12
7-9 thru 7-12 7-9 thru 7-12 H-21 and H-22 H-21 and H-22
7-27 thru 7-34 7-27 thru 7-34 H-25 thru H-28 H-25 thru H-28
7-37 and 7-38 7-37 and 7-38 H-31 and H-32 H-31 and H-32
none 7-38.1 thru 7-38.4 none K-1 thru K-4
7-43 and 7-44 7-43 and 7-44 INDEX-1 thru INDEX-14 INDEX-1 thru INDEX-13/
7-47 and 7-48 7-47 and 7-48 (INDEX-14 Blank)
7-55 and 7-56 7-55 and 7-56 FO-1 FP-1/(FP-2 Blank) FO-1 FP-1/(FP-2 Blank)
7-59 and 7-60 7-59 and 7-60 thru FP-21/(FP-22 Blank) thru FP-21/(FP-22 Blank)
7-67 and 7-68 7-67 and 7-68 FO-1 FP-25/(FP-26 Blank) FO-1 FP-25/(FP-26 Blank)
7-73 and 7-74 7-73 and 7-74 FO-1 FP-29/(FP-30 Blank) FO-1 FP-29/(FP-30 Blank)
7-79 and 7-80 7-79 and 7-80 thru FP-67/(FP-68 Blank) thru FP-67/(FP-68 Blank)
7-83 and 7-84 7-83 and 7-84 FO-1 FP-75/(FP-76 Blank) FO-1 FP-75/(FP-76 Blank)
7-91 thru 7-94 7-91 thru 7-94 thru FP-79/(FP-80 Blank) thru FP-79/(FP-80 Blank)
7-109 and 7-110 7-109 and 7-110 DA FORM 2028-2 Sample DA FORM 2028-2 Sample
7-123 and 7-124 7-123 and 7-124 DA FORM 2028-2 DA FORM 2028-2
7-137 and 7-138 7-137 and 7-138 DA FORM 2028-2 DA FORM 2028-2
7-145 and 7-146 7-145 and 7-146 DA FORM 2028-2 DA FORM 2028-2
none 7-146.1/(7-146.2 Blank) Metric Conversion Chart Metric Conversion Chart
none 7-150.1/(7-150.2 Blank) Cover Cover
7-151 and 7-152 7-151 and 7-152
7-159 and 7-160 7-159 and 7-160
none 7-166.1/(7-166.2Blank)
7-167 and 7-168 7-167 and 7-168
7-171 and 7-172 7-171 and 7-172
none 7-172.1/(7-172.2 Blank)
7-189 thru 7-200 7-189 thru 7-200
none 7-200.1/(7-200.2 Blank)
7-201 and 7-202 7-201 and 7-202
7-207 thru 7-216 7-207 thru 7-216
7-219 thru 7-230 7-219 thru 7-230
7-241 and 7-242 7-241 and 7-242
none 7-242.1/(7-242.2 Blank)
7-243 thru 7-248 7-243 thru 7-248
7-253 thru 7-256 7-253 thru 7-256
7-275 and 7-276 7-275 and 7-276
7-279 thru 7-286 7-279 thru 7-286
none 7-286.1 and 7-286.2
7-287 thru 7-290 7-287 thru 7-290
7-295 thru 7-300 7-295 thru 7-300
7-305 thru 7-316 7-305 thru 7-316
7-319 thru 7-324 7-319 thru 7-324
7-335 thru 7-338 7-335 thru 7-338
7-345 and 7-346 7-345 and 7-346
7-351 thru 7-356 7-351 thru 7-356
A-1 thru A-4 A-1 thru A-4
B-3 and B-4 B-3 and B-4
B-23 thru B-30 B-23 thru B-29/(B-30 Blank)
C-1 thru C-4 C-1 thru C-4
D-1 thru D-5/(D-6 Blank) D-1 thru D-6
Place this change sheet in the front of the publication for reference purposes.

2 of 2
By Order of the Secretary of the Army:

JOHN M. KEANE
General, United States Army
Official: Acting Chief of Staff

JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0110111

DISTRIBUTION: To be distributed in accordance with the initial distribution number

(IDN) 380940, requirements for TM 9-2320-366-20-3
 TM 9-2320-366-20-3

LIST OF EFFECTIVE PAGES Insert latest changed pages. Destroy superseded pages.

NOTE: New or changed material is indicated by a

vertical bar in the outer margin of the page.
Dates of issue for original and changed pages are:
Original ...................... 0 ......... 15 September 1998
Change ...................... 1 .................... 1 July 2003
Change ...................... 2 ................20 August 2005
Change ...................... 3 .............10 February 2006

THE TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 1376, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change

No. No. No. No. No. No.

Cover .........................................1 2-2204 Blank.............................. 0 2-2373 thru 2-2407.................... 0

Blank..........................................0 2-2205 thru 2-2211 .................... 0 2-2408 Blank ............................. 0
a thru e.......................................0 2-2212 Blank.............................. 0 2-2409 thru 2-2411.................... 0
f ..................................................2 2-2213 thru 2-2217 .................... 0 2-2412 Blank ............................. 0
g thru l........................................0 2-2218 Blank.............................. 0 2-2413 and 2-2414.................... 1
m and n......................................1 2-2219 thru 2-2228 .................... 1 2-2414.1 Added......................... 1
A thru D......................................3 2-2228.1 thru 2-2228.18 2-2414.2 Blank Added............... 1
i ..................................................1 Added ........................................ 1 2-2414.3 thru 2-2414.9 Added .. 1
ii .................................................0 2-2229 and 2-2230 .................... 1 2-2414.10 Blank Added............. 1
iii thru vi......................................1 2-2230.1 thru 2-2230.14 2-2414.11 and 2-2414.12
2-2006.1 Added .........................1 Added ........................................ 1 Added ........................................ 1
2-2006.2 Blank Added ...............1 2-2231 thru 2-2234 .................... 1 2-2415 and 2-2416.................... 1
2-2007 thru 2-2009 ....................1 2-2234.1 thru 2-2234.22 2-2416.1 Added......................... 1
2-2010 thru 2-2069 ....................0 Added ........................................ 1 2-2416.2 Blank Added............... 1
2-2070 thru 2-2074 ....................2 2-2235........................................ 1 2-2416.3 thru 2-2416.7
2-2075........................................1 2-2236 Blank.............................. 0 Added ........................................ 1
2-2076........................................2 2-2237 and 2238........................ 2 2-2416.8 Blank Added............... 1
2-2077........................................1 2-2239 and 2-2240 Added......... 2 2-2416.9 and 2-2416.10
2-2078........................................2 2-2240.1 thru 2-2240.6 Added ........................................ 1
2-2079........................................1 Added ........................................ 2 2-2417 ....................................... 1
2-2080 Blank..............................1 2-2241 Added ............................ 2 2-2418 Blank ............................. 0
2-2081 thru 2-2100 Deleted.......1 2-2242 Blank Added .................. 2 2-2419 thru 2-2426.................... 1
2-2101 Blank..............................1 2-2243 thru 2-2253 .................... 0 2-2426.1 and 2-2426.2 Added .. 1
2-2102 .......................................2 2-2254........................................ 2 2-2427 and 2-2428.................... 1
2-2103........................................1 2-2254.1 Added ......................... 1 2-2428.1 thru 2-2428.8 Added .. 1
2-2104 thru 2-2109 ....................0 2-2254.2..................................... 2 2-2429 and 2-2430.................... 1
2-2110 thru 2-2117 ....................1 2-2255........................................ 1 2-2430.1 and 2-2430.8 Added .. 1
2-2118 Blank..............................1 2-2256 thru 2-2263 .................... 0 2-2431 and 2-2432.................... 1
2-2119 Blank..............................1 2-2264........................................ 2 2-2432.1 and 2-2432.2 Added .. 1
2-2120 and 2-2121 ....................1 2-2264.1 Added ......................... 1 2-2433 ....................................... 1
2-2122 thru 2-2141 ....................0 2-2264.2..................................... 2 2-2434 Blank ............................. 0
2-2142 Blank..............................0 2-2265........................................ 1 2-2435 thru 2-2439.................... 0
2-2143 .......................................0 2-2266 thru 2-2269 .................... 0 2-2440 Blank ............................. 0
2-2144 thru 2-2149 ....................1 2-2270 Blank.............................. 0 2-2441 thru 2-2446.................... 0
2-2150 Blank..............................0 2-2271 and 2-2272 .................... 2 2-2446.1 Added......................... 1
2-2151 thru 2-2171 ....................0 2-2273 thru 2-2307 Added......... 2 2-2446.2 Blank Added............... 1
2-2172 Blank..............................0 2-2308 Blank Added .................. 2 2-2447 ....................................... 1
2-2173 thru 2-2187 ....................0 2-2309 thru 2-2370 Deleted....... 1 2-2448 and 2-2449.................... 0
2-2188 Blank..............................0 2-2371 Blank.............................. 1 2-2450 Blank ............................. 0
2-2189 thru 2-2203 ....................0 2-2372........................................ 1 3-1 ............................................. 1

* Zero in this column indicates an original page.

Change 3 A
TM 9-2320-366-20-3

LIST OF EFFECTIVE PAGES (CONT) Insert latest changed pages. Destroy superseded pages.

Page *Change Page *Change Page *Change

No. No. No. No. No. No.

3-2 thru 3-9 ................................0 6-8 and 6-9 ................................ 0 7-41 ........................................... 2
3-10............................................2 6-10 thru 6-13 ............................ 1 7-42 ........................................... 0
3-11 thru 3-14 ............................0 6-14............................................ 0 7-43 ........................................... 1
3-15 thru 3-17 ............................1 6-15 thru 6-18 ............................ 1 7-44 thru 7-47............................ 0
3-18 and 3-19 ............................0 6-19............................................ 0 7-48 ........................................... 1
3-20 and 3-21 ............................1 6-20 thru 6-24 ............................ 1 7-49 thru 7-54............................ 0
3-22 Blank..................................0 6-24.1 Added ............................. 1 7-55 ........................................... 1
4-1..............................................1 6-24.2 Blank Added ................... 1 7-56 thru 7-59............................ 0
4-2 thru 4-4 ................................0 6-25............................................ 1 7-60 ........................................... 1
4-5..............................................1 6-26 and 6-27 ............................ 0 7-61 and 7-62............................ 2
4-6 thru 4-8 ................................0 6-28............................................ 1 7-63 thru 7-65............................ 0
4-9..............................................1 6-29 thru 6-33 ............................ 0 7-66 ........................................... 2
4-10............................................0 6-34............................................ 1 7-67 ........................................... 0
4-10.1 and 4-10.2 Added...........1 6-35 thru 6-38 ............................ 0 7-68 ........................................... 1
4-11............................................0 6-39............................................ 1 7-69 thru 7-72............................ 0
4-12 and 4-13 ............................1 6-40 thru 6-45 ............................ 0 7-73 ........................................... 1
4-14............................................0 6-46............................................ 2 7-74 thru 7-79............................ 0
4-15............................................1 6-47 and 6-48 ............................ 0 7-80 ........................................... 1
4-16 and 4-17 ............................0 6-49............................................ 1 7-81 thru 7-83............................ 0
4-18............................................1 6-50 thru 6-52 ............................ 0 7-84 ........................................... 1
4-19 thru 4-41 ............................0 6-53............................................ 1 7-85 and 7-86............................ 2
4-42 and 4-43 ............................1 6-54 thru 6-62 ............................ 0 7-87 thru 7-91............................ 0
4-44............................................0 6-63............................................ 2 7-92 and 7-93............................ 2
4-45............................................1 6-64 thru 6-66 ............................ 0 7-94 ........................................... 1
4-46............................................0 6-67............................................ 1 7-95 thru 7-108.......................... 0
4-47............................................1 6-68 and 6-69 ............................ 0 7-109 ......................................... 2
4-48 thru 4-59 ............................0 6-70............................................ 2 7-110 thru 7-112........................ 0
4-60............................................1 6-71............................................ 1 7-113 ......................................... 2
4-61 and 4-62 ............................0 6-72............................................ 0 7-114 thru 7-123........................ 0
4-63............................................1 6-72.1 Added ............................. 1 7-124 ......................................... 1
4-64 thru 4-68 ............................0 6-72.2 Blank Added ................... 1 7-125 thru 7-137........................ 0
4-69............................................1 6-73 thru 6-78 ............................ 1 7-138 ......................................... 1
4-70 thru 4-81 ............................0 7-1 thru 7-3 ................................ 1 7-139 thru 7-145........................ 0
4-82 thru 4-84 ............................1 7-4 thru 7-6 ................................ 2 7-146 ......................................... 1
4-85 thru 4-105 ..........................0 7-7 and 7-8 ................................ 0 7-146.1 Added........................... 1
4-106 Blank................................0 7-9.............................................. 2 7-146.2 Blank Added................. 1
5-1..............................................1 7-10 and 7-11 ............................ 1 7-147 thru 7-150........................ 0
5-2 thru 5-6 ................................0 7-12 thru 7-19 ............................ 0 7-150.1 ...................................... 2
5-7 and 5-8 ................................1 7-20............................................ 2 7-150.2 Blank Added................. 1
5-9..............................................0 7-21............................................ 0 7-151 ......................................... 1
5-10 and 5-11 ............................1 7-22............................................ 2 7-152 thru 7-158........................ 0
5-12 and 5-13 ............................0 7-23 thru 7-26 ............................ 0 7-159 ......................................... 1
5-14 and 5-15 ............................1 7-27 thru 7-33 ............................ 1 7-160 thru 7-166........................ 0
5-16 Blank..................................0 7-34............................................ 2 7-166.1 Added........................... 1
6-1 thru 6-3 ................................1 7-34.1 Added ............................. 2 7-166.2 Blank Added................. 1
6-4..............................................0 7-34.2 Blank Added ................... 2 7-167 ......................................... 1
6-4.1 and 6-4.2 Added ...............1 7-35 thru 7-37 ............................ 2 7-168 thru 7-171........................ 0
6-5..............................................1 7-38............................................ 1 7-172 ......................................... 2
6-6..............................................0 7-38.1 thru 7-38.4 Added........... 1 7-172.1 Added........................... 1
6-7..............................................1 7-39 and 7-40 ............................ 0 7-172.2 Blank Added................. 1

* Zero in this column indicates an original page.

B Change 3
 TM 9-2320-366-20-3

LIST OF EFFECTIVE PAGES (CONT) Insert latest changed pages. Destroy superseded pages.

Page *Change Page *Change Page *Change

No. No. No. No. No. No.

7-173 thru 7-189 ........................0 7-334 and 7-335 ........................ 0 H-18 thru H-20 .......................... 2
7-190 thru 7-200 ........................1 7-336 and 7-337 ........................ 1 H-21........................................... 1
7-200.1 Added ...........................1 7-338 thru 7-345 ........................ 0 H-22........................................... 2
7-200.2 Blank Added .................1 7-346.......................................... 1 H-23........................................... 0
7-201..........................................1 7-347 thru 7-351 ........................ 0 H-24........................................... 2
7-202 thru 7-206 ........................0 7-352 and 7-353 ........................ 1 H-25........................................... 0
7-207..........................................1 7-354.......................................... 0 H-26 thru H-28 .......................... 2
7-208 and 7-209 ........................0 7-355.......................................... 1 H-29........................................... 0
7-210 and 7-211 ........................1 7-356 thru 7-361 ........................ 0 H-30 thru H-32 .......................... 2
7-212..........................................0 7-362 Blank................................ 0 J-1 ............................................. 0
7-213 thru 7-215 ........................1 A-1 ............................................. 0 J-2 Blank ................................... 0
7-216 thru 7-218 ........................0 A-2 and A-3................................ 1 K-1 Added ................................. 1
7-219 and 7-220 ........................1 A-4 ............................................. 0 K-2 and K-3 ............................... 2
7-221..........................................0 B-1 ............................................. 3 K-4 Added ................................. 1
7-222 thru 7-230 ........................1 B-2 ............................................. 0 INDEX-1 thru INDEX-3.............. 1
7-231 thru 7-241 ........................0 B-3 thru B-29 (B-30 Blank) ........ 3 INDEX-4 and INDEX-5.............. 2
7-242..........................................1 C-1 ............................................. 0 INDEX-6 and INDEX-7.............. 1
7-242.1 Added ...........................1 C-2 thru C-4 ............................... 2 INDEX-8 and INDEX-9.............. 2
7-242.2 Blank Added .................1 D-1 ............................................. 1 INDEX-10 and INDEX-11.......... 1
7-243..........................................1 D-2 and D-3 ............................... 2 INDEX-12 .................................. 2
7-244 and 7-245 ........................2 D-4 and D-5 ............................... 1 INDEX-13 .................................. 1
7-246 and 7-247 ........................1 D-6 ............................................. 2 INDEX-14 Blank ........................ 1
7-248 thru 7-253 ........................0 D-7 Added.................................. 1 Glossary-1 and Glossary-2 ....... 0
7-254..........................................1 D-8 Blank Added........................ 1 FO-1 FP-1 ................................. 1
7-255..........................................0 E-1 ............................................. 1 FO-1 FP-2 Blank ....................... 0
7-256..........................................2 E-2 and E-3................................ 0 FO-1 FP-3 ................................. 1
7-257 thru 7-268 ........................0 E-4 and E-5................................ 1 FO-1 FP-4 Blank ....................... 0
7-269 and 7-270 ........................2 E-6 thru E-14 ............................. 0 FO-1 FP-5 ................................. 1
7-271..........................................0 E-15 ........................................... 1 FO-1 FP-6 Blank ....................... 0
7-272 and 7-273 ........................2 E-16 thru E-26 ........................... 0 FO-1 FP-7 ................................. 1
7-274..........................................0 E-27 thru E-31 Added................ 1 FO-1 FP-8 Blank ....................... 0
7-275 and 7-276 ........................1 E-32 Blank Added...................... 1 FO-1 FP-9 ................................. 1
7-277 and 7-278 ........................0 F-1 thru F-8................................ 0 FO-1 FP-10 Blank ..................... 0
7-279..........................................1 G-1............................................. 2 FO-1 FP-11 ............................... 1
7-280..........................................0 G-2............................................. 1 FO-1 FP-12 Blank ..................... 0
7-281 thru 7-286 ........................1 G-3 thru G-6............................... 2 FO-1 FP-13 ............................... 1
7-286.1 and 7-286.2 Added.......1 G-7............................................. 1 FO-1 FP-14 Blank ..................... 0
7-287 thru 7-289 ........................1 G-8............................................. 2 FO-1 FP-15 ............................... 1
7-290 thru 7-295 ........................0 G-9............................................. 1 FO-1 FP-16 Blank ..................... 0
7-296 thru 7-300 ........................1 G-10 thru G-12........................... 2 FO-1 FP-17 ............................... 1
7-301 thru 7-305 ........................0 H-1 thru H-6 ............................... 2 FO-1 FP-18 Blank ..................... 0
7-306 thru 7-314 ........................1 H-7 ............................................. 2 FO-1 FP-19 ............................... 1
7-315..........................................0 H-8 ............................................. 2 FO-1 FP-20 Blank ..................... 0
7-316..........................................1 H-9 ............................................. 0 FO-1 FP-21 ............................... 1
7-317 thru 7-319 ........................0 H-10 ........................................... 2 FO-1 FP-22 Blank ..................... 0
7-320 and 7-321 ........................1 H-11 ........................................... 1 FO-1 FP-23 ............................... 0
7-322..........................................0 H-12 thru H-14 ........................... 2
7-323..........................................1 H-15 ........................................... 0
7-324 thru 7-330 ........................0 H-16 ........................................... 2
7-331 thru 7-333 ........................2 H-17 ........................................... 0

* Zero in this column indicates an original page.

Change 3 C
TM 9-2320-366-20-3

LIST OF EFFECTIVE PAGES (CONT) Insert latest changed pages. Destroy superseded pages.

Page *Change Page *Change

No. No. No. No.

FO-1 FP-24 Blank......................0 FO-1 FP-69 ................................. 2

FO-1 FP-25................................1 FO-1 FP-70 Blank ....................... 0
FO-1 FP-26 Blank......................0 FO-1 FP-71 ................................. 0
FO-1 FP-27................................0 FO-1 FP-72 Blank ....................... 0
FO-1 FP-28 Blank......................0 FO-1 FP-73 ................................. 0
FO-1 FP-29................................1 FO-1 FP-74 Blank ....................... 0
FO-1 FP-30 Blank......................0 FO-1 FP-75 ................................. 1
FO-1 FP-31................................1 FO-1 FP-76 Blank ....................... 0
FO-1 FP-32 Blank......................0 FO-1 FP-77 ................................. 1
FO-1 FP-33................................1 FO-1 FP-78 Blank ....................... 0
FO-1 FP-34 Blank......................0 FO-1 FP-79 ................................. 1
FO-1 FP-35................................1 FO-1 FP-80 Blank ....................... 0
FO-1 FP-36 Blank......................0 FO-2 FP-1 ................................... 0
FO-1 FP-37................................1 FO-2 FP-2 Blank ......................... 0
FO-1 FP-38 Blank......................0 FO-2 FP-3 ................................... 0
FO-1 FP-39................................1 FO-2 FP-4 Blank ......................... 0
FO-1 FP-40 Blank......................0 FO-2 FP-5 ................................... 0
FO-1 FP-41................................1 FO-2 FP-6 Blank ......................... 0
FO-1 FP-42 Blank......................0 FO-2 FP-7 ................................... 0
FO-1 FP-43................................1 FO-2 FP-8 Blank ......................... 0
FO-1 FP-44 Blank......................0 FO-3 FP-1 ................................... 0
FO-1 FP-45................................1 FO-3 FP-2 Blank ......................... 0
FO-1 FP-46 Blank......................0 FO-3 FP-3 ................................... 0
FO-1 FP-47................................1 FO-3 FP-4 Blank ......................... 0
FO-1 FP-48 Blank......................0 FO-3 FP-5 ................................... 0
FO-1 FP-49................................1 FO-3 FP-6 Blank ......................... 0
FO-1 FP-50 Blank......................0 FO-3 FP-7 ................................... 0
FO-1 FP-51................................1 FO-3 FP-8 Blank ......................... 0
FO-1 FP-52 Blank......................0 FO-3 FP-9 ................................... 0
FO-1 FP-53................................1 FO-3 FP-10 Blank ....................... 0
FO-1 FP-54 Blank......................0 FO-3 FP-11 ................................. 0
FO-1 FP-55................................1 FO-3 FP-12 Blank ....................... 0
FO-1 FP-56 Blank......................0 FO-3 FP-13 ................................. 0
FO-1 FP-57................................1 FO-3 FP-14 Blank ....................... 0
FO-1 FP-58 Blank......................0 FO-3 FP-15 ................................. 0
FO-1 FP-59................................1 FO-3 FP-16 Blank ....................... 0
FO-1 FP-60 Blank......................0 FO-4 FP-1 ................................... 0
FO-1 FP-61................................1 FO-4 FP-2 Blank ......................... 0
FO-1 FP-62 Blank......................0 FO-4 FP-3 ................................... 0
FO-1 FP-63................................1 FO-4 FP-4 Blank ......................... 0
FO-1 FP-64 Blank......................0 FO-5 FP-1 ................................... 0
FO-1 FP-65................................1 FO-5 FP-2 Blank ......................... 0
FO-1 FP-66 Blank......................0 FO-5 FP-3 ................................... 0
FO-1 FP-67................................1 FO-5 FP-4 Blank ......................... 0
FO-1 FP-68 Blank......................0 FO-5 FP-5 ................................... 0
FO-5 FP-6 Blank ......................... 0

* Zero in this column indicates an original page.

D Change 3
 ARMY TM 9-2320-366-20-3
AIR FORCE T.O. 36A12-1C-1102-3

TECHNICAL MANUAL HEADQUARTERS

NO. 9-2320-366-20-3 DEPARTMENTS OF THE ARMY
AND THE AIR FORCE
TECHNICAL ORDER Washington, D.C., 15 September 1998
NO. 36A12-1C-1102-3

Unit Maintenance Manual

M1083 SERIES, 5-TON, 6 x 6,
MEDIUM TACTICAL VEHICLES (MTV)
VOLUME NO. 3 OF 5
MODEL NSN EIC
TRK, CAR., MTV, M1083
W/WN 2320-01-360-1895 BT3
W/O WN 2320-01-354-3386 BR2

TRK, CAR., MTV, W/MATL

HDLG EQPT (MHE), M1084 2320-01-354-3387 BR3

TRK, CAR., MTV, LWB, M1085

W/WN 2320-01-360-1897 BT5
W/O WN 2320-01-354-4530 BR7

TRK, CAR., MTV, LWB, W/MATL

HDLG EQPT (MHE), M1086 2320-01-354-4531 BR8

TRK, TRACTOR, MTV, M1088

W/WN 2320-01-360-1892 BTY
W/O WN 2320-01-355-4332 BTJ

TRK, WKR, MTV, M1089 2320-01-354-4528 BR4

TRK, DUMP, MTV, M1090

W/WN 2320-01-360-1893 BTZ
W/O WN 2320-01-354-4529 BR5

TRK, CHAS, MTV, M1092 2320-01-354-3382 BRZ

TRK, CAR., MTV, AIR DROP, M1093

W/WN 2320-01-360-1896 BT4
W/O WN 2320-01-355-3063 BR9

TRK, DUMP, MTV, AIR DROP, M1094

W/WN 2320-01-360-1984 BT2
W/O WN 2320-01-355-3062 BTK

TRK, CHAS, MTV, LWB, M1096 2320-01-354-4527 BR6

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,
please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publications),
through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is
http://aeps.ria.army.mil. If you need a password, scroll down and click on "ACCESS REQUEST FORM". The DA
Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on
SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the
DA Form 2028 program. You may also mail, fax or Email your letter or DA Form 2028 direct to: AMSTA-LC-CI/TECH
PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email address is TACOM-TECH-
PUBS@ria.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

i
TM 9-2320-366-20-3

TABLE OF CONTENTS

Page

HOW TO USE THIS MANUAL ........................................................................................................................... iii

CENTRAL TIRE INFLATION SYSTEM (CTIS) TROUBLESHOOTING

...................................... 2-2007
AXLE TROUBLESHOOTING ............................................................................................................................. 2-2143

STEERING TROUBLESHOOTING .................................................................................................................. 2-2151

FIFTH WHEEL TROUBLESHOOTING ........................................................................................................... 2-2173

SUSPENSION SYSTEM TROUBLESHOOTING ........................................................................................ 2-2189

15K SELF-RECOVERY WINCH (SRW) SYSTEM TROUBLESHOOTING ........................................ 2-2205

STEERING HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................. 2-2213

AIR TRANSPORT TROUBLESHOOTING

............................................................................................. 2-2219
DUMP BODY HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................... 2-2237

WRECKER HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................... 2-2243

SPECIAL PURPOSE KIT TROUBLESHOOTING....................................................................................... 2-2271

M1084/M1086 MATERIAL HANDLING CRANE (MHC) TROUBLESHOOTING............................. 2-2409

CAB TILT AND SPARE TIRE RETAINER TROUBLESHOOTING ............................................ 2-2413

M1089 AIR SYSTEM TROUBLESHOOTING ............................................................................................... 2-2419

FRAME TROUBLESHOOTING .................................................................................................................. 2-2435

CHAPTER 3 ENGINE MAINTENANCE ........................................................................................................ 3-1

Section I Introduction ............................................................................................................................................ 3-1

Section II Maintenance Procedures ..................................................................................................................... 3-2

ii
 TM 9-2320-366-20-3

CHAPTER 4 FUEL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

CHAPTER 5 EXHAUST SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

CHAPTER 6 COOLING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

CHAPTER 7 ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

APPENDIXES
A. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . A-1
B. MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . B-1
C. TOOLS IDENTIFICATION LIST . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . C-1
D. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST ....... . . . . . . . . . . . . . . . . . . . . D-1
E. ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . E-1
F. TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . F-1
G. MANDATORY REPLACEMENT PARTS . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . G-1
H. LUBRICATION ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . H-1
J. ADDITIONAL AUTHORIZATION LIST (AAL) . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . J-1
K. TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILTY CHART . . . . . . . . . . . . . . . . . . . . K-1

SUBJECT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1

LIST OF ILLUSTRATIONS

Figure No. Figure Title Page

7-1. Power Distribution Panel (PDP) Circuit Beakers, Diodes, and Relays . . . . . . . . . . . . . . . . . . . . 7-38
E-1. Brake Adjusting Tool Support . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . E-5
E-2. Brake Plunger Seal Driver . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . E-6
E-3. Cab Support Tool Strut and Cab Rest . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . E-7
E-4. Cab Support Tool Seat . . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . E-8
E-5. Cab Support Tool Seat Layout . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . . E-9
E-6. Cab Support Tool Assembly . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . E-10
E-7. Dump Body Lifting Bracket . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . E-11
E-8. Rear, Top, and Guide Plate . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . E-12
E-9. Front and Mounting Plate . . . . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . E-13
E-10. Headlight Adjustment Screen . . . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . E-14
E-11. M1089 30K Winch Test Adapter . . . . . . . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . . . . . E-15

Change 1 iii
TM 9-2320-366-20-3

Figure No. Figure Title Page

E-12. M1089 Solenoid Test Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16

E-13. Not Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
E-14. Lanyard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-23
E-15. CTIS Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-25
E-16. Wheel Hub Grease Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-26
E-17. Purge Valve Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-28
E-18. M1089 30K Winch Pneumatic Test Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-31

LIST OF TABLES

Table No. Table Title Page

2-52. Central Tire Inflation System (CTIS) Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2007

2-53. Axle Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2143
2-54. Steering Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2151
2-55. Fifth Wheel Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2173
2-56. Suspension System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2189
2-57. 15K Self-Recovery Winch (SRW) System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2205
2-58. Steering Hydraulic System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2213
2-59. Air Transport Components Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2219
2-60. Dump Body Hydraulic System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2237
2-61. Wrecker Hydraulic System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2243
2-62. Special Purpose Kit Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2271
2-63. M1084/M1086 Material Handling Crane (MHC) Hydraulic Fault Index . . . . . . . . . . . . . . . 2-2409
2-64. Cab Tilt and Spare Tire Retainer Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2413
2-65. M1089 Air System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2419
2-65.1. 30K Winch Freespool Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2421
2-65.2. 30K Winch Pneumatic Manifold Drum Tensioner Solenoids . . . . . . . . . . . . . . . . . . . . 2-2430.5
2-66. Wrecker Function Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2432.1
2-67. Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-68. Frame Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2435
7-1. Power Distribution Panel (PDP) Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7-1.1. Power Distribution Panel (PDP) Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-1.2. Electrical Gages Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
7-2. Rocker Switch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
7-3. M1093/M1094 Cab Clearance and Marker Lights Connectors . . . . . . . . . . . . . . . . . . . . . 7-307
7-4. Cab Clearance Marker Light Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-322
E-1. Pneumatic Tube Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17
E-2. Non-Metallic Electrical Cable Conduit Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-21
E-3. M1089 30K Air Hose Lengths and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-29
F-1. Dry Torque Limits for SAE and ANSI Screws and Free Spinning Nuts . . . . . . . . . . . . . . . . . F-2
F-2. Dry Torque Limits for SAE and ANSI Prevailing Torque Nuts . . . . . . . . . . . . . . . . . . . . . . . . F-4
F-3. Dry Torque Limits for Metric Screws and Free Spinning Nuts . . . . . . . . . . . . . . . . . . . . . . . . F-5
F-4. Dry Torque Limits for Metric Prevailing Torque Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
F-5. Wet Torque Limits for SAE and ANSI Screws and Free Spinning Nuts . . . . . . . . . . . . . . . . . F-7

iv Change 1
 TM 9-2320-366-20-3

HOW TO USE THIS MANUAL

OVERVIEW

This Technical Manual (TM) is provided to help you maintain the MTV at the Unit Maintenance level. Because of its
size, it is divided into five volumes. Volume 3 contains the following major sections in order of appearance:

• WARNING SUMMARY. Provides a summary of the most important warnings that apply throughout the
manual.

• CHAPTER 2, TROUBLESHOOTING (CONT)

• CHAPTER 3, ENGINE MAINTENANCE

• CHAPTER 4, FUEL SYSTEM MAINTENANCE

• CHAPTER 5, EXHAUST SYSTEM MAINTENANCE

• CHAPTER 6, COOLING SYSTEM MAINTENANCE

• CHAPTER 7, ELECTRICAL SYSTEM MAINTENANCE

• APPENDIX A, REFERENCES. Lists publications used with the MTV.

• APPENDIX B, MAINTENANCE ALLOCATION CHART. The maintenance allocation chart denotes the level
of maintenance which performs specific maintenance tasks and the time required. It also lists tools and
special tools required for each task.

• APPENDIX C, TOOLS IDENTIFICATION LIST. Lists equipment used in the performance of maintenance
and references publications which contain information regarding the equipment.

• APPENDIX D, EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST. Lists expendable and durable
items used in the performance of maintenance.

• APPENDIX E, ILLUSTRATED LIST OF MANUFACTURED ITEMS. Illustrates and describes items that must
be fabricated from bulk materials for repair of the MTV.

• APPENDIX F, TORQUE LIMITS. Lists the standard torque values for specific attaching hardware.

• APPENDIX G, MANDATORY REPLACEMENT PARTS.

• APPENDIX H, LUBRICATION ORDER.

• APPENDIX J, ADDITIONAL AUTHORIZATION LIST (AAL).

• APPENDIX K, TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART. Lists actions

required to mate different transmission configurations with WTEC II or WTEC III controls.

• SUBJECT INDEX. Lists important subjects contained in volume 3 in alphabetical order and gives the
associated paragraph number.

Change 1 v
TM 9-2320-366-20-3

FINDING INFORMATION

There are several ways to find the information you need in this manual. They are as follows:

• FRONT COVER INDEX. The front cover index contains a list of the most important topics contained in each
volume. It features a black box at the right edge of the cover which corresponds with a black box on the
page containing the topic. The topics listed on the front cover are highlighted in the table of contents with
a box.

• TABLE OF CONTENTS. Lists chapters, sections, appendixes, and indexes with page numbers in order of
appearance.

• CHAPTER INDEXES. List paragraphs contained in the individual chapters with paragraph and page numbers
in order of appearance.

• SYMPTOM INDEX. Lists malfunctions contained in the troubleshooting table with page numbers in order of
appearance.

TROUBLESHOOTING

Troubleshooting is contained in chapter 2. When a malfunction occurs, look at the symptom index for the vehicle
troubleshooting table in chapter 2. Find the malfunction in the index. Turn to the page number listed for the
malfunction in the troubleshooting table. Perform the steps required to correct the malfunction. If you can’t find the
malfunction, or the malfunction is not corrected, notify your supervisor.

MAINTENANCE

• SCHEDULED MAINTENANCE. Your scheduled maintenance is located in Volume 1, table 2-1, PMCS.
These checks and services are mandatory at the intervals listed. Always follow the WARNINGS and
CAUTIONS.

• UNSCHEDULED MAINTENANCE. Unscheduled maintenance is located in chapters 3 through 24. The

PMCS and troubleshooting tables often reference you to these procedures. When you perform maintenance,
look over the entire procedure before starting. Make sure you have the necessary tools and materials at
hand. Always follow the WARNINGS and CAUTIONS.

FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:

• Become familiar with the entire maintenance procedure before beginning a maintenance task.

• Read all WARNINGS and CAUTIONS before performing any procedures.

vi Change 1
 TM 9-2320-366-20-3

CHAPTER 2
VEHICLE MAINTENANCE (CONT)

2-24. CENTRAL TIRE INFLATION SYSTEM (CTIS) TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 2-2007

2-25. AXLE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2143
2-26. STEERING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2151
2-27. FIFTH WHEEL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2173
2-28. SUSPENSION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2189
2-29. 15K SELF-RECOVERY WINCH (SRW) SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . 2-2205
2-30. STEERING HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2213
2-31. AIR TRANSPORT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2219
2-32. DUMP BODY HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2237
2-33. WRECKER HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2243
2-34. SPECIAL PURPOSE KIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2271
2-35. M1084/M1086 MATERIAL HANDLING CRANE (MHC) HYDRAULIC TROUBLESHOOTING . . . 2-2409
2-36. CAB TILT AND SPARE TIRE RETAINER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 2-2413
2-37. M1089 AIR SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2419
2-38. FRAME TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2435

Section V. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2441

2-39. MAINTENANCE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2441
2-40. GROUND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2441
2-41. GENERAL REMOVAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2441
2-42. GENERAL DISASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2442
2-43. GENERAL CLEANING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2443
2-44. GENERAL INSPECTION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2446
2-45. GENERAL REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2446
2-46. GENERAL ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2447
2-47. GENERAL INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2448
2-48. PREPARATION FOR STORAGE OR SHIPMENT INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 2-2448
2-49. PREPARATION FOR STORAGE OR SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2448
2-50. STORAGE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2449

Change 1 2-2006.1/(2-2006.2 Blank)

 TM 9-2320-366-20-3

2-24. CENTRAL TIRE INFLATION SYSTEM (CTIS) TROUBLESHOOTING

This paragraph covers Central Tire Inflation System (CTIS) Troubleshooting. The Central Tire Inflation System (CTIS)
Fault Index, Table 2-52, lists faults for the CTIS System of the vehicle.

Table 2-52. Central Tire Inflation System (CTIS) Fault Index

Fault No. Description Page

m1. Two Steady Mode Lights Illuminate on Central Tire Inflation System (CTIS) ECU . . . . . . . . . . . 2-2008
m2. Four CTIS ECU Indicator Lights Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2042
m3. Five Central Tire Inflation System (CTIS) ECU Indicator Lights Flashing . . . . . . . . . . . . . . . . . 2-2070
m4. CTIS Repeatedly Resumes Cycling 30 Seconds After
Indicator Lights Stop Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2104
m5. Central Tire Inflation System (CTIS) ECU Indicates No Fault Code But System Fails
to Inflate or Deflate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2110
m6. No Overspeed Warning Light and/or Overspeed Pressure Change . . . . . . . . . . . . . . . . . . . . . 2-2122

Change 1 2-2007
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Materials/Parts
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts Goggles, Industrial (Item 15, Appendix C)
Soap, Laundry (Item 63, Appendix D) Trestle, Motor Vehicle Maintenance (2)
(Item 47, Appendix C)
Personnel Required Pan, Wash (Item 25, Appendix C)
(2) Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Visual Inspection
Nothing
REASON FOR QUESTION
Are two steady mode lights
POSSIBLE PROBLEMS
illuminated during inflation? If two mode lights illuminate
Faulty air hose from wet tank during inflation, air supply to
to manifold valve assembly. manifold valve assembly may
Faulty air compressor or not be adequate.
governor adjustment.
Faulty wheel valve venting.
Faulty manifold valve assembly
relief valve. NO
Faulty manifold valve
assembly.
Faulty quick release valve(s).
Faulty rear axle quick release
valve fittings.
Faulty intermediate axle quick YES Go to step 4 of this fault.
release valve fittings.
Faulty intermediate axle tee
fittings.
Faulty front quick release valve
fittings.
Faulty front tee fittings.
Faulty manifold valve assembly
delivery port fittings.
Faulty cab floor supply hose
fittings.
Faulty supply hoses from quick
release valve(s) to wheel
valve(s).
Faulty wheel valve filters.
Faulty electrical connections at
CTIS ECU and manifold valve
assembly.
Faulty CTIS ECU.

2-2008 Change 1
 TM 9-2320-366-20-3

WARNING

Wear appropriate eye protection when working

under vehicle due to the possibility of falling
debris. Failure to comply may result in injury
to personnel.

NOTE
Two steady mode lights are an indication
that the CTIS has disconnected operation
because of particular inflation or deflation
sequence has taken longer than limits
allow (40 minutes for inflate; 20 minutes
for deflate).
Two steady mode lights indicates that
system shut off with air pressure between
modes.

The CTIS may still operate including

modes that are illuminated by manually
pressing the desired mode.

To perform deflate or inflate checks

throughout this task, it will be necessary
to perform the opposite function first from
time to time so that a desired mode
selection is available.

(1) Start engine (TM 9-2320-366-10-1).

(2) Select an inflation mode on CTIS ECU
(TM 9-2320-366-10-1) and determine if two
light mode is displayed.
(3) Select RUN FLAT mode or shut down engine
and restart engine (TM 9-2320-366-10-1)
again to reset ECU.
(4) Select a deflation mode on CTIS ECU (TM 9-
2320-366-10-1) and determine if two light
mode is displayed.
(5) Shut down engine (TM 9-2320-266-10-1).
(6) If two steady light mode lights do not
illuminate during inflation, go to step 4 of
this fault.

Change 1 2-2009
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

2.
Two steady mode lights
Soapy Water Leak Test
illuminate during inflation.
POSSIBLE PROBLEMS Are air hoses from wet tank REASON FOR QUESTION
Faulty air hoses from wet to manifold valve assembly Steady Mode lights may
tank to manifold valve free from leaks? light if an air leak is
assembly. present.
Faulty air compressor or
governor adjustment.
Faulty wheel valve venting.
Faulty manifold valve
assembly relief valve.
Faulty manifold valve
assembly.
Faulty quick release
NO
valve(s).
Faulty rear axle quick
release valve fittings.
Faulty intermediate axle
quick release valve Tighten loose air hoses.
fittings. Replace damaged air hoses
Faulty intermediate and/or fittings (para 23-2).
axle tee fittings.
Faulty front quick
release valve fittings.
Faulty front tee fittings.
Faulty manifold valve YES
assembly delivery port
fittings.
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2010
 TM 9-2320-366-20-3

NOTE

Two steady mode lights are

an indication that the CTIS
has discontinued operation
because a particular
inflate or deflate sequence
has taken longer than limits
allow (40 minutes for inflate;
20 minutes for deflate).

Two steady mode lights indicate

that CTIS is shut off with air
pressure between modes.

The CTIS may still operate

including modes that are
lit, by manually pressing
the desired mode.

To perform deflate or
inflate checks throughout
this task, it may be
necessary to perform the
opposite function first
so that a desired mode
selection is available.
SOAPY WATER LEAK TEST
(1) Remove kick panel (para 16-3).
(2) Apply soapy water solution to supply
air hose fitting at manifold valve
assembly.
(3) Check for air escaping at manifold
valve assembly, indicated by air
bubbles.
(4) Remove two screws and washers from front
grille.
(5) Remove screw and washer from front grille.
(6) Remove front grille from cab.
(7) Apply soapy water solution to supply
air hose from wet tank at cab floor.
(8) Check for air escaping at cab floor
fittings, indicated by air bubbles.

2-2011
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

3.
Air hoses from wet tank Visual inspection
to manifold valve REASON FOR QUESTION
Is air compressor
assembly OK. If two mode lights persist
supplying enough air to
POSSIBLE PROBLEMS during inflation with engine
CTIS for operation of
Faulty air compressor or operating at 1,000 RPM for
inflation mode?
governor adjustment. more than five minutes, air
Faulty wheel valve venting. supply from air compressor
Faulty manifold valve may be inadequate.
assembly relief valve.
Faulty manifold valve
assembly.
Faulty quick release
valve(s).
Faulty rear axle quick
NO
release valve fittings.
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate Perform Air System
axle tee fittings. Troubleshooting (j1.
Faulty front quick Air System Loses Pressure
release valve fittings. During Operation).
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings. YES
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

Go to step 6 of this fault.

2-2012
 TM 9-2320-366-20-3

(1) Start engine (TM 9-2320-366-10-1) and

operate at 1,000 RPM for five minutes.
(2) Select an inflation mode at CTIS ECU
and check if two steady mode light returns.
(3) Apply and release brakes once or
twice and check if pressure gages are
slow to reach 120 psi.
(4) If two steady mode lights remain illuminated
and brake air pressure gages are
slow to reach 120 psi, Perform Air System
Troubleshooting (j1. Air System Loses Pressure
During Operation).
(5) Shut down engine (TM 9-2320-366-10-1).

2-2013
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
4.
Air hoses from wet tank on following page.
Wheel Valve Vent Test
to manifold valve
assembly OK. REASON FOR QUESTION
Are all wheel valves
Air compressor and
properly vented? Changes in temperature
governor adjustment OK.
can cause wheel valves to
POSSIBLE PROBLEMS
stay closed and prevent
Faulty wheel valve venting.
deflation to lower settings
Faulty manifold valve
causing two steady mode
assembly relief valve.
lights to illuminate.
Faulty manifold valve
assembly.
Faulty quick release
valve(s).
Faulty rear axle quick
NO
release valve fittings.
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate Replace faulty CTIS wheel
axle tee fittings. valve(s) (para 12-5).
Faulty front quick
release valve fittings.
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings. YES
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2014
 TM 9-2320-366-20-3

WARNING

Do not loosen screw on wheel

valve while CTIS is in use.
Failure to comply may
result in injury to personnel.

NOTE
At high temperatures, air
pressure increases in cap
chamber of wheel valve,
adding to spring pressure
so that valve cannot open
to allow tire deflation to
lower settings.

WHEEL VALVE VENT TEST

(1) Release air from all CTIS wheel valves
by backing off vent screws approximately
three turns.
(2) If CTIS wheel valve fails to release air,
replace CTIS wheel valve (para 12-5).
(3) Tighten vent screws. Do
not overtighten.

2-2015
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

5.
Air hoses from wet tank Relief Valve Test
to manifold valve REASON FOR QUESTION
assembly OK. Is relief valve on A damaged relief valve
Air compressor and manifold valve assembly may cause continual air
governor adjustment OK. operating? loss and prevent proper
Wheel valves venting OK. inflation of tires for CTIS
POSSIBLE PROBLEMS mode.
Faulty manifold valve
assembly relief valve.
Faulty manifold valve
assembly.
Faulty quick release
valve(s).
Faulty rear axle quick
NO
release valve fittings.
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate Replace relief valve
axle tee fittings. (para 12-7).
Faulty front quick
release valve fittings.
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings. YES
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2016
 TM 9-2320-366-20-3

RELIEF VALVE TEST

(1) Remove kick panel (para 16-3).
(2) Check if relief valve poppet on manifold valve
assembly is missing.
(3) Position master power switch to on
(TM 9-2320-366-10-1).
(4) Select a mode that is lower on CTIS ECU
(TM 9-2320-366-10-1).
(5) Check if air escapes continuously from relief
valve during deflation sequence.
(6) If air escapes continuously, replace relief valve
(para 12-7).
(7) Position master power switch to off
(TM 9-2320-366-10-1).

2-2017
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

6.
Air hoses from wet tank Manifold Valve Assembly
to manifold valve Test
assembly OK. REASON FOR QUESTION
Is manifold valve
Air compressor and If manifold valve
assembly operating?
governor adjustment OK. assembly is not operating,
Wheel valves venting OK. CTIS cannot inflate or
Manifold valve assembly deflate, and will cause two
relief valve OK. steady mode lights to
POSSIBLE PROBLEMS illuminate.
Faulty manifold valve
assembly.
Faulty quick release
valve(s).
Faulty rear axle quick
NO
release valve fittings.
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate Repair or replace manifold
axle tee fittings. valve assembly (para 12-7).
Faulty front quick
release valve fittings.
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings. YES
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2018
 TM 9-2320-366-20-3

NOTE

When checking manifold valve

assembly, ensure air pressure
in air tanks is 120 psi. Manifold
valve assembly cannot be
checked if air supply is not
available to it.

MANIFOLD VALVE ASSEMBLY TEST

(1) Position master power switch to on
(TM 9-2320-366-10-1).
(2) If two mode lights illuminate during deflation:
(a) Select a mode that is lower on CTIS
ECU (TM 9-2320-366-10-1).
(b) Check if manifold valve assembly
clicks when no air is escaping
from relief valve.
(c) If manifold valve assembly clicks
and no air escapes at relief valve,
replace manifold valve assembly
(para 12-7).
(3) If two mode lights illuminate during
inflation:
(a) Select a mode that is higher on
CTIS ECU (TM 9-2320-366-10-1).
(b) Disconnect air hose at delivery
port of manifold valve assembly.
(c) Check if manifold valve assembly
clicks and no air escapes at
delivery port.
(d) If no air escapes at delivery port
during inflation mode, replace
manifold valve assembly (para 12-7).

2-2019
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

7.
Air hoses from wet tank Visual inspection
to manifold valve REASON FOR QUESTION
assembly OK. Is CTIS quick release If air leaks continuously
Air compressor and valve(s) free from leaks from quick release valve(s)
governor adjustment OK. and damage? during inflation or deflation,
Wheel valves venting OK. CTIS will not to selected
Manifold valve assembly tire pressure and two
relief valve OK. steady mode lights will
Manifold valve assembly illuminate.
OK.
POSSIBLE PROBLEMS
Faulty CTIS quick release
valve(s).
Faulty rear axle quick
NO
release valve fittings.
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate Replace or clean quick
axle tee fittings. release valve(s)
Faulty front quick (para 12-8 or 12-9).
release valve fittings.
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings. YES
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2020
 TM 9-2320-366-20-3

(1) Position CTIS ECU in a mode that is

higher.
(2) Check for air escaping continuously
from exhaust port of quick release
valve.
(3) If air escapes continuously from
quick release valve during
inflation, quick release valve diaphragm
is damaged, replace quick release
valve(s) (para 12-9).

2-2021
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

8.
Air hoses from wet tank Visual Inspection and
to manifold valve Soapy Water Leak Test
Are rear axle quick
assembly OK. REASON FOR QUESTION
release valve fittings
Air compressor and CTIS may be unable to
free from leaks and
governor adjustment OK. reach selected pressure
damage?
Wheel valves venting OK. and two lights will flash if
Manifold valve assembly air leaks from CTIS air
relief valve OK. hoses during inflation/
Manifold valve assembly deflation sequences.
OK.
Quick release valves OK.
POSSIBLE PROBLEMS
Faulty rear axle quick
release valve fittings.
NO
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate
axle tee fittings. Tighten loose air hoses.
Faulty front quick Replace damaged air hoses
release valve fittings. or fittings (para 23-2).
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor supply YES
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2022
 TM 9-2320-366-20-3

(1) Select an inflation mode at CTIS

ECU (TM 9-2320-366-10-1).
(2) If obvious air escape is heard,
tighten loose air hoses or replace
damaged air hoses and/or fittings
(para 23-2).
(3) If no obvious air escape is heard,
proceed to Soapy Water Leak
Test.

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to quick
release valve fittings at rear axle.
(2) Check for air bubbles indicating
leaks.

2-2023
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

9.
Air hoses from wet tank Visual Inspection and
to manifold valve Soapy Water Leak Test
Are intermediate axle
assembly OK. REASON FOR QUESTION
quick release valve
Air compressor and CTIS may be unable to
fittings free from leaks
governor adjustment OK. reach selected pressure
and damage?
Wheel valves venting OK. and two lights will flash if
Manifold valve assembly air leaks from CTIS air
relief valve OK. hoses during inflation/
Manifold valve assembly deflation sequences.
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
POSSIBLE PROBLEMS
NO
Faulty intermediate axle
quick release valve
fittings.
Faulty intermediate
axle tee fittings. Tighten loose air hoses.
Faulty front quick Replace damaged air hoses
release valve fittings. or fittings (para 23-2).
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor supply YES
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2024
 TM 9-2320-366-20-3

(1) Select an inflation mode at CTIS

ECU (TM 9-2320-366-10-1).
(2) If obvious air escape is heard.
Tighten loose air hoses and/or
replace damaged air hoses and/or
fittings (para 23-2).
(3) If no obvious air escape is heard,
proceed to Soapy Water Leak
Test.

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to quick
release valve fittings at intermediate axle.
(2) Check for air bubbles indicating
leaks.

2-2025
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

10.
Air hoses from wet tank
Soapy Water Leak Test
to manifold valve
assembly OK. Are intermediate axle tee REASON FOR QUESTION
Air compressor and fittings free from leaks CTIS may be unable to
governor adjustment OK. and damage? reach selected pressure
Wheel valves venting OK. and two lights will flash if
Manifold valve assembly air leaks from CTIS air
relief valve OK. hoses during inflation/
Manifold valve assembly deflation sequences.
OK.
Quick release valves OK.
Rear axle quick release
valve fittings OK.
Intermediate axle quick
NO
release valve fittings OK.
POSSIBLE PROBLEMS
Faulty intermediate
axle tee fittings.
Faulty front quick Tighten loose air hoses.
release valve fittings. Replace damaged air hoses
Faulty front tee fittings. and/or fittings (para 23-2).
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor supply
hose fittings. YES
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2026
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to tee
fittings at intermediate axle.
(2) Check for air bubbles indicating
leaks.

2-2027
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

11.
Air hoses from wet tank Soapy Water Leak Test
to manifold valve
Is CTIS front quick release REASON FOR QUESTION
assembly OK.
valve fittings free from CTIS may be unable to
Air compressor and
leaks and damage? reach selected pressure
governor adjustment OK.
and two lights will flash if
Wheel valves venting OK.
air leaks from CTIS air
Manifold valve assembly
hoses during inflation/
relief valve OK.
deflation sequences.
Manifold valve assembly
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick NO
release valve fittings OK.
Intermediate axle tee
fittings OK.

POSSIBLE PROBLEMS Tighten loose air lines.

Replace damaged air lines
Faulty front quick
and/or fittings (para 23-2).
release valve fittings.
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings.
YES
Faulty cab floor supply
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2028
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to front
quick release valve fittings.
(2) Check for air bubbles indicating
leaks.

2-2029
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

12.
Air hoses from wet tank Soapy Water Leak Test
to manifold valve
Are fittings for tee at REASON FOR QUESTION
assembly OK.
muffler free from CTIS may be unable to
Air compressor and
leaks and damage? reach selected pressure
governor adjustment OK.
and two lights will flash if
Wheel valves venting OK.
air leaks from CTIS air
Manifold valve assembly
hoses during inflation/
relief valve OK.
deflation.
Manifold valve assembly
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick NO
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
Tighten loose air hoses.
fittings OK.
Replace damaged air hoses
POSSIBLE PROBLEMS or fittings (para 23-2).
Faulty front tee fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor supply YES
hose fittings.
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2030
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to fittings
at tee above muffler.
(2) Check for air bubbles indicating
leaks.

2-2031
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

13.
Air hoses from wet tank
Soapy Water Leak Test
to manifold valve
assembly OK. Are manifold valve assembly REASON FOR QUESTION
Air compressor and delivery port fittings free from CTIS may be unable to
governor adjustment OK. leaks and damage? reach selected pressure
Wheel valves venting OK. and two lights will flash if
Manifold valve assembly air leaks from CTIS air
relief valve OK. hoses during inflation/
Manifold valve assembly deflation.
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick
NO
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK. Tighten loose air hoses.
Front tee fittings OK. Replace damaged air hoses
POSSIBLE PROBLEMS or fittings (para 23-2).
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor supply
hose fittings. YES
Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2032
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to manifold
valve assembly delivery port fittings.
(2) Check for air bubbles indicating
leaks.

2-2033
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

14.
Air hoses from wet tank
Soapy Water Leak Test
to manifold valve
assembly OK. Are cab floor supply hose REASON FOR QUESTION
Air compressor and fittings free from CTIS may be unable to
governor adjustment OK. leaks and damage? reach selected pressure
Wheel valves venting OK. and two lights will flash if
Manifold valve assembly air leaks from CTIS air
relief valve OK. hoses during inflation/
Manifold valve assembly deflation.
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick
NO
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK. Tighten loose air hoses.
Front tee fittings OK. Replace damaged air hoses
Manifold valve assembly and/or fittings (para 23-2).
delivery port fittings OK.
POSSIBLE PROBLEMS
Faulty cab floor supply
hose fittings.
Faulty supply hoses from YES
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2034
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Remove two screws and washers from front
grille.
(2) Remove screw and washer from front grille.
(3) Remove front grille from cab.
(4) Apply soapy water solution to cab floor
supply hose fittings.
(5) Check for air bubbles indicating
leaks.
(6) Position front grille on cab with washer and
screw.
(7) Position two washers and screws in front grille.
(8) Tighten screw to 48-60 lb-in. (5-7 N·m).
(9) Tighten two screws to 24 lb-in. (3 N·m).

2-2035
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

15.
Air hoses from wet tank Wheel Valve Air Line Test
to manifold valve Are air supply hoses from
REASON FOR QUESTION
assembly OK. quick release valves to
Leaking or blocked air
Air compressor and wheel valves free from
supply hoses to wheel
governor adjustment OK. leaks and damage?
valves will prevent CTIS
Wheel valves venting OK.
from coming to selected
Manifold valve assembly
pressure during inflation
relief valve OK.
or deflation and cause two
Manifold valve assembly
steady mode lights to
OK.
illuminate.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick NO
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
Tighten loose air hoses.
fittings OK.
Replace damaged air hoses
Front tee fittings OK.
and/or fittings (para 23-2).
Manifold valve assembly
delivery port fittings OK.
Cab floor supply line
fittings OK.

POSSIBLE PROBLEMS YES

Faulty supply hoses from
quick release valve(s) to
wheel valve(s).
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2036
 TM 9-2320-366-20-3

WHEEL VALVE AIR LINE TEST

(1) Check tire pressures after a
deflation or inflation sequence.
If one or more tires are at a
different pressure than the rest,
air hose to affected wheel(s) may
be faulty.
(2) Disconnect supply air hose at
banjo fitting on affected wheel(s).
(3) Select an inflation sequence at
CTIS ECU (TM 9-2320-366-10-1).
(4) Check if air escapes at wheel
during inflation.
(5) If air does not escape, locate
leak or blockage by tracing hose
between quick release valve and
affected wheel(s) (refer to pneumatic
schematic).

2-2037
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

16.
Air hoses from wet tank Wheel Valve Filter Inspection
to manifold valve
Are filters at wheel REASON FOR QUESTION
assembly OK.
valves clean? Clogged wheel valve filters
Air compressor and
prevent air from passing
governor adjustment OK.
into or escaping from tires
Wheel valves venting OK.
during inflation or deflation
Manifold valve assembly
and cause two steady mode
relief valve OK.
lights to illuminate.
Manifold valve assembly
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick NO
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK. Clean or replace wheel
Front tee fittings OK. valve filters (para 12-5).
Manifold valve assembly
delivery port fittings OK.
Cab floor supply hose
fittings OK.
Supply hoses from quick
YES
release valve to wheel
valves OK.

POSSIBLE PROBLEMS
Faulty wheel valve filters.
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

2-2038
 TM 9-2320-366-20-3

WHEEL VALVE FILTER INSPECTION

(1) Jack up axle at affected wheel and
support with trestles.
(2) Remove two screws from wheel
valve.
(3) Remove wheel valve and unscrew
from delivery hose.
(4) Unscrew wheel valve filter from
wheel valve.
(5) Check if filter is clean and free
from obstruction.
(6) If filter is plugged with dirt, clean
or replace wheel valve filters (para 12-5).
(7) Install wheel valve on delivery
hose.
(8) Install wheel valve with two screws.
(9) Install supply air line on banjo
fitting.

2-2039
TM 9-2320-366-20-3

m1. TWO STEADY MODE LIGHTS ILLUMINATE ON CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU (CONT)

KNOWN INFO TEST OPTIONS

17.
Visual inspection
Air hoses from wet tank
REASON FOR QUESTION
to manifold valve Are electrical connectors
Erratic operation of CTIS
assembly OK. at CTIS ECU and at
system can often be
Air compressor and manifold valve assembly
traced to poor electrical
governor adjustment OK. clean and secure?
connections.
Wheel valves venting OK.
Manifold valve assembly
relief valve OK.
Manifold valve assembly
OK.
Quick release valves OK.
Rear axle quick
release valve fittings OK.
Intermediate axle quick NO
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
Clean and/or tighten
fittings OK.
electrical connections.
Front tee fittings OK.
Notify DS maintenance if
Manifold valve assembly
electrical connectors are
delivery port fittings OK.
damaged.
Cab floor supply hose
fittings OK.
Supply hoses from quick
YES
release valve to wheel
valves OK.
Wheel valve filters OK.

POSSIBLE PROBLEMS
Faulty electrical connections
at CTIS ECU and manifold
valve assembly.
Faulty ECU.

Replace CTIS ECU

(para 12-6).

2-2040
 TM 9-2320-366-20-3

(1) Disconnect connectors P110 at CTIS ECU,

P112 at manifold valve assembly solenoid,
and P113 at manifold valve assembly
pressure transducer.
(2) Check if connectors are clean and pins are
undamaged.
(3) Connect and tighten connectors P113, P112,
and P110.
(4) Install kick panel (para 16-3).

2-2041
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine running (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Parking brake on (TM 9-2320-366-10-1). Goggles, Industrial (Item 15, Appendix C)
Wheels chocked (TM 9-2320-366-10-1). Gage, Tire Pressure (Item 11, Appendix C)
Pan, Wash (Item 25, Appendix C)
Materials/Parts Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Soap, Laundry (Item 63, Appendix D)

START

WARNING
CAUTION
Read WARNING and
KNOWN INFO CAUTION on following TEST OPTIONS
1.
Air pressure at wet tank OK. page. Tire Pressure Measurement
POSSIBLE PROBLEMS REASON FOR QUESTION
Are tires free
Faulty tire(s). Low tire pressure or tire
from leaks?
Faulty CTIS wheel damage may cause CTIS
seal(s). to shut down to
Faulty kneeling protect tire pressure in
NO
valve(s) at front other wheels. Four
wheel(s). CTIS ECU indicator lights
Faulty CTIS wheel will flash.
valve(s).
Faulty air hoses from
quick release valve
to affected wheel(s). YES
Repair wheel (para 12-2).
Faulty front axle
quick release valve.
Faulty rear axle
quick release valve(s).
Faulty rear axle
quick release valve
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2042
 TM 9-2320-366-20-3

WARNING

Wear appropriate eye protection

when working under vehicle and
around CTIS due to the
possibility of falling or
blown debris. Failure to comply
may result in injury to personnel.

CAUTION

When RUN FLAT has been

selected to perform a
troubleshooting step, be
sure to press RUN FLAT
again when step is
completed to terminate
CTIS operation and
prevent excessive air
loss.

NOTE

Four mode lights flashing

indicate CTIS has shut off
due to uneven tire pressure
(one tire 50 percent less than
other pressures will do it),
tire damage, or major leak.
Operator can continue CTIS
operation by pressing RUN
FLAT on CTIS ECU. When RUN
FLAT has been selected
CTIS ECU checks pressures
at 15 second
intervals.

TIRE PRESSURE MEASUREMENT

(1) Measure and record the tire pressure
of each tire (TM 9-2320-366-10-1).
(2) If any tire pressure is lower than the rest,
visually inspect tire for damage.
(3) Apply soapy water solution to tire
bead.
(4) Observe tire for bubbles indicating
leaks.

2-2043
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

2.
Air pressure at wet tank OK. CTIS Wheel Seal Test
Tires OK. Are CTIS wheel seals REASON FOR QUESTION
POSSIBLE PROBLEMS free from leaks at Four CTIS ECU indicator
Faulty CTIS wheel affected wheel(s)? lights may flash if CTIS
seal(s). wheel seal is damaged.
Faulty kneeling
NO
valve(s) at front
wheel(s).
Faulty CTIS wheel
valve(s).
Replace CTIS wheel
Faulty air hoses from
seal (para 10-2).
quick release valve
to affected wheel(s). YES
Faulty front axle
quick release valve.
Faulty rear axle
quick release valve(s).
Faulty rear axle
quick release valve
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2044
 TM 9-2320-366-20-3

CTIS WHEEL SEAL TEST

(1) Check axle hubs for presence of oil leaks that
indicate a damaged CTIS wheel seal.
(2) Ensure wheel is at rest with hub plug at top of
hub.
(3) Remove hub oil plug.
(4) Select RUN FLAT at CTIS ECU (TM
9-2320-366-10-1).
(5) Determine if air is escaping from hub. If air
escapes, replace CTIS wheel seal (para 10-2).
(6) Install hub oil plug on wheel hub.

2-2045
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

3.
Air pressure at wet tank OK. Soapy Water Leak Test
Tires OK. Are CTIS wheel valves REASON FOR QUESTION
CTIS wheel seals OK. and front wheel Air leaks from wheel
POSSIBLE PROBLEMS kneeling valves free valves and kneeling valve
from leaks and damage at front wheels may cause
Faulty kneeling
at affected wheel(s)? four CTIS ECU indicator
valve(s) at front
lights to flash.
wheel(s).
Faulty CTIS wheel
NO
valve(s).
Faulty air hoses from
quick release valve
to affected wheel(s).
Clean or replace
Faulty front axle
kneeling valve (para
quick release valve.
12-5). Replace wheel
Faulty rear axle YES
seal (para 12-5).
quick release valve(s).
Faulty rear axle
quick release valve
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2046
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) If front wheel is leaking, ensure kneeling valve
is tight and secure in valve seat.
(2) Apply soapy water to kneeling valve and check
for leaks.
(3) Apply soapy water solution to fittings on either
side of wheel valve and observe fittings for
bubbles indicating leaks.
(4) With wheel valve still connected to tire,
disconnect wheel valve air supply hose from hub
at banjo fitting.
(5) Place open end of air supply hose in container of
water. Look for bubbles. Persistent bubbles from
air supply hose indicate leaking wheel valve.
(6) Connect air supply hose to hub at banjo fitting.

2-2047
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

4.
Air pressure at wet tank OK. Soapy Water Leak Test
Tires OK. Are air hoses and fittings REASON FOR QUESTION
CTIS wheel seals OK. from quick release A leak in supply hose to
Kneeling valves at front valve to affected affected wheel will prevent
wheels OK. wheel(s) free from leaks wheel from coming to
CTIS wheel valves OK. and damage? matching pressure with all
POSSIBLE PROBLEMS other wheels and will cause
four CTIS ECU indicator
Faulty air hoses from NO lights to flash.
quick release valve
to affected wheel(s).
Faulty front axle
quick release valve.
Tighten loose air hoses.
Faulty rear axle
Replace damaged air hoses
quick release valve(s).
YES or fittings (para 23-2).
Faulty rear axle
quick release valve
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2048
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) If affected wheel is on intermediate axle:

(a) Apply soapy water solution to air supply
fittings at affected wheel(s).
(b) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(c) Check for bubbles indicating leaks at fittings.
(d) Inspect air hose from wheel to quick release
valve for leaks and damage.
(2) If affected wheel is on front axle:
(a) Apply soapy water solution to air supply
fittings at affected wheel(s) and at frame
adapter.

NOTE
CTIS air supply is front fitting on
left front wheel; back fitting on
right front wheel.

(b) Select RUN FLAT at CTIS ECU

(TM 9-2320-366-10-1).
(c) Check for bubbles indicating leaks at fittings.
(d) Inspect air hose from frame adapter to quick
release valve for leaks and damage.

2-2049
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

5.
Air pressure at wet tank OK. Visual inspection
Tires OK. REASON FOR QUESTION
Is front axle quick release
CTIS wheel seals OK. Four CTIS ECU indicator
valve free from constant
Kneeling valves at front lights will flash if quick
escape of air during
wheels OK. release valve continually
inflation sequence?
CTIS wheel valves OK. purges air.
Air hoses from quick release
valve to affected wheels OK.
POSSIBLE PROBLEMS NO
Faulty front axle
quick release valve.
Faulty rear axle
quick release valve(s). Clean or replace quick
Faulty rear axle release valve (para 12-8).
quick release valve
YES
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2050
 TM 9-2320-366-20-3

(1) Select RUN FLAT at CTIS ECU

(TM 9-2320-366-10-1).
(2) Check front axle quick release valve
for constant escape of air during
inflation sequence.
(3) If air escapes from quick release
valve exhaust port during inflation
attempt, quick release valve diaphragm
is damaged or a foreign object is
lodged under diaphragm preventing it
from closing.

2-2051
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

6.
Air pressure at wet tank OK. Visual inspection
Tires OK. REASON FOR QUESTION
Are rear axle quick release
CTIS wheel seals OK. Four CTIS ECU indicator
valves free from constant
Kneeling valves at front lights will flash if quick
escape of air during
wheels OK. release valve continually
inflation sequence?
CTIS wheel valves OK. purges air.
Air hoses from quick release
valve to affected wheels OK.
Front axle quick release NO
valve OK.
POSSIBLE PROBLEMS

Faulty rear axle

Clean or replace rear quick
quick release valve(s).
release valve (para 12-9).
Faulty rear axle
quick release valve YES
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2052
 TM 9-2320-366-20-3

(1) Select RUN FLAT at CTIS ECU

(TM 9-2320-366-10-1).
(2) Check rear axle quick release valve
for constant escape of air during
inflation sequence.
(3) If air escapes from quick release
valve exhaust port during inflation
attempt, quick release valve diaphragm
is damaged or a foreign object is
lodged under diaphragm preventing it
from closing.

2-2053
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

7.
Air pressure at wet tank OK. Soapy Water Leak Test
Tires OK. REASON FOR QUESTION
Are rear axle quick
CTIS wheel seals OK. CTIS may be unable to
release valve fittings
Kneeling valves at front reach selected pressure
free from leaks and
wheels OK. and four CTIS ECU indicator
damage?
CTIS wheel valves OK. lights will flash if air leaks
Air hoses from quick release from CTIS air hoses during
valve to affected wheels OK. inflation/deflation sequence.
Front axle quick release NO
valve OK.
Rear axle quick release
valves OK.
POSSIBLE PROBLEMS Tighten loose air hoses.
Faulty rear axle Replace damaged air hoses
quick release valve or fittings (para 23-2).
YES
fittings.
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2054
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1) and listen for
obvious air escape in CTIS system.
(2) If obvious air escape is heard,
perform repair at damaged area.
If no obvious air escape is heard,
proceed to quick release valve
leak check.
(3) Apply soapy water solution to quick
release valve fittings at rear axle.
(4) Check for bubbles indicating leaks.

2-2055
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

8.
Air pressure at wet tank OK. Soapy Water Leak Test
Tires OK. REASON FOR QUESTION
Are intermediate axle
CTIS wheel seals OK. CTIS may be unable to
quick release valve
Kneeling valves at front reach selected pressure
fittings free from leaks
wheels OK. and four CTIS ECU indicator
and damage?
CTIS wheel valves OK. lights will flash if air leaks
Air hoses from quick release from CTIS air hoses during
valve to affected wheels OK. inflation/deflation sequence.
Front axle quick release NO
valve OK.
Rear axle quick release
valves OK.
Rear axle quick release Tighten loose air hoses.
valve fittings OK. Replace damaged air hoses
POSSIBLE PROBLEMS or fittings (para 23-2).
YES
Faulty intermediate
axle quick release valve
fittings.
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2056
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1) and listen for
obvious air escape in CTIS system.
(2) If obvious air escape is heard,
perform repair at damaged area.
If no obvious air escape is heard,
proceed to quick release valve
leak check.
(3) Apply soapy water solution to quick
release valve fittings at intermediate
axle.
(4) Check for bubbles indicating leaks.

2-2057
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

9.
Air pressure at wet tank OK. Soapy Water Leak Test
Tires OK. REASON FOR QUESTION
CTIS wheel seals OK. Are intermediate axle tee CTIS may be unable to
Kneeling valves at front fittings free from leaks reach selected pressure
wheels OK. and damage? and four CTIS ECU indicator
CTIS wheel valves OK. lights will flash if air leaks
Air hoses from quick release from CTIS air hoses during
valve to affected wheels OK. inflation/deflation sequence.
Front axle quick release NO
valve OK.
Rear axle quick release
valves OK.
Rear axle quick release Tighten loose air hoses.
valve fittings OK. Replace damaged air hoses
Intermediate axle quick or fittings (para 23-2).
YES
release valve fittings OK.
POSSIBLE PROBLEMS
Faulty intermediate axle
tee fittings.
Faulty front axle quick
release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2058
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to
intermediate axle tee fittings.
(2) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(3) Check for bubbles indicating leaks.

2-2059
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

10.
Soapy Water Leak Test
Air pressure at wet tank OK.
REASON FOR QUESTION
Tires OK. Are front axle quick
CTIS may be unable to
CTIS wheel seals OK. release valve fittings
reach selected pressure
Kneeling valves at front free from leaks and
and four CTIS ECU indicator
wheels OK. damage?
lights will flash if air leaks
CTIS wheel valves OK.
from CTIS air hoses during
Air hoses from quick release
inflation/deflation sequence.
valve to affected wheels OK.
NO
Front axle quick release
valve OK.
Rear axle quick release
valves OK.
Tighten loose air hoses.
Rear axle quick release
Replace damaged air hose
valve fittings OK.
and/or fittings (para 23-2).
Intermediate axle quick YES
release valve fittings OK.
Intermediate axle tee
fittings OK.

POSSIBLE PROBLEMS

Faulty front axle quick

release valve fittings.
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2060
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to front
quick release valve fittings.
(2) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(3) Check for bubbles indicating leaks.

2-2061
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

11.
Soapy Water Leak Test
Air pressure at wet tank OK.
REASON FOR QUESTION
Tires OK.
Are front tee fittings CTIS may be unable to
CTIS wheel seals OK.
free from leaks and reach selected pressure
Kneeling valves at front
damage? and four CTIS ECU indicator
wheels OK.
lights will flash if air leaks
CTIS wheel valves OK.
from CTIS air hoses during
Air hoses from quick release
inflation/deflation sequence.
valve to affected wheels OK.
NO
Front axle quick release
valve OK.
Rear axle quick release
valves OK.
Tighten loose air hoses
Rear axle quick release
Replace damaged air hoses
valve fittings OK.
or fittings (para 23-2).
Intermediate axle quick YES
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK.

POSSIBLE PROBLEMS
Faulty front tee
fittings.
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2062
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to tee
fittings at muffler.
(2) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(3) Check for bubbles indicating leaks.

2-2063
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

12.
Soapy Water Leak Test
Air pressure at wet tank OK.
REASON FOR QUESTION
Tires OK.
Are manifold valve assembly CTIS may be unable to
CTIS wheel seals OK.
delivery port fittings free reach selected pressure
Kneeling valves at front
from leaks and damage? and four CTIS ECU indicator
wheels OK.
lights will flash if air leaks
CTIS wheel valves OK.
from CTIS air hoses during
Air hoses from quick release
inflation/deflation sequence.
valve to affected wheels OK.
NO
Front axle quick release
valve OK.
Rear axle quick release
valves OK.
Tighten loose air hoses.
Rear axle quick release
Replace damaged air hoses
valve fittings OK.
or fittings (para 23-2).
Intermediate axle quick YES
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK.
Front tee fittings OK.

POSSIBLE PROBLEMS
Faulty manifold valve
assembly delivery port
fittings.
Faulty cab floor air
hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2064
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Remove kick panel (para 16-3).
(2) Apply soapy water solution to manifold valve
assembly delivery port fittings.
(3) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(4) Check for bubbles indicating leaks.

2-2065
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

13.
Soapy Water Leak Test
Air pressure at wet tank OK.
REASON FOR QUESTION
Tires OK.
Are cab floor supply hose CTIS may be unable to
CTIS wheel seals OK.
fittings free from leaks reach selected pressure
Kneeling valves at front
and damage? and four CTIS ECU indicator
wheels OK.
lights will flash if air leaks
CTIS wheel valves OK.
from CTIS air hoses during
Air hoses from quick release
inflation/deflation sequence.
valve to affected wheels OK.
NO
Front axle quick release
valve OK.
Rear axle quick release
valves OK.
Tighten loose air hoses.
Rear axle quick release
Replace damaged air hoses
valve fittings OK.
or fittings (para 23-2).
Intermediate axle quick YES
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK.
Front tee fittings OK.
Manifold valve assembly
delivery port fittings OK.

POSSIBLE PROBLEMS

Faulty cab floor air

hose fittings.
Faulty manifold valve
assembly.
Faulty CTIS ECU.

2-2066
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Remove two screws and washers from front
grille.
(2) Remove screw and washer from front grille.
(3) Remove front grille from cab.
(4) Apply soapy water solution to cab floor supply
hose fittings.
(5) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(6) Check for bubbles indicating leaks.
(7) Position front grille on cab with washer and
screw.
(8) Position two washers and screws in front grille.
(9) Tighten screw to 48-60 lb-in. (5-7 N·m).
(10) Tighten two screws to 24 lb-in. (3 N·m).

2-2067
TM 9-2320-366-20-3

m2. FOUR CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING (CONT)

KNOWN INFO TEST OPTIONS

14.
Air pressure at wet tank Manifold Valve Assembly
OK. Does manifold valve Test
Tires OK. assembly click when REASON FOR QUESTION
CTIS wheel seals OK. selecting mode change Four CTIS ECU indicator
Kneeling valves at front and is no air heard blowing lights will flash if manifold
wheels OK. through valve? valve assembly is defective.
CTIS wheel valves OK.
Air hoses from quick
release valve to affected NO
wheels OK.
Front axle quick release
valve OK.
Rear axle quick release Repair or replace
valves OK. manifold valve
Rear axle quick release assembly (para 12-7).
YES
valve fittings OK.
Intermediate axle quick
release valve fittings OK.
Intermediate axle tee
fittings OK.
Front quick release valve
fittings OK.
Front tee fittings OK.
Manifold valve assembly
delivery port fittings OK.
Cab floor air hose fittings
OK.
POSSIBLE PROBLEMS
Faulty manifold valve
assembly.
Faulty CTIS ECU.

Replace CTIS ECU

(para 12-6).

2-2068
 TM 9-2320-366-20-3

MANIFOLD VALVE ASSEMBLY TEST

(1) Select RUN FLAT at CTIS ECU
(TM 9-2320-366-10-1).
(2) Check manifold valve assembly by listening for
clicking when selecting mode change. If no
clicking is heard or if air blows through
manifold valve assembly, manifold valve
assembly is faulty.
(3) If manifold valve is ok, ECU may be faulty.
(4) Install kick panel (para 16-3).

2-2069
TM 9-2320-366-20-3

m3. FIVE CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Kick panel removed (para 16-3). Multimeter, Digital (Item 22, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Personnel Required Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
(2)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Front and rear air gages read Visual Inspection
120 PSI. Is CTIS manifold valve vent
REASON FOR QUESTION
hose or bulkhead fitting
POSSIBLE PROBLEMS
plugged or restricted? If CTIS manifold valve vent
CTIS manifold valve vent hose hose or bulkhead fitting is
or bulkhead fitting plugged or plugged, CTIS system will not
restricted. operate correctly.
Faulty air hose or fittings.
Faulty front axle CTIS quick NO
release valve.
Faulty intermediate axle
CTIS quick release valve.
Faulty rear axle CTIS quick
release valve.
Faulty wheel valve. YES Go to step 2 of this fault.
Faulty front wheel kneeling
valve.
Faulty wheel seals.
Faulty electrical system.

Clean CTIS manifold valve vent

hose (para 2-43).

2-2070 Change 2
 TM 9-2320-366-20-3

WARNING

The sudden release of high pressure air

can cause damage to eyes. Wear
appropriate eye protection when working
near pressurized air. Failure to comply
may result in injury to personnel.

(1) Check to see if vehicles is equipped vent cover

and vent cover is in good condition.
(2) If vehicle is not equipped with vent cover or vent
cover is damaged perform steps (4) through (18)
of this test.
(3) If vehicle is equipped with vent cover and vent
cover is in good condition, go to step 2 of this
fault.
(4) Disconnect CTIS manifold valve vent hose from
CTIS manifold valve assembly.
(5) Disconnect CTIS manifold valve vent hose from
bulkhead fitting in cab floor.
(6) Check to see if CTIS manifold valve vent hose or
bulkhead fitting is plugged or restricted.
(7) If CTIS manifold vale vent hose and bulkhead
fitting are not plugged or restricted, go to step 2
of this fault.
(8) If CTIS manifold valve vent hose or bulkhead
fitting is plugged or restricted, clean CTIS
manifold valve vent hose and bulkhead fitting
(para 2-43).
(9) Connect CTIS manifold valve vent hose to CTIS
manifold valve assembly.
(10) Connect CTIS manifold valve vent hose to
bulkhead fitting in cab floor.
(11) Remove two screws and washer from front grille.
(12) Remove screw, washer, and front grille from cab.
NOTE
Perform step (13) if vent cover is damaged.

(13) Remove retaining nut and vent cover from

bulkhead fitting. Discard retaining nut and
vent cover.
NOTE
Part number 12422659 is required for step
(14).

(14) Install vent cover on bulkhead fitting with

retaining nut.
(15) Position front grille on cab with washer and
screw.
(16) Position two washers and screws in front grille.
(17) Tighten screw to 48-60 lb-in. (5-7 N.m).
(18) Tighten two screws to 24 lb-in. (3 N.m).

Change 2 2-2071
TM 9-2320-366-20-3

m3. FIVE CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
(CONT)

KNOWN INFO TEST OPTIONS

2.
Front and rear air gages read Visual Inspection
120 PSI. Is air present from port C
REASON FOR QUESTION
CTIS manifold valve vent hose on CTIS manifold valve?
and bulkhead fitting OK. This question eliminates
possible problems and
POSSIBLE PROBLEMS determines where
troubleshooting continues.
Faulty air hose or fittings.
Faulty front axle CTIS quick
release valve. NO
Faulty intermediate axle
CTIS quick release valve.
Faulty rear axle CTIS quick
release valve. Go to Electrical System Troubleshooting
Faulty wheel valve. YES (e85. Central Tire Inflation System (CTIS)
Faulty front wheel kneeling Does Not Operate).
valve.
Faulty wheel seals.
Faulty electrical system.

KNOWN INFO TEST OPTIONS

3.
Front and rear air gages read Visual Inspection
120 PSI. Is CTIS air hoses and
REASON FOR QUESTION
CTIS manifold valve vent hose fittings free from air leaks
and bulkhead fitting OK. during inflation mode? If air is leaking during inflation
mode, CTIS pneumatic system
POSSIBLE PROBLEMS
is faulty.
Faulty air hose or fittings.
Faulty front axle CTIS quick
release valve.
Faulty intermediate axle NO
CTIS quick release valve.
Faulty rear axle CTIS quick
release valve.
Faulty wheel valve.
Faulty front wheel kneeling Replace or repair air hose
YES
valve. or fittings (para 2-45).
Faulty wheel seals.
Faulty electrical system.

2-2072 Change 2
 TM 9-2320-366-20-3

(1) Disconnect CTIS manifold output hose from

CTIS manifold valve assembly port C.
(2) Start engine (TM 9-2320-366-10-1).
(3) Select CTIS inflation mode
(TM 9-2320-366-10-1).
(4) Wait for CTIS to cycle and check for quick
bursts of air to expel from CTIS manifold valve
assembly port C.
(5) Check for five CTIS ECU indicator lights flashing.
(6) If air does not expel from CTIS manifold valve
assembly or CTIS ECU does not have five flashing
indicator lights, go to Electrical System
Troubleshooting (e85. Central Tire Inflation
System (CTIS) Does Not Operate).
(7) Shut down engine (TM 9-2320-366-10-1).
(8) Connect CTIS manifold output hose to
CTIS manifold valve assembly port C.
(9) Install kick panel (para 16-3).

NOTE
Five flashing indicator lights indicate
a defect in CTIS critical component(s)
causing system to shut off. Override
cannot be applied but system can be
activated by turning vehicle off and
then on again.
(1) Start engine (TM 9-2320-366-10-1).
(2) Set CTIS ECU to RUN FLAT mode
(TM 9-2320-366-10-1).
(3) Check CTIS air hoses and fittings for leaks
(Table 23-2 Central Tire Inflation System (CTIS)
Air Hose Locations).
(4) If any leaks are found, repair or replace CTIS
air hose and/or fittings (para 2-45).
(5) Shut down engine (TM 9-2320-366-10-1).

Change 2 2-2073
TM 9-2320-366-20-3

m3. FIVE CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
(CONT)

KNOWN INFO TEST OPTIONS

4.
Front and rear air gages read Visual Inspection
Is front axle CTIS quick
120 PSI.
release valve free from REASON FOR QUESTION
CTIS manifold valve vent hose
exhausting air during
and bulkhead fitting OK. If air exhausts from CTIS quick
inflation mode?
Air hose and fittings OK. release valve during inflation
mode, CTIS quick release valve
POSSIBLE PROBLEMS is faulty.
Faulty front axle CTIS quick
release valve.
Faulty intermediate axle NO
CTIS quick release valve.
Faulty rear axle CTIS quick
release valve.
Faulty wheel valve. Replace front axle CTIS
Faulty front wheel kneeling YES quick release valve
valve. (para 12-8).
Faulty wheel seals.
Faulty electrical system.

2-2074 Change 2
 TM 9-2320-366-20-3

(1) Start engine (TM 9-2320-366-10-1).

(2) Select CTIS inflation mode
(TM 9-2320-366-10-1).
(3) Check for air escaping from front axle
CTIS quick release valve during inflation
mode.
(4) If air is escaping from front axle CTIS
quick release valve during inflation
mode, replace front axle CTIS quick
release valve (para 12-8).
(5) Shut down engine (TM 9-2320-366-10-1).

Change 1 2-2075
TM 9-2320-366-20-3

m3. FIVE CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
(CONT)

KNOWN INFO TEST OPTIONS

5.
Front and rear air gages read Visual Inspection
120 PSI.
Are intermediate and rear REASON FOR QUESTION
CTIS manifold valve vent hose
axle CTIS quick release
and bulkhead fitting OK
valves free from exhausting If air exhausts from CTIS quick
Air hose and fittings OK.
air during inflation mode? release valve during inflation
Front axle CTIS quick
release valve OK. mode, CTIS quick release valve
is faulty.
POSSIBLE PROBLEMS
Faulty intermediate axle
CTIS quick release valve. NO
Faulty rear axle CTIS quick
release valve.
Faulty wheel valve.
Faulty front wheel kneeling Replace intermediate or
valve. YES rear axle CTIS quick release
Faulty wheel seals. valve (para 12-9).
Faulty electrical system.

2-2076 Change 2
 TM 9-2320-366-20-3

(1) Start engine (TM 9-2320-366-10-1).

(2) Select CTIS inflation mode
(TM 9-2320-366-10-1).
(3) Check for air escaping from intermediate
and rear axle CTIS quick release valves
during inflation mode. (Intermediate CTIS
quick release valve shown.)
(4) If air is escaping from intermediate or
rear axle CTIS quick release valve
during inflation mode, replace affected
CTIS quick release valve (para 12-9).
(5) Shut down engine (TM 9-2320-366-10-1).

Change 1 2-2077
TM 9-2320-366-20-3

m3. FIVE CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
(CONT)

KNOWN INFO TEST OPTIONS

6.
Front and rear air gages read Visual Inspection
120 PSI. Are CTIS wheel valves and
CTIS manifold valve vent hose REASON FOR QUESTION
front wheel kneeling valves
and bulkhead fitting OK. free from leaks and Leaks at wheel valves and
Air hose and fittings OK. damage? front wheel kneeling valve(s)
Front axle CTIS quick
that cause rapid tire deflation
release valves OK.
will make five CTIS ECU
Intermediate axle CTIS
mode lights flash.
quick release valve OK.
Rear axle CTIS quick
release valve OK. NO
POSSIBLE PROBLEMS

Faulty wheel valve.

Faulty front wheel kneeling
Replace kneeling valve(s)
valve. YES
or wheel valve(s) (para 12-5).
Faulty wheel seals.
Faulty electrical system.

2-2078 Change 2
 TM 9-2320-366-20-3

(1) Start engine (TM 9-2320-366-10-1).

(2) Select CTIS inflation mode
(TM 9-2320-366-10-1).
(3) Listen for audible escape of air at
kneeling valve (front wheels only)
and CTIS wheel valves on each wheel.
(4) If audible escape of air is present,
replace wheel kneeling valve(s) or
wheel valve(s) (para 12-5).
(5) Shut down engine (TM 9-2320-366-10-1).

All data on pages 2-2080 through 2-2101,

including pages 2-2081 through 2-2100 deleted. Change 1 2-2079/(2-2080 Blank)
TM 9-2320-366-20-3

m3. FIVE CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATOR LIGHTS FLASHING
(CONT)

KNOWN INFO TEST OPTIONS

7.
Front and rear air gages read Visual Inspection
120 PSI. Are wheel seals free from
REASON FOR QUESTION
CTIS manifold valve vent hose major leaks?
and bulkhead fitting OK. Seriously damaged wheel
Air hose and fittings OK. seals will audibly exhaust
Front axle CTIS quick air and cause CTIS to
release valves OK. shutdown with five CTIS
Intermediate axle CTIS ECU mode lights flashing.
quick release valve OK.
Rear axle CTIS quick
release valve OK. NO
Wheel valves OK.
Front wheel kneeling
valves OK.

POSSIBLE PROBLEMS Replace wheel seals

YES
(para 12-2).
Faulty wheel seals.
Faulty electrical system.

Go to Electrical System Troubleshooting

(e85. Central Tire Inflation System (CTIS)
Does Not Operate).

(2-2101 Blank)/2-2102 Change 2

 TM 9-2320-366-20-3

(1) Move vehicle until hub plug on wheel is

in 12 o'clock position.
(2) Remove wheel hub plug.
(3) Start engine (TM 9-2320-366-10-1).
(4) Select CTIS inflation mode
(TM 9-2320-366-10-1).
(5) Listen at wheel hub for audible
escape of air.
(6) If audible escape of air is present,
replace wheel seal (para 12-2).
(7) Install wheel hub plug.
(8) Perform steps 1 through 5 on remaining
wheels.
(9) If no air is audibly present from wheel
hub, Go to Electrical System
Troubleshooting (e85. Central Tire
Inflation System (CTIS) Does Not Operate).
(10) Shut down engine (TM 9-2320-366-10-1).

Change 1 2-2103
TM 9-2320-366-20-3

m4. CENTRAL TIRE INFLATION SYSTEM (CTIS) REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER
INDICATOR LIGHTS STOP FLASHING
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Materials/Parts Gage, Tire Pressure (Item 11, Appendix C)
Soap, Laundry (Item 63, Appendix D) Pan, Wash (Item 25, Appendix C)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Front and rear pressure on following page. Tire Pressure Measurement
gages read 120 psi. REASON FOR QUESTION
CTIS system operates Are front tires Low tire pressure caused by
OK. losing pressure? leaking kneeling valve(s)
POSSIBLE PROBLEMS (front tires only), damaged
Faulty kneeling valve(s). tire(s) or CTIS wheel valve(s)
Faulty tire(s). may cause system to
Faulty wheel valve(s). recycle.
Faulty air hose(s) from
quick release valve to
NO
affected wheel(s).
Faulty quick release
valve(s).

Go to step 3 of this fault.

YES

2-2104
 TM 9-2320-366-20-3

WARNING

Wear appropriate eye protection

when working under vehicle and
around CTIS system due to the
possibility of falling and/or
blown debris. Failure to comply
may result in injury to personnel.

NOTE
CTIS ECU checks tire pressure 30
seconds after completing a
pressure change sequence. If tire
pressures are the same, system
reverts to checking pressure every
15 minutes. If tires are losing
pressure, ECU inflates tires and
checks pressure again in 30
seconds. If CTIS has to repeat this
process more than 10 times, ECU
will display four flashing lights.

(1) Measure and record the tire pressure of

each tire (TM 9-2320-366-10-1).
(2) If front tire(s) have lower pressure than the
rest, kneeling valve, tire or CTIS wheel valve
is faulty.
(3) If rear tire(s) have lower pressure than the
rest, tire or CTIS wheel valve is faulty.

2-2105
TM 9-2320-366-20-3

m4. CENTRAL TIRE INFLATION SYSTEM (CTIS) REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER
INDICATOR LIGHTS STOP FLASHING (CONT)

KNOWN INFO TEST OPTIONS

2.
Front and rear pressure Soapy Water Leak Test
gages read 120 psi. REASON FOR QUESTION
Is kneeling valve on
CTIS system operates OK. A leaking kneeling valve
affected wheel(s)
POSSIBLE PROBLEMS can cause tire to loose
free from leaks?
Faulty kneeling valve(s). air pressure and CTIS
Faulty tire(s). system may repeat
Faulty wheel valve(s). inflation sequence.
Faulty air hose(s) from NO
quick release valve to
affected wheel(s).
Faulty quick release
Clean and tighten or replace kneeling valve
valve(s).
(para 12-5).

YES

KNOWN INFO TEST OPTIONS

3.
Front and rear pressure Soapy Water Leak Test
gages read 120 psi. REASON FOR QUESTION
CTIS system operates OK. Are tires free from A leaking tire can cause CTIS
Kneeling valve(s) OK. leaks or damage? system to detect a pressure
POSSIBLE PROBLEMS loss and repeat inflation
Faulty tire(s). sequence.
Faulty wheel valve(s).
Faulty air hose(s) from
NO
quick release valve to
affected wheel(s).
Faulty quick release
valve(s). Repair tire(s) (para 12-2) or replace tire(s)
(TM 9-2320-366-10).

YES

2-2106
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Check kneeling valve is tight and secure in valve

seat.
(2) Apply soapy water to valve and check for leaks.

SOAPY WATER LEAK TEST

(1) Visually inspect tire for damage.

(2) Apply soapy water solution to tire bead.
(3) Observe tire for bubbles indicating leaks.

2-2107
TM 9-2320-366-20-3

m4. CENTRAL TIRE INFLATION SYSTEM (CTIS) REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER
INDICATOR LIGHTS STOP FLASHING (CONT)

KNOWN INFO TEST OPTIONS

4.
Front and rear pressure Soapy Water Leak Test
gages read 120 psi. Are CTIS wheel valves REASON FOR QUESTION
CTIS system operates OK. free from leaks and If CTIS wheel valves are
Kneeling valve(s) OK. damage at affected leaking, CTIS ECU may
Tire(s) OK. wheel(s)? detect loss of pressure
POSSIBLE PROBLEMS on system and repeat
Faulty wheel valve(s). inflation sequence.
Faulty air hose(s) from
quick release valve to
affected wheel(s).
NO
Faulty quick release
valve(s).

Replace wheel valve

(para 12-5).

YES

KNOWN INFO TEST OPTIONS

5.
Front and rear pressure Visual inspection
gages read 120 psi. Are air lines between affected REASON FOR QUESTION
CTIS system operates OK. wheel(s) and quick release If air line(s) between wheel(s)
Kneeling valve(s) OK. valve(s) free from folds or and quick release valves are
Tire(s) OK. constrictions? constricted, wheel valve(s)
Wheel valve(s) OK. may not close immediately
POSSIBLE PROBLEMS and tires will lose air, causing
Faulty air hose(s) from CTIS to recycle.
quick release valve to
affected wheel(s).
NO
Faulty quick release
valve(s).

Replace damaged air

lines (para 23-2).

YES

Replace faulty quick release valve(s)

(para 12-8 and/or 12-9).

2-2108
 TM 9-2320-366-20-3

SOAPY WATER LEAK TEST

(1) Apply soapy water solution to CTIS fittings on

outside of wheel.
(2) Observe fittings for bubbles indicating leaks.
(3) With wheel valve still connected to tire,
disconnect wheel valve air supply line from hub
at banjo bolt.
(4) Place open end of air supply line in container of
water. Look for air bubbles.
(5) Persistent bubbles from air line indicate faulty
wheel valve.
(6) Connect wheel valve to hub at banjo bolt.

NOTE
If air line from quick release valve
to affected wheel is partially
obstructed, air line to wheel cannot
escape back to quick release valve
immediately after tire is pressurized
causing wheel valve to remain
partially open and tire to lose
pressure. System will cycle again
when low pressure is checked after
30 seconds.

(1) Check air supply line(s) from quick release

valve(s) to affected wheel(s) for constrictions.
See illustration for fitting and quick release
valve locations.
(2) If air supply line is not constricted, quick
release valve for affected wheel is faulty.

2-2109
TM 9-2320-366-20-3

m5. CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATES NO FAULT CODE BUT SYSTEM
FAILS TO INFLATE OR DEFLATE
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Wash (Item 25, Appendix C)
Materials/Parts Goggles, Industrial (Item 15, Appendix C)
Soap, Laundry (Item 63, Appendix D)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Front and rear air Visual Inspection
gages read 120 psi. REASON FOR QUESTION
Is CTIS air hoses and
POSSIBLE PROBLEMS
fittings free from air leaks If air is leaking during inflation
Leaking air hoses or fittings. during inflation mode? mode, CTIS air hose(s) and/or
Faulty pressure protection fittings are faulty.
valve.
Faulty main air supply hose.
Faulty CTIS manifold input
hose.
Faulty electrical system. NO

Replace air hose(s) and/or

YES
fittings (para 23-2).

2-2110 Change 1
 TM 9-2320-366-20-3

WARNING

Wear appropriate eye protection when working

under vehicle due to the possibility of falling
debris. Failure to comply may result in injury
to personnel.

(1) Start engine (TM 9-2320-366-10-1).

(2) Set CTIS ECU to RUN FLAT mode
(TM 9-2320-366-10-1).
(3) Apply soapy water solution to CTIS air
hoses and fittings (Table 23-2 Central
Tire Inflation System (CTIS) Air Hose
Locations).
(4) Check for soap bubbles indicating leaks.
(5) If any leaks are found, replace CTIS air
hose and/or fittings (para 23-2).
(6) Shut down engine (TM 9-2320-366-10-1).

Change 1 2-2111
TM 9-2320-366-20-3

m5. CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATES NO FAULT CODE BUT SYSTEM
FAILS TO INFLATE OR DEFLATE (CONT)

KNOWN INFO TEST OPTIONS

2.
Front and rear air Visual Inspection
gages read 120 psi. REASON FOR QUESTION
Are air transportability
POSSIBLE PROBLEMS
air hoses and fittings If air is leaking from air
Leaking air hoses or fittings. free from leaks? transportability air hose(s)
Faulty pressure protection and/or fittings, air hose(s)
valve. and/or fittings are faulty.
Faulty main air supply hose.
Faulty CTIS manifold input
hose.
Faulty electrical system. NO

Replace air hose(s) and/or

YES
fittings (para 23-3).

2-2112 Change 1
 TM 9-2320-366-20-3

(1) Start engine (TM 9-2320-366-10-1).

(2) Apply soapy water solution to air
transportability air hoses and fittings
(Table 23-3. Air Transportability Air Hose
Locations).
(3) Check for soap bubbles indicating leaks.
(4) If any leaks are found, replace air
transportability air hose and/or fittings
(para 23-3).
(5) Shut down engine (TM 9-2320-366-10-1).

Change 1 2-2113
TM 9-2320-366-20-3

m5. CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATES NO FAULT CODE BUT SYSTEM
FAILS TO INFLATE OR DEFLATE (CONT)

KNOWN INFO TEST OPTIONS

3.
Front and rear air Visual Inspection
gages read 120 psi. REASON FOR QUESTION
Air hoses and fittings Is air present from
free from leaks. pressure protection If air is not present from
valve? pressure protection valve,
POSSIBLE PROBLEMS
pressure protection valve
Faulty pressure protection is faulty.
valve.
Faulty main air supply hose.
Faulty CTIS manifold input
hose. NO
Faulty electrical system.

Replace pressure
YES
protection valve (para 11-29).

2-2114 Change 1
 TM 9-2320-366-20-3

(1) Disconnect main air supply hose

from pressure protection valve.
(2) Start engine (TM 9-2320-366-10-1).
(3) If air is not present from pressure
protection valve, replace pressure
protection valve (para 11-29).
(4) Shut down engine (TM 9-2320-366-10-1).
(5) Connect main air supply hose to
pressure protection valve.

Change 1 2-2115
TM 9-2320-366-20-3

m5. CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATES NO FAULT CODE BUT SYSTEM
FAILS TO INFLATE OR DEFLATE (CONT)

KNOWN INFO TEST OPTIONS

4.
Front and rear air Visual Inspection
gages read 120 psi. REASON FOR QUESTION
Is air present from
Air hoses and fittings
main air supply hose? If air is not present from
free from leaks.
Pressure protection valve OK. main air supply hose, main
air supply hose is faulty.
POSSIBLE PROBLEMS
Faulty main air supply hose.
Faulty CTIS manifold input
hose.
Faulty electrical system. NO

Replace main air supply

YES
hose (para 23-2).

2-2116 Change 1
 TM 9-2320-366-20-3

(1) Remove kick panel (para 16-3).

(2) Disconnect CTIS manifold input hose
from cab bulkhead fitting.
(3) Start engine (TM 9-2320-366-10-1).
(4) If air is not present from cab bulkhead
fitting, replace main air supply hose
(para 23-2).
(5) Shut down engine (TM 9-2320-366-10-1).
(6) Connect CTIS manifold input hose to cab
bulkhead fitting.

All data on pages 2-2118 and 2-2119 deleted. Change 1 2-2117/(2-2118 Blank)
TM 9-2320-366-20-3

m5. CENTRAL TIRE INFLATION SYSTEM (CTIS) ECU INDICATES NO FAULT CODE BUT SYSTEM
FAILS TO INFLATE OR DEFLATE (CONT)

KNOWN INFO TEST OPTIONS

5.
Front and rear air gages read Visual Inspection
120 psi. REASON FOR QUESTION
Is air present from CTIS
Air hoses and fittings free
manifold input hose? If air is not present from
from leaks.
Pressure protection valve OK. CTIS manifold input hose,
Main air supply hose OK. CTIS manifold input hose
is faulty.
POSSIBLE PROBLEMS

Faulty CTIS manifold input

hose.
NO
Faulty electrical system.

Replace CTIS manifold

YES
input hose (para 23-2).

Go to Electrical System Troubleshooting

(e85. Central Tire Inflation System (CTIS)
Does Not Operate).

(2-2119 Blank)/2-2120 Change 1

 TM 9-2320-366-20-3

(1) Disconnect CTIS manifold input hose

from CTIS manifold valve.
(2) Start engine (TM 9-2320-366-10-1).
(3) If air is not present from CTIS manifold
input hose, replace CTIS manifold
input hose (para 23-2).
(4) If air is present from CTIS manifold
input hose go to Electrical Troubleshooting
(e85. Central Tire Inflation System (CTIS)
Does Not Operate).
(5) Shut down engine (TM 9-2320-366-10-1).
(6) Connect CTIS manifold input hose to
CTIS manifold valve.
(7) Install kick panel (para 16-3).

Change 1 2-2121
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine running (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Multimeter, Digital (Item 22, Appendix C)
Personnel Required Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
(2) Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)
STE/ICE-R (Item 41, Appendix C)
References
TM 9-4910-571-12&P

START

KNOWN INFO TEST OPTIONS

1.
Circuit breakers OK. Visual inspection
Power supplied to CTIS. Do overspeed warning REASON FOR QUESTION
Speedometer OK. light and overspeed If ECU does not receive a
Indicator display lights OK. pressure change bolts speed signal it cannot
POSSIBLE PROBLEMS fail to operate? activate the overspeed
Faulty CTIS cable-speed protection system.
signal.
Faulty cab dashboard
wiring harness - speed NO
signal.
Faulty cab dashboard
wiring harness - LED input
to CTIS cable.
Go to step 6 of this fault.
Faulty CTIS cable - LED
YES
input to ECU.
Faulty ECU - O.S pressure
change function.
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2122
 TM 9-2320-366-20-3

(1) Select X-C mode at CTIS ECU

(TM 9-2320-366-10-1).
(2) Turn on headlights (TM 9-2320-366-10-1).
(3) Perform road test.
(4) Increase speed to 40 mph.
(5) Check if overspeed warning light flashes.
(6) After about one minute, check if overspeed
pressure change is activated to raise tire pressure
to HWY mode.
(7) If both functions fail to activate, speed signal to
ECU is faulty or ECU may be faulty.
(8) Shut down engine (TM 9-2320-366-10-1).

2-2123
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

2.
Circuit breakers OK. Continuity Test or
Power supplied to CTIS. STE/ICE-R Test #91
Speedometer OK. Is continuity present REASON FOR QUESTION
Indicator display lights OK. from P110U to P111B? CTIS overspeed warning
POSSIBLE PROBLEMS light and overspeed
Faulty CTIS cable-speed pressure change will not
signal. operate if CTIS ECU does
Faulty cab dashboard not receive speed signal
wiring harness - speed NO through CTIS cable
signal. assembly.
Faulty cab dashboard
wiring harness - LED input
Repair wire 1528 (para 2-45)
to CTIS cable.
or replace CTIS cable
Faulty CTIS cable - LED
YES assembly (para 7-60).
input to ECU.
Faulty ECU - O.S pressure
change function.
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2124
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove kick panel (para 16-3).
(2) Disconnect connector P110 from CTIS ECU.
(3) Disconnect connector P111 from connector
J111.
(4) Set multimeter to ohms.
(5) Connect positive (+) probe of multimeter to
connector P110U.
(6) Connect negative (-) probe of multimeter to
connector P111B and note reading on
multimeter.
(7) If continuity is not present, repair wire 1528
(para 2-45) or replace CTIS cable assembly
(para 7-60).

2-2125
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

3.
Circuit breakers OK. Continuity Test or
Power supplied to CTIS. STE/ICE-R Test #91
Speedometer OK. Is continuity present REASON FOR QUESTION
Indicator display lights OK. from J111B to PX8-4? CTIS overspeed warning
CTIS cable-speed signal light and overspeed
OK. pressure change will not
POSSIBLE PROBLEMS operate if CTIS ECU does
Faulty cab dashboard not receive speed signal
wiring harness - speed NO through cab dashboard
signal. wiring harness.
Faulty cab dashboard
wiring harness - LED input Repair wire 1793 (para 2-45)
to CTIS cable. or replace WTEC II dashboard cable
Faulty CTIS cable - LED assembly (para 7-10) or WTEC III
YES
input to ECU. dashboard cable assembly (para 7-11).
Faulty ECU - O.S pressure
change function.
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2126
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove instrument panel assembly for access
(para 7-15).
(2) Disconnect connector clamp from speedometer
connector.
(3) Disconnect connector PX8 from speedometer.
(4) Set multimeter to ohms position.
(5) Connect positive (+) probe of multimeter to
connector J111B.
(6) Connect negative (-) probe of multimeter to
connector PX8-4 and note reading on
multimeter.
(7) If continuity is not present, repair wire 1793
(para 2-45) or replace WTEC II dashboard
cable assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).
(8) Connect connector PX8 to speedometer.
(9) Connect connector clamp to speedometer
connector.
(10) Install instrument panel assembly (para 7-15).

2-2127
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
4.
Circuit breakers OK. on following page. Voltage Test or
Power supplied to CTIS. STE/ICE-R Test #89
Is 24 vdc present on P111D
Speedometer OK. REASON FOR QUESTION
power input to CTIS
Indicator display lights OK. CTIS overspeed indicator
harness for warning light?
CTIS cable-speed signal will not work without 24
OK. vdc to P111D.
Cab dashboard wiring
harness - speed signal OK.
POSSIBLE PROBLEMS NO
Faulty cab dashboard
wiring harness - LED input
to CTIS cable. Repair wire 1793 (para 2-45)
Faulty CTIS cable - LED or replace WTEC II dashboard cable
input to ECU. assembly (para 7-10) or WTEC III
YES
Faulty ECU - O.S pressure dashboard cable assembly (para 7-11).
change function.
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2128
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches,

necklaces, and any other jewelry
before working around vehicle.
Jewelry can catch on equipment
and cause injury or short across
electrical circuit and cause severe
burns or electrical shock.

VOLTAGE TEST
(1) Position master power switch to on
(TM 9-2320-366-10-1).
(2) Connect positive (+) probe of multimeter to
connector P111D.
(3) Connect negative (-) probe of multimeter to
ground and note reading on multimeter.
(4) If 24 vdc is not present, repair wire 1793
(para 2-45) or replace WTEC II dashboard
cable assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).
(5) Position master power switch to off
(TM 9-2320-366-10-1).
(6) Connect connector P111 to connector J111.

2-2129
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
5.
Circuit breaker OK. on following page. Voltage Test or
Power supplied to CTIS. STE/ICE-R Test #89
Is 24 vdc present on P110E
Speedometer OK. REASON FOR QUESTION
power input to ECU for
Indicator display lights OK. CTIS overspeed indicator
warning light?
CTIS cable-speed signal will not work without 24
OK. vdc to P110E.
Cab dashboard wiring
harness - speed signal OK.
Cab dashboard wiring NO
harness - LED input to
CTIS cable OK.
POSSIBLE PROBLEMS
Faulty CTIS cable - LED
Go to step 9 of this fault.
input to ECU.
YES
Faulty ECU - O.S pressure
change function.
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

Replace CTIS ECU

(para 12-6).

2-2130
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches,

necklaces, and any other jewelry
before working around vehicle.
Jewelry can catch on equipment
and cause injury or short across
electrical circuit and cause severe
burns or electrical shock.
VOLTAGE TEST
(1) Position master power switch to on
(TM 9-2320-366-10-1).
(2) Connect positive (+) probe of multimeter to
connector P110E.
(3) Connect negative (-) probe of multimeter to
ground and note reading on multimeter.
(4) If 24 vdc is not present, CTIS wiring harness is
faulty.
(5) If 24 vdc is present, replace CTIS ECU
(para 12-6).
(6) Position master power switch to off
(TM 9-2320-366-10-1).
(7) Connect connector P110 to CTIS ECU.

2-2131
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

6.
Circuit breaker OK. Visual inspection
Power supplied to CTIS. REASON FOR QUESTION
Was the overspeed light
Speedometer OK. If overspeed warning light
the function that failed
Indicator display lights OK. failed, warning lamp or
during road test?
CTIS cable-speed signal warning lamp circuit may
OK. be faulty.
Cab dashboard wiring
harness - speed signal OK.
Cab dashboard wiring NO
harness - LED input to
CTIS cable OK.
CTIS cable - LED input
to ECU OK.
Replace CTIS ECU
POSSIBLE PROBLEMS
YES (para 12-6).
Faulty ECU - O.S pressure
change function.
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2132
 TM 9-2320-366-20-3

(1) If overspeed warning light failed on road test

while overspeed pressure change occurred;
(a) Warning lamp may be faulty.
(b) Wiring from ECU to lamp or lamp to ground
may be faulty.
(c) ECU may be faulty.
(2) If overspeed warning light flashed on road test
while overspeed pressure change did not occur,
ECU has received a good speed signal but has
not translated the signal into an overspeed
inflation, replace CTIS ECU (para 12-6).

2-2133
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

7.
Circuit breaker OK. Continuity Test or
Power supplied to CTIS. STE/ICE-R Test #91
Is continuity verified on
Speedometer OK. REASON FOR QUESTION
indicator display lights
Indicator display lights OK. CTIS overspeed indicator
socket 9 to socket 17?
CTIS cable-speed signal will not work if continuity
OK. is not present from indicator
Cab dashboard wiring display lights socket 9 to
harness - speed signal OK. socket 17.
Cab dashboard wiring NO
harness - LED input to
CTIS cable OK.
CTIS cable - LED input
to ECU OK.
Replace lighted indicator
ECU - O.S. pressure
YES display (para 7-16).
change function OK.
POSSIBLE PROBLEMS
Faulty overspeed indicator
LED.
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2134
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove four screws from lighted indicator
display.
(2) Remove lighted indicator display from
instrument panel assembly.
(3) Disconnect connector PX7 from lighted
indicator display.
(4) Set multimeter to ohms.
(5) Connect positive (+) probe of multimeter to
lighted indicator display terminal 17.
(6) Connect negative (-) probe of multimeter to
lighted indicator terminal 9 and note reading on
multimeter.
(7) If continuity is not present, replace lighted
indicator display (para 7-16).

2-2135
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

8.
Continuity Test or
Circuit breaker OK.
STE/ICE-R Test #91
Power supplied to CTIS.
Is continuity present from REASON FOR QUESTION
Speedometer OK.
PX7-17 to ground? CTIS overspeed indicator
Indicator display lights OK.
requires continuity from
CTIS cable-speed signal
PX7-17 to ground.
OK.
Cab dashboard wiring
harness - speed signal OK.
NO
Cab dashboard wiring
harness - LED input to
CTIS cable OK.
CTIS cable - LED input Repair wire 3130 (para 2-45)
to ECU OK. or replace WTEC II dashboard cable
ECU - O.S. pressure YES assembly (para 7-10) or WTEC III
change function OK. dashboard cable assembly (para 7-11).
Overspeed indicator
LED OK.

POSSIBLE PROBLEMS
Faulty cab dashboard
wiring harness - ground
for LED.
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2136
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
connector PX7-17.
(3) Connect negative (-) probe of multimeter to
ground and note reading on multimeter.
(4) If continuity is not present, repair wire 3130
(para 2-45) or replace WTEC II dashboard
cable assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).

2-2137
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

9.
Circuit breaker OK. Continuity Test or
Power supplied to CTIS. STE/ICE-R Test #91
Speedometer OK. Is continuity present from REASON FOR QUESTION
Indicator display lights OK. J111D to PX7-9? CTIS overspeed indicator
CTIS cable-speed signal requires continuity from
OK. J111D to PX7-9.
Cab dashboard wiring
harness - speed signal OK.
Cab dashboard wiring NO
harness - LED input to
CTIS cable OK.
CTIS cable - LED input
Repair wire 1528 (para 2-45)
to ECU OK.
or replace WTEC II dashboard cable
ECU - O.S. pressure
YES assembly (para 7-10) or WTEC III
change function OK.
dashboard cable assembly (para 7-11).
Overspeed indicator
LED OK.
Cab dashboard wiring
harness - ground for
LED OK.
POSSIBLE PROBLEMS
Faulty cab dashboard
wiring harness - power
to LED.
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

2-2138
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
connector PX7-9.
(3) Connect negative (-) probe of multimeter to
connector J111D and note reading on multimeter.
(4) If continuity is not present, repair wire 1528
(para 2-45) or replace WTEC II dashboard
cable assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).
(5) Connect lighted indicator display to connector
PX7.
(6) Position lighted indicator display in instrument
panel assembly with four screws.
(7) Tighten four screws to 6-10 lb-in. (1 N·m).

2-2139
TM 9-2320-366-20-3

m6. CTIS OVERSPEED WARNING LIGHT DOES NOT ILLUMINATE AND/OR OVERSPEED PRESSURE CHANGE
(CONT)

KNOWN INFO TEST OPTIONS

10.
Circuit breaker OK. Continuity Test or
Power supplied to CTIS. STE/ICE-R Test #91
Speedometer OK. Is continuity present from REASON FOR QUESTION
Indicator display lights OK. P111D to P110E? CTIS overspeed indicator
CTIS cable-speed signal requires continuity from
OK. P111D to P110E.
Cab dashboard wiring
harness - speed signal OK.
Cab dashboard wiring NO
harness - LED input to
CTIS cable OK.
CTIS cable - LED input
to ECU OK. Repair wire 1528 (para 2-45)
ECU - O.S. pressure or replace CTIS cable
YES
change function OK. assembly (para 7-60).
Overspeed indicator
LED OK.
Cab dashboard wiring
harness - ground for
LED OK.
Cab dashboard wiring
harness - power to LED OK.
POSSIBLE PROBLEMS
Faulty CTIS cable power
to LED.
Faulty ECU - O.S. warning
indicator function.

Replace CTIS ECU

(para 12-6).

2-2140
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Disconnect connector P110 from CTIS ECU.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
connector P111D.
(4) Connect negative (-) probe of multimeter to
connector P110E and note reading on
multimeter.
(5) If continuity is not present, repair wire 1528
(para 2-45) or replace CTIS cable assembly
(para 7-60).
(6) If continuity is present, replace CTIS ECU
(para 12-6).
(7) Connect connector P110 to CTIS ECU.
(8) Connect connector P111 to connector J111.
(9) Install kick panel (para 16-3).

2-2141/(2-2142 Blank)
 TM 9-2320-366-20-3

2-25. AXLE TROUBLESHOOTING

This paragraph covers Axle Troubleshooting. The Axle Fault Index, Table 2-53, lists faults for the axles of the vehicle.

Table 2-53. Axle Fault Index

Fault No. Description Page

n1. Axle Differential(s) Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2144

2-2143
TM 9-2320-366-20-3

n1. AXLE DIFFERENTIAL(S) NOISY

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Nothing Visual inspection
Are planetary wheel ends,
POSSIBLE PROBLEMS REASON FOR QUESTION
and wheel bearings free
Leaking planetary wheel ends from leaks? Leaks may indicate worn
and/or wheel bearings. or damaged seals and cause
Leaking axle differential and/or planetary wheel ends or wheel
pinion drive yoke. bearings to make noise.
Damaged axle differential.
Low or contaminated oil in
differential.
Faulty pinion drive yoke. NO

YES Replace seal (para 10-2).

KNOWN INFO TEST OPTIONS

2.
No visible leaks of planetary Visual inspection
wheel ends or wheel bearings. Are axle differentials and
REASON FOR QUESTION
pinion drive yoke free
POSSIBLE PROBLEMS
from leaks? Leaks may indicate worn
Leaking axle differential and/or or damaged seals and cause
pinion drive yoke. axle differential or pinion drive
Damaged axle differential. yoke to make noise.
Low or contaminated oil in
differential.
Faulty pinion drive yoke.
NO

YES Notify DS Maintenance.

2-2144 Change 1
 TM 9-2320-366-20-3

WARNING

Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may result
in injury to personnel.

(1) Check planetary wheel ends for leaks

(para 10-2).
(2) Check wheel bearings for leaks (para 10-2).
(3) If leaks are found replace seal(s)
(para 10-2).

(1) Check differential and pinion drive yoke seal for

leaks.
(2) If leaks are found, notify unit maintenance.

Change 1 2-2145
TM 9-2320-366-20-3

n1. AXLE DIFFERENTIAL(S) NOISY (CONT)

KNOWN INFO TEST OPTIONS

3.
No visible leaks of planetary Visual inspection
wheel ends or wheel bearings. Are the axle differentials
REASON FOR QUESTION
No visible leaks of axle free from damage?
differential or pinion drive Axle differential(s) may be
yoke. unusually noisy when operating
if damaged.
POSSIBLE PROBLEMS

Damaged axle differential. NO

Low or contaminated oil in
axle differential.
Faulty pinion drive yoke.

YES Notify DS Maintenance.

KNOWN INFO TEST OPTIONS

4.
No visible leaks of planetary Visual inspection
wheel ends or wheel bearings.
Is the axle differential oil at
No visible leaks of axle REASON FOR QUESTION
proper level and free of
differential or pinion drive
contamination? Low oil level will cause axle
yoke.
Axle differential(s) free from differential(s) to make unusual
damage. noises and lead to damage.

POSSIBLE PROBLEMS

Low or contaminated oil in NO

axle differential.
Faulty pinion drive yoke.

YES Add/change oil (Appendix H).

2-2146 Change 1
 TM 9-2320-366-20-3

(1) Check input and output shafts for leaks

and damage.
(2) Check axle differential for loose, missing,
or damaged hardware.
(3) If axle differential is damaged, Notify DS
Maintenance.
(4) Check drive shaft and bearing caps for
looseness.
(5) If drive shaft is loose, perform Drive Shaft
Troubleshooting (para 2-18).

(1) Check oil level according to (Appendix H).

(2) Remove axle differential fill plug.
(3) Insert finger into axle differential to check
oil level.
(4) Remove axle differential drain plug.
(5) Allow differential oil to drain into pan.
(6) Check oil for contamination. If metal chips
are present, notify DS Maintenance.
(7) Install axle differential drain plug.
(8) Fill axle differential with oil (Appendix H).
(9) Install axle differential fill plug.

Change 1 2-2147
TM 9-2320-366-20-3

n1. AXLE DIFFERENTIAL(S) NOISY (CONT)

KNOWN INFO TEST OPTIONS

5.
No visible leaks of planetary Visual inspection
wheel ends or wheel bearings. Is pinion drive yoke secure
No visible leaks of axle REASON FOR QUESTION
and free from damage?
differential or pinion drive
yoke. A loose or damaged pinion
Axle differential(s) free from drive yoke may cause axle
damage. differential(s) to be unusually
Axle differential oil OK. noisy when operating.

POSSIBLE PROBLEMS
NO
Faulty pinion drive yoke.

YES Notify DS Maintenance.

Notify DS Maintenance.

2-2148 Change 1
 TM 9-2320-366-20-3

(1) Check pinion drive yoke for looseness by

attempting to rotate pinion drive yoke in both
directions and listening for unusual backlash
noise.
(2) If pinion drive yoke is damaged, notify DS
Maintenance.
(3) If pinion drive yoke is not damaged, notify
DS Maintenance.

Change 1 2-2149/(2-2150 Blank)

 TM 9-2320-366-20-3

2-26. STEERING TROUBLESHOOTING

This paragraph covers Steering Troubleshooting. The Steering Fault Index, Table 2-54, lists faults for the Steering of
the vehicle.

Table 2-54. Steering Fault Index

Fault No. Description Page

p1. Hard to Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2152

p2. Wanders, Pulls to One Side, or Shimmies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2158
p3. Excessive Play When Turning Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2164
p4. No Response When Turning Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2168

2-2151
TM 9-2320-366-20-3

p1. HARD TO STEER

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine running (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

Personnel Required Materials/Parts

(2) Locknut (Item 68, Appendix G)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Tires OK. on following page. Visual inspection
Steering oil level OK. REASON FOR QUESTION
Are reservior components
POSSIBLE PROBLEMS Vehicle may steer hard
and steering pump hoses
Damaged power steering if oil lines are leaking,
and fittings free from leaks,
pump hoses or fittings. kinked, or damaged.
kinks and damage?
Faulty air compressor.
Faulty power steering pump.
Faulty steering gear
Replace damaged oil
assembly.
NO hose(s) and fitting(s)
Faulty steering shaft and
(para 13-7).
tie rod.
Faulty pitman arm and
YES
drag link.

KNOWN INFO TEST OPTIONS

2.
Tires OK. Visual inspection
Steering level oil OK. Is air compressor secure, REASON FOR QUESTION
Power steering pump free from damage and Vehicle may steer hard
hoses and fittings OK. noisy operation? if air compressor is not
POSSIBLE PROBLEMS secure and is damaged or
Faulty air compressor. noisy or does not rotate.
Faulty power steering pump.
Faulty steering gear NO
assembly.
Faulty steering shaft and
tie rod. YES Tighten hardware if loose.
Faulty pitman arm and Notify DS maintenance
drag link. of damaged air compressor.

2-2152
 TM 9-2320-366-20-3

WARNING

Engine compartment
and its components may
be hot to the touch. Extreme
care should be taken when
checking for leaks in the
engine compartment. Failure
to comply may result in burns
or injury to personnel.

Engine compartment
includes a partially
covered fan blade. Extreme
care should be taken when
working in the engine
compartment. Failure to
comply may cause injury to
personnel.

NOTE

Refer to steering hydraulic

hose schematic for steering
hose locations.

Check reservoir components and steering hoses

and fittings for leakage, kinks and damage.

Check air compressor for loose or missing mounting

hardware, damage and noisy operation and rotation.

2-2153
TM 9-2320-366-20-3

p1. HARD TO STEER (CONT)

KNOWN INFO TEST OPTIONS

3.
Tires OK. Visual inspection
Steering oil level OK. Steering Shaft/Tie Rod Test
Power steering pump oil Is steering shaft and REASON FOR QUESTION
hoses and fittings OK. tie rod properly Vehicle may steer hard
Air compressor OK. lubricated, secure, if steering shaft or tie
Power steering pump OK. and free from damage? rod is loose, damaged,
Steering gear assembly OK. or requires lubrication.
POSSIBLE PROBLEMS
Faulty steering shaft and
tie rod. NO
Faulty pitman arm and
drag link.

Lubricate tie rods (Appendix H).

Replace damaged tie rods (para 13-4).
Notify DS maintenance of damaged
steering shaft.

YES

KNOWN INFO TEST OPTIONS

4.
Tires OK. Visual inspection
Steering oil level OK. Pitman Arm/Drag Link Test
Is pitman arm and
Power steering pump oil REASON FOR QUESTION
drag link secure,
hoses and fittings OK. Vehicle may steer hard
and free from damage?
Air compressor OK. if pitman arm or drag link
Power steering pump OK. is loose or damaged.
Steering gear assembly OK.
Steering shaft and tie
rods OK.
POSSIBLE PROBLEMS NO
Faulty pitman arm and
drag link.
Tighten loose drag link.
Replace drag link (para 13-3).
Notify DS maintenance of
loose or damaged pitman
YES
arm.

2-2154
 TM 9-2320-366-20-3

Check steering shaft and tie rod for damage, and

loose or missing mounting hardware. Refer to
Appendix H to lubricate tie rods.

STEERING SHAFT/TIE ROD TEST

(1) Grasp steering shaft to ensure there is no up
and down play.
(2) Grasp tie rod to ensure there is no up and
down or left and right play.

Check pitman arm and drag link for damage, and

loose or missing mounting hardware.

PITMAN ARM/DRAG LINK TEST

(1) Check nut securing pitman arm to steering
gear assembly. Ensure there is no play.
(2) Grasp drag link and ensure there is no play
left and right or up and down.
(3) Check for loose bolts, nuts, and clamps on
drag link.

2-2155
TM 9-2320-366-20-3

p1. HARD TO STEER (CONT)

KNOWN INFO TEST OPTIONS

5.
Tires OK. Visual inspection
Steering oil level OK Is power steering pump free REASON FOR QUESTION
Power steering pump oil from leaks or damage and is Vehicle may be hard
hoses and fittings OK. required mounting hardware to steer if power steering
Air compressor OK. secure and free from damage? pump is leaking,
POSSIBLE PROBLEMS or mounting is loose
or damaged.
Faulty power steering pump.
Faulty steering gear
Tighten power steering pump and
assembly.
NO hoses. Notify DS maintenance of
Faulty steering shaft and
damaged power steering pump.
tie rod.
Faulty pitman arm and
drag link.

YES

KNOWN INFO TEST OPTIONS

6.
Tires OK. Steering Gear Assembly Test
Steering oil level OK. REASON FOR QUESTION
Does steering gear
Power steering pump oil Vehicle may steer hard
assembly output
hoses and fittings OK. if steering gear assembly
shaft turn freely
Air compressor OK. output shaft is binding.
by hand?
Power steering pump OK.
POSSIBLE PROBLEMS
Faulty steering gear
assembly.
Faulty steering shaft and
tie rod.
Faulty pitman arm and
drag link.

NO Notify DS Maintenance.

YES

Notify DS Maintenance.

2-2156
 TM 9-2320-366-20-3

Check power steering pump for leaks, and for loose,

missing, or damaged mounting hardware. Lower cab
(TM 9-2320-366-10-1). Shutdown engine (TM
9-2320-366-10-1). Raise cab (TM 9-2320-366-10-1).

NOTE

An alignment mark shall be marked

on yoke and steering gear assembly
to ensure ease during installation.

STEERING GEAR TEST

(1) Remove bolt and self-locking nut from lower
yoke of steering gear arm. Discard self-
locking nut.
(2) Remove yoke from top steering gear
assembly shaft.
(3) Remove drag link (para 13-3).
(4) Turn top steering gear assembly shaft to
check for binding and proper output.
Notify DS maintenance if steering gear
assembly fails to turn smoothly or if it
binds when top shaft is turned.
(5) Install drag link (para 13-3).
(6) Position yoke onto top steering gear
assembly shaft.
(7) Install belt and self-locking nut into yoke to
secure yoke to top steering gear assembly
shaft.

2-2157
TM 9-2320-366-20-3

p2. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Lugnuts OK. Visual inspection
Tires OK. Manual check
Is steering shaft
POSSIBLE PROBLEMS REASON FOR QUESTION
and tie rod properly
Faulty steering shaft and A steering shaft or tie rod
lubricated, secure,
tie rod. that is loose, damaged,
and free from
Faulty pitman arm and or requires lubrication may
damage?
drag link. cause vehicle to wander,
Faulty steering gear pull to one side, or
assembly. shimmy.
Brakes out of adjustment.
Faulty U-joints, splines Lubricate tie rods (Appendix H).
or yokes. Replace loose or damaged tie rods
NO
(para 13-4). Notify DS maintenance
of damaged steering shaft or U-joint.

YES

2-2158
 TM 9-2320-366-20-3

(1) Raise cab (TM 9-2320-366-10-1).

(2) Check steering shaft and tie rods for damage, and
loose or missing mounting hardware. Refer to
Appendix H to lubricate tie rods.
(3) Grasp the steering gear shaft and ensure there
is no up and down play.
(4) Grasp the tie rod and ensure there is no up and
down or sideways play.

2-2159
TM 9-2320-366-20-3

p2. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES (CONT)

KNOWN INFO TEST OPTIONS

2.
Lugnuts OK. Visual inspection
Tires OK. Manual check
Steering shaft and Is pitman arm and REASON FOR QUESTION
tie rod OK. drag link properly A pitman arm or drag link
U-joints, splines secure and free from that is loose, damaged,
and yoke OK. damage? may cause vehicle to
POSSIBLE PROBLEMS wander, pull to one side,
Faulty pitman arm and or shimmy.
drag link.
Faulty steering gear
assembly.
Brakes out of adjustment.
NO

Tighten loose drag link.

Replace drag link (para 13-3).
Notify DS maintenance of
loose or damaged pitman
arm.

YES

KNOWN INFO TEST OPTIONS

3.
Lugnuts OK. Visual inspection
Tires OK. Manual check
Is steering gear
Steering shaft and REASON FOR QUESTION
assembly free from
tie rod OK. Damaged steering gear
damage, and mounted
U-joints, splines assembly or mounting
securely?
and yokes OK. hardware may cause
Pitman arm and drag vehicle to wander, pull
link OK. to one side, or shimmy.
NO
POSSIBLE PROBLEMS
Faulty steering gear
assembly. YES
Brakes out of adjustment. Notify DS Maintenance.

2-2160
 TM 9-2320-366-20-3

(1) Check pitman arm and drag link for damage, and
loose or missing mounting hardware.
(2) Grasp pitman arm and ensure it and drag link are
free of play.

(1) Check steering gear assembly for damage, and

loose or missing mounting hardware.
(2) Lower cab (TM 9-2320-366-10-1).

2-2161
TM 9-2320-366-20-3

p2. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES (CONT)

KNOWN INFO TEST OPTIONS

4.
Lugnuts OK. Refer to brake adjustment
Tires OK. procedure (para 11-2 or
Are brakes properly
Steering shaft and 11-3).
adjusted?
tie rod OK. REASON FOR QUESTION
U-joints, splines Vehicle may wander, pull
and yoke OK. to one side, or shimmy if
Pitman arm and drag brakes are not properly
link OK. adjusted.
Steering gear assembly OK.
POSSIBLE PROBLEMS
Brakes out of adjustment.

NO

Adjust brakes
(para 11-2 or 11-3).

YES

Fault not corrected.

Perform Suspension
System Troubleshooting
(r1. Wanders, Pulls To
One Side, Or Shimmies).

2-2162
 TM 9-2320-366-20-3

Refer to para 11-2 or 11-3 to adjust brakes.

2-2163
TM 9-2320-366-20-3

p3. EXCESSIVE PLAY WHEN TURNING STEERING WHEEL

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Cab raised (TM 9-2320-366-10-1).
Materials/Parts
Personnel Required Locknut (Item 68, Appendix G)
(2)

START

KNOWN INFO TEST OPTIONS

1.
Steering oil level OK. Visual inspection
Steering lines OK. Is steering shaft U-joint, Steering Gear Shaft
POSSIBLE PROBLEMS steering gear assembly Tie Rod Test
Faulty steering shaft shaft and tie rod properly REASON FOR QUESTION
U-joints and tie rod. lubricated, secure, and A steering shaft U-joint,
Faulty pitman arm and free from damage? steering gear assembly
drag link. shaft or tie rod that is
Faulty steering gear loose, damaged, or
assembly. requires lubrication may
cause vehicle to have
excessive play when
NO
turning steering wheel.

Lubricate tie rods (Appendix H).

Replace damaged tie rod (para 13-4).
Notify DS maintenance of damaged
YES steering shaft.

KNOWN INFO TEST OPTIONS

2.
Steering oil level OK. Visual inspection
Steering lines OK. Pitman Arm/Drag Link Test
Is pitman arm and
Steering shaft and tie REASON FOR QUESTION
drag link secure and
rod OK. A pitman arm or drag
free from damage?
POSSIBLE PROBLEMS link which is loose,
Faulty pitman arm and damaged or may cause
drag link. vehicle to have
Faulty steering gear excessive play when
assembly. NO turning steering wheel.

Tighten loose drag link.

YES Replace drag link (para 13-3).
Notify DS maintenance of
loose or damaged pitman
arm.

2-2164
 TM 9-2320-366-20-3

Check steering shaft U-joint, steering gear assembly

shafts, and tie rod for damage and loose or missing
mounting hardware. Refer to Appendix H to lubricate
tie rods.

NOTE
An aligment mark shall be
used on yoke and steering
gear assembly to ensure ease
during installation.

STEERING GEAR SHAFT TIE ROD TEST

(1) Grasp steering shaft and ensure there is no up
and down play.
(2) Remove self-locking nut and bolt securing yoke of
top steering shaft to steering gear assembly shaft.
Discard self-locking nut.
(3) Remove yoke from top steering gear
assembly shaft.
(4) Ensure spline shaft of steering gear assembly
and yoke of steering shaft are not damaged.
(5) Grasp tie rod and ensure there is no up and
down or left or right play.

Check pitman arm and drag link for damage and loose
or missing mounting hardware.

PITMAN ARM/DRAG LINK TEST

(1) Check nut securing pitman arm to steering
gear assembly. Ensure there is no play.
(2) Grasp drag link and ensure there is no play
left or right and up or down.
(3) Check for loose bolts, nuts, and clamps on
drag link.

2-2165
TM 9-2320-366-20-3

p3. EXCESSIVE PLAY WHEN TURNING STEERING WHEEL (CONT)

KNOWN INFO TEST OPTIONS

3.
Steering oil level OK. Steering Gear Preload Test
Steering lines OK. REASON FOR QUESTION
Does pitman arm
Steering linkage OK. If steering gear input
move immediately
POSSIBLE PROBLEMS shaft turns before pitman
when turning
Faulty steering gear arm begins to move,
steering wheel?
assembly. steering gear assembly
has excessive play.

NO

Notify DS Maintenance.

YES

Notify DS Maintenance.

2-2166
 TM 9-2320-366-20-3

STEERING GEAR PRELOAD TEST

(1) Remove drag link (para 13-3).
(2) Pull pitman arm back and forth to check
for binding and proper output. If pitman
arm fails to turn smoothly or if it binds
and top shaft does not turn immediately,
steering gear assembly is damaged.
(3) Install drag link (para 13-3).
(4) Position yoke onto top steering gear
assembly shaft.
(5) Install bolt and self-locking nut onto
yoke to secure yoke to top steering
gear assembly shaft.
(6) Lower cab (TM 9-2320-366-10-1).

2-2167
TM 9-2320-366-20-3

p4. NO RESPONSE WHEN TURNING STEERING WHEEL

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Cab raised (TM 9-2320-366-10-1).
Materials/Parts
Locknut (Item 68, Appendix G)

START

KNOWN INFO TEST OPTIONS

1.
Nothing Visual inspection
POSSIBLE PROBLEMS Manual check
Are steering shaft, U- joints,
Faulty steering shaft, REASON FOR QUESTION
splines and yoke secure and
U-joints and tie rod. A steering shaft, U-joint,
free from damage?
Faulty pitman arm and splines or yoke that is
drag link. loose or damaged may
Faulty steering gear cause no response when
assembly. turning steering wheel.
NO
Faulty U-joints, splines
and yoke.

YES Notify DS Maintenance.

KNOWN INFO TEST OPTIONS

2.
U-joints, splines and Visual inspection
yoke OK. Manual check
Is pitman arm and
POSSIBLE PROBLEMS REASON FOR QUESTION
drag link properly
Faulty pitman arm and A pitman arm or drag
secure and free
drag link. link which is loose or
from damage?
Faulty steering gear damaged may cause
assembly. no response when
turning steering wheel.

Tighten loose drag link.

Replace drag link (para 13-3).
NO Notify DS maintenance of
loose or damaged pitman
arm.

YES

2-2168
 TM 9-2320-366-20-3

(1) Check steering shaft for looseness and damage.

(2) Grasp steering shaft and ensure it is free of
play.
(3) Repeat step (2) while observing yoke, U-joint
and locknuts.

(1) Check pitman arm and drag link for damage and loose
or missing mounting hardware.
(2) Grasp pitman arm and ensure it and drag link are
free of play.

2-2169
TM 9-2320-366-20-3

p4. NO RESPONSE WHEN TURNING STEERING WHEEL (CONT)

KNOWN INFO TEST OPTIONS

3.
Steering oil level OK. Visual inspection
Steering shaft OK. Manual check
Pitman arm and drag Does steering gear REASON FOR QUESTION
link OK. assembly output A faulty steering gear
U-joints, splines and shaft turn freely? assembly may cause
yokes OK. no response when
POSSIBLE PROBLEMS turning steering wheel.
Faulty steering gear
assembly.

NO Notify DS Maintenance.

YES

Notify DS Maintenance.

2-2170
 TM 9-2320-366-20-3

NOTE
An alignment mark shall be made on
yoke and steering gear assembly shaft
prior to disassembly to ensure proper
alignment during installation.

STEERING GEAR TEST

(1) Remove bolt and locknut from lower yoke
of steering gear arm. Discard locknut.
(2) Remove yoke from top steering gear
assembly shaft.
(3) Remove drag link (para 13-3).
(4) Turn pitman arm to check for binding and
proper output. Notify DS Maintenance if
steering gear assembly fails to turn
smoothly or if it binds when top shaft is
turned.
(5) Install drag link (para 13-3).
(6) Position yoke on steering gear assembly.
(7) Install bolt and locknut into yoke to top
steering gear assembly shaft.
(8) Lower cab (TM 9-2320-366-10-1).

2-2171/(2-2172 Blank)
 TM 9-2320-366-20-3

2-27. FIFTH WHEEL TROUBLESHOOTING

This paragraph covers Fifth Wheel Troubleshooting. The Fifth Wheel Fault Index, Table 2-55, lists faults for the Fifth
Wheel of the vehicle.

Table 2-55. Fifth Wheel Fault Index

Fault No. Description Page

q1. Fifth Wheel Does Not Lock When Coupling Trailer to Tractor . . . . . . . . . . . . . . . . . . . . . . . . . 2-2174
q2. Excessive Movement of Trailer King Pin in Fifth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2178
q3. Fifth Wheel Does Not Unlock When Disconnecting Trailer From Tractor . . . . . . . . . . . . . . . . . . 2-2182
q4. Fifth Wheel Sliding Mechanism Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2186

2-2173
TM 9-2320-366-20-3

q1. FIFTH WHEEL WILL NOT LOCK WHEN COUPLING TRAILER TO TRACTOR
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Gun, Lubricating (Item 16, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Primary and secondary Visual inspection
release handles in lock REASON FOR QUESTION
Is fifth wheel
position. Fifth wheel may not
properly
POSSIBLE PROBLEMS lock if it requires
lubricated?
Fifth wheel lubrication. lubrication.
Fifth wheel adjustment.
Loose, broken, or missing
Lubricate fifth
king pin jaws. NO
wheel (Appendix H).

YES

KNOWN INFO TEST OPTIONS

2.
Primary and secondary Refer to fifth wheel
release handles in lock adjustment procedure
Is fifth wheel
position. (para 14-11).
properly
Fifth wheel lubrication OK. REASON FOR QUESTION
adjusted?
POSSIBLE PROBLEMS Fifth wheel may not
Fifth wheel adjustment. lock if improperly
Loose, broken, or missing adjusted.
king pin jaws.
Adjust fifth wheel
NO
(para 14-11).

YES

2-2174
 TM 9-2320-366-20-3

Refer to Appendix H to
lubricate fifth wheel.

Refer to para 14-11 to

check for proper fifth
wheel adjustment.

2-2175
TM 9-2320-366-20-3

q1. FIFTH WHEEL WILL NOT LOCK WHEN COUPLING TRAILER TO TRACTOR (CONT)

KNOWN INFO TEST OPTIONS

3.
Fifth wheel lubrication OK. Visual inspection
Primary and secondary REASON FOR QUESTION
Are king pin jaws
release handles in lock Fifth wheel may not
secure and free
position. lock if king pin jaws
from damage or
Fifth wheel is properly are loose, broken,
missing parts?
adjusted. or missing.
POSSIBLE PROBLEMS

Loose, broken, or
missing king pin jaws.

NO Notify DS Maintenance.

YES

Perform Fifth Wheel Troubleshooting

(q2. Excessive Movement of Trailer
King Pin in Fifth Wheel.

2-2176
 TM 9-2320-366-20-3

Check for loose, damaged, or missing king pin jaws.

Check that king pin jaws stay open when primary lock
release handle is in locked position
(TM 9-2320-366-10-1).

2-2177
TM 9-2320-366-20-3

q2. EXCESSIVE MOVEMENT OF TRAILER KING PIN IN FIFTH WHEEL

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Nothing Visual inspection
POSSIBLE PROBLEMS REASON FOR QUESTION
Is fifth wheel mounting
Fifth wheel mounting There may be excessive
hardware secure and free
hardware loose, missing, movement of trailer king
from damage?
or broken. pin in fifth wheel if
Fifth wheel adjustment. mounting hardware is
Loose, broken, or missing loose, missing, or
king pin jaws. broken.
Loose or broken spring
cushions or bushings.
NO Notify DS Maintenance.

YES

KNOWN INFO TEST OPTIONS

2.
Fifth wheel mounting Visual inspection
hardware OK. Are fifth wheel spring REASON FOR QUESTION
POSSIBLE PROBLEMS cushions and bushings There will be excessive
Loose or broken spring secure and free of cracks movement of trailer king
cushions or bushings. and breaks? pin in fifth wheel if spring
Fifth wheel adjustment. cushions and bushings
Loose, broken or missing are damaged.
king pin jaws.

NO Notify DS Maintenance.

YES

2-2178
 TM 9-2320-366-20-3

Check fifth wheel for loose, missing or broken

mounting hardware.

Check spring cushions and bushings in fifth wheel for

looseness, cracks or breaks.

2-2179
TM 9-2320-366-20-3

q2. EXCESSIVE MOVEMENT OF TRAILER KING PIN IN FIFTH WHEEL (CONT)

KNOWN INFO TEST OPTIONS

3.
Fifth wheel mounting Refer to fifth wheel
hardware OK. adjustment procedure
Is fifth wheel properly
Fifth wheel spring (para 14-11).
adjusted?
cushions and bushings OK. REASON FOR QUESTION
POSSIBLE PROBLEMS There will be excessive
Fifth wheel adjustment. movement of trailer king
Loose, broken, or missing pin in fifth wheel if
king pin jaws. improperly adjusted.

Adjust fifth wheel

NO
(para 14-11).

YES

KNOWN INFO TEST OPTIONS

4.
Fifth wheel mounting Visual inspection
hardware OK. REASON FOR QUESTION
Are king pin jaws
Fifth wheel spring Fifth wheel may have
secure and free
cushions and bushings OK. excessive movement
from damage or
Fifth wheel is properly if king pin jaws are
missing parts?
adjusted. loose, broken, or
POSSIBLE PROBLEMS missing.
Loose, broken, or missing
king pin jaws.

NO Notify DS Maintenance.

YES

Notify DS Maintenance.

2-2180
 TM 9-2320-366-20-3

Refer to para 14-11 to check for proper fifth wheel

adjustment.

Check for loose, damaged, or missing king pin jaws.

Check that king pin jaws stay open when primary lock
release handle is in locked position
(TM 9-2320-366-10-1).

2-2181
TM 9-2320-366-20-3

q3. FIFTH WHEEL WILL NOT UNLOCK WHEN DISCONNECTING TRAILER FROM TRACTOR
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Gun, Lubricating (Item 16, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Primary and secondary Refer to fifth wheel
release handles in lock adjustment procedure
Is fifth wheel properly
position. (para 14-11).
adjusted?
POSSIBLE PROBLEMS REASON FOR QUESTION
Fifth wheel adjustment. Fifth wheel may not
Fifth wheel lubrication. unlock if it requires
Loose or broken fifth adjustment.
wheel spring cushions NO
or bushings.
Release handles broken
Adjust fifth wheel
or disconnected.
YES (para 14-11).

KNOWN INFO TEST OPTIONS

2.
Primary and secondary Visual inspection
release handles in lock REASON FOR QUESTION
Is fifth wheel properly
position. Fifth wheel may not
lubricated?
Fifth wheel is properly unlock if it requires
adjusted. lubrication.
POSSIBLE PROBLEMS
Fifth wheel lubrication.
Loose or broken fifth
Lubricate fifth
wheel spring cushions NO
wheel (Appendix H).
or bushings.
Release handles broken
or disconnected.
YES

2-2182
 TM 9-2320-366-20-3

Refer to para 14-11 to check for proper fifth wheel

adjustment.

Refer to Appendix H to lubricate fifth wheel.

2-2183
TM 9-2320-366-20-3

q3. FIFTH WHEEL WILL NOT UNLOCK WHEN DISCONNECTING TRAILER FROM TRACTOR (CONT)

KNOWN INFO TEST OPTIONS

3.
Primary and secondary Visual inspection
release handles in lock Are fifth wheel spring REASON FOR QUESTION
position. cushions and bushings Fifth wheel may not un-
Fifth wheel is properly secure and free of lock if spring cushions
adjusted. cracks and breaks? and bushings are damaged.
Fifth wheel lubrication OK.
POSSIBLE PROBLEMS
Loose or broken fifth NO Notify DS Maintenance.
wheel spring cushions
or bushings.
Release handles broken
YES
or disconnected.

KNOWN INFO TEST OPTIONS

4.
Primary and secondary Visual inspection
release handles in lock REASON FOR QUESTION
Do primary or secondary
position. Fifth wheel may not
lock release handles
Fifth wheel is properly unlock if release
operate freely?
adjusted. handles are
Fifth wheel lubrication OK. separated from jaws.
Fifth wheel spring cushions
and bushings OK. Notify DS Maintenance
POSSIBLE PROBLEMS NO (fifth wheel needs
Release handles broken replacement).
or disconnected.

YES

Notify DS Maintenance.

2-2184
 TM 9-2320-366-20-3

Check spring cushions and bushings in fifth wheel for

looseness, cracks, or breaks.

Attempt to perform trailer disconnect procedure

(TM 9-2320-366-10-1).

2-2185
TM 9-2320-366-20-3

q4. FIFTH WHEEL SLIDING MECHANISM DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Primary and secondary Refer to fifth wheel
release handles in lock sliding mechanism
Is fifth wheel sliding
position. adjustment procedure
mechanism properly
POSSIBLE PROBLEMS (para 14-11).
adjusted?
Fifth wheel sliding REASON FOR QUESTION
mechanism adjustment. Fifth wheel sliding
mechanism will not
NO operate unless adjusted
properly.

Adjust fifth wheel

YES
sliding mechanism
(para 14-11).

Notify DS Maintenance.

2-2186
 TM 9-2320-366-20-3

Refer to para 14-11 to check for proper fifth wheel

sliding mechanism adjustment.

2-2187/(2-2188 Blank)
 TM 9-2320-366-20-3

2-28. SUSPENSION SYSTEM TROUBLESHOOTING

This paragraph covers Suspension System Troubleshooting. The Suspension System Fault Index, Table 2-56, lists
faults for the Suspension System of the vehicle.

Table 2-56. Suspension System Fault Index

Fault No. Description Page

r1. Wanders, Pulls to One Side, or Shimmies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2190

r2. Leans to One Side or Rear of Vehicle Sags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2200

2-2189
TM 9-2320-366-20-3

r1. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Iron, Tire (Item 20, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Lugnuts OK. Visual inspection
Steering shaft and Shock Absorber Test
Are front shock absorbers
components OK. REASON FOR QUESTION
and bracket(s) secure and
Brake adjustment OK. Vehicle may wander, pull
free from damage?
POSSIBLE PROBLEMS to one side, or shimmy if
Faulty or damaged front shock absorbers and
shock absorbers. bracket(s) are loose or
Faulty or damaged front damaged.
leaf springs.
Faulty or damaged rear
shock absorbers or
shock absorber brackets.
Faulty or damaged spring
NO
bushings or spring
shackles.
Faulty or damaged rear
leaf springs.
Faulty or damaged
control vehicular Replace damaged
suspension arms. shock absorber(s) or
Faulty or damaged bracket(s) (para 15-3).
resilient mounts.
Faulty or damaged v-rod
YES
control arms.
Faulty or damaged
stabilizer bar.

2-2190
 TM 9-2320-366-20-3

NOTE

Perform Steering System

Troubleshooting (p2,
Wanders, Pulls To One
Side, Or Shimmies) before
starting the steps given
below.

(1) Check shock absorbers for damage or leaks, and

for missing mounting hardware.
(2) Check shock absorbers bushings for movement.
(3) Check shock absorber brackets for damage and
for missing mounting hardware.

SHOCK ABSORBER TEST

(1) Grasp shock absorber and ensure there is not
excessive play.
(2) Replace worn bushings.

2-2191
TM 9-2320-366-20-3

r1. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES (CONT)

KNOWN INFO TEST OPTIONS

2.
Lugnuts OK. Visual inspection
Steering shaft and REASON FOR QUESTION
Are front leaf springs
components OK. Vehicle may wander, pull
secure and free from
Brake adjustment OK. to one side, or shimmy if
damage?
Front shock absorbers leaf springs are loose or
OK. damaged.
POSSIBLE PROBLEMS
Faulty or damaged front
leaf springs.
Faulty or damaged rear
shock absorbers or
shock absorber brackets.
Faulty or damaged spring
NO
bushings or spring
shackles.
Faulty or damaged rear
leaf springs.
Faulty or damaged
control vehicular Notify DS Maintenance.
suspension arms.
Faulty or damaged
resilient mounts.
Faulty or damaged
YES
v-rod control arms.
Faulty or damaged
stabilizer bar.

KNOWN INFO TEST OPTIONS

3.
Visual inspection
Lugnuts OK.
Are spring shackles Spring Shackle/Bushing Test
Steering shaft and
and spring bushings REASON FOR QUESTION
components OK.
secure and free from Vehicle may wander, pull
Brake adjustment OK.
damage? to one side, or shimmy if
Front shock absorbers OK.
spring shackles and
Front leaf springs OK.
spring bushings are
POSSIBLE PROBLEMS loose or damaged.

Faulty or damaged spring

bushings or spring
shackles.
Faulty rear shock
absorbers and shock NO
absorber brackets.
Faulty or damaged rear
leaf springs.
Faulty or damaged
control vehicular
Lubricate spring
suspension arms.
bushings (Appendix H)
Faulty or damaged
or notify DS Maintenance.
resilient mounts.
Faulty or damaged YES
v-rod control arms.
Faulty or damaged
stabilizer bar.

2-2192
 TM 9-2320-366-20-3

(1) Check leaf springs for cracked or broken leaves or

missing spring clips and U-bolts.
(2) Check seats for looseness or damage.

Check spring shackles and spring bushings for

damage and for missing mounting hardware.
Refer to Appendix H for lubrication of spring bushings.

SPRING SHACKLE/BUSHING TEST

(1) Position tire iron between spring assembly and
frame.
(2) Pry up and down and ensure there is no
movement.
(3) Shackles or bushings are damaged if
movement occurs.

2-2193
TM 9-2320-366-20-3

r1. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES (CONT)

KNOWN INFO TEST OPTIONS

3.
Visual inspection
Lugnuts OK.
Spring Shackle/Bushing Test
Steering shaft and Are spring shackles and
REASON FOR QUESTION
components OK. spring bushings secure and
Vehicle may wander, pull
Brake adjustment OK. free from damage?
to one side, or shimmy if
Front shock absorbers OK.
spring shackles and
Front leaf springs OK.
spring bushings are
POSSIBLE PROBLEMS loose or damaged.

Faulty or damaged spring

bushings or spring
shackles.
Faulty rear shock
absorbers and shock NO
absorber brackets.
Faulty or damaged rear
leaf springs.
Faulty or damaged
control vehicular
Lubricate spring
suspension arms.
bushings (Appendix H)
Faulty or damaged
or notify DS Maintenance.
resilient mounts.
Faulty or damaged YES
v-rod control arms.
Faulty or damaged
stabilizer bar.

2-2194
 TM 9-2320-366-20-3

Check spring shackles and spring bushings for

damage and for missing mounting hardware.
Refer to Appendix H for lubrication of spring bushings.

SPRING SHACKLE/BUSHING TEST

(1) Position tire iron between spring assembly and
frame.
(2) Pry up and down and ensure there is no
movement.
(3) Shackles or bushings are damaged if
movement occurs.

2-2195
TM 9-2320-366-20-3

r1. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES (CONT)

KNOWN INFO TEST OPTIONS

4.
Lugnuts OK. Visual inspection
Steering shaft and Are rear shock absorbers Shock Absorber Test
components OK. and shock absorber REASON FOR QUESTION
Brake adjustment OK. brackets secure and free Vehicle may wander, pull
Front shock absorbers OK. from damage? to one side, or shimmy if
Front leaf springs OK. shock absorber and
Spring bushings or shock absorber brackets
spring shackles OK. are loose or damaged.
POSSIBLE PROBLEMS
Faulty or damaged rear
shock absorbers or
shock absorber brackets.
Faulty or damaged rear
NO
leaf springs.
Faulty or damaged
control vehicular
suspension arms.
Faulty or damaged
resilient mounts. Replace damaged shock absorber(s)
Faulty or damaged or brackets (para 15-4).
v-rod control arms.
Faulty or damaged
stabilizer bar.
YES

KNOWN INFO TEST OPTIONS

5.
Lugnuts OK. Visual inspection
Steering shaft and REASON FOR QUESTION
Are leaf springs secure and
components OK. Vehicle may wander, pull
free from damage?
Brake adjustment OK. to one side, or shimmy if
Front shock absorbers OK. leaf springs are loose or
Front leaf springs OK. damaged.
Rear shock abosrbers and
shock absorber brackets
OK.
Spring bushings and spring
shackles OK.
POSSIBLE PROBLEMS
Faulty or damaged rear leaf
NO
springs.
Faulty or damaged control
vehicular suspension arms.
Faulty or damaged resilient
mounts.
Faulty or damaged v-rod Notify DS Maintenance.
control arms.
Faulty or damaged
stabilizer bar.
YES

2-2196
 TM 9-2320-366-20-3

(1) Check shock absorbers for damage or leaks, and

for missing mounting hardware.
(2) Check shock absorber brackets for damage and
for missing mounting hardware.
(3) Check shock absorber bushings for movement.

SHOCK ABSORBER TEST

(1) Grasp shock absorber and ensure there is no
excessive play.
(2) Replace worn bushings.

Check rear leaf springs for damage and for missing

mounting hardware.

2-2197
TM 9-2320-366-20-3

r1. WANDERS, PULLS TO ONE SIDE, OR SHIMMIES (CONT)

KNOWN INFO TEST OPTIONS

5.
Visual inspection
Lugnuts OK.
REASON FOR QUESTION
Steering shaft and Are leaf springs secure and
Vehicle may wander, pull
components OK. free from damage?
to one side, or shimmy if
Brake adjustment OK.
leaf springs are loose or
Front shock absorbers
damaged.
OK.
Front leaf springs OK.
Rear shock abosrbers
and shock absorber
brackets OK.
Spring bushings and
spring shackles OK.
NO
POSSIBLE PROBLEMS
Faulty or damaged rear
leaf springs.
Faulty or damaged
control vehicular
suspension arms. Notify DS Maintenance.
Faulty or damaged
resilient mounts.
Faulty or damaged
YES
v-rod control arms.
Faulty or damaged
stabilizer bar.

2-2198
 TM 9-2320-366-20-3

Check rear leaf springs for damage and for missing

mounting hardware.

2-2199
TM 9-2320-366-20-3

r2. LEANS TO ONE SIDE OR REAR OF VEHICLE SAGS

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Nothing. Visual inspection
POSSIBLE PROBLEMS REASON FOR QUESTION
Are front shock absorbers
Faulty or damaged front Vehicle may lean to one
secure and free from
shock absorbers. side if shock absorbers
damage?
Faulty or damaged front are loose or damaged.
leaf springs.
Faulty or damaged rear
shock absorbers. Replace damaged
Faulty or damaged rear NO shock absorber(s)
leaf springs. (para 15-3).
Faulty or damaged control
vehicular suspension
arms.
YES

KNOWN INFO TEST OPTIONS

2.
Front shock absorbers OK. Visual inspection
POSSIBLE PROBLEMS REASON FOR QUESTION
Are front leaf springs
Faulty or damaged front
secure and free from Vehicle may lean to one
leaf springs.
damage? side if front leaf springs
Faulty or damaged rear
are loose or damaged.
shock absorbers.
Faulty or damaged rear
leaf springs.
Faulty or damaged control NO Notify DS Maintenance.
vehicular suspension
arms.

YES

2-2200
 TM 9-2320-366-20-3

Check shock absorbers for damage or leaks, and

for missing or cracked mounting hardware.

Check front leaf springs for damage and for loose or

missing mounting hardware.

2-2201
TM 9-2320-366-20-3

r2. LEANS TO ONE SIDE OR REAR OF VEHICLE SAGS (CONT)

KNOWN INFO TEST OPTIONS

3.
Visual inspection
Front shock absorbers OK.
REASON FOR QUESTION
Front leaf springs OK. Are rear shock absorbers
Vehicle may lean to one
secure and free from
POSSIBLE PROBLEMS side if shock absorbers
damage?
Faulty or damaged rear are loose or damaged.
shock absorbers.
Faulty or damaged rear
leaf springs. Replace damaged
Faulty or damaged control NO shock absorber(s)
vehicular suspension (para 15-4).
arms.
YES

KNOWN INFO TEST OPTIONS

4.
Visual inspection
Front shock absorbers OK.
REASON FOR QUESTION
Front leaf springs OK. Are rear leaf springs
Rear shock absorbers OK. secure and free from Vehicle may lean to one
damage? side if rear leaf springs
POSSIBLE PROBLEMS
are loose or damaged.
Faulty or damaged rear
leaf springs.
Faulty or damaged control Notify DS Maintenance
vehicular suspension NO if rear leaf springs
arms. are loose or damaged.

YES

KNOWN INFO TEST OPTIONS

5.
Front shock absorbers OK. Visual inspection
Front leaf springs OK. REASON FOR QUESTION
Is control vehicular
Rear shock absorbers OK. Vehicle may lean to one
suspension arm secure and
Rear leaf springs OK. side or rear of vehicle sag if
free from damage?
POSSIBLE PROBLEMS control vehicular suspension
Faulty or damaged control arms are loose or
vehicular suspension damaged.
arms.
Notify DS Maintenance
if control vehicular
NO
suspension arms are
loose or damaged.

YES

Notify DS Maintenance.

2-2202
 TM 9-2320-366-20-3

Check shock absorbers for damage or leaks, and for

missing or cracked mounting hardware.

Check rear leaf springs for damage or leaks, and for

missing mounting hardware.

Check control vehicular suspension arms for damage

or bushing failure, and for missing mounting
hardware.

2-2203/(2-2204 Blank)
 TM 9-2320-366-20-3

2-29. 15K SELF-RECOVERY WINCH (SRW) SYSTEM TROUBLESHOOTING

This paragraph covers 15K Self-Recovery Winch (SRW) System Troubleshooting. The 15K Self-Recovery Winch
(SRW) System Fault Index, Table 2-57, lists faults for the 15K Self-Recovery Winch (SRW) system of the vehicle.

Table 2-57. 15K Self-Recovery Winch (SRW) System Fault Index

Fault No. Description Page

s1. 15K Self-Recovery Winch (SRW) Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2206

2-2205
TM 9-2320-366-20-3

s1. 15K SELF-RECOVERY WINCH DOES NOT WORK

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Pan, Drain (Item 24, Appendix C)
(2) Transducer, STE/ICE-R (Item 1, Appendix J)
Goggles, Industrial (Item 15, Appendix C)
References
TM 9-4910-571-12&P Materials/Parts
Rag, Wiping (Item 50, Appendix D)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic oil level OK. on following page. Input Flow Test
Hydraulic tubes and fittings REASON FOR QUESTION
Is hydraulic pressure
OK. Faulty hydraulic pump
to winch control
POSSIBLE PROBLEMS will cause winch to not
valve OK?
Faulty hydraulic pump. operate.
Faulty 15K self-recovery
winch.
Faulty winch control valve.
Faulty electrical supply/
control valve solenoid. NO

YES

Notify DS maintenance.

2-2206
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic hoses, tubes or fittings.
Failure to comply may result in
injury to personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

INPUT FLOW TEST

(1) Place drain pan under control valve.
(2) Disconnect hose from port P of winch control
valve.
(3) Connect STE/ICE-R with 5/8 in. tee and adapter
kit between hose fitting and port P.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position PTO switch to on
(TM 9-2320-366-10-1).
(6) Attach stall load to winch cable
(TM 9-2320-366-10-1).
(7) Position WINCH POWER switch to on
(TM 9-2320-366-10-1).
(8) Engage winch clutch (TM 9-2320-366-10-1).
(9) Toggle WINCH IN/OUT switch to IN
(TM 9-2320-366-10-1) and perform STE/ICE-R
test #51 (TM 9-4910-574-12&P) and note
pressure reading.
(10) Check if pressure is between 2450-2600 psi
(16893-17927 kPa), if pressure is lower than
2450 psi, notify DS Maintenance.
(11) Position WINCH POWER and PTO switches
to off (TM 9-2320-366-10-1).
(12) Shut down engine (TM 9-2320-366-10-1).
(13) Disconnect STE/ICE-R, tee, and adapter kit.
(14) Connect hose fitting to port P.
(15) Remove drain pan.

2-2207
TM 9-2320-366-20-3

s1. 15K SELF-RECOVERY WINCH DOES NOT WORK (CONT)

KNOWN INFO TEST OPTIONS

2.
Hydraulic oil level OK. Winch Control Valve
Hydraulic tubes and Is pressure absent or Pressure Test
fittings OK. 2450-2600 psi (16893- REASON FOR QUESTION
Hydraulic pump OK. 17927 kPa) at V1and/or Faulty winch control valve
POSSIBLE PROBLEMS V2 on 15K self-recovery will cause 15K
Faulty 15K self-recovery winch? self-recovery winch not to
winch. operate due to low or
Faulty winch control valve. absent hydraulic pressure.
Faulty electrical supply/
control valve solenoid.

NO

Notify DS maintenance.

YES

2-2208
 TM 9-2320-366-20-3

WINCH CONTROL VALVE PRESSURE TEST

(1) Disconnect hose from fitting below elbow
at port V1 (on side of 15K self-recovery winch
toward front of vehicle).
(2) Connect STE/ICE-R with tee between port
V1 and hose.
(3) Start engine (TM 9-2320-366-10-1).
(4) Attach stall load to winch cable
(TM 9-2320-366-10-1).
(5) Position PTO switch and WINCH POWER
switch to ON (TM 9-2320-366-10-1).
(6) Engage winch clutch (TM 9-2320-366-10-1).
(7) Perform STE/ICE-R test #51 and toggle
WINCH IN/OUT switch to IN position and hold
(TM 9-4910-571-12&P).
(8) Check if pressure reading is between
2450-2600 psi (16893-17927 kPa) on
STE/ICE-R.
(9) If pressure is less than 2600 psi, notify DS
Maintenance.
(10) Position WINCH POWER and PTO switches
to off (TM 9-2320-366-10-1).
(11) Shut down engine (TM 9-2320-366-10-1).
(12) Disconnect STE/ICE-R and tee.
(13) Connect hose fitting to port V1.
(14) Disconnect hose (below elbow) from port V2.
(15) Connect STE/ICE-R with tee between hose and
port V2.
(16) Start engine (TM 9-2320-366-10-1).
(17) Position PTO and WINCH POWER switches
to on (TM 9-2320-366-10-1).
(18) Perform STE/ICE-R test #51 and toggle
WINCH IN/OUT switch to OUT (TM 9-4910-
571-12&P).
(19) Check if pressure reading is between 2450-
2600 psi (16893-17927 kPa).
(20) If pressure is lower than 2450 psi, notify DS
Maintenance.
(21) Release load and retrieve cable
(TM 9-2320-366-10-1).
(22) Position WINCH POWER and PTO switches to
off (TM 9-2320-366-10-1).
(23) Disengage winch clutch (TM 9-2320-366-10-1).
(24) Shut down engine (TM 9-2320-366-10-1).
(25) Disconnect STE/ICE-R and tee.
(26) Connect hose fitting to port V2.

2-2209
TM 9-2320-366-20-3

s1. 15K SELF-RECOVERY WINCH DOES NOT WORK (CONT)

KNOWN INFO TEST OPTIONS

3.
Hydraulic oil level OK. Winch Control Valve
Hydraulic lines and Fault Check
Is pressure totally absent
fittings OK. REASON FOR QUESTION
at V1 and/or V2 on
Hydraulic pump OK. A faulty electrical system
15K self-recovery winch?
15K self-recovery or winch control valve will
winch OK. cause pressure to be
POSSIBLE PROBLEMS absent at both ports on
Faulty winch control valve. 15K self-recovery winch.
Faulty electrical supply/
NO
control valve solenoid.

Replace winch control valve

(para 17-25).

YES

Perform Electrical System

Troubleshooting (e88. Self-
Recovery Winch Does Reel
In or Pay Out).

2-2210
 TM 9-2320-366-20-3

WINCH CONTROL VALVE FAULT CHECK

(1) If hydraulic pressure was absent in winch
control valve pressure test (step 2.), perform
electrical system troubleshooting (e88. 15K Self-
Recovery Winch Does Not Reel In or Pay Out).
(2) If hydraulic pressure was low in winch control
valve pressure test (step 2.), replace winch
control valve (para 17-25).

2-2211/(2-2212 Blank)
 TM 9-2320-366-20-3

2-30. STEERING HYDRAULIC SYSTEM TROUBLESHOOTING

This paragraph covers Steering Hydraulic System Troubleshooting. The Steering Hydraulic System Fault Index, Table
2-58, lists faults for the Steering Hydraulic System of the vehicle.

Table 2-58. Steering Hydraulic System Fault Index

Fault No. Description Page

t1. Steering Hard or Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2214

2-2213
TM 9-2320-366-20-3

t1. STEERING HARD OR DOES NOT WORK

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Personnel Required
(2) Materials/Parts
Rag, Wiping (Item 50, Appendix D)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Steering oil level OK. on following page. Visual inspection
Hydraulic lines and Are visible or audible REASON FOR QUESTION
fittings OK. indications of faulty Faulty steering components
POSSIBLE PROBLEMS steering components are often revealed by noise,
Faulty steering pump. absent? or visible clues.
Faulty steering gear.
Faulty steering gear
adjustment.

NO

Notify DS Maintenance.

YES

2-2214
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic line. Failure to comply
may result in injury to
personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

(1) Check steering oil level and fill as required

(Appendix H).
(2) Start engine (TM 9-2320-366-10-1).
(3) Turn steering wheel from lock-to-lock.
(4) Listen for unusual sounds. Faulty steering pump
or steering gear may be noisy.
(5) Shut down engine (TM 9-2320-366-10-1).

2-2215
TM 9-2320-366-20-3

t1. STEERING HARD OR DOES NOT WORK (CONT)

KNOWN INFO TEST OPTIONS

2.
Steering oil level OK. Visual inspection
Hydraulic lines and fittings REASON FOR QUESTION
OK. Is steering hard in If steering is hard to one
Steering pump not noisy. both directions? side but not the other,
Steering gear not noisy. adjustment may be faulty.
POSSIBLE PROBLEMS
Faulty steering gear
adjustment.

NO

Notify DS Maintenance.

YES

Perform Steering Troubleshooting

(p1. Hard to Steer).

2-2216
 TM 9-2320-366-20-3

(1) Raise cab (TM 9-2320-366-10-1).

(2) Inspect point on each end of front axle housing
where wheel stop contacts axle. If this spot is
gouged or peened or if steering is harder in one
direction than the other, steering adjustment may
be faulty.
(3) Lower cab (TM 9-2320-366-10-1).

2-2217/(2-2218 Blank)
 TM 9-2320-366-20-3

2-31. AIR TRANSPORT TROUBLESHOOTING

This paragraph covers Air Transport Components Troubleshooting. The Air Transport Components Fault Index, Table
2-59, lists faults for the Air Transport Components of the vehicle.

Table 2-59. Air Transport Components Fault Index

Fault No. Description Page

u1. Cab Tilt, Spare Tire Retainer, and Suspension Compression Do Not Operate . . . . . . . . . . . . . 2-2220
u2. Suspension Does Not Compress or Return to Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2230
u3. Cab Leveling Air Springs Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2232

Change 1 2-2219
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO NOT OPERATE

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Pan, Drain (Item 24, Appendix C)
(2) Goggles, Industrial (Item 15, Appendix C)
Transducer, 10,000 PSI (Item 1, Appendix J)
Material/Parts Gloves, Rubber (Item 13, Appendix C)
Filter Assembly (2) (Item 14, Appendix G)
Rag, Wiping (Item 50, Appendix D) References
TM 9-4910-571-12&P

START

KNOWN INFO TEST OPTIONS

1.
Visual Inspection
Hydraulic hoses free from
leaks.
REASON FOR QUESTION
Does either PUMP button or
back-up hydraulic pump This question eliminates
POSSIBLE PROBLEMS possible problems and
operate?
determines where
Faulty air/hydraulic manifold troubleshooting continues.
filter(s).
Faulty hydraulic hose 515.
Faulty air/hydraulic power unit.
Faulty air hose 507.
Faulty secondary air tank
inversion valve.
NO
Faulty air hose 502.
Faulty hydraulic hose 514.
Faulty back-up hydraulic pump.
Faulty hydraulic hose 521.
Faulty hydraulic hose 520.
Faulty air/hydraulic manifold.
Go to step 10
YES
of this fault.

2-2220 Change 1
 TM 9-2320-366-20-3

(1) Attempt to raise cab using PUMP button

(TM 9-2320-366-10-1).
(2) Attempt to raise cab using back-up
hydraulic pump (TM 9-2320-366-10-1).
(3) If cab does not raise in both steps (1) and (2),
go to step 10 of this fault.

Change 1 2-2221
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
Visual Inspection
Hydraulic hoses free from
REASON FOR QUESTION
leaks. Does back-up hydraulic
Air/hydraulic manifold filters pump operate? This question eliminates
OK. possible problems and
determines where
POSSIBLE PROBLEMS troubleshooting continues.

Faulty hydraulic hose 515.

Faulty air/hydraulic power unit.
Faulty air hose 507. NO
Faulty secondary air tank
inversion valve.
Faulty air hose 502.
Faulty hydraulic hose 514.
Faulty back-up hydraulic pump. Go to step 12
Faulty hydraulic hose 521. YES
of this fault.
Faulty hydraulic hose 520.
Faulty air/hydraulic manifold.

KNOWN INFO TEST OPTIONS

3.
Hydraulic hoses free from Pressure Test or
leaks. STE/ICE-R Test #51
Is 2,500-4,000 psi REASON FOR QUESTION
Air/hydraulic manifold filters
(17,238-27,580 kPa)
OK. This question eliminates
present at air/hydraulic
Back-up hydraulic pump OK. possible problems and
power unit return port?
Hydraulic hose 521 OK. determines where
Hydraulic hose 520 OK. troubleshooting continues.
POSSIBLE PROBLEMS
Faulty hydraulic hose 515.
Faulty air/hydraulic power unit.
Faulty air hose 507.
Faulty secondary air tank NO
inversion valve.
Faulty air hose 502.
Faulty hydraulic hose 514.
Faulty air/hydraulic manifold.
Go to step 11
YES
of this fault.

2-2222 Change 1
 TM 9-2320-366-20-3

(1) Attempt to raise cab using back-up

hydraulic pump (TM 9-2320-366-10-1).
(2) If cab does not raise, go to step 12 of
this fault.
(3) Lower cab (TM 9-2320-366-10-1).

PRESSURE TEST
(1) Position drain pan under air/hydraulic
power unit.
(2) Disconnect hydraulic hose 514 from
air/hydraulic power unit return port.
(3) Connect STE/ICE-R between hydraulic
hose 514 and return port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 11 of this fault.
(9) Disconnect STE/ICE-R from hydraulic hose
514 and return port.
(10) Connect hydraulic hose 514 to return port.

Change 1 2-2223
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

4.
Hydraulic hoses free from Pressure Test or
leaks. STE/ICE-R Test #51
Air/hydraulic manifold filters Is 2,500-4,000 psi REASON FOR QUESTION
OK. (17,238-27,580 kPa)
Hydraulic hose 514 OK. present at port P1? If 2,500-4,000 psi (17,238-
Back-up hydraulic pump OK. 27,580 kPa) is present,
Hydraulic hose 521 OK. air/hydraulic manifold is faulty.
Hydraulic hose 520 OK.
POSSIBLE PROBLEMS
Faulty hydraulic hose 515.
Faulty air/hydraulic power unit.
Faulty air hose 507.
Faulty secondary air tank
inversion valve. NO
Faulty air hose 502.
Faulty air/hydraulic manifold.

Go to step 5
YES
of this fault.

Replace air/hydraulic
manifold (para 19-4).

2-2224 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Position drain pan under air/hydraulic

manifold.
(2) Disconnect hydraulic hose 515 from
port P1.
(3) Connect STE/ICE-R between hydraulic
hose 515 and port P1.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 5 of this fault.
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace air/hydraulic manifold
(para 19-4).
(10) Disconnect STE/ICE-R from hydraulic hose
515 and port P1.
(11) Connect hydraulic hose 515 to port P1.

Change 1 2-2225
 TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

5.
Hydraulic hoses free from Pressure Test or
leaks. STE/ICE-R Test #51
Is 2,500-4,000 psi REASON FOR QUESTION
Air/hydraulic manifold filters
(17,238-27,580 kPa)
OK.
present at air/hydraulic If 2,500-4,000 psi (17,238-
Hydraulic hose 514 OK.
power unit output port? 27,580 kPa) is present,
Back-up hydraulic pump OK.
Hydraulic hose 521 OK. hydraulic hose 515 is faulty.
Hydraulic hose 520 OK.
POSSIBLE PROBLEMS
Faulty hydraulic hose 515.
Faulty air/hydraulic power unit.
Faulty air hose 507.
Faulty secondary air tank
inversion valve.
Faulty air hose 502. NO
Faulty air/hydraulic manifold.

Go to step 6
YES
of this fault.

Replace hydraulic hose

515 (para 19-12).

2-2226 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Position drain pan under air/hydraulic

power unit.
(2) Disconnect hydraulic hose 515 from
output port.
(3) Connect STE/ICE-R between hydraulic
hose 515 and output port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 6 of this fault.
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 515
(para 19-12).
(10) Disconnect STE/ICE-R from hydraulic hose
515 and output port.
(11) Connect hydraulic hose 515 to output port.

Change 1 2-2227
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

6.
Hydraulic hoses free from Visual Inspection
leaks. REASON FOR QUESTION
Is air present at
Air/hydraulic manifold filters air/hydraulic power unit If air is present, air/hydraulic
OK. supply port? power unit is faulty.
Hydraulic hose 515 OK.
Hydraulic hose 514 OK.
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.
Hydraulic hose 520 OK.
POSSIBLE PROBLEMS
Faulty air/hydraulic power unit.
Faulty air hose 507.
Faulty secondary air tank
inversion valve.
Faulty air hose 502. NO
Faulty air/hydraulic manifold.

Go to step 7
YES
of this fault.

Replace air/hydraulic
power unit (para 19-3).

2-2228 Change 1
 TM 9-2320-366-20-3

(1) Drain air tanks (TM 9-2320-366-10-1).

(2) Loosen air hose 507 at air/hydraulic
power unit.
(3) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(4) Check for presence of air at air hose 507.
(5) If air is not present, go to step 7 of this
fault.
(6) If air is present, replace air/hydraulic
power unit (para 19-3).
(7) Drain air tanks (TM 9-2320-366-10-1).
(8) Tighten air hose 507 at air/hydraulic power
unit.

Change 1 2-2228.1
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

7.
Hydraulic hoses free from
Visual Inspection
leaks. REASON FOR QUESTION
Is air present at PUMP CYL
Air/hydraulic manifold filters port? If air is present, air hose 507
OK. is faulty.
Hydraulic hose 515 OK.
Air/hydraulic power unit OK.
Hydraulic hose 514 OK.
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.
Hydraulic hose 520 OK.
POSSIBLE PROBLEMS

Faulty air hose 507.

Faulty secondary air tank
inversion valve.
NO
Faulty air hose 502.
Faulty air/hydraulic manifold.

Go to step 8
YES
of this fault.

Replace air hose

507 (para 23-3).

2-2228.2 Change 1
 TM 9-2320-366-20-3

(1) Drain air tanks (TM 9-2320-366-10-1).

(2) Loosen air hose 507 at PUMP CYL port.
(3) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(4) Check for presence of air at PUMP CYL port.
(5) If air is not present, go to step 8 of this
fault.
(6) If air is present, replace air hose 507
(para 23-3).
(7) Drain air tanks (TM 9-2320-366-10-1).
(8) Tighten air hose 507 at PUMP CYL port.

Change 1 2-2228.3
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

8.
Visual Inspection
Hydraulic hoses free from
REASON FOR QUESTION
leaks. Is air present at AIR IN P
Air/hydraulic manifold filters port? If air is present, air/hydraulic
OK. manifold is faulty.
Hydraulic hose 515 OK.
Air/hydraulic power unit OK.
Air hose 507.
Hydraulic hose 514 OK.
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.
Hydraulic hose 520 OK.
POSSIBLE PROBLEMS

Faulty air/hydraulic manifold.

Faulty secondary air tank
NO
inversion valve.
Faulty air hose 502.

Go to step 9
YES
of this fault.

Replace air/hydraulic
manifold (para 19-4).

2-2228.4 Change 1
 TM 9-2320-366-20-3

(1) Drain air tanks (TM 9-2320-366-10-1).

(2) Loosen air hose 502 at AIR IN P port.
(3) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(4) Check for presence of air at air hose 502.
(5) If air is not present, go to step 9 of this
fault.
(6) If air is present, replace air/hydraulic manifold
(para 19-4).
(7) Drain air tanks (TM 9-2320-366-10-1).
(8) Tighten air hose 502 at AIR IN P port.

Change 1 2-2228.5
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

9.
Visual Inspection
Hydraulic hoses free from
REASON FOR QUESTION
leaks. Is air present at secondary
Air/hydraulic manifold filters air tank inversion valve If air is not present, secondary
OK. delivery port? air tank inversion valve is
Hydraulic hose 515 OK. faulty. If air is present, air
Air/hydraulic power unit OK. hose 502 is faulty.
Air hose 507.
Hydraulic hose 514 OK.
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.
Hydraulic hose 520 OK.
Air/hydraulic manifold OK.

POSSIBLE PROBLEMS

Faulty secondary air tank

NO
inversion valve.
Faulty air hose 502.

Replace secondary air tank

YES
inversion valve (para 23-6).

Replace air hose

502 (para 23-3).

2-2228.6 Change 1
 TM 9-2320-366-20-3

(1) Drain air tanks (TM 9-2320-366-10-1).

(2) Loosen air hose 502 at secondary air tank
inversion valve delivery port.
(3) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(4) Check for presence of air at secondary air tank
inversion valve delivery port.
(5) If air is not present, replace secondary air tank
inversion valve (para 23-6).
(6) If air is present, replace air hose 502
(para 23-3).
(7) Drain air tanks (TM 9-2320-366-10-1).
(8) Tighten air hose 502 at secondary air tank
inversion valve delivery port.

Change 1 2-2228.7
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
10. on following page.
Visual Inspection
Hydraulic hoses free from
REASON FOR QUESTION
leaks. Are air/hydraulic manifold
Hydraulic hose 515 OK. filters free from debris? If air/hydraulic manifold
Air/hydraulic power unit OK. filter(s) is clogged, filter(s) is
Air hose 507 OK.
faulty.
Secondary air tank inversion
valve OK.
Air hose 502 OK.
Hydraulic hose 514 OK. NO
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.
Hydraulic hose 520 OK.

POSSIBLE PROBLEMS

Debris in air/hydraulic manifold

filter(s).
Faulty air/hydraulic manifold.
Replace air/hydraulic
YES
manifold filter(s) (para 19-5).

Replace air/hydraulic
manifold (para 19-4).

2-2228.8 Change 1
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC. Wear

protective goggles and gloves; use only in well
ventilated area; avoid contact with skin, eyes,
and clothes. Skin and clothing that come into
contact with hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply may
result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use only
with effective chip guarding and personal
protective equipment (goggles, shields,
gloves, etc.). Failure to comply may result
in injury to personnel.

(1) Remove two plugs from air/hydraulic

manifold. Discard plugs.
(2) Remove two retainers, filters, and springs
from air/hydraulic manifold. Discard
retainers and springs.
(3) Inspect filters for debris or signs of damage.
(4) Discard filters.
(5) If filters are free from debris and damage,
repair or replace air/hydraulic manifold
(para 19-4).
(6) Position two springs and filters in hydraulic
manifold with two retainers.
(7) Install two preformed packings on plugs.
(8) Install two plugs in air/hydraulic manifold.

Change 1 2-2228.9
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

11.
Pressure Test or
Hydraulic hoses free from
STE/ICE-R Test #51
leaks.
Is 2,500-4,000 psi REASON FOR QUESTION
Air/hydraulic manifold filters
OK. (17,238-27,580 kPa) If 2,500-4,000 psi (17,238-
Hydraulic hose 515. present at port T1? 27,580 kPa) is not present,
Air/hydraulic power unit OK. air/hydraulic manifold is faulty.
Air hose 507 OK. If 2,500-4,000 psi (17,238-
Secondary air tank inversion 27,580 kPa) is present,
valve OK. hydraulic hose 514 is faulty.
Air hose 502 OK.
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.
Hydraulic hose 520 OK.

POSSIBLE PROBLEMS NO

Faulty hydraulic hose 514.

Faulty air/hydraulic manifold.

Replace air/hydraulic
YES
manifold (para 19-4).

Replace hydraulic hose

514 (para 19-12).

2-2228.10 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Position drain pan under air/hydraulic

manifold.
(2) Disconnect hydraulic hose 514 from
port T1.
(3) Connect STE/ICE-R between hydraulic
hose 514 and port T1.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, replace air/hydraulic manifold
(para 19-4).
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 514
(para 19-12).
(10) Disconnect STE/ICE-R from hydraulic hose
514 and port T1.
(11) Connect hydraulic hose 514 to port T1.

Change 1 2-2228.11
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

12.
Pressure Test or
Hydraulic hoses free from
STE/ICE-R Test #51
leaks. Is 2,500-4,000 psi
Air/hydraulic manifold filters REASON FOR QUESTION
(17,238-27,580 kPa)
OK. present at back-up hydraulic This question eliminates
Hydraulic hose 515 OK. pump return port? possible problems and
Air/hydraulic power unit OK. determines where
Air hose 507 OK. troubleshooting continues.
Secondary air tank inversion
valve OK.
Air hose 502 OK.
Air hose 514 OK.

POSSIBLE PROBLEMS

Faulty back-up hydraulic pump. NO

Faulty hydraulic hose 521.
Faulty hydraulic hose 520.
Faulty air/hydraulic manifold.

Go to step 15
YES
of this fault.

2-2228.12 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Position drain pan under back-up hydraulic
pump.
(2) Disconnect hydraulic hose 520 from
back-up hydraulic pump return port.
(3) Connect STE/ICE-R between hydraulic
hose 520 and return port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 15 of this fault.
(9) Disconnect STE/ICE-R from hydraulic hose
520 and return port.
(10) Connect hydraulic hose 520 to return port.

Change 1 2-2228.13
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

13.
Pressure Test or
Hydraulic hoses free from
STE/ICE-R Test #51
leaks.
Air/hydraulic manifold filters Is 2,500-4,000 psi REASON FOR QUESTION
OK. (17,238-27,580 kPa)
present at port P2? If 2,500-4,000 psi (17,238-
Hydraulic hose 515 OK. 27,580 kPa) is present,
Air/hydraulic power unit OK. air/hydraulic manifold is faulty.
Air hose 507 OK.
Secondary air tank inversion
valve OK.
Air hose 502 OK.
Air hose 514 OK.
Air hose 520 OK.

POSSIBLE PROBLEMS
NO
Faulty back-up hydraulic pump.
Faulty hydraulic hose 521.
Faulty air/hydraulic manifold.

Go to step 14
YES
of this fault.

Replace air/hydraulic
manifold (para 19-4).

2-2228.14 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Position drain pan under air/hydraulic
manifold.
(2) Disconnect hydraulic hose 521 from
port P2.
(3) Connect STE/ICE-R between hydraulic
hose 521 and port P2.
(4) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(5) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(6) Operate back-up hydraulic pump
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(7) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 14 of this fault.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace air/hydraulic manifold
(para 19-4).
(9) Disconnect STE/ICE-R from hydraulic hose
521 and port P2.
(10) Connect hydraulic hose 521 to port P2.

Change 1 2-2228.15
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

14.
Pressure Test or
Hydraulic hoses free from
STE/ICE-R Test #51
leaks. Is 2,500-4,000 psi REASON FOR QUESTION
Air/hydraulic manifold filters (17,238-27,580 kPa)
OK. present at back-up hydraulic If 2,500-4,000 psi (17,238-
Hydraulic hose 515 OK. pump output port? 27,580 kPa) is not present,
Air/hydraulic power unit OK. back-up hydraulic pump is
Air hose 507 OK. faulty. If 2,500-4,000 psi
Secondary air tank inversion (17,238-27,580 kPa) is
valve OK. present, hydraulic hose 521 is
Air hose 502 OK. faulty.
Air hose 514 OK.
Hydraulic hose 520 OK.
Air/hydraulic manifold OK.

POSSIBLE PROBLEMS NO

Faulty back-up hydraulic pump.

Faulty hydraulic hose 521.

Replace back-up
YES
hydraulic pump (para 19-2).

Replace hydraulic hose

521 (para 19-12).

2-2228.16 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Position drain pan under back-up hydraulic
pump.
(2) Disconnect hydraulic hose 521 from
back-up hydraulic pump output port.
(3) Connect STE/ICE-R between hydraulic
hose 521 and output port.
(4) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(5) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(6) Operate back-up hydraulic pump
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(7) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, replace back-up hydraulic
pump (para 19-2).
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 521
(para 19-12).
(9) Disconnect STE/ICE-R from hydraulic hose
521 and output port.
(10) Connect hydraulic hose 521 to output port.

Change 1 2-2228.17
TM 9-2320-366-20-3

u1. CAB TILT, SPARE TIRE RETAINER, AND SUSPENSION COMPRESSION DO

NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

15.
Pressure Test or
Hydraulic hoses free from
STE/ICE-R Test #51
leaks.
Is 2,500-4,000 psi REASON FOR QUESTION
Air/hydraulic manifold filters
OK. (17,238-27,580 kPa) If 2,500-4,000 psi (17,238-
Hydraulic hose 515. present at port T2? 27,580 kPa) is not present,
Air/hydraulic power unit OK. air/hydraulic manifold is faulty.
Air hose 507 OK. If 2,500-4,000 psi (17,238-
Secondary air tank inversion 27,580 kPa) is present,
valve OK. hydraulic hose 520 is faulty.
Air hose 502 OK.
Hydraulic hose 514 OK.
Back-up hydraulic pump OK.
Hydraulic hose 521 OK.

POSSIBLE PROBLEMS NO

Faulty hydraulic hose 520.

Faulty air/hydraulic manifold.

Replace air/hydraulic
YES
manifold (para 19-4).

Replace hydraulic hose

520 (para 19-12).

2-2228.18 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Position drain pan under air/hydraulic

manifold.
(2) Disconnect hydraulic hose 520 from
port T2.
(3) Connect STE/ICE-R between hydraulic
hose 520 and port T2.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, replace air/hydraulic manifold
(para 19-4).
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 520
(para 19-12).
(10) Disconnect STE/ICE-R from hydraulic hose
520 and port T2.
(11) Connect hydraulic hose 520 to port T2.

Change 1 2-2229
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Pan, Drain (Item 24, Appendix C)
(2) Goggles, Industrial (Item 15, Appendix C)
Transducer, 10,000 PSI (Item 1, Appendix J)
Material/Parts Gloves, Rubber (Item 13, Appendix C)
Rag, Wiping (Item 50, Appendix D)
References
TM 9-4910-571-12&P

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Pressure Test or
Other hydraulic manifold STE/ICE-R Test #51
functions OK. Is 2,500-4,000 psi REASON FOR QUESTION
Hydraulic hoses free from (17,238-27,580 kPa)
leaks. present at suspension This question eliminates
cylinder input ports? possible problems and
POSSIBLE PROBLEMS determines where
troubleshooting continues.
Faulty hydraulic hose(s) 508
and/or 510.
Faulty suspension compression
tee fitting.
Faulty air/hydraulic manifold.
Faulty hydraulic hose 512.
Faulty hydraulic hose 513.
Faulty suspension release tee NO
fitting.
Faulty suspension cylinder(s).
Faulty hydraulic hose(s) 509
and/or 511.

Go to step 3
YES
of this fault.

2-2230 Change 1
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic oil (MIL-H 5605) is TOXIC.

Wear protective goggles and gloves. Use
only in well ventilated area. Avoid
contract with skin, eyes, and clothes.
Skin and clothing that come into contact
with hydraulic oil should be washed
immediately. Failure to comply may
result in injury to personnel.

NOTE
SYSTEM PARK control must be engaged
(TM 9-2320-366-10-1) before operating
SUSPENSION compression.

PRESSURE TEST

(1) Position drain pan under RH suspension

cylinder.
(2) Disconnect hydraulic hose 508 from RH
suspension cylinder input port.
(3) Connect STE/ICE-R between hydraulic
hose 508 and RH suspension cylinder
input port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(6) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(7) Shut down engine (TM 9-2320-366-10-1).
(8) Disconnect STE/ICE-R from RH suspension
cylinder input port and hydraulic hose 508.
(9) Connect hydraulic hose 508 to RH
suspension cylinder input port.
(10) Repeat steps (1) through (9) on LH
suspension cylinder and hydraulic hose
510.
(11) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present at either suspension cylinder,
go to step 3 of this fault.

Change 1 2-2230.1
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

2.
Other hydraulic manifold Pressure Test or
functions OK. Is 2,500-4,000 psi STE/ICE-R Test #51
Hydraulic hoses free from (17,238-27,580 kPa) REASON FOR QUESTION
leaks. present at PILOT
input port? If 2,500-4,000 psi (17,238-
Hydraulic hoses 508 and 510
27,580 kPa) is present,
OK.
air/hydraulic manifold is faulty.
Suspension compression tee
fitting OK.
Hydraulic hose 512 OK.
POSSIBLE PROBLEMS
Faulty air/hydraulic manifold.
Faulty hydraulic hose 513.
Faulty suspension release tee
fitting.
NO
Faulty suspension cylinder(s).
Faulty hydraulic hose(s) 509
and/or 511.

Go to step 6
YES
of this fault.

Repair or replace air/hydraulic

manifold (para 19-4).

2-2230.2 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Position drain pan under air/hydraulic

manifold
(2) Disconnect hydraulic hose 513 from
PILOT port.
(3) Connect STE/ICE-R between hydraulic
hose 513 and PILOT port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob
to SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 6 of this fault.
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, repair or replace air/hydraulic
manifold (para 19-4).
(10) Disconnect STE/ICE-R from hydraulic hose
513 and PILOT port.
(11) Connect hydraulic hose 513 to PILOT port.

Change 1 2-2230.3
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

3.
Pressure Test or
Other hydraulic manifold
functions OK. STE/ICE-R Test #51
Is 2,500-4,000 psi REASON FOR QUESTION
Hydraulic hoses free from (17,238-27,580 kPa)
leaks. present at suspension If 2,500-4,000 psi (17,238-
Hydraulic hose 513 OK. compression tee fitting 27,580 kPa) is present,
Suspension release tee fitting output ports? hydraulic hose(s) 508 and/or
OK.
510 is faulty.
Suspension cylinders OK.
Hydraulic hoses 509 and 511
OK.
POSSIBLE PROBLEMS
Faulty hydraulic hose(s) 508
and/or 510.
Faulty suspension compression NO
tee fitting.
Faulty air/hydraulic manifold.
Faulty hydraulic hose 512.

Go to step 4
YES
of this fault.

Replace hydraulic
hose(s) 508 and/or 510
(para 19-12).

2-2230.4 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Position drain pan under suspension
compression tee fitting.
(2) Disconnect hydraulic hose 510 from
suspension compression tee fitting LH
output port.
(3) Connect STE/ICE-R between hydraulic
hose 510 and suspension compression
tee fitting LH output port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to RAISE
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob
to SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 4 of this fault.
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 510
(para 19-12).
(10) Disconnect STE/ICE-R from hydraulic hose
510 and suspension compression tee fitting
LH output port.
(11) Connect hydraulic hose 510 to suspension
compression tee fitting LH output port.
(12) Repeat steps (2) through (12) on hydraulic
hose 508 and suspension compression tee
fitting RH output port.

Change 1 2-2230.5
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

4.
Pressure Test or
Other hydraulic manifold
STE/ICE-R Test #51
functions OK. Is 2,500-4,000 psi
Hydraulic hoses free from REASON FOR QUESTION
(17,238-27,580 kPa)
leaks. present at suspension If 2,500-4,000 psi (17,238-
Hydraulic hoses 508 and 510 compression tee fitting 27,580 kPa) is present,
OK. input port? suspension compression tee
Hydraulic hose 513 OK.
fitting is faulty.
Suspension release tee fitting
OK.
Suspension cylinders OK.
Hydraulic hoses 509 and 511
OK.

POSSIBLE PROBLEMS
NO
Faulty suspension compression
tee fitting.
Faulty air/hydraulic manifold.
Faulty hydraulic hose 512.

Go to step 5
YES
of this fault.

Replace suspension
compression tee fitting
(para 19-12).

2-2230.6 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Disconnect hydraulic hose 512 from

suspension compression tee fitting input
port.
(2) Connect STE/ICE-R between hydraulic
hose 512 and suspension compression
tee fitting input port.
(3) Start engine (TM 9-2320-366-10-1).
(4) Position SUSPENSION knob to RAISE
(TM 9-2320-366-10-1).
(5) Position FUNCTION SELECT knob
to SUSPENSION (TM 9-2320-366-10-1).
(6) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(7) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 5 of this fault.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace suspension
compression tee fitting (para 19-12).
(9) Disconnect STE/ICE-R from hydraulic hose
512 and suspension compression tee
fitting input port.
(10) Connect hydraulic hose 512 to suspension
compression tee fitting input port.

Change 1 2-2230.7
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

5.
Pressure Test or
Other hydraulic manifold STE/ICE-R Test #51
functions OK. Is 2,500-4,000 psi REASON FOR QUESTION
Hydraulic hoses free from (17,238-27,580 kPa)
leaks. present at SUSP If 2,500-4,000 psi (17,238-
Hydraulic hoses 508 and 510 COMPRESS output port? 27,580 kPa) is not present,
OK. air/hydraulic manifold is faulty.
Suspension compression tee If 2,500-4,000 psi (17,238-
fitting OK. 27,580 kPa) is present,
Hydraulic hose 513 OK. hydraulic hose 512 is faulty.
Suspension release tee fitting
OK.
Suspension cylinders OK.
Hydraulic hoses 509 and 511
OK.
NO
POSSIBLE PROBLEMS

Faulty air/hydraulic manifold.

Faulty hydraulic hose 512.

Repair or replace air/hydraulic

YES
manifold (para 19-4).

Replace hydraulic
hose 512 (para 19-12).

2-2230.8 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST

(1) Position drain pan under air/hydraulic

manifold
(2) Disconnect hydraulic hose 512 from
SUSP COMPRESS port.
(3) Connect STE/ICE-R between hydraulic
hose 512 and SUSP COMPRESS port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to RAISE
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob
to SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, repair or replace air/hydraulic
manifold (para 19-4).
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 512
(para 19-12).
(10) Disconnect STE/ICE-R from hydraulic hose
512 and SUSP COMPRESS port.
(11) Connect hydraulic hose 512 to SUSP
COMPRESS port.

Change 1 2-2230.9
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

6.
Pressure Test or
Other hydraulic manifold
functions OK. STE/ICE-R Test #51
Is 2,500-4,000 psi REASON FOR QUESTION
Hydraulic hoses free from (17,238-27,580 kPa)
leaks. present at suspension If 2,500-4,000 psi (17,238-
Hydraulic hoses 508 and 510 release tee fitting 27,580 kPa) is present,
OK. output port? hydraulic hose 513 is faulty.
Suspension compression tee
fitting OK.
Air/hydraulic manifold OK.
Hydraulic hose 512 OK.
POSSIBLE PROBLEMS
Faulty hydraulic hose 513.
Faulty suspension release tee
fitting. NO
Faulty suspension cylinder(s).
Faulty hydraulic hose(s) 509
and/or 511.

Go to step 7
YES
of this fault.

Replace hydraulic
hose 513 (para 19-12).

2-2230.10 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Position drain pan under suspension
release tee fitting.
(2) Disconnect hydraulic hose 513 from
suspension release tee fitting
output port.
(3) Connect STE/ICE-R between hydraulic
hose 513 and suspension release
tee fitting output port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 7 of this fault.
(9) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 513
(para 19-12).
(10) Disconnect STE/ICE-R from hydraulic hose
513 and suspension release tee fitting
output port.
(11) Connect hydraulic hose 513 to suspension
release tee fitting output port.

Change 1 2-2230.11
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

7.
Pressure Test or
Other hydraulic manifold
STE/ICE-R Test #51
functions OK. Is 2,500-4,000 psi
Hydraulic hoses free from REASON FOR QUESTION
(17,238-27,580 kPa)
leaks. present at suspension If 2,500-4,000 psi (17,238-
Hydraulic hoses 508 and 510 release tee fitting 27,580 kPa) is present,
OK. input ports? suspension release tee
Suspension compression tee
fitting is faulty.
fitting OK.
Air/hydraulic manifold OK.
Hydraulic hose 512 OK.
Hydraulic hose 513 OK.
POSSIBLE PROBLEMS

Faulty suspension release tee NO

fitting.
Faulty suspension cylinder(s).
Faulty hydraulic hose(s) 509
and/or 511.

Go to step 8
YES
of this fault.

Replace suspension
release tee fitting
(para 19-12).

2-2230.12 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Disconnect hydraulic hose 511 from
suspension release tee fitting LH
input port.
(2) Connect STE/ICE-R between hydraulic
hose 511 and suspension release
tee fitting LH input port.
(3) Start engine (TM 9-2320-366-10-1).
(4) Position SUSPENSION knob to LOWER
(TM 9-2320-366-10-1).
(5) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(6) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(7) If 2,500-4,000 psi (17,238-27,580 kPa) is
not present, go to step 5 of this fault.
(8) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose 511
(para 19-12).
(9) Disconnect STE/ICE-R from hydraulic hose
511 and suspension release tee fitting
LH input port.
(10) Connect hydraulic hose 511 to suspension
release tee fitting LH input port.
(11) Repeat steps (2) through (12) on hydraulic
hose 509 and suspension release tee
fitting RH input port.

Change 1 2-2230.13
TM 9-2320-366-20-3

u2. SUSPENSION DOES NOT COMPRESS AND/OR RETURN TO NORMAL (CONT)

KNOWN INFO TEST OPTIONS

8.
Pressure Test or
Other hydraulic manifold
STE/ICE-R Test #51
functions OK. Is 2,500-4,000 psi REASON FOR QUESTION
Hydraulic hoses free from (17,238-27,580 kPa)
leaks. present at suspension If 2,500-4,000 psi (17,238-
Hydraulic hoses 508 and 510 cylinder output ports? 27,580 kPa) is not present,
OK. suspension cylinder(s) is faulty.
Suspension compression tee If 2,500-4,000 psi (17,238-
fitting OK. 27,580 kPa) is present,
Air/hydraulic manifold OK. hydraulic hose 509 and/or 511
Hydraulic hose 512 OK. is faulty.
Hydraulic hose 513 OK.
Suspension release tee fitting
OK.
NO
POSSIBLE PROBLEMS

Faulty suspension cylinder(s).

Faulty hydraulic hose(s) 509
and/or 511.

Replace suspension
YES
cylinder(s) (para 19-10).

Replace hydraulic hose(s)

509 and/or 511 (para 19-12).

2-2230.14 Change 1
 TM 9-2320-366-20-3

PRESSURE TEST
(1) Position drain pan under RH suspension
cylinder.
(2) Disconnect hydraulic hose 509 from RH
suspension cylinder output port.
(3) Connect STE/ICE-R between hydraulic
hose 509 and RH suspension cylinder
output port.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position SUSPENSION knob to RAISE
(TM 9-2320-366-10-1).
(6) Position FUNCTION SELECT knob to
SUSPENSION (TM 9-2320-366-10-1).
(7) Push and hold PUMP plunger button
(TM 9-2320-366-10-1) and perform
STE/ICE-R Test #51.
(8) Shut down engine (TM 9-2320-366-10-1).
(9) Disconnect STE/ICE-R from RH suspension
cylinder output port and hydraulic hose
509.
(10) Connect hydraulic hose 509 to RH
suspension cylinder output port.
(11) Repeat steps (1) through (10) on LH
suspension cylinder and hydraulic hose
511.
(12) If 2,500-4,000 psi (17,238-27,580 kPa)
is not present, replace suspension
cylinder(s) (para 19-10).
(13) If 2,500-4,000 psi (17,238-27,580 kPa) is
present, replace hydraulic hose(s) 509
and/or 511.

Change 1 2-2231
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Personnel Required
(2) References
TM 9-4910-571-12&P

START

KNOWN INFO TEST OPTIONS

1.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Do cab air springs
leaks. deflate? This question eliminates
possible problems and
POSSIBLE PROBLEMS determines where
troubleshooting continues.
Faulty variable control check
valve.
Faulty air hose 503.
Faulty air hose 522.
Faulty cab leveling valve tee NO
fitting.
Faulty air hose 506.
Faulty air/hydraulic manifold.
Faulty pressure protection
valve.
Faulty air hose 501.
Faulty cab leveling valve.
Faulty air spring cylinder(s).
Go to step 5
Faulty air hose(s) 504 and/or YES
of this fault.
505.

2-2232 Change 1
 TM 9-2320-366-20-3

NOTE
SYSTEM PARK control must be engaged
(TM 9-2320-366-10-1) before operating
SUSPENSION compression.

(1) Attempt to deflate cab air springs

(TM 9-2320-366-10-1).
(2) If cab air springs do not deflate, go to step 5
of this fault.

Change 1 2-2233
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
CTIS operates. Visual Inspection
Air hoses free from kinks and REASON FOR QUESTION
Do cab air springs
leaks. inflate? This question eliminates
Air hose 522 OK. possible problems and
Air hose 506 OK. determines where
Air/hydraulic manifold OK. troubleshooting continues.
Pressure protection valve OK.
Air hose 501 OK.
POSSIBLE PROBLEMS NO
Faulty variable control check
valve.
Faulty air hose 503.
Faulty cab leveling valve tee
fitting.
Faulty cab leveling valve. Go to step 13
Faulty air spring cylinder(s). YES
of this fault.
Faulty air hose(s) 504 and/or
505.

KNOWN INFO TEST OPTIONS

3.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Is air present at variable
leaks. control check valve input If air is present, variable
Air hose 522 OK. port? control check valve is faulty.
Air hose 506 OK.
Air/hydraulic manifold OK.
Pressure protection valve OK.
Air hose 501 OK.
Cab leveling valve OK.
Air spring cylinders OK. NO
Air hoses 504 and 505 OK.
POSSIBLE PROBLEMS

Faulty variable control check

valve. Go to step 4
YES
Faulty air hose 503. of this fault.
Faulty cab leveling valve tee
fitting.

Replace variable control

check valve (para 16-9).

2-2234 Change 1
 TM 9-2320-366-20-3

(1) Attempt to inflate cab air springs

(TM 9-2320-366-10-1).
(2) If cab air springs do not inflate, go to step 13
of this fault.

(1) Start engine and allow air tanks to pressurize

(TM 9-2320-366-10-1).
(2) Shut down engine (TM 9-2320-366-10-1).
(3) Raise cab (TM 9-2320-366-10-1).
(4) Loosen air hose 503 at variable control check
valve input port.
(5) Check for pressure of air at air hose 503.
(6) Tighten air hose 503 to variable control
check valve.
(7) If air is not present, go to step 4 of this fault.
(8) If air is present, replace variable control check
valve (para 16-9).

Change 1 2-2234.1
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

4.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Is air present at cab leveling
leaks. valve tee fitting check valve If air is not present, cab
Variable control check valve output port? leveling valve tee fitting. If air
OK. is present, air hose 503 is
Air hose 522 OK. faulty.
Air hose 506 OK.
Air/hydraulic manifold OK.
Pressure protection valve OK.
Air hose 501 OK.
Cab leveling valve OK.
Air spring cylinders OK. NO
Air hoses 504 and 505 OK.

POSSIBLE PROBLEMS

Faulty air hose 503.

Faulty cab leveling valve tee
fitting. Replace cab leveling
YES
valve tee fitting (para 16-8).

Replace air hose

503 (para 23-3).

2-2234.2 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 503 at cab leveling valve tee

fitting check valve output port.
(2) Check for pressure of air at cab leveling valve
tee fitting check valve output port.
(3) Tighten air hose 503 at cab leveling valve tee
fitting check valve output port.
(4) If air is not present, replace cab leveling valve
tee fitting (para 16-8).
(5) If air is present, replace air hose 503
(para 23-3).

Change 1 2-2234.3
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

TEST OPTIONS
KNOWN INFO 5.
Visual Inspection
CTIS operates. REASON FOR QUESTION
Air hoses free from kinks and Is air present at air spring
leaks. cylinder input ports? If air is present, air spring
Variable control check valve cylinder(s) is faulty.
OK.
Air hose 503 OK.
POSSIBLE PROBLEMS

Faulty air hose 522.

Faulty cab leveling valve tee
fitting.
Faulty air hose 506. NO
Faulty air/hydraulic manifold.
Faulty pressure protection
valve.
Faulty air hose 501.
Faulty cab leveling valve.
Faulty air spring cylinder(s).
Faulty air hose(s) 504 and/or Go to step 6
YES
505. of this fault.

Replace air spring

cylinder(s) (para 16-9).

2-2234.4 Change 1
 TM 9-2320-366-20-3

(1) Start engine and allow air tanks to pressurize

(TM 9-2320-366-10-1).
(2) Shut down engine (TM 9-2320-366-10-1).
(3) Raise cab (TM 9-2320-366-10-1).
(4) Loosen air hose 504 at RH air spring cylinder.
(5) Turn CAB knob to the right and push in
(TM 9-2320-366-10-1).
(6) Check for presence of air at air hose 504.
(7) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(8) Tighten air hose 504 at RH air spring cylinder.
(9) Repeat steps (4) through (8) on LH air spring
cylinder and air hose 505.
(10) If air is not present, go to step 6 of this
fault.
(11) If air is present, replace air spring
cylinder(s) (para 16-9).

Change 1 2-2234.5
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

6.
CTIS operates. Visual Inspection
Air hoses free from kinks and REASON FOR QUESTION
Is air present at cab leveling
leaks. valve output ports? If air is present, air hose(s) 504
Variable control check valve
and/or 505 is faulty.
OK.
Air hose 503 OK.
Air spring cylinders OK.
POSSIBLE PROBLEMS

Faulty air hose 522. NO

Faulty cab leveling valve tee
fitting.
Faulty air hose 506.
Faulty air/hydraulic manifold.
Faulty pressure protection
valve. Go to step 7
YES
Faulty air hose 501. of this fault.
Faulty cab leveling valve.
Faulty air hose(s) 504 and/or
505.

Replace air hose(s) 504

and/or 505 (para 23-3).

2-2234.6 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hoses 504 and 505 at cab

leveling valve output ports.
(2) Turn CAB knob to the right and push in
(TM 9-2320-366-10-1).
(3) Check for presence of air at cab leveling
valve ouput ports.
(4) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(5) Tighten air hoses 504 and 505 at cab leveling
valve output ports.
(6) If air is not present, go to step 7 of this
fault.
(7) If air is present, replace air hose(s) 504
and/or 505 (para 23-3).

Change 1 2-2234.7
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

7.
CTIS operates. Visual Inspection
Air hoses free from kinks and REASON FOR QUESTION
Is air present at cab leveling
leaks. valve input port? If air is present, cab leveling
Variable control check valve
valve is faulty.
OK.
Air hose 503 OK.
Air spring cylinders OK.
Air hoses 504 and 505 OK.
POSSIBLE PROBLEMS
NO
Faulty air hose 522.
Faulty cab leveling valve tee
fitting.
Faulty air hose 506.
Faulty air/hydraulic manifold.
Faulty pressure protection Go to step 8
YES
valve. of this fault.
Faulty air hose 501.
Faulty cab leveling valve.

Replace cab leveling

valve (para 16-8).

2-2234.8 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 522 at cab leveling

valve input port.
(2) Turn CAB knob to the right and push in
(TM 9-2320-366-10-1).
(3) Check for presence of air at air hose 522.
(4) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(5) Tighten air hose 522 at cab leveling valve
input port.
(6) If air is not present, go to step 8 of this
fault.
(7) If air is present, replace cab leveling valve
(para 16-8).

Change 1 2-2234.9
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

8.
Visual Inspection
CTIS operates.
Air hoses free from kinks and REASON FOR QUESTION
Is air present at cab leveling
leaks. valve tee fitting output port? If air is present, air hose 522
Variable control check valve is faulty.
OK.
Air hose 503 OK.
Cab leveling valve OK.
Air spring cylinders OK.
Air hoses 504 and 505 OK.
NO
POSSIBLE PROBLEMS
Faulty air hose 522
Faulty cab leveling valve tee
fitting.
Faulty air hose 506.
Go to step 9
Faulty air/hydraulic manifold. YES
of this fault.
Faulty pressure protection
valve.
Faulty air hose 501.

Replace air hose

522 (para 23-3).

2-2234.10 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 522 at cab leveling

valve tee fitting output port.
(2) Turn CAB knob to the right and push in
(TM 9-2320-366-10-1).
(3) Check for presence of air at cab leveling
valve tee fitting output port.
(4) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(5) Tighten air hose 522 at cab leveling valve
tee fitting output port.
(6) If air is not present, go to step 9 of this
fault.
(7) If air is present, replace cab leveling valve tee
fitting (para 16-8).

Change 1 2-2234.11
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

9.
Visual Inspection
CTIS operates.
Air hoses free from kinks and REASON FOR QUESTION
Is air present at cab
leaks. leveling valve tee fitting If air is present, cab leveling
Variable control check valve input port? valve tee fitting is faulty.
OK.
Air hose 503 OK.
Air hose 522 OK.
Cab leveling valve OK.
Air spring cylinders OK.
Air hoses 504 and 505 OK.
POSSIBLE PROBLEMS
Faulty cab leveling valve tee NO
fitting.
Faulty air hose 506.
Faulty air/hydraulic manifold.
Faulty pressure protection
valve.
Faulty air hose 501.
Go to step 10
YES
of this fault.

Replace cab leveling

valve tee fitting (para 16-8).

2-2234.12 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 506 at cab leveling

valve tee fitting input port.
(2) Turn CAB knob to the right and push in
(TM 9-2320-366-10-1).
(3) Check for presence of air at air hose 506.
(4) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(5) Tighten air hose 506 at cab leveling valve
tee fitting input port.
(6) If air is not present, go to step 10 of this
fault.
(7) If air is present, replace cab leveling valve tee
fitting (para 16-8).

Change 1 2-2234.13
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

10.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Is air present at air/hydraulic
leaks. manifold BAG CYL port? If air is present, air hose 506
Variable control check valve is faulty.
OK.
Air hose 503 OK.
Air hose 522 OK.
Cab leveling valve tee fitting
OK.
Cab leveling valve OK.
Air spring cylinders OK.
Air hoses 504 and 505 OK.
NO
POSSIBLE PROBLEMS

Faulty air hose 506.

Faulty air/hydraulic manifold.
Faulty pressure protection
valve.
Faulty air hose 501. Go to step 11
YES
of this fault.

Replace air hose

506 (para 23-3).

2-2234.14 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 506 at air/hydraulic

manifold BAG CYL port.
(2) Turn CAB knob to the right and push in
(TM 9-2320-366-10-1).
(3) Check for presence of air at air/hydraulic
manifold BAG CYL port.
(4) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(5) Tighten air hose 506 at air/hydraulic
manifold BAG CYL port.
(6) If air is not present, go to step 11 of this
fault.
(7) If air is present, replace air hose 506
(para 23-3).

Change 1 2-2234.15
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

11.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Is air present at air/hydraulic
leaks. manifold AIR IN B port? If air is present, air/hydraulic
Variable control check valve manifold is faulty.
OK.
Air hose 503 OK.
Air hose 522 OK.
Cab leveling valve tee fitting
OK.
Air hose 506 OK.
Cab leveling valve OK.
Air spring cylinders OK.
NO
Air hoses 504 and 505 OK.

POSSIBLE PROBLEMS

Faulty air/hydraulic manifold.

Faulty pressure protection
valve.
Faulty air hose 501. Go to step 12
YES
of this fault.

Repair or replace air/hydraulic

manifold (para 19-4).

2-2234.16 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 501 at air/hydraulic

manifold AIR IN B port.
(2) Check for presence of air at air hose 501.
(3) Tighten air hose 501 at air/hydraulic
manifold AIR IN B port.
(4) If air is not present, go to step 12 of this
fault.
(5) If air is present, repair or replace air/hydraulic
manifold (para 19-4).

Change 1 2-2234.17
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

12.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Is air present at pressure
leaks. protection valve output If air is not present, pressure
Variable control check valve port? protection valve is faulty. If air
OK. is present, air hose 501 is
Air hose 503 OK. faulty.
Air hose 522 OK.
Cab leveling valve tee fitting
OK.
Air hose 506 OK.
Cab leveling valve OK.
Air spring cylinders OK.
NO
Air hoses 504 and 505 OK.
Air/hydraulic manifold OK.

POSSIBLE PROBLEMS

Faulty pressure protection

valve.
Faulty air hose 501. Replace pressure protection
YES
valve (para 11-29).

Replace air hose

501 (para 23-3).

2-2234.18 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 501 at pressure protection

valve output port.
(2) Check for presence of air at pressure
protection valve output port.
(3) Tighten air hose 501 at pressure protection
valve output port.
(4) If air is not present, replace pressure
protection valve (para 11-29).
(5) If air is present, replace air hose 501
(para 23-3).

Change 1 2-2234.19
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

13.
Visual Inspection
CTIS operates.
REASON FOR QUESTION
Air hoses free from kinks and Is air present at cab leveling
leaks. valve input ports? If air is present, cab leveling
Variable control check valve valve is faulty.
OK.
Air hose 503 OK.
Air hose 522 OK.
Cab leveling valve tee
fitting OK.
Air hose 506 OK. NO
Air/hydraulic manifold OK.
Pressure protection valve OK.
Air hose 501 OK.

POSSIBLE PROBLEMS
Go to step 14
YES
Faulty cab leveling valve. of this fault.
Faulty air spring cylinder(s).
Faulty air hose(s) 504 and/or
505.

Replace cab leveling

valve (para 16-8).

2-2234.20 Change 1
 TM 9-2320-366-20-3

(1) Start engine and allow air tanks to pressurize

(TM 9-2320-366-10-1).
(2) Shut down engine (TM 9-2320-366-10-1).
(3) Raise cab (TM 9-2320-366-10-1).
(4) Loosen air hoses 504 and 505 at cab
leveling valve input ports.
(5) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(6) Check for presence of air at air hoses 504
and 505.
(7) Tighten air hoses 504 and 505 at cab leveling
valve input ports.
(8) If air is not present, go to step 14 of this fault.
(9) If air is present, replace cab leveling valve
(para 16-8).

Change 1 2-2234.21
TM 9-2320-366-20-3

u3. CAB LEVELING AIR SPRINGS DO NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

14.
Visual Inspection
CTIS operates. REASON FOR QUESTION
Air hoses free from kinks and Is air present at air spring
leaks. cylinder output ports? If air is present, air hose(s) 504
Variable control check valve and/or 505 is faulty. If air is
OK. not present, air spring
Air hose 503 OK. cylinder(s) is faulty.
Air hose 522 OK.
Cab leveling valve tee
fitting OK.
Air hose 506 OK.
Air/hydraulic manifold OK.
Pressure protection valve OK.
NO
Air hose 501 OK.
Cab leveling valve OK.

POSSIBLE PROBLEMS

Faulty air spring cylinder(s).

Faulty air hose(s) 504 and/or
505. Replace air spring
YES
cylinder(s) (para 16-9).

Replace air hose(s)

504 and/or 505 (para 23-3).

2-2234.22 Change 1
 TM 9-2320-366-20-3

(1) Loosen air hose 504 at RH air spring cylinder.

(2) Turn CAB knob to the left
(TM 9-2320-366-10-1).
(3) Check for presence of air at RH air spring
cylinder.
(4) Tighten air hose 504 at RH air spring cylinder.
(5) Repeat steps (1) through (4) on LH air spring
cylinder and air hose 505.
(6) Lower cab (TM 9-2320-366-10-1).
(7) If air is not present, replace air spring
cylinder(s) (para 16-9).
(8) If air is present, replace air hose(s) 504
and/or 505 (para 23-3).

Change 1 2-2235/(2-2236 Blank)

 TM 9-2320-366-20-3

2-32. DUMP BODY HYDRAULIC SYSTEM TROUBLESHOOTING

This paragraph covers Dump Body Hydraulic System Troubleshooting. The Dump Body Hydraulic System Fault Index,
Table 2-60, lists faults for the Dump Body Hydraulic System of the vehicle.

Table 2-60. Dump Body Hydraulic System Fault Index

Fault No. Description Page

V1. Dump Body Does Not Raise............................................................................................................ 2-2238

V2. Dump Body Does Not Lower......................................................................................................... 2-2240.2
V3. Dump Body Drifts Down From Raised Position ............................................................................... 2-2240.6

Change 2 2-2237
TM 9-2320-366-20-3

v1. DUMP BODY DOES NOT RAISE

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shutdown (TM 9-2320-366-10-1). Rag, Wiping (Item 50, Appendix D)

Personnel Required Tools and Special Tools

(2) Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

WARNING
CAUTION
Read WARNING and
CAUTION on
KNOWN INFO TEST OPTIONS
1. following page.
Hydraulic oil level OK. Visual Inspection
PTO OK. Are hydraulic lines and hose
REASON FOR QUESTION
free from Class III leaks and
POSSIBLE PROBLEMS
damage? If Class III leaks or damage is
Faulty hydraulic hoses and present, dump body may not
fittings. raise.
Faulty hydraulic oil filter.
Faulty electrical system.
Faulty hydraulic rotary pump.
NO
Faulty four-way relief valve.
Faulty pressure reducing valve.
Faulty dump body hoist
cylinder.

Replace leaking hydraulic hose

YES
or fitting (para 19-15).

2-2238 Change 2
 TM 9-2320-366-20-3

WARNING

Wear approved eye protection when

performing pressure checks. Failure to
comply may result in oil getting into eyes.
If oil contacts eyes, seek medical
attention immediately.

(1) Start engine (TM 9-2320-366-10-1).

(2) Position PTO switch to on
(TM 9-2320-366-10-1).

CAUTION

Keep tachometer within 1,250-1,450

RPM when PTO is engaged. Failure to
comply may result in damage to
equipment.
NOTE
In the event of a tachometer failure, a
HAND THROTTLE lever positioned to L is
approximately 1,250-1,450 RPM.

(3) Set engine speed to 1250-1450 RPM

(TM 9-2320-366-10-1).
(4) Toggle DUMP UP/DOWN switch to UP
position momentarily (TM 9-2320-366-10-1).
(5) Check hydraulic hoses and fittings for Class III
leaks.
NOTE

In the event of a tachometer failure, a

HAND THROTTLE lever positioned to L is
approximately 1,250-1,450 RPM.

(6) Set engine speed to 750 RPM

(TM 9-2320-366-10-1).
(7) Position PTO switch to off
(TM 9-2320-366-10-1).
(8) Shut down engine (TM 9-2320-366-10-1).
(9) If Class III leaks are present, replace leaking
hydraulic hose or fitting (para 19-15).

Change 2 2-2239
TM 9-2320-366-20-3

v1. DUMP BODY DOES NOT RAISE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Hydraulic oil level OK. Visual Inspection
PTO OK. Is hydraulic oil filter free of
REASON FOR QUESTION
Hydraulic hoses and fittings debris.
OK. If hydraulic oil filter is clogged
or damaged, dump body may
POSSIBLE PROBLEMS
not raise.
Faulty hydraulic oil filter.
Faulty electrical system.
Faulty hydraulic rotary pump.
NO
Faulty four-way relief valve.
Faulty pressure reducing valve.
Faulty dump body hoist
cylinder.

Replace hydraulic oil filter

YES
(para 19-13).

Perform Electrical System troubleshooting task

e143. M1090/M1094 Dump Body Does Not Raise.

2-2240 Change 2
 TM 9-2320-366-20-3

WARNING

Dump body weighs approximately 3,034 lbs

(1,376 kgs). Attach a suitable lifting device
prior to lifting. Failure to comply may result in
injury to personnel or damage to equipment..
Prolonged contact with lubricating oil (MIL-L-21
04) may cause a skin rash. Skin and clothing
that come in contact with lubricating oil should
be thoroughly washed immediately. Saturated
clothing should be removed immediately. Areas
in which lubricating oil is used should be well
ventilated to keep fumes to a minimum. Failure
to comply may result in injury to personnel.
Lubricating oil is slippery and can cause falls.
Wipe up spilled oil with rags. Failure to comply
may result in injury to personnel.
(1) Service hydraulic oil filter (para 19-13).
(2) If hydraulic oil filter is damaged or blocked,
replace hydraulic oil filter (para 19-13).
(3) If hydraulic oil filter is not damaged or
blocked, perform Electrical System
troubleshooting task e143. M1090/M1094
Dump Body Does Not Raise.

Change 2 2-2240.1
TM 9-2320-366-20-3

v2. DUMP BODY DOES NOT LOWER

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shutdown (TM 9-2320-366-10-1). Rag, Wiping (Item 50, Appendix D)

Personnel Required Tools and Special Tools

(2) Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

WARNING
CAUTION
Read WARNING and
CAUTION on
KNOWN INFO TEST OPTIONS
1. following page.
Hydraulic oil level OK. Visual Inspection
PTO OK. Are hydraulic lines and hose
REASON FOR QUESTION
free from Class III leaks and
POSSIBLE PROBLEMS
damage? If Class III leaks or damage is
Faulty hydraulic hoses and present, dump body may not
fittings. lower.
Faulty electrical system.
Faulty hydraulic oil filter.
Faulty four-way relief valve.
Faulty dump body hoist NO
cylinder.

Replace leaking hydraulic hose

YES
or fitting (para 19-15).

2-2240.2 Change 2
 TM 9-2320-366-20-3

WARNING

Wear approved eye protection when

performing pressure checks. Failure to
comply may result in oil getting into eyes.
If oil contacts eyes, seek medical
attention immediately.
(1) Start engine (TM 9-2320-366-10-1).
(2) Position PTO switch to on
(TM 9-2320-366-10-1).

CAUTION
Keep tachometer within 1,250-1,450
RPM when PTO is engaged. Failure to
comply may result in damage to
equipment.

NOTE
In the event of a tachometer failure, a
HAND THROTTLE lever positioned to L is
approximately 1,250-1,450 RPM.

(3) Set engine speed to 1250-1450 RPM

(TM 9-2320-366-10-1).
(4) Toggle DUMP UP/DOWN switch to UP
position momentarily (TM 9-2320-366-10-1).
(5) Check hydraulic hoses and fittings for Class III
leaks.
NOTE

In the event of a tachometer failure, a

HAND THROTTLE lever positioned to L is
approximately 1,250-1,450 RPM.

(6) Set engine speed to 750 RPM

(TM 9-2320-366-10-1).
(7) Position PTO switch to off
(TM 9-2320-366-10-1).
(8) Shut down engine (TM 9-2320-366-10-1).
(9) If Class III leaks are present, replace leaking
hydraulic hose or fitting (para 19-15).

Change 2 2-2240.3
TM 9-2320-366-20-3

v2. DUMP BODY DOES NOT LOWER (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Hydraulic oil level OK. Visual Inspection
PTO OK. Is hydraulic oil filter free of
REASON FOR QUESTION
Hydraulic hoses and fittings debris.
OK. If hydraulic oil filter is clogged
or damaged, dump body may
POSSIBLE PROBLEMS
not lower.
Faulty hydraulic oil filter.
Faulty electrical system.
Faulty four-way relief valve. NO
Faulty dump body hoist
cylinder.

Replace hydraulic oil filter

YES
(para 19-13).

Perform Electrical System troubleshooting task

e144. M1090/M1094 Dump Body Does Not Lower.

2-2240.4 Change 2
 TM 9-2320-366-20-3

WARNING

Dump body weighs approximately 3,034 lbs

(1,376 kgs). Attach a suitable lifting device
prior to lifting. Failure to comply may result in
injury to personnel or damage to equipment..
Prolonged contact with lubricating oil (MIL-L-21
04) may cause a skin rash. Skin and clothing
that come in contact with lubricating oil should
be thoroughly washed immediately. Saturated
clothing should be removed immediately. Areas
in which lubricating oil is used should be well
ventilated to keep fumes to a minimum. Failure
to comply may result in injury to personnel.
Lubricating oil is slippery and can cause falls.
Wipe up spilled oil with rags. Failure to comply
may result in injury to personnel.
(1) Service hydraulic oil filter (para 19-13).
(2) If hydraulic oil filter is damaged or blocked,
replace hydraulic oil filter (para 19-13).
(3) If hydraulic oil filter is not damaged or
blocked, perform Electrical System
troubleshooting task e144. M1090/M1094
Dump Body Does Not Lower.

Change 2 2-2240.5
TM 9-2320-366-20-3

v3. DUMP BODY DRIFTS DOWN FROM RAISED POSITION

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shutdown (TM 9-2320-366-10-1). Rag, Wiping (Item 50, Appendix D)

Personnel Required Tools and Special Tools

(2) Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

WARNING
CAUTION
Read WARNING and
CAUTION on
KNOWN INFO TEST OPTIONS
1. following page.
Hydraulic oil level OK. Visual Inspection
PTO OK. Are hydraulic lines and hose
REASON FOR QUESTION
free from Class III leaks and
POSSIBLE PROBLEMS
damage? If Class III leaks or damage is
Faulty hydraulic hoses and present, dump body may drift
fittings. down from raised position.
Faulty counterbalance valve.
Faulty dump body hoist cylinder.
NO

Replace leaking hydraulic hose

YES
or fitting (para 19-15).

Notify DS Maintenance.

2-2240.6 Change 2
 TM 9-2320-366-20-3

WARNING

Wear approved eye protection when

performing pressure checks. Failure to
comply may result in oil getting into eyes.
If oil contacts eyes, seek medical
attention immediately.
(1) Start engine (TM 9-2320-366-10-1).
(2) Position PTO switch to on
(TM 9-2320-366-10-1).

CAUTION
Keep tachometer within 1,250-1,450
RPM when PTO is engaged. Failure to
comply may result in damage to
equipment.

NOTE
In the event of a tachometer failure, a
HAND THROTTLE lever positioned to L is
approximately 1,250-1,450 RPM.

(3) Set engine speed to 1250-1450 RPM

(TM 9-2320-366-10-1).
(4) Toggle DUMP UP/DOWN switch to UP
position momentarily (TM 9-2320-366-10-1).
(5) Check hydraulic hoses and fittings for Class III
leaks.
NOTE

In the event of a tachometer failure, a

HAND THROTTLE lever positioned to L is
approximately 1,250-1,450 RPM.

(6) Set engine speed to 750 RPM

(TM 9-2320-366-10-1).
(7) Position PTO switch to off
(TM 9-2320-366-10-1).
(8) Shut down engine (TM 9-2320-366-10-1).
(9) If Class III leaks are present, replace leaking
hydraulic hose or fitting (para 19-15).
(10) If Class III leaks are not present, notify DS
Maintenance.

Change 2 2-2241/(2-2242 Blank)

 TM 9-2320-366-20-3

2-33. WRECKER HYDRAULIC SYSTEM TROUBLESHOOTING

This paragraph covers Wrecker Hydraulic System Troubleshooting. The Wrecker Hydraulic System Fault Index, Table
2-61, lists faults for the Wrecker Hydraulic System of the vehicle.

Table 2-61. Wrecker Hydraulic System Fault Index

Fault No. Description Page

w1. M1089 Material Handling Crane (MHC) Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2244
w2. M1089 Stifflegs/Left 30K Winch/15K SRW Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2246
w3. M1089 Stiffleg(s) Does Not Operate or Operates Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2248
w4. M1089 Left 30K Winch Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2254
w5. M1089 Stinger/Telescopic Lift Cylinders/Fold Cylinder/Right 30K Winch Do Not
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2256
w6. M1089 Stinger Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2258
w7. M1089 Underlift Telescopic Lift Cylinder(s) Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . 2-2260
w8. M1089 Fold Cylinder Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2262
w9. M1089 Right 30K Winch Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2264
w10. M1089 Material Handling Crane (MHC) Hand Pump Does Not Work . . . . . . . . . . . . . . . . . . . . 2-2266
w11. No Service or External Hydraulic Power From M1089 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2268

2-2243
TM 9-2320-366-20-3

w1. M1089 MATERIAL HANDLING CRANE (MHC) DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
PTO OK. Visual inspection
Left 30K winch OK. REASON FOR QUESTION
Are hydraulic tubes
Right 30K winch OK. Oil quantity may be
and fittings to MHC
Stifflegs OK. insufficient to operate
free from leaks and
15K self-recovery MHC if hydraulic hoses
damage?
winch OK. are leaking or damaged.
Underlift OK.
POSSIBLE PROBLEMS
NO
Damaged hydraulic tube(s)
or fitting(s).
Faulty electrical system.
Replace damaged oil
YES tube(s) and fitting(s)
(para 17-15).

Perform Electrical System

Troubleshooting (e120. M1089
Material Handling Crane (MHC)
Does Not Operate).

2-2244
 TM 9-2320-366-20-3

(1) Check hydraulic tube and fittings between pump

and check valve for leaks and damage.
(2) Check hydraulic tube and fittings between check
valve and port P of MHC for leaks and damage.
(3) Check for proper hydraulic fluid level at reservoir
(TM 9-2320-366-10-1).
(4) If hydraulic tube(s) or fitting(s) is not free from
leaks or damage, replace tube(s) or fitting(s) (para
17-15).
(5) If hydraulic tubes and fitting are free from leaks
and damage, perform Electrical System
Troubleshooting (e120. M1089 Material Handling
Crane (MHC) Does Not Operate).

2-2245
TM 9-2320-366-20-3

w2. M1089 STIFFLEGS/LEFT 30K WINCH/15K SELF-RECOVERY WINCH

DO NOT OPERATE
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Pan, Drain (Item 24, Appendix C)
(2) Goggles, Industrial (Item 15, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Materials/Parts Transducer, STE/ICE-R (Item 1, Appendix J)
Rag, Wiping (Item 50, Appendix D)
Cap and Plug Set (Item 14, Appendix D) References
TM 9-4910-571-12&P

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic oil level OK. on following page. CK4 Check Valve
PTO OK. Pressure Test
Right 30K winch OK. Is pressure present at REASON FOR QUESTION
Stinger OK. pump output? If pressure is between
Folding cylinder OK. 2400-3000 psi at output
Lift cylinders OK. hose of hydraulic pump,
MHC OK. main control valve is
POSSIBLE PROBLEMS faulty. If pressure is
NO
Faulty hydraulic pump. below 2400 psi, pump
Faulty linear directional is faulty.
valve.
Faulty upper main control Notify DS Maintenance.
valve.
YES

Notify DS Maintenance.

2-2246
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic hoses, tubes and
fittings. Failure to comply may
result in injury to personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

NOTE
Adapter and tee kit used in this STE/ICE
test, includes:
(a) 3/4" swivel nut run tee.
(b) 1/2" internal pipe, 3/4" 37 degree
flare swivel adapter.

PRESSURE TEST
(1) Place drain pan under vehicle.
(2) Disconnect hydraulic pressure hose from
lower main pressure tube.
(3) Connect STE/ICE-R, with adapter and tee,
between hydraulic pressure hose and tube.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position PTO switch to on (TM
9-2320-366-10-1).
(6) Perform STE/ICE-R test #51
(TM 9-4910-571-12&P) and note pressure
reading is between 2400-3000 psi (16,548-
20,685 kPa).
(7) If pressure noted in step (6) is below 2400
psi (16,548 kPa), notify DS Maintenance.
(8) If pressure noted in step (6) is between
2400-3000 kPa) notify DS Maintenance.
(9) Position PTO switch to off (TM
9-2320-366-10-1).
(10) Shut down engine (TM 9-2320-366-10-1).
(11) Disconnect STE/ICE-R, tee, and adapter from
pressure line.
(12) Connect hydraulic pressure hose to lower
main pressure tube.
(13) Tighten hydraulic hose to 36-39 lb-ft (49-53
N·m).

2-2247
TM 9-2320-366-20-3

w3. M1089 STIFFLEG(S) DOES NOT OPERATE OR OPERATES SLOWLY

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE-ICE-R (Item 41, Appendix C)
Personnel Required Pan, Drain (Item 24, Appendix C
(2) Trestle, Motor Vehicle Maintenance (Item 47, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Materials/Parts Transducer, STE/ICE-R (Item 1, Appendix J)
Rag, Wiping (Item 50, Appendix D)
Lockwasher (6) (Item 100, Appendix G) References
Cap and Plug Set (Item 14, Appendix D) TM 9-4910-571-12&P

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic oil level OK. on following page. Visual inspection
PTO OK. REASON FOR QUESTION
Are hydraulic hoses, tubes
Left 30K winch OK. Leaking hydraulic
and fittings free from leaks
15K self-recovery hoses, tubes or fittings
or damage?
winch OK. will cause stifflegs to
POSSIBLE PROBLEMS operate slowly or not at
Faulty hydraulic hoses all.
tubes and fittings.
Faulty upper main control NO
valve.
Faulty stiffleg relief valve.
Tighten loose fitting(s) and replace damaged
Faulty stiffleg cylinder.
hydraulic hose(s), tubes(s) and fitting(s)
(para 19-16, 19-17).

YES

2-2248
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic hoes, tubes, and
fittings. Failure to comply may
result in injury to personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

(1) Place drain pan under vehicle.

(2) Remove four screws, lockwashers, and washers
from middle control panel cover. Discard
lockwashers.
(3) Remove two screws, washers, lockwashers, nuts
and middle control panel cover from control
panel. Discard lockwashers.
(4) Check hydraulic hoses, tubes and fittings for
leakage and damage from upper main control
valve to stiffleg cylinders.
(5) Position middle control panel cover on
control panel with two screws, washers,
lockwashers and nuts.
(6) Install four washers, lockwashers and
screws in middle control panel cover.

2-2249
TM 9-2320-366-20-3

w3. M1089 STIFFLEG(S) DOES NOT OPERATE OR OPERATES SLOWLY (CONT)

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
2.
Hydraulic oil level OK. on following page. V1 Pressure Test
PTO OK. REASON FOR QUESTION
Is pressure present at
Left 30K winch OK. Stiffleg(s) will not operate
port V1 of cylinder
15K self-recovery if upper main control valve
for affected stiffleg?
winch OK. is faulty.
Hydraulic hoses, tubes
and fittings OK.
POSSIBLE PROBLEMS
NO
Faulty upper main control
valve.
Faulty stiffleg relief valve.
Faulty stiffleg cylinder. Notify DS Maintenance.

YES

2-2250
 TM 9-2320-366-20-3

WARNING

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

V1 PRESSURE TEST
(1) If stiffleg has failed in an off-the-ground
position, place trestle under foot of stiffleg
before doing tests.
(2) Open box lid over affected stiffleg and slide
off cylinder cover.
(3) Disconnect UP pressure hose at V1 port of
affected stiffleg cylinder.
(4) Cap V1 fitting on top of cylinder.
(5) Connect STE/ICE-R transducer and adapter onto
end of disconnected UP pressure hose.
(6) Start engine (TM 9-2320-366-10-1).
(7) Position PTO switch to on (TM
9-2320-366-10-1).
(8) Perform STE/ICE-R test # 51.
(TM 9-4910-571-12&P).
(9) Momentarily position stiffleg lever for affected
stiffleg to UP position, release lever.
(10) Observe pressure reading. If pressure is
below 3000 psi (20,685 kPa), notify DS
Maintenance.
(11) Position PTO switch to off (TM
9-2320-366-10-1).
(12) Shut down engine (TM 9-2320-366-10-1).
(13) Disconnect STE/ICE-R from UP pressure hose.
(14) Remove cap from V1 fitting on top of
cylinder.
(15) Connect UP pressure hose to V1 port of
cylinder.
(16) Close box lid cover over affected stiff
leg cylinder.
(17) Remove trestle if required.

2-2251
TM 9-2320-366-20-3

w3. M1089 STIFFLEG(S) DOES NOT OPERATE OR OPERATES SLOWLY (CONT)

KNOWN INFO TEST OPTIONS

3.
Hydraulic oil level OK. Stiffleg cylinder inspection
PTO OK. REASON FOR QUESTION
Left 30K winch OK. Is affected stiffleg Faulty relief valve or
15K self-recovery cylinder leaking oil? stiffleg cylinder will
winch OK. cause stiffleg to drift
Hydraulic hoses, tubes or to not work.
and fittings OK.
POSSIBLE PROBLEMS
NO
Faulty stiffleg relief valve.
Faulty left stiffleg cylinder.

Notify DS Maintenance.

YES

Notify DS Maintanence.

2-2252
 TM 9-2320-366-20-3

STIFFLEG CYLINDER INSPECTION

(1) Start engine (TM 9-2320-366-10-1).
(2) Position PTO switch to on (TM
9-2320-366-10-1).
(3) If stiffleg will operate, lower and raise left
stiffleg two or more times (TM 9-2320-366-10-1)
and observe stiffleg for leaks.
(4) If leaks are observed in step (3) notify
DS Maintenance.
(5) If cylinder is dry, notify DS Maintenance.
(6) Position PTO switch to off (TM
9-2320-366-10-1).
(7) Shut down engine (TM 9-2320-366-10-1).
(8) Slide cover over cylinder into closed position.
(9) Remove drain pan from under vehicle.

2-2253
TM 9-2320-366-20-3

w4. M1089 LH 30K WINCH DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)
Materials/Parts Goggles, Industrial (Item 15, Appendix C)
Rag, Wiping (Item 50, Appendix D)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Hydraulic tank oil level OK. Visual Inspection
MAIN WINCH LH FREESPOOL Are hydraulic tubes and
REASON FOR QUESTION
switch to OFF. fittings free from leaks or
MAIN WINCH LH FREESPOOL damage? Leaking hydraulic tubes or
switch OK. fittings will cause LH 30K
winch not to operate.
POSSIBLE PROBLEMS
Faulty hydraulic tubes and
fittings.
Faulty upper main valve NO
assembly.
Faulty pressure relief valve
assembly.
Faulty LH 30K winch Tighten loose fitting(s) and
assembly. YES replace damaged hydraulic
tube(s) and fitting(s) (para 17-27).

2-2254 Change 2
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses, tubes,
and fittings. Failure to comply may result
in injury to personnel.
Wear approved eye protection when
performing pressure checks. Failure to
comply may result in oil getting into eyes.
If oil contacts eyes, seek medical attention
immediately.
Fuel and oil are slippery and can cause
falls. Wipe up spilled fuel or oil with rags.
Failure to comply may result in injury to
personnel.
(1) Check hydraulic tubes and fittings for leakage
and damage.
(2) If hydraulic tubes and fittings are leaking or
damaged, tighten loose fitting(s) and replace
damaged hydraulic tube(s) and fitting(s).

Change 1 2-2254.1
TM 9-2320-366-20-3

w4. M1089 LH 30K WINCH DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
Hydraulic tank oil level OK. Operational Test
MAIN WINCH LH FREESPOOL Do LH and RH stifflegs
switch to OFF. REASON FOR QUESTION
operate?
MAIN WINCH LH FREESPOOL This question eliminates
switch OK. possible problems and
Hydraulic tubes and fittings determines where to continue
OK. troubleshooting.
POSSIBLE PROBLEMS
Faulty upper main valve
assembly. NO
Faulty pressure relief valve
assembly.
Faulty LH 30K winch
assembly. Perform Wrecker Hydraulic System
Troubleshooting task w2. M1089
YES
STIFFLEGS/ LEFT 30K WINCH/ 15K
SRW DO NOT OPERATE.

Notify DS Maintenance.

2-2254.2 Change 2
 TM 9-2320-366-20-3

OPERATIONAL TEST
(1) Attempt to operate LH and RH stifflegs
(TM 9-2320-366-10-2).
(2) If LH and RH stifflegs do not operate,
perform Wrecker Hydraulic System
Troubleshooting task w2. M1089
STIFFLEGS/ LEFT 30K WINCH/ 15K SRW
DO NOT OPERATE.
(3) If LH and RH stifflegs does operate, notify
DS Maintenance.

Change 1 2-2255
TM 9-2320-366-20-3

w5. M1089 STINGER/TELESCOPIC LIFT CYLINDERS/FOLDING CYLINDERS/RIGHT 30K WINCH

DO NOT OPERATE
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Gen Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Pan, Drain (Item 24, Appendix C)
(2) Goggles, Industrial (Item 15, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Material/Parts Transducer, STE/ICE-R (Item 1, Appendix J)
Rag, Wiping (Item 50, Appendix D)
References
TM 9-4910-571-12&P

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic oil level OK. on following page. Pressure Test
PTO OK. REASON FOR QUESTION
Is pressure present at
Left 30K winch OK. If pressure is between
three stage hydraulic
Stifflegs OK. 2400-3000 psi at output
pump output?
15K self-recovery hose of three stage
winch OK. hydraulic pump, main
POSSIBLE PROBLEMS control valve is faulty.
Faulty lower main control NO If pressure is below 2400
valve. psi, pump is faulty.
Faulty three stage
hydraulic pump.
YES Notify DS Maintenance.

Notify DS Maintenance.

2-2256
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic hoses, tubes, and
fittings. Failure to comply may
result in injury to personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

NOTE
Tee and adapter used in STE/ICE test are:
(a) 3/4'' swivel nut run tee.
(b) Internal pipe 1/2" F/ 37 degree flair
3/4"F swivel adapter.

PRESSURE TEST
(1) Place drain pan under vehicle.
(2) Disconnect hydraulic pressure hose from
upper main pressure tube.
(3) Connect STE/ICE-R, with adapter and tee
between hydraulic pressure hose and tube.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position PTO switch to on (TM
9-2320-366-10-1).
(6) Perform STE/ICE-R test #51
(TM 9-4910-571-12&P) and note pressure
reading is between 2400-3000 psi (16,548-
20,685 kPa).
(7) If pressure noted in step (6) is below 2400
psi (16,548 kPa), notify DS Maintenance.
(8) If pressure noted in step (6) is between
2400-3000 psi (16,548-20,685 kPa), notify DS
Maintenance.
(9) Position PTO switch to off (TM
9-2320-366-10-1).
(10) Shut down engine (TM 9-2320-366-10-1).
(11) Disconnect STE/ICE-R test equipment, adapter
and tee from hydraulic pressure hose.
(12) Connect hydraulic pressure hose to upper
main pressure tube valve.
(13) Tighten hydraulic tube fitting to 36-39 lb-ft
(49-53 N·m).
(14) Remove drain pan from under vehicle.

2-2257
TM 9-2320-366-20-3

w6. M1089 STINGER DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Gen Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Hydraulic oil level OK. Stinger Operation Check
PTO OK. REASON FOR QUESTION
Does stinger operate
Right main winch OK. If stinger operates from
from wrecker control
Folding cylinder OK. wrecker control panel and
panel only?
Stiffleg cylinder OK. not from remote, stinger
POSSIBLE PROBLEMS electrical system is faulty.
Faulty stinger hydraulic
system. NO
Faulty stinger electrical
system.

YES Notify DS Maintenance.

Perform Electrical System

Troubleshooting (e138. All
Wrecker Functions Do Not Operate
From Wrecker Control Panel).

2-2258
 TM 9-2320-366-20-3

STINGER OPERATIONAL CHECK

(1) Connect remote control unit to RH remote
control hook-up (J2) at rear of vehicle.
(2) Start engine (TM 9-2320-366-10-1).
(3) Position PTO switch to on (TM
9-2320-366-10-1).
(4) Position STATION SELECTOR switch to
REMOTE CONTROL.
(5) Check if stinger operates at remote control
(TM 9-2320-366-10-1).
(6) Position STATION SELECTOR switch to
WRECKER CONTROL panel.
(7) Check if stinger operates IN or OUT from
wrecker control panel (TM 9-2320-366-10-1).
(8) If stinger does not operate from remote or
wrecker control panel, notify DS Maintenance.
(9) If stinger operates from wrecker control panel
but not remote, perform Electrical System
Troubleshooting (e138. All Wrecker Functions
Do Not Operate From Wrecker Control Panel).
(10) Position PTO switch to off (TM
9-2320-366-10-1).
(11) Shut down engine (TM 9-2320-366-10-1).
(12) Remove and stow remote control unit and cable.

2-2259
TM 9-2320-366-20-3

w7. M1089 UNDERLIFT TELESCOPIC LIFT CYLINDER(S) DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Gen Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Hydraulic oil level OK. Underlift Operation Check
PTO OK. REASON FOR QUESTION
Do underlift cylinders
Right 30K winch OK. If underlift operates from
operate from wrecker
Folding cylinder OK. wrecker control panel and
control panel only?
Stinger cylinder OK. not from remote, underlift
POSSIBLE PROBLEMS electrical system is faulty.
Faulty underlift hydraulic
system. NO
Faulty underlift electrical
system.

YES Notify DS Maintenance.

Perform Electrical System

Troubleshooting (e137. All
Wrecker Functions Do Not Operate
From Wrecker Remote Control).

2-2260
 TM 9-2320-366-20-3

UNDERLIFT OPERATIONAL CHECK

(1) Connect remote control unit to RH remote
control hook-up (J2) at rear of vehicle.
(2) Start engine (TM 9-2320-366-10-1).
(3) Position PTO switch to on (TM
9-2320-366-10-1).
(4) Position STATION SELECTOR switch to
REMOTE CONTROL.
(5) Check if underlift operates at remote control
(TM 9-2320-366-10-1).
(6) Position STATION SELECTOR switch to
WRECKER CONTROL panel.
(7) Check if underlift operates UP or DOWN from
wrecker control panel (TM 9-2320-366-10-1).
(8) If underlift does not operate from remote or
wrecker control panel, notify DS Maintenance.
(9) If underlift operates from wrecker control panel
but not remote, perform Electrical System
Troubleshooting (e137. All Wrecker Functions
Do Not Operate From Wrecker Remote
Control).
(10) Position PTO switch to off (TM
9-2320-366-10-1).
(11) Shut down engine (TM 9-2320-366-10-1).
(12) Remove and stow remote control.

2-2261
TM 9-2320-366-20-3

w8. M1089 FOLDING CYLINDER DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

START

KNOWN INFO TEST OPTIONS

1.
Hydraulic oil level OK. Remote Control Test
PTO OK. REASON FOR QUESTION
Does folding cylinder
Right 30K winch OK. If folding cylinder operates
operate from wrecker
Stinger cylinder OK. from wrecker control panel
control panel only?
Underlift OK. and not from remote,
POSSIBLE PROBLEMS electrical system is faulty.
Faulty underlift fold
hydraulic system.
NO
Faulty electrical system.

Notify DS Maintenance.
YES

Perform Electrical System

Troubleshooting (e137. All
Wrecker Functions Do Not
Operate From Wrecker
Remote Control).

2-2262
 TM 9-2320-366-20-3

REMOTE CONTROL TEST

(1) Connect remote control unit to RH remote
control connector (J2) at rear of wrecker
(TM 9-2320-366-10-1).
(2) Start engine (TM 9-2320-366-10-1).
(3) Position PTO switch to on (TM
9-2320-366-10-1).
(4) Position STATION SELECTOR switch to
REMOTE CONTROL (TM 9-2320-366-10-1).
(5) Check if folding cylinder operates (UP or
DOWN) at REMOTE CONTROL panel
(TM 9-2320-366-10-1).
(6) Position STATION SELECTOR switch to
WRECKER CONTROL panel
(TM 9-2320-366-10-1).
(7) Check if folding cylinder operates (UP or
DOWN) from wrecker control panel.
(8) If folding cylinder does not operate from
remote or wrecker control panels, notify DS
Maintenance.
(9) If folding cylinder operates from wrecker
control panel but not from remote, perform
Electrical System Troubleshooting (e137. All
Wrecker Functions Do Not Operate
From Wrecker Remote Control).
(10) Position PTO switch to off (TM
9-2320-366-10-1).
(11) Shut down engine (TM 9-2320-366-10-1).
(12) Disconnect remote control unit and stow.

2-2263
TM 9-2320-366-20-3

w9. M1089 RH 30K WINCH DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)
Materials/Parts Goggles, Industrial (Item 15, Appendix C)
Rag, Wiping (Item 50, Appendix D)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Hydraulic tank oil level OK. Visual Inspection
MAIN WINCH RH FREESPOOL Are hydraulic tubes and
REASON FOR QUESTION
switch to OFF. fittings free from leaks or
MAIN WINCH RH FREESPOOL damage? Leaking hydraulic tubes or
switch OK. fittings will cause RH 30K
winch not to operate.
POSSIBLE PROBLEMS
Faulty hydraulic tubes and
fittings.
Faulty lower main valve NO
assembly.
Faulty pressure relief valve
assembly.
Faulty RH 30K winch Tighten loose fitting(s) and
assembly. YES replace damaged hydraulic
tube(s) and fitting(s) (para 17-27).

2-2264 Change 2
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses, tubes,
and fittings. Failure to comply may result
in injury to personnel.
Wear approved eye protection when
performing pressure checks. Failure to
comply may result in oil getting into eyes.
If oil contacts eyes, seek medical attention
immediately.
Fuel and oil are slippery and can cause
falls. Wipe up spilled fuel or oil with rags.
Failure to comply may result in injury to
personnel.

(1) Place drain pan under vehicle.

(2) Check hydraulic tubes and fittings for leakage
and damage.

Change 1 2-2264.1
 TM 9-2320-366-20-3

w9. M1089 RH 30K WINCH DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
Hydraulic tank oil level OK. Operational Test
MAIN WINCH RH FREESPOOL Does underlift fold cylinder
switch to OFF. REASON FOR QUESTION
operate?
MAIN WINCH RH FREESPOOL This question eliminates
switch OK. possible problems and
Hydraulic tubes and fittings determines where to continue
OK. troubleshooting.
POSSIBLE PROBLEMS
Faulty lower main valve
assembly. NO
Faulty pressure relief valve
assembly.
Faulty RH 30K winch
assembly. Perform Wrecker Hydraulic System
Troubleshooting task w5. M1089 STINGER/
YES
TELESCOPIC LIFT CYLINDERS/FOLD CYLINDER/
RIGHT 30K WINCH DO NOT OPERATE.

Notify DS Maintenance.

2-2264.2 Change 2
 TM 9-2320-366-20-3

OPERATIONAL TEST
(1) Attempt to operate underlift
(TM 9-2320-366-10-2).
(2) If underlift does not operate, perform
Wrecker Hydraulic System Troubleshooting
task w5. M1089 STINGER/TELESCOPIC
LIFT CYLINDERS/FOLD CYLINDER/RIGHT
30K WINCH DO NOT OPERATE.
(3) If underlift does operate, notify DS
Maintenance.

Change 1 2-2265
TM 9-2320-366-20-3

w10. M1089 MATERIAL HANDLING CRANE (MHC) HAND PUMP DOES NOT WORK
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

Materials/Parts
Rag, Wiping (Item 50, Appendix D)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic oil level OK. on following page. Hand Pump Test
Hydraulic lines REASON FOR QUESTION
and fittings OK. Does hand pump Faulty check valve or hand
All functions operate build pressure? pump will prevent manual
with PTO engaged. operation of crane.
POSSIBLE PROBLEMS
Faulty input check valve.
Faulty hand pump.

NO

YES

Notify DS Maintenance.

Notify DS Maintenance.

2-2266
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic line. Failure to comply
may result in injury to
personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

HAND PUMP TEST

(1) Disconnect hand pump delivery line from elbow
at hand pump.
(2) Place drain pan under port at pump to catch
hydraulic fluid.
(3) Pump hand pump (TM 9-2320-366-10-1).
(4) Check if hydraulic fluid pumps out of port with
each stroke.
(5) If little or no hydraulic fluid pumps out, hand
pump is faulty.
(6) Connect delivery line to elbow at hand pump.
(7) Remove drain pan.

2-2267
TM 9-2320-366-20-3

w11. NO SERVICE OR EXTERNAL HYDRAULIC POWER FROM M1089

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

Materials/Parts
Rag, Wiping (Item 50, Appendix D)
Lockwasher (6) (Item 100, Appendix G)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic oil level OK. on following page. Visual inspection
PTO OK. REASON FOR QUESTION
Are hydraulic hoses,
Normal wrecker functions Hydraulic oil quantity may
tubes and fittings free
OK. be insufficient to operate
from leaks and damage?
POSSIBLE PROBLEMS slave or external power if
Leaking or damaged hoses, tubes or fittings
hydraulic hoses, tubes are damaged.
fittings.
Faulty linear directional
NO
valve.
Faulty slaved vehicle or
external power tool.

YES
Tighten loose fitting(s) and replace damaged
hydraulic hose(s), tube(s) and/or fitting(s)
(para 19-17, 19-18).

Perform Electrical System

Troubleshooting (e138. All
Wrecker Functions Do Not
Operate From Wrecker
Control Panel).

2-2268
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic line. Failure to comply
may result in injury to
personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

(1) Place drain pan under vehicle.

(2) Remove four screws, lockwashers and
washers from middle control panel
cover. Discard lockwashers.
(3) Remove two screws, washers,
lockwashers, nuts and middle control
panel cover from control panel.
Discard lockwashers.
(4) Check hydraulic hoses, tubes and fittings
from linear directional valve to slave and
external output ports.
(5) Position middle control panel cover on
control panel with two screws, washers
and nuts.
(6) Install four washers, lockwashers, and
screws in middle control panel cover.

2-2269/(2-2270 Blank)
 TM 9-2320-366-20-1

2-34. SPECIAL PURPOSE KIT TROUBLESHOOTING

This paragraph covers Special Purpose Kit Troubleshooting. The Special Purpose Kit Fault Index, Table 2-62, lists faults
for the Special Purpose Kits of the vehicle.

Table 2-62. Special Purpose Kit Fault Index

Fault No. Description Page

x1. No Power to Digitization Rack ......................................................................................................... 2-2272

x2. No Power to Mobile Tracking System (MTS) Sense........................................................................... 2-2282
x3. No Power to Enhanced Position Location Reporting System (EPLRS)................................................. 2-2288
x4. No Power to Precision Lightweight Global Positioning System Receiver (PLGR)................................... 2-2292
x5. No Power to Drive Visual Enhancement (DVE) .................................................................................. 2-2296
x6. No Power to SINCGAR/Force XXI Battle Command Brigade and Below (FBCB).................................... 2-2300
x7. No Power to Mobile Tracking System (MTS) ..................................................................................... 2-2304
x8. Deleted.......................................................................................................................................... 2-2310
x9. Deleted.......................................................................................................................................... 2-2314
x10. Deleted.......................................................................................................................................... 2-2324
x11. Deleted.......................................................................................................................................... 2-2326
x12. Deleted.......................................................................................................................................... 2-2332
x13. Deleted.......................................................................................................................................... 2-2344
x14. Deleted.......................................................................................................................................... 2-2354
x15. Deleted.......................................................................................................................................... 2-2356
x16. Deleted.......................................................................................................................................... 2-2362
x17. Deleted.......................................................................................................................................... 2-2368
x18. Troop Transport Alarm Does Not Operate.......................................................................................... 2-2372
x19. Light Material Handling Crane (LMHC) Does Not Operate ................................................................... 2-2382
x20. Light Material Handling Crane (LMHC) Hoist In Does Not Operate ....................................................... 2-2400
x21. Light Material Handling Crane (LMHC) Hoist Out Does Not Operate .................................................... 2-2404

Change 2 2-2271
TM 9-2320-366-20-3

x1. NO POWER TO DIGITIZATION RACK

INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Voltage Test or
Nothing.
STE/ICE-R Test #89
Is 24 VDC present at
POSSIBLE PROBLEMS REASON FOR QUESTION
terminal lug TL16?
This question eliminates
Circuit breaker CB11 tripped.
possible problems and
Faulty circuit breaker CB11.
determines where
Faulty power cable from
troubleshooting continues.
terminal lug TL24 to terminal
lug TL20.
Faulty power cable from
terminal lug TL23 to terminal
NO
lug TL16.
Faulty power cable from
terminal lug TL18 to terminal
block TB2.
Faulty Power Distribution YES Go to step 2 of this fault.
Panel (PD1).

Go to step 5 of this fault.

2-2272 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Remove dust boot from terminal lug TL16.
(5) Set multimeter to volts DC.
(6) Connect positive (+) probe of multimeter to
terminal lug TL16.
(7) Connect negative (-) probe of multimeter to
known good ground and note reading on
multimeter.
(8) If 24 VDC is not present, go to step 2 of
this fault.
(9) If 24 VDC is present, go to step 5 of this
fault.
(10) Install dust boot on terminal lug TL16.

Change 2 2-2273
TM 9-2320-366-20-3

x1. NO POWER TO DIGITIZATION RACK (CONT)

TEST OPTIONS TEST OPTIONS

2.
Nothing. Visual Inspection
Is circuit breaker CB11
POSSIBLE PROBLEMS REASON FOR QUESTION
tripped?
Circuit breaker CB11 tripped. If circuit breaker CB11 is
Faulty circuit breaker CB11. tripped, digitization rack will
Faulty power cable from not have power.
terminal
lug TL24 to terminal lug TL20.
Faulty power cable from
terminal
lug TL23 to terminal lug TL16. NO

YES Go to step 3 of this fault.

Reset circuit breaker CB11.

If circuit breaker CB11, trips agian
replace circuit breaker CB11
(para 20-81).

2-2274 Change 2
 TM 9-2320-366-20-3

(1) Remove three screws and washers from

Power Distribution Panel (PDP).
(2) Remove three screws from Power Distribution
Panel (PDP).
(3) Lift Power Distribution Panel (PDP) to gain
access.
(4) Push in reset button on circuit breaker CB11
to see if it is tripped.
(5) If circuit breaker CB11 is not tripped, go to
step 3 of this fault.
(6) If circuit breaker CB11 trips agian, replace
circuit breaker CB11 (para 20-81).

NOTE
Perform steps (7) through (9) if circuit
breaker CB11 is faulty.

(7) Position electrical distribution block cover on

power distribution shelf.
(8) Tighten wing screw on electrical distribution
block cover.
(9) Install wing screw in power distribution shelf.

Change 2 2-2275
TM 9-2320-366-20-3

x1. NO POWER TO DIGITIZATION RACK (CONT)

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
3. on following page.
Voltage Test or
Circuit breaker CB11 not tripped.
STE/ICE-R Test #89
Is 24 VDC present at
POSSIBLE PROBLEMS REASON FOR QUESTION
terminal lug TL24?
Faulty circuit breaker CB11. If 24 VDC is not present,
Faulty power cable from power cable from terminal lug
terminal lug TL24 to terminal TL24 to terminal lug TL20 is
lug TL20. faulty.
Faulty power cable from
terminal lug TL23 to terminal
lug TL16.
NO

Replace power cable from

YES terminal lug TL24 to terminal
lug TL20 (para 20-81).

2-2276 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove dust boot from terminal lug TL24.
(2) Set multimeter to volts DC.
(3) Connect positive (+) probe of multimeter to
terminal lug TL24.
(4) Connect negative (-) probe of multimeter to
a known good ground and note reading on
multimeter.
(5) If 24 VDC is not present, replace power cable
from terminal lug TL24 to terminal lug TL20
(para 20-81).
(6) Install dust boot on terminal lug TL24.

Change 2 2-2277
TM 9-2320-366-20-3

x1. NO POWER TO DIGITIZATION RACK (CONT)

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
4. on following page.
Circuit breaker CB11 not tripped. Voltage Test or
Power cable from terminal lug STE/ICE-R Test #89
TL24 to terminal lug TL20 OK. Is 24 VDC present at terminal
REASON FOR QUESTION
lug TL23?
POSSIBLE PROBLEMS If 24 VDC is not present, circuit
Faulty circuit breaker CB11. breaker CB11 is faulty. If 24
Faulty power cable from terminal VDC is present, power cable
lug TL23 to terminal lug TL16. from terminal lug TL23 to
terminal lug TL16 is faulty.

NO

Replace circuit breaker CB11

YES
(para 20-81).

Replace power cable from terminal

TL23 to terminal TL16 (para 20-81).

2-2278 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST

(1) Remove dust boot from terminal lug TL23.

(2) Set multimeter to volts DC.
(3) Connect positive (+) probe of multimeter to
terminal lug TL23.
(4) Connect negative (-) probe of multimeter to
a known good ground and note reading on
multimeter.
(5) If 24 VDC is not present, replace circuit
breaker CB11 (para 20-81).
(6) If 24 VDC is present, replace power cable
from terminal lug TL23 to terminal lug TL16
(para 20-81).
NOTE
Perform steps (7) through (9) if circuit
breaker CB11 is faulty.

(7) Position electrical distribution block cover

on power distribution shelf.
(8) Tighten wing screw on electrical
distribution block cover.
(9) Install wing screw on power distribution
shelf.

Change 2 2-2279
TM 9-2320-366-20-3

x1. NO POWER TO DIGITIZATION RACK (CONT)

TEST OPTIONS TEST OPTIONS

5.
Circuit breaker CB11 not Continuity Test or
tripped. STE/ICE-R Test #91
Is continuity present from
Circuit breaker CB11 OK. REASON FOR QUESTION
terminal lug TL18 to a
Power cable from terminal lug If continuity is not present,
known good ground?
TL24 to terminal lug TL20 OK. power cable from terminal lug
Power cable from terminal lug TL18 to terminal board TB2 is
TL23 to terminal lug TL16 OK. faulty. If continuity is present,
POSSIBLE PROBLEMS Power Distribution Panel (PD1)
is faulty.
Faulty power cable from
terminal NO
lug TL18 to terminal block
TB2.
Faulty Power Distribution Panel
(PD1). Replace power cable from terminal lug
YES
TL18 to terminal board TB2 (para 20-81).

Replace Power Distribution Panel

(PD1) (para 20-81).

2-2280 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
terminal lug TL18.
(3) Connect negative (-) probe of multimeter to
a known good ground and note reading on
multimeter.
(4) If continuity is not present, replace power
cable from terminal lug TL18 to terminal
board TB2 (para 20-81).
(5) If continuity is present, replace Power
Distribution Panel (PD1) (para 20-81).

Change 2 2-2281
TM 9-2320-366-20-3

x2. NO POWER TO MOBILE TRACKING SYSTEM (MTS) SENSE

INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Voltage Test or
Circuit breaker CB1 is not
STE/ICE-R Test #89
tripped. Is 24 VDC present at
REASON FOR QUESTION
terminal lug TL6?
POSSIBLE PROBLEMS
If 24 VDC is not present, go to
Faulty circuit breaker CB1. step 2 of this fault. If 24 VDC
Faulty power cable from is present perform Mobile
terminal lug TL15 to terminal Tracking System (MTS) Sense
lug TL22. troubleshooting.
Faulty Power Distribution Panel
(PD2).
Faulty Mobile Tracking System NO
(MTS) Sense.

YES Go to step 2 of this fault.

Contact supervisor, Mobile Tracking System

(MTS) Sense troubleshooting needs to be
performed.

2-2282 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Set multimeter to volts DC.
(5) Connect positive (+) probe of multimeter to
terminal lug TL6.
(6) Connect negative (-) probe of multimeter to
known good ground.
(7) Position master power switch to on
(TM 9-2320-366-10-1) and note reading on
multimeter.
(8) Position master power switch to off
(TM 9-2320-366-10-1).
(9) If 24 VDC is not present, go to step 2 of
this fault.
(10) If 24 VDC is present, contact supervisor,
Mobile Tracking System (MTS) Sense
troubleshooting needs to be performed.

Change 2 2-2283
TM 9-2320-366-20-3

x2. NO POWER TO MOBILE TRACKING SYSTEM (MTS) SENSE (CONT)

TEST OPTIONS TEST OPTIONS

2.
Continuity Test or
Circuit breaker CB1 is not
STE/ICE-R Test #91
tripped. Is continuity present through
REASON FOR QUESTION
circuit breaker CB1?
POSSIBLE PROBLEMS
If continuity is not present,
Faulty circuit breaker CB1. circuit breaker CB1 is faulty.
Faulty power cable from
terminal lug TL15 to terminal
lug TL22.
Faulty Power Distribution
Panel (PD2).
NO

Replace circuit breaker

YES
CB1 (para 20-80).

2-2284 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST

(1) Remove circuit breaker CB1 from Power

Distribution Panel (PD2).
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one terminal of circuit breaker CB1.
(4) Connect negative (-) probe of multimeter to
other terminal of circuit breaker CB1 and
note reading on multimeter.
(5) If continuity is not present, replace circuit
breaker CB1 (para 20-80).
(6) Install circuit breaker CB1 in Power
Distribution Panel (PD2).

Change 2 2-2285
TM 9-2320-366-20-3

x2. NO POWER TO MOBILE TRACKING SYSTEM (MTS) SENSE (CONT)

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
3. on following page.
Voltage Test or
Circuit breaker CB1 is not STE/ICE-R Test #89
tripped. Is 24 VDC present at
REASON FOR QUESTION
Circuit breaker CB1 OK. terminal lug TL15?
If 24 VDC is not present,
POSSIBLE PROBLEMS power cable from terminal lug
TL15 to terminal lug TL22 is
Faulty power cable from faulty. If 24 VDC is present,
terminal Power Distribution Panel (PD2)
lug TL15 to terminal lug TL22. is faulty.
Faulty Power Distribution
Panel (PD2). NO

Replace power cable from terminal lug

YES
TL15 to terminal lug TL22 (para 20-81).

Replace Power Distribution Panel

(PD2) (para 20-81).

2-2286 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove dust boot from terminal lug TL15.
(2) Set multimeter to volts DC.
(3) Connect positive (+) probe of multimeter to
terminal lug TL15.
(4) Connect negative (-) probe of multimeter to
known good ground.
(5) Position master power switch to on
(TM 9-2320-366-10-1) and note reading on
multimeter.
(6) Position master power switch to off
(TM 9-2320-366-10-1).
(7) If 24 VDC is not present, replace power
cable from terminal lug TL15 to terminal
lug TL22.
(8) If 24 VDC is present, replace Power
Distribution Panel (PD2).

Change 2 2-2287
TM 9-2320-366-20-3

x3. NO POWER TO ENHANCED POSITION LOCATION REPORTING SYSTEM (EPLRS)

INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Voltage Test or
Circuit breaker CB5 is not
STE/ICE-R Test #89
tripped. Is 24 VDC present at
REASON FOR QUESTION
terminal lug TL8?
POSSIBLE PROBLEMS If 24 VDC is not present, go to
Faulty circuit breaker CB5. step 2 of this fault. If 24 VDC
Faulty digitization rack power is present, perform Enhanced
supply. Position Location Reporting
Faulty Enhanced System (EPLRS)
Position Location Reporting troubleshooting.
System (EPLRS).
NO

YES Go to step 2 of this fault.

Contact supervisor, Ehanced Position

Location Reporting System (EPLRS)
troubleshooting needs to be performed.

2-2288 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Set multimeter to volts DC.
(5) Connect positive (+) probe of multimeter to
terminal lug TL8.
(6) Connect negative (-) probe of multimeter to
known good ground and note reading on
multimeter.
(7) If 24 VDC is not present, go to step 2 of
this fault.
(8) If 24 VDC is present, contact supervisor,
Enhanced Position Location Reporting
System (EPLRS) troubleshooting needs to
be performed.

Change 2 2-2289
TM 9-2320-366-20-3

x3. NO POWER TO ENHANCED POSITION LOCATION REPORTING SYSTEM (EPLRS) (CONT)

TEST OPTIONS TEST OPTIONS

2.
Continuity Test or
Circuit breaker CB5 is not
STE/ICE-R Test #91
tripped. Is continuity present through
REASON FOR QUESTION
circuit breaker CB5?
POSSIBLE PROBLEMS If continuity is not present,
circuit breaker CB5 is faulty.
Faulty circuit breaker CB5.
If continuity is present,
Faulty digitization rack power
perform Special Purpose Kits
supply.
Troubleshooting task x1. No
Power to Digitization Rack.

NO

Replace circuit breaker CB5

YES
(para 20-80).

Perform Special Purpose Kit

Troubleshooting task x1. No Power
to Digitization Rack.

2-2290 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove circuit breaker CB5 from Power
Distribution Panel (PD1).
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one terminal of circuit breaker CB5.
(4) Connect negative (-) probe of multimeter to
other probe of circuit breaker CB5 and note
reading on multimeter.
(5) If continuity is not present, replace circuit
breaker CB5 (para 20-80).
(6) If continuity is present, perform Special
Purpose Kit Troubleshooting task x1. No
Power to Digitization Rack.

NOTE
Perform steps (7) through (10), if continuity
is present through circuit breaker CB5.

(7) Install circuit breaker CB5 in Power

Distribution Panel (PD1)
(8) Position electrical distribution block cover on
power distribution shelf.
(9) Tighten wing nut on electrical distribution
block cover.
(10) Install wing screw on power distribution shelf.

Change 2 2-2291
TM 9-2320-366-20-3

x4. NO POWER TO PRECISION LIGHTWEIGHT GLOBAL POSITIONING SYSTEM RECEIVER

(PLGR)
INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Voltage Test or
Circuit breaker CB7 is not
STE/ICE-R Test #89
tripped. Is 24 VDC present at
REASON FOR QUESTION
terminal lug TL9?
POSSIBLE PROBLEMS If 24 VDC is not present, go to
Faulty circuit breaker CB7. step 2 of this fault. If 24 VDC
Faulty digitization rack power is present, perform Precision
supply. Lightweight Global
Faulty Precision Lightweight Positioning System Receiver
Global Positioning System (PLGR) troubleshooting.
Receiver (PLGR).
NO

YES Go to step 2 of this fault.

Contact supervisor, Precision Lightweight Global

Positioning System Receiver (PLGR) troubleshooting
needs to be performed.

2-2292 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Set multimeter to volts DC.
(5) Connect positive (+) probe of multimeter to
terminal lug TL9.
(6) Connect negative (-) probe of multimeter to
known good ground and note reading on
multimeter.
(7) If 24 VDC is not present, go to step 2 of
this fault.
(8) If 24 VDC is present, contact supervisor,
Precision Lightweight Global Positioning
System Receiver (PLGR) troubleshooting
needs to be performed.

Change 2 2-2293
TM 9-2320-366-20-3

x4. NO POWER TO PRECISION LIGHTWEIGHT GLOBAL POSITIONING SYSTEM RECEIVER

(PLGR) (CONT)

TEST OPTIONS TEST OPTIONS

2.
Continuity Test or
Circuit breaker CB7 is not
STE/ICE-R Test #91
tripped. Is continuity present through
REASON FOR QUESTION
circuit breaker CB7?
POSSIBLE PROBLEMS If continuity is not present,
circuit breaker CB7 is faulty.
Faulty circuit breaker CB7.
If continuity is present,
Faulty digitization rack power
perform Special Purpose Kits
supply.
Troubleshooting task x1. No
Power to Digitization Rack.

NO

Replace circuit breaker CB7

YES
(para 20-80).

Perform Special Purpose Kit

Troubleshooting task x1. No Power
to Digitization Rack.

2-2294 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove circuit breaker CB7 from Power
Distribution Panel (PD1).
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one terminal of circuit breaker CB7.
(4) Connect negative (-) probe of multimeter to
other probe of circuit breaker CB7 and note
reading on multimeter.
(5) If continuity is not present, replace circuit
breaker CB7 (para 20-80).
(6) If continuity is present, perform Special
Purpose Kit Troubleshooting task x1. No
Power to Digitization Rack.
NOTE
Perform steps (7) through (10), if
continuity is present through circuit
breaker CB7.

(7) Install circuit breaker CB7 in Power

Distribution Panel (PD1)
(8) Position electrical distribution block cover
on power distribution shelf.
(9) Tighten wing nut on electrical distribution
block cover.
(10) Install wing screw on power distribution
shelf.

Change 2 2-2295
TM 9-2320-366-20-3

x5. NO POWER TO DRIVER VISUAL ENHANCEMENT (DVE)

INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Voltage Test or
Circuit breaker CB6 is not
STE/ICE-R Test #89
tripped. Is 24 VDC present at terminal
REASON FOR QUESTION
lug TL3?
POSSIBLE PROBLEMS
If 24 VDC is not present, go to
Faulty circuit breaker CB6. step 2 of this fault. If 24 VDC
Faulty digitization rack power is present, perform Driver
supply. Visual Enhancement (DVE)
Faulty Driver Visual troubleshooting.
Enhancement (DVE) system.
NO

YES Go to step 2 of this fault.

Contact supervisor, Driver Visual

Enhancement (DVE) troubleshooting
needs to be performed.

2-2296 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Set multimeter to volts DC.
(5) Connect positive (+) probe of multimeter to
terminal lug TL3.
(6) Connect negative (-) probe of multimeter to
known good ground and note reading on
multimeter.
(7) If 24 VDC is not present, go to step 2 of
this fault.
(8) If 24 VDC is present, contact supervisor,
Driver Visual Enhancement (DVE)
troubleshooting needs to be performed.

Change 2 2-2297
TM 9-2320-366-20-3

x5. NO POWER TO DRIVER VISUAL ENHANCEMENT (DVE) (CONT)

TEST OPTIONS TEST OPTIONS

2.
Continuity Test or
Circuit breaker CB6 is not
STE/ICE-R Test #91
tripped. Is continuity present through
REASON FOR QUESTION
circuit breaker CB6?
POSSIBLE PROBLEMS If continuity is not present,
circuit breaker CB6 is faulty.
Faulty circuit breaker CB6.
If continuity is present,
Faulty digitization rack power
perform Special Purpose Kits
supply.
Troubleshooting task x1. No
Power to Digitization Rack.

NO

Replace circuit breaker CB6

YES
(para 20-80).

Perform Special Purpose Kit

Troubleshooting task x1. No Power
to Digitization Rack.

2-2298 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove circuit breaker CB6 from Power
Distribution Panel (PD1).
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one terminal of circuit breaker CB6.
(4) Connect negative (-) probe of multimeter to
other probe of circuit breaker CB6 and note
reading on multimeter.
(5) If continuity is not present, replace circuit
breaker CB6 (para 20-80).
(6) If continuity is present, perform Special
Purpose Kit Troubleshooting task x1. No
Power to Digitization Rack.

NOTE
Perform steps (7) through (10), if
continuity is present through circuit
breaker CB6.

(7) Install circuit breaker CB6 in Power

Distribution Panel (PD1)
(8) Position electrical distribution block cover
on power distribution shelf.
(9) Tighten wing nut on electrical distribution
block cover.
(10) Install wing screw on power distribution
shelf.

Change 2 2-2299
TM 9-2320-366-20-3

x6. NO POWER TO SINGLE CHANNEL GROUND & AIR BORNE RADIO (SINCGARS)/FORCE XXI
BATTLE COMMAND BRIGADE OR BELOW (FBCB)
INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Voltage Test or
Circuit breaker CB8 is not
STE/ICE-R Test #89
tripped. Is 24 VDC present at
REASON FOR QUESTION
terminal lug TL2?
POSSIBLE PROBLEMS
If 24 VDC is not present, go to
Faulty circuit breaker CB8. step 2 of this fault. If 24 VDC
Faulty digitization rack power is present, perform SINCGARS/
supply. FBCB troubleshooting.
Faulty SINCGARS/FBCB.

NO

YES Go to step 2 of this fault.

Contact supervisor, SINCGARS/FBCB

troubleshooting needs to be performed.

2-2300 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Set multimeter to volts DC.
(5) Connect positive (+) probe of multimeter
to terminal lug TL2.
(6) Connect negative (-) probe of multimeter to
known good ground and note reading on
multimeter.
(7) If 24 VDC is not present, go to step 2 of
this fault.
(8) If 24 VDC is present, contact supervisor,
SINCGARS/FBCB troubleshooting needs to
be performed.

Change 2 2-2301
TM 9-2320-366-20-3

x6. NO POWER TO SINGLE CHANNEL GROUND & AIR BORNE RADIO (SINCGARS)/FORCE XXI
BATTLE COMMAND BRIGADE OR BELOW (FBCB) (CONT)

TEST OPTIONS TEST OPTIONS

2.
Continuity Test or
Circuit breaker CB8 is not
STE/ICE-R Test #91
tripped. Is continuity present through
REASON FOR QUESTION
circuit breaker CB8?
POSSIBLE PROBLEMS If continuity is not present,
circuit breaker CB8 is faulty.
Faulty circuit breaker CB8.
If continuity is present,
Faulty digitization rack power
perform Special Purpose Kits
supply.
Troubleshooting task x1. No
Power to Digitization Rack.

NO

Replace circuit breaker CB8

YES
(para 20-80).

Perform Special Purpose Kit

Troubleshooting task x1. No Power
to Digitization Rack.

2-2302 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST

(1) Remove circuit breaker CB8 from Power

Distribution Panel (PD1).
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one terminal of circuit breaker CB8.
(4) Connect negative (-) probe of multimeter to
other probe of circuit breaker CB8 and note
reading on multimeter.
(5) If continuity is not present, replace circuit
breaker CB8 (para 20-80).
(6) If continuity is present, perform Special
Purpose Kit Troubleshooting task x1. No
Power to Digitization Rack.
NOTE

Perform steps (7) through (10), if continuity

is present through circuit breaker CB8.

(7) Install circuit breaker CB8 in Power

Distribution Panel (PD1)
(8) Position electrical distribution block cover
on power distribution shelf.
(9) Tighten wing nut on electrical distribution
block cover.
(10) Install wing screw on power distribution shelf.

Change 2 2-2303
TM 9-2320-366-20-3

x7. NO POWER TO MOBILE TRACKING SYSTEM (MTS)

INITIAL SETUP

Equipment Conditions Tools/Special Tools

Engine shut down (TM 9-2320-366-10-2) Multimeter, Digital (Item 22, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D) Personnel Required
(2)

START

WARNING
Read WARNING
TEST OPTIONS TEST OPTIONS
1. on following page.
Circuit breaker CB10 is not Voltage Test or
tripped. STE/ICE-R Test #89
Is 24 VDC present at terminal
POSSIBLE PROBLEMS REASON FOR QUESTION
lug TL1?
Faulty circuit breaker CB10.
If 24 VDC is not present, go to
Faulty digitization rack power
step 2 of this fault. If 24 VDC
supply.
is present, perform Mobile
Faulty Mobile Tracking System
Tracking System (MTS)
(MTS).
troubleshooting.

NO

YES Go to step 2 of this fault.

Contact supervisor, Mobile Tracking

System (MTS) troubleshooting needs
to be performed.

2-2304 Change 2
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches, necklaces,

and any other jewelry before working around
vehicle. Jewelry can catch on equipment and
cause injury or short across electrical circuits
and cause severe burns or electrical shock.

VOLTAGE TEST
(1) Remove wing screw from power
distribution shelf.
(2) Loosen wing screw on electrical
distribution block cover.
(3) Remove electrical distribution block cover
from power distribution shelf.
(4) Set multimeter to volts DC.
(5) Connect positive (+) probe of multimeter to
terminal lug TL1.
(6) Connect negative (-) probe of multimeter to
known good ground and note reading on
multimeter.
(7) If 24 VDC is not present, go to step 2 of
this fault.
(8) If 24 VDC is present, contact supervisor,
Mobile Tracking System (MTS)
troubleshooting needs to be performed.

Change 2 2-2305
TM 9-2320-366-20-3

x7. NO POWER TO MOBILE TRACKING SYSTEM (MTS) (CONT)

TEST OPTIONS TEST OPTIONS

2.
Continuity Test or
Circuit breaker CB10 is not
STE/ICE-R Test #91
tripped. Is continuity present through
REASON FOR QUESTION
circuit breaker CB10?
POSSIBLE PROBLEMS If continuity is not present,
circuit breaker CB10 is faulty.
Faulty circuit breaker CB10.
If continuity is present,
Faulty digitization rack power
perform Special Purpose Kits
supply.
Troubleshooting task x1. No
Power to Digitization Rack.

NO

Replace circuit breaker CB10

YES
(para 20-80).

Perform Special Purpose Kit

Troubleshooting task x1. No Power
to Digitization Rack.

2-2306 Change 2
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove circuit breaker CB10 from Power
Distribution Panel (PD1).
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one terminal of circuit breaker CB10.
(4) Connect negative (-) probe of multimeter to
other probe of circuit breaker CB10 and
note reading on multimeter.
(5) If continuity is not present, replace circuit
breaker CB10 (para 20-80).
(6) If continuity is present, perform Special
Purpose Kit Troubleshooting task x1. No
Power to Digitization Rack.
NOTE
Perform steps (7) through (10), if
continuity is present through circuit
breaker CB10.

(7) Install circuit breaker CB10 in Power

Distribution Panel (PD1)
(8) Position electrical distribution block cover
on power distribution shelf.
(9) Tighten wing nut on electrical distribution
block cover.
(10) Install wing screw on power distribution
shelf.

All data on pages 2-2308 through 2-2371,

including pages 2-2309 through 2-2370 deleted. Change 2 2-2307/(2-2308 Blank)
TM 9-2320-366-20-3

x18. TROOP TRANSPORT ALARM DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Multimeter, Digital (Item 22, Appendix C)
(2) Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Wire, Elect, 50 ft (Item 71, Appendix D)

References
TM 9-4910-571-12&P

START

KNOWN INFO TEST OPTIONS

1.
Continuity Test or
Nothing.
STE/ICE-R Test #91
Is continuity present across
POSSIBLE PROBLEMS REASON FOR QUESTION
troop transport alarm
Faulty troop transport alarm switch? If continuity is not present,
switch. troop transport alarm switch is
Faulty troop transport alarm faulty.
cable assembly.
Faulty troop transport alarm
switch connector.
Faulty engine control cable
assembly. NO
Faulty dashboard cable
assembly.
Faulty audible alarm.

Replace troop transport

YES
alarm switch (para 20-70).

(2-2371 Blank)/2-2372 Change 1

 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Disconnect connector P921 from connector
J921.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
pin 1 of troop transport alarm switch.
(4) Connect negative (-) probe of multimeter to
pin 2 of troop transport alarm switch.
(5) Press troop transport alarm switch and note
reading on multimeter.
(6) If continuity is not present, replace troop
transport alarm switch (para 20-70).

2-2373
TM 9-2320-366-20-3

x18. TROOP TRANSPORT ALARM DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
Troopseat alarm Continuity Test or
switch OK. STE/ICE-R #91
Is continuity present
POSSIBLE PROBLEMS REASON FOR QUESTION
from terminal lug TL164
Faulty troop transport If continuity is not present,
to connector J921-A?
alarm switch connector. wire 32 is faulty.
Faulty troop transport
alarm cable assembly.
Faulty engine control NO
cable assembly.
Faulty dashboard cable
Repair wire 32 (para 2-45) or
assembly.
YES replace troop transport switch
Faulty audible alarm.
connector (para 20-70).

KNOWN INFO TEST OPTIONS

3.
Troop transport alarm Continuity Test or
switch OK. STE/ICE-R #91
Is continuity present
POSSIBLE PROBLEMS REASON FOR QUESTION
from terminal lug TL165
Faulty troop transport If continuity is not present,
to connector J921-C?
alarm switch connector. wire 3028 is faulty.
Faulty troop transport
alarm cable assembly.
Faulty engine control NO
cable assembly.
Faulty dashboard cable
assembly. Repair wire 3028 (para 2-45) or
YES
Faulty audible alarm. replace troop transport switch
connector (para 20-70).

2-2374
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter
to terminal lug TL164.
(3) Connect negative (-) probe of multimeter
to connector J921-A and note reading on
multimeter.
(4) If continuity is not present, repair wire 32
(para 2-45) or replace troop transport
alarm switch connector (para 20-70).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter
to terminal lug TL165.
(3) Connect negative (-) probe of multimeter
to connector J921-C and note reading on
multimeter.
(4) If continuity is not present, repair wire
3028 (para 2-45) or replace troop transport
alarm switch connector (para 20-70).

2-2375
TM 9-2320-366-20-3

x18. TROOP TRANSPORT ALARM DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

4.
Troop transport alarm Continuity Test or
switch OK. STE/ICE-R #91
Is continuity present
Troop transport switch REASON FOR QUESTION
from connector P921-A
connector OK.
to connector J39-2? If continuity is not present,
POSSIBLE PROBLEMS
wire 32 is faulty.
Faulty troop transport
alarm cable assembly.
Faulty engine control NO
cable assembly.
Faulty dashboard cable
Repair wire 32 (para 2-45) or
assembly.
YES replace troop transport alarm cable
Faulty audible alarm.
assembly (para 20-69).

KNOWN INFO TEST OPTIONS

5.
Troop transport alarm Continuity Test or
switch OK. STE/ICE-R #91
Is continuity present
Troop transport alarm REASON FOR QUESTION
from connector P921-C
switch connector OK.
to connector J39-1? If continuity is not present,
POSSIBLE PROBLEMS
wire 3028 is faulty.
Faulty troop transport
alarm cable assembly.
Faulty engine control NO
cable assembly.
Faulty dashboard cable
assembly. Repair wire 3028 (para 2-45) or
YES
Faulty audible alarm. replace troop transport alarm cable
assembly (para 20-69).

2-2376
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Disconnect connector clamp from connector
J39.
(3) Disconnect connector J39 from connector
P39.
(4) Connect positive (+) probe of multimeter
to connector P921-A.
(5) Connect negative (-) probe of multimeter
to connector J39-2 and note reading on
multimeter.
(6) If continuity is not present, repair wire 32
(para 2-45) or replace troop transport
alarm cable assembly (para 20-69).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter
to connector P921-C.
(3) Connect negative (-) probe of multimeter
to connector J39-1 and note reading on
multimeter.
(4) If continuity is not present, repair wire
3028 (para 2-45) or replace troop transport
alarm cable assembly (para 20-69).
(5) Connect connector P921 to connector J921.

2-2377
TM 9-2320-366-20-3

x18. TROOP TRANSPORT ALARM DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

6.
Troop transport Continuity Test or
alarm switch OK. STE/ICE-R #91
Is continuity present
Troop transport alarm REASON FOR QUESTION
from connector P39-2
switch connector OK.
to connector P31-17? If continuity is not present,
Troop transport alarm
wire 32 is faulty.
cable assembly OK.
POSSIBLE PROBLEMS
Faulty engine control NO
cable assembly.
Faulty dashboard
Repair wire 32 (para 2-45) or
cable assembly.
YES replace engine control cable
Faulty audible alarm.
assembly (para 7-80).

KNOWN INFO
TEST OPTIONS
Troop transport 7.
Continuity Test or
alarm switch OK.
STE/ICE-R #91
Troop transport alarm Is continuity present
REASON FOR QUESTION
switch connector OK. from connector P39-1
Troop transport alarm to connector P31-9? If continuity is not present,
cable assembly OK. wire 3028 is faulty.
POSSIBLE PROBLEMS
Faulty engine control
NO
cable assembly.
Faulty dashboard cable
assembly.
Repair wire 3028 (para 2-45) or
Faulty audible alarm.
YES replace engine control cable
assembly (para 7-80).

2-2378
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Lift instrument panel assembly outward to
gain access (para 7-15).
(2) Disconnect connector P31 from connector
J31.
(3) Set multimeter to ohms.
(4) Connect positive (+) probe of multimeter
to connector P39-2.
(5) Connect negative (-) probe of multimeter
to connector P31-17 and note reading
on multimeter.
(6) If continuity is not present, repair wire 32
(para 2-45) or replace engine control cable
assembly (para 7-80).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
connector P39-1.
(3) Connect negative (-) probe of multimeter to
connector P31-9 and note reading on
multimeter.
(4) If continuity is not present, repair wire 3028
(para 2-45) or replace engine control cable
assembly (para 7-80).
(5) Connect connector P39 to connector J39.
(6) Connect connector clamp to connector J39.

2-2379
TM 9-2320-366-20-3

x18. TROOP TRANSPORT ALARM DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

8.
Troop transport alarm Continuity Test or
switch OK. STE/ICE-R #91
Is continuity present
Troop transport alarm REASON FOR QUESTION
from connector J31-9
switch connector OK.
to ground? If continuity is not present,
Troop transport alarm
wire 3028 is faulty.
cable assembly OK.
Engine control cable
assembly OK. NO
POSSIBLE PROBLEMS
Faulty dashboard cable
assembly. Repair wire 3028 (para 2-45) or
YES
Faulty audible alarm. replace WTEC II dashboard cable
assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).

KNOWN INFO TEST OPTIONS

9.
Troop transport alarm Continuity Test or
switch OK. STE/ICE-R #91
Is continuity present
Troop transport alarm REASON FOR QUESTION
from connector J31-17
switch connector OK. If continuity is not present,
to terminal lug TL178?
Troop transport alarm wire 32 is faulty. If
cable assembly OK. continuity is present,
Engine control cable audible alarm is faulty.
assembly OK. NO
POSSIBLE PROBLEMS
Faulty dashboard cable
assembly. Repair wire 32 (para 2-45) or
Faulty audible alarm. YES replace WTEC II dashboard cable
assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).

Replace audible
alarm (para 7-43).

2-2380
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
connector J31-9.
(3) Connect negative (-) probe of multimeter to
ground and note reading on multimeter.
(4) If continuity is not present, repair wire 3028
(para 2-45) or replace WTEC II dashboard
cable assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).

CONTINUITY TEST
(1) Remove screw and terminal lug TL178
from audible alarm.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
connector J31-17.
(4) Connect negative (-) probe of multimeter to
terminal lug TL178 and note reading on
multimeter.
(5) If continuity is not present, repair wire 32
(para 2-45) or replace WTEC II dashboard
cable assembly (para 7-10) or WTEC III
dashboard cable assembly (para 7-11).
(6) If continuity is present, replace audible
alarm (para 7-43).
(7) Install terminal lug TL178 on audible
alarm with screw.
(8) Connect connector P31 to connector J31.
(9) Install instrument panel assembly (para 7-15).

2-2381
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Multimeter, Digital (Item 22, Appendix C)
(2)
References
TM 9-4910-571-12&P

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Engine starts. Voltage Test or
POSSIBLE PROBLEMS STE/ICE-R #89
Is 24 vdc present
Faulty NATO power cable. REASON FOR QUESTION
across NATO power
Faulty NATO plug. If 24 vdc is not present,
receptacle?
Faulty wire 150. NATO power cable is
Faulty circuit breaker. faulty.
Faulty wire 170.
Faulty wire 592. NO
Faulty power cable.
Faulty power harness.
Faulty out solenoid. Replace NATO power
YES
Faulty in solenoid. cable (para 7-70).
Faulty LMHC winch
assembly.
Faulty winch cable.

2-2382
 TM 9-2320-366-20-3

WARNING

Remove rings, bracelets, watches,

necklaces, and any other jewelry
before working around vehicle.
Jewelry can catch on equipment
and cause injury or short across
electrical circuit and cause severe
burns or electrical shock. Batteries
can explode from a spark. Battery
acid is harmful to skin and eyes.
Always wear eye protection when
working with batteries.

VOLTAGE TEST
(1) Disconnect NATO plug from NATO power
cable receptacle.
(2) Set multimeter to volts dc.
(3) Connect positive (+) probe of multimeter to
inside of NATO power cable receptacle.
(4) Connect negative (-) probe of multimeter to
outside of NATO power cable receptacle and
note reading on multimeter.
(5) If 24 vdc is not present, replace NATO
power cable (para 7-70).

2-2383
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
POSSIBLE PROBLEMS from NATO plug pin REASON FOR QUESTION
Faulty NATO plug. to NATO plug positive If continuity is not present,
Faulty wire 150. (+) terminal? NATO plug is faulty.
Faulty circuit breaker.
Faulty wire 170.
Faulty wire 592. NO
Faulty power cable.
Faulty power harness.
Faulty out solenoid. Replace NATO plug
YES
Faulty in solenoid. (para 20-70).
Faulty LMHC winch
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

3.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
POSSIBLE PROBLEMS from NATO plug outer REASON FOR QUESTION
Faulty NATO plug. wall to NATO plug If continuity is not present,
Faulty wire 150. negative (-) terminal? NATO plug is faulty.
Faulty circuit breaker.
Faulty wire 170.
Faulty wire 592. NO
Faulty power cable.
Faulty power harness.
Faulty out solenoid. Replace NATO plug
YES
Faulty in solenoid. (para 20-70).
Faulty LMHC winch
assembly.
Faulty winch cable.

2-2384
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove eight screws, cover, and retainer from
NATO plug.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
NATO plug pin.
(4) Connect negative (-) probe of multimeter to
NATO plug positive (+) terminal lug and
note reading on multimeter.
(5) If continuity is not present, replace NATO
plug (para 20-70).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
NATO plug outer wall.
(3) Connect negative (-) probe of multimeter to
NATO plug negative (-) terminal lug and
note reading on multimeter.
(4) If continuity is not present, replace NATO
plug (para 20-70).

2-2385
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

4.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
NATO plug OK. from NATO plug positive REASON FOR QUESTION
POSSIBLE PROBLEMS (+) terminal to LMHC If continuity is not present,
Faulty wire 170. control box circuit wire 170 is faulty.
Faulty circuit breaker. breaker supply post?
Faulty wire 150.
Faulty wire 592.
Faulty power cable. NO
Faulty power harness.
Faulty out solenoid.
Faulty in solenoid. Replace wire 170
Faulty LMHC winch YES (para 20-70).
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

5.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
NATO plug OK. from NATO plug negative REASON FOR QUESTION
Wire 170 OK. (-) terminal to LMHC If continuity is not present,
POSSIBLE PROBLEMS control box connector wire 150 is faulty.
Faulty wire 150. pin B?
Faulty circuit breaker.
Faulty wire 592.
Faulty power cable. NO
Faulty power harness.
Faulty out solenoid.
Faulty in solenoid. Replace wire 150
Faulty LMHC winch YES (para 20-70).
assembly.
Faulty winch cable.

2-2386
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Open cover on LMHC control box.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
NATO plug positive (+) terminal.
(4) Connect negative (-) probe of multimeter to
LMHC control box circuit breaker supply post
and note reading on multimeter.
(5) If continuity is not present, replace wire 170
(para 20-70).

CONTINUITY TEST
(1) Disconnect LMHC control box power cable
from LMHC control box connector.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
NATO plug negative (-) terminal.
(4) Connect negative (-) probe of multimeter to
LMHC control box connector pin B and note
reading on multimeter.
(5) If continuity is not present, replace wire 150
(para 20-70).
(6) Install cover and retainer on NATO plug with
eight screws.

2-2387
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

6.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
NATO plug OK. Is continuity present REASON FOR QUESTION
Wire 170 OK. across LMHC control If continuity is not present,
Wire 150 OK. box circuit breaker? circuit breaker is faulty.
POSSIBLE PROBLEMS
Faulty circuit breaker.
Faulty wire 592.
Faulty power cable. NO
Faulty power harness.
Faulty out solenoid.
Replace LMHC control
Faulty in solenoid.
box circuit breaker
Faulty LMHC winch YES
(para 20-67).
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

7.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
NATO plug OK. from LMHC control box REASON FOR QUESTION
Wire 170 OK. circuit breaker outlet If continuity is not present,
Wire 150 OK. post to LMHC control wire 592 is faulty.
Circuit breaker OK. box connector pin A?
POSSIBLE PROBLEMS
Faulty wire 592.
Faulty power cable. NO
Faulty power harness.
Faulty out solenoid.
Faulty in solenoid. Replace wire 592
Faulty LMHC winch YES (para 20-70).
assembly.
Faulty winch cable.

2-2388
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
one end of LMHC control box circuit breaker.
(3) Connect negative (-) probe of multimeter to
other end of LMHC control box circuit breaker.
(4) Position LMHC control box circuit breaker to
ON and note reading on multimeter.
(5) If continuity is not present, replace LMHC
control box circuit breaker (para 20-67).
(6) Position LMHC control box circuit breaker to
OFF.

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
LMHC control box circuit breaker outlet post.
(3) Connect negative (-) probe of multimeter to
LMHC control box connector pin A and note
reading on multimeter.
(4) If continuity is not present, replace wire 592
(para 20-70).
(5) Close cover on LMHC control box.
(6) Connect LMHC control box power cable to
LMHC control box connector.

2-2389
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

8.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
NATO plug OK. from one end of LMHC REASON FOR QUESTION
Wire 170 OK. control box power cable If continuity is not present,
Wire 150 OK. socket A to other end of LMHC control box power
Circuit breaker OK. LHMC control box power cable is faulty.
Wire 592 OK. cable socket A?
POSSIBLE PROBLEMS
Faulty power cable.
NO
Faulty power harness.
Faulty out solenoid.
Faulty in solenoid.
Replace LMHC control
Faulty LMHC winch YES
box power cable.
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

9.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
NATO plug OK. from one end of LMHC REASON FOR QUESTION
Wire 170 OK. control box power cable If continuity is not present,
Wire 150 OK. socket B to other end of LMHC control box power
Circuit breaker OK. LHMC control box power cable is faulty.
Wire 592 OK. cable socket B?
POSSIBLE PROBLEMS
Faulty power cable.
Faulty power harness. NO
Faulty out solenoid.
Faulty in solenoid.
Faulty LMHC winch Replace LMHC control
assembly. YES box power cable.
Faulty winch cable.

2-2390
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Disconnect LMHC control power cable from
LMHC winch assembly power connector.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
one end of LMHC control box power cable
socket A.
(4) Connect negative (-) probe of multimeter to
other end of LMHC control box power cable
socket A and note reading on multimeter.
(5) If continuity is not present, replace LMHC
control box power cable.

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
LMHC control box power cable socket B.
(3) Connect negative (-) probe of multimeter to
LMHC control box power cable socket B and
note reading on multimeter.
(4) If continuity is not present, replace LMHC
control box power cable.

2-2391
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

10.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
Is continuity present
NATO plug OK. REASON FOR QUESTION
from power harness
Wire 170 OK. If continuity is not present,
connector pin A to
Wire 150 OK. power harness is faulty.
top post of out
Circuit breaker OK.
solenoid?
Wire 592 OK.
Power cable OK.
POSSIBLE PROBLEMS
NO
Faulty power harness.
Faulty out solenoid.
Faulty in solenoid.
Replace power harness
Faulty LMHC winch YES
(para 20-60).
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

11.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
NATO plug OK. Is continuity present REASON FOR QUESTION
Wire 170 OK. across out solenoid If continuity is not present,
Wire 150 OK. top and bottom right out solenoid is faulty.
Circuit breaker OK. post?
Wire 592 OK.
Power cable OK.
POSSIBLE PROBLEMS
Faulty out solenoid. NO
Faulty power harness.
Faulty in solenoid.
Faulty LMHC winch Replace out solenoid
assembly. YES (para 20-60).
Faulty winch cable.

2-2392
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove 18 screws and cover from base plate.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
power harness connector pin A.
(4) Connect negative (-) probe of multimeter to
top post of out solenoid and note reading on
multimeter.
(5) If continuity is not present, replace power
harness (para 20-60).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
top right post of out solenoid.
(3) Connect negative (-) probe of multimeter to
bottom right post of out solenoid and note
reading on multimeter.
(4) If continuity is not present, replace out
solenoid (para 20-60).

2-2393
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

12.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
Is continuity present
NATO plug OK. REASON FOR QUESTION
from bottom post of out
Wire 170 OK. If continuity is not present,
solenoid to winch
Wire 150 OK. power harness is faulty.
assembly top terminal
Circuit breaker OK.
lug?
Wire 592 OK.
Power cable OK.
Out solenoid OK.
NO
POSSIBLE PROBLEMS
Faulty power harness.
Faulty in solenoid.
Replace power harness
Faulty LMHC winch YES
(para 20-60).
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

13.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
Is continuity present
NATO plug OK. REASON FOR QUESTION
from power harness
Wire 170 OK. If continuity is not present,
connector pin B to
Wire 150 OK. power harness is faulty.
left top post of in
Circuit breaker OK.
solenoid?
Wire 592 OK.
Power cable OK.
Out solenoid OK.
POSSIBLE PROBLEMS NO
Faulty power harness.
Faulty in solenoid.
Faulty LMHC winch Replace power harness
assembly. YES (para 20-60).
Faulty winch cable.

2-2394
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
bottom post of out solenoid.
(3) Connect negative (-) probe of multimeter to
winch assembly top terminal lug and note
reading on multimeter.
(4) If continuity is not present, replace power
harness (para 20-60).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
power harness connector pin B.
(3) Connect negative (-) probe of multimeter to
left top post of in solenoid and note
reading on multimeter.
(4) If continuity is not present, replace power
harness (para 20-60).

2-2395
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

14.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
NATO plug OK. Is continuity present REASON FOR QUESTION
Wire 170 OK. from left top post to If continuity is not present,
Wire 150 OK. left bottom post of in in solenoid is faulty.
Circuit breaker OK. solenoid?
Wire 592 OK.
Power cable OK.
Out solenoid OK.
NO
POSSIBLE PROBLEMS
Faulty in solenoid.
Faulty power harness.
Replace in solenoid
Faulty LMHC winch YES
(para 20-60).
assembly.
Faulty winch cable.

KNOWN INFO TEST OPTIONS

15.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
Is continuity present
NATO plug OK. REASON FOR QUESTION
from left bottom post of
Wire 170 OK. If continuity is not present,
in solenoid to winch
Wire 150 OK. power harness is faulty.
assembly bottom
Circuit breaker OK.
terminal lug?
Wire 592 OK.
Power cable OK.
Out solenoid OK.
In solenoid OK. NO
POSSIBLE PROBLEMS
Faulty power harness.
Faulty LMHC winch Replace power harness
assembly. YES (para 20-60).
Faulty winch cable.

2-2396
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
left top post of in solenoid.
(3) Connect negative (-) probe of multimeter to
left bottom post of in solenoid and note
reading on multimeter.
(4) If continuity is not present, replace in
solenoid (para 20-60).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
left bottom post of in solenoid.
(3) Connect negative (-) probe of multimeter to
winch assembly bottom terminal lug and note
reading on multimeter.
(4) If continuity is not present, replace power
harness (para 20-60).

2-2397
TM 9-2320-366-20-3

x19. LIGHT MATERIAL HANDLING CRANE (LMHC) DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

16.
Engine starts. Continuity Test or
NATO power cable OK. STE/ICE-R #91
Is continuity present
NATO plug OK. REASON FOR QUESTION
from top middle post
Wire 170 OK. If continuity is not present,
of in solenoid to
Wire 150 OK. power harness is faulty.
winch remote control
Circuit breaker OK.
connector pin A?
Wire 592 OK.
Power cable OK.
Out solenoid OK.
NO
In solenoid OK.
POSSIBLE PROBLEMS
Faulty power harness.
Replace power harness
Faulty LMHC winch YES
(para 20-60).
assembly.
Faulty winch remote
control cable.

KNOWN INFO TEST OPTIONS

17.
Engine starts. Continuity Test or
NATO power cable OK. Is continuity present STE/ICE-R #91
NATO plug OK. from winch remote REASON FOR QUESTION
Wire 170 OK. control cable connector If continuity is not present,
Wire 150 OK. socket A to socket B and winch remote control cable
Circuit breaker OK. from socket A to is faulty. If continuity is
Wire 592 OK. socket C? present, LMHC winch
Power cable OK. assembly is faulty.
Out solenoid OK.
In solenoid OK. NO
Power harness OK.
POSSIBLE PROBLEMS
Faulty LMHC winch Replace winch remote
assembly. YES control cable.
Faulty winch remote
control cable.

Replace LMHC winch

assembly (para 20-60).

2-2398
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Disconnect winch remote control cable from
winch remote control connector.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
top middle post of in solenoid.
(4) Connect negative (-) probe of multimeter to
winch remote control connector pin A and note
reading on multimeter.
(5) If continuity is not present, replace power
harness (para 20-60).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
winch remote control cable connector socket
A.
(3) Connect negative (-) probe of multimeter to
winch remote control cable connector socket
B.
(4) Position winch remote control switch to OUT
and note reading on multimeter.
(5) Connect positive (+) probe of multimeter to
winch remote control cable connector socket
A.
(6) Connect negative (-) probe of multimeter to
winch remote control cable connector socket
C.
(7) Position winch remote control switch to in and
note reading on multimeter.
(8) If continuity is not present, replace winch
remote control cable.
(9) If continuity is present, replace LMHC winch
assembly (para 20-60).
(10) Connect LMHC control power cable to LMHC
winch assembly power connector.
(11) Connect winch remote control cable to
winch remote control connector.
(12) Install cover on base plate with 18 screws.

2-2399
TM 9-2320-366-20-3

x20. LIGHT MATERIAL HANDLING CRANE (LMHC) HOIST IN DOES NOT OPERATE
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Multimeter, Digital (Item 22, Appendix C)
(2)
References
TM 9-4910-571-12&P

START

KNOWN INFO TEST OPTIONS

1.
LMHC hoist out operates. Continuity Test or
POSSIBLE PROBLEMS Is continuity present STE/ICE-R #91
Faulty in solenoid. from left top post to REASON FOR QUESTION
Faulty power harness. left bottom post of If continuity is not present,
Faulty LMHC winch in solenoid? in solenoid is faulty.
assembly.
Faulty winch cable.
NO

Replace in solenoid
YES
(para 20-60).

2-2400
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove 18 screws and cover from base plate.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
left top post of in solenoid.
(4) Connect negative (-) probe of multimeter to
left bottom post of in solenoid and note
reading on multimeter.
(5) If continuity is not present, replace in
solenoid (para 20-60).

2-2401
TM 9-2320-366-20-3

x20. LIGHT MATERIAL HANDLING CRANE (LMHC) HOIST IN DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
LMHC hoist out operates. Continuity Test or
In solenoid OK. Is continuity present STE/ICE-R #91
POSSIBLE PROBLEMS from middle top post REASON FOR QUESTION
Faulty power harness. of in solenoid to If continuity is not present,
Faulty LMHC winch LMHC remote control power harness is faulty.
assembly. connector pin C?
Faulty winch cable.

NO

Replace power harness

YES
(para 20-60).

KNOWN INFO TEST OPTIONS

3.
LMHC hoist out operates. Continuity Test or
In solenoid OK. STE/ICE-R #91
Is continuity present
Power harness OK. REASON FOR QUESTION
from winch remote
POSSIBLE PROBLEMS If continuity is not present,
control cable socket A
Faulty LMHC winch winch remote control cable
to socket C?
assembly. is faulty. If continuity is
Faulty winch cable. present, LMHC winch
assembly is faulty.

NO

Replace winch remote

YES
control cable.

Replace LMHC winch

assembly (para 20-60).

2-2402
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Disconnect winch remote control cable from
winch remote control connector.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
left middle post of in solenoid.
(4) Connect negative (-) probe of multimeter to
winch remote control connector pin C and note
reading on multimeter.
(5) If continuity is not present, replace power
harness (para 20-60).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
winch remote control cable socket A.
(3) Connect negative (-) probe of multimeter to
winch remote control cable socket C.
(4) Position winch remote control switch to
in and note reading on multimeter.
(5) If continuity is not present, replace winch
remote control cable.
(6) If continuity is present, replace LMHC winch
assembly (para 20-60).
(7) Connect winch remote control cable to winch
remote control connector.
(8) Install cover on base plate with 18 screws.

2-2403
TM 9-2320-366-20-3

x21. LIGHT MATERIAL HANDLING CRANE (LMHC) HOIST OUT DOES NOT OPERATE
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)
Personnel Required Multimeter, Digital (Item 22, Appendix C)
(2)
References
TM 9-4910-571-12&P

START

KNOWN INFO TEST OPTIONS

1.
LMHC hoist in operates. Continuity Test or
POSSIBLE PROBLEMS Is continuity present STE/ICE-R #91
Faulty out solenoid. from right top post to REASON FOR QUESTION
Faulty power harness. right bottom post of If continuity is not present,
Faulty LMHC winch out solenoid? out solenoid is faulty.
assembly.
Faulty winch cable.
NO

Replace out solenoid

YES
(para 20-60).

2-2404
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Remove 18 screws and cover from base plate.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
right top post of out solenoid.
(4) Connect negative (-) probe of multimeter to
right bottom post of out solenoid and note
reading on multimeter.
(5) If continuity is not present, replace out
solenoid (para 20-60).

2-2405
TM 9-2320-366-20-3

x21. LIGHT MATERIAL HANDLING CRANE (LMHC) HOIST OUT DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

2.
LMHC hoist in operates. Continuity Test or
Out solenoid OK. Is continuity present STE/ICE-R #91
POSSIBLE PROBLEMS from middle top post REASON FOR QUESTION
Faulty power harness. of out solenoid to If continuity is not present,
Faulty LMHC winch LMHC remote control power harness is faulty.
assembly. connector pin B?
Faulty winch cable.

NO

Replace power harness

YES
(para 20-60).

KNOWN INFO TEST OPTIONS

3.
LMHC hoist in operates. Continuity Test or
Out solenoid OK. STE/ICE-R #91
Is continuity present
Power harness OK. REASON FOR QUESTION
from winch remote
POSSIBLE PROBLEMS If continuity is not present,
control cable socket A
Faulty LMHC winch winch remote control cable
to socket B?
assembly. is faulty. If continuity is
Faulty winch cable. present, LMHC winch
assembly is faulty.

NO

Replace winch remote

YES
control cable.

Replace LMHC winch

assembly (para 20-60).

2-2406
 TM 9-2320-366-20-3

CONTINUITY TEST
(1) Disconnect winch remote control cable from
winch remote control connector.
(2) Set multimeter to ohms.
(3) Connect positive (+) probe of multimeter to
right middle post of out solenoid.
(4) Connect negative (-) probe of multimeter to
winch remote control connector pin B and note
reading on multimeter.
(5) If continuity is not present, replace power
harness (para 20-60).

CONTINUITY TEST
(1) Set multimeter to ohms.
(2) Connect positive (+) probe of multimeter to
winch remote control cable socket A.
(3) Connect negative (-) probe of multimeter to
winch remote control cable socket B.
(4) Position winch remote control switch to
out and note reading on multimeter.
(5) If continuity is not present, replace winch
remote control cable.
(6) If continuity is present, replace LMHC winch
assembly (para 20-60).
(7) Connect winch remote control cable to winch
remote control connector.
(8) Install cover on base plate with 18 screws.

2-2407/(2-2408 Blank)
 TM 9-2320-366-20-3

2-35. M1084/M1086 MATERIAL HANDLING CRANE (MHC) HYDRAULIC

TROUBLESHOOTING

This paragraph covers M1084/M1086 Material Handling Crane (MHC) Hydraulic Troubleshooting. The M1084/ M1086
Material Handling Crane (MHC) Hydraulic Fault Index, Table 2-63, lists faults for the M1084/M1086 MHC Hydraulic
system.

Table 2-63. M1084/M1086 Material Handling Crane (MHC) Hydraulic Fault Index

Fault No. Description Page

y1. M1084/M1086 Material Handling Crane (MHC) Hand Pump Does Not Work . . . . . . . . . . . . . . . 2-2410

2-2409
TM 9-2320-366-20-3

y1. M1084/M1086 MATERIAL HANDLING CRANE (MHC) HAND PUMP DOES NOT WORK
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

Materials/Parts
Rag, Wiping (Item 50, Appendix D)

START

WARNING
KNOWN INFO Read WARNING TEST OPTIONS
1.
Hydraulic fluid level OK. on following page. Hand Pump Test
Hydraulic lines REASON FOR QUESTION
and fittings OK. Does hand pump Faulty check valve or hand
All functions operate build pressure? pump will prevent manual
with PTO engaged. operation of crane.
POSSIBLE PROBLEMS
Faulty input check valve.
Faulty hand pump.

NO

YES

Replace hand pump

(para 17-10).

Notify DS Maintenance.

2-2410
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero

before disconnecting any
hydraulic line. Failure to comply
may result in injury to
personnel.

Wear approved eye protection when

performing pressure checks. Failure
to comply may result in oil getting
into eyes. If oil contacts eyes, seek
medical attention immediately.

Fuel and oil are slippery and can

cause falls. Wipe up spilled fuel
or oil with rags. Failure to comply
may result in injury to personnel.

HAND PUMP TEST

(1) Disconnect hand pump delivery line from elbow
at hand pump.
(2) Place drain pan under port at pump to catch
hydraulic fluid.
(3) Pump hand pump (TM 9-2320-366-10-1).
(4) Check if hydraulic fluid pumps out of port with
each stroke.
(5) If little or no fluid pumps out, replace hand pump
(para 17-10).
(6) Connect delivery line to elbow at hand pump.
(7) Remove drain pan.

2-2411/(2-2412 Blank)
 TM 9-2320-366-20-3

2-36. CAB AND SPARE TIRE RETAINER TROUBLESHOOTING

This paragraph covers Cab and Spare Tire Retainer Troubleshooting. The Cab and Spare Tire Retainer Fault Index,
Table 2-64, lists faults for the cab and spare tire retainer of the vehicle.

Table 2-64. Cab and Spare Tire Retainer Fault Index

Fault No. Description Page

z1. Cab Does Not Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2414

z2. Cab Does Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2414.8
z3. Spare Tire Retainer Does Not Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2416
z4. Spare Tire Retainer Does Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2416.6

Change 1 2-2413
TM 9-2320-366-20-3

z1. CAB DOES NOT RAISE

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-232-366-10-1). STE/ICE-R (Item 41, Appendix C)
Pan, Drain (Item 24, Appendix C)
Personnel Required Goggles, Industrial (Item 15, Appendix C)
(2) Transmitter, Pressure (Item 1, Appendix J)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Material/Parts Key, Socket Head Screw (Item 38.1, Appendix B)
Rag, Wiping (Item 50, Appendix D)
Filter Element, Fluid (Item 21.1, Appendix G) References
TM 9-4910-571-12&P

NOTE
On vehicles S/N 0001 through 7558, the hydraulic manifold,
P/N 12420621, was not originally equipped with an orifice
filter. Orifice filter, P/N 117073098-000, however, may have
been installed during previous maintenance to the hydraulic
manifold.

START

KNOWN INFO TEST OPTIONS

1.
Visual Inspection
Air/hydraulic power unit
oil level OK. Is orifice screw or orifice REASON FOR QUESTION
Air/hydraulic power unit filter (if equipped) free of If orifice screw and/or orifice
primed. debris? filter (if equipped) is clogged,
Hydraulic and air hoses orifice screw and/or orifice
OK. filter is faulty.
Air tanks charged.
Hydraulic oil filter OK.
Other hydraulic manifold
functions OK. NO

POSSIBLE PROBLEMS
Debris in orifice filter (if
equipped).
Debris in orifice screw. Clean orifice screw and/or replace
YES
Faulty cab hydraulic latch. orifice filter (if equipped).
Faulty hydraulic manifold CAB
TILT valve.
Faulty cab hydraulic cylinder.

2-2414 Change 1
 TM 9-2320-366-20-3

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (1) through (12) on
hydraulic manifolds installed on vehicles
S/N 001 through 7558.
(1) Remove pin from hydraulic manifold cover
and lower cover.
(2) Cycle FUNCTION SELECT knob through all
settings.
(3) Cycle CAB TILT knob through both
selector settings.
(4) Remove screw, knob, and CAB TILT valve
from hydraulic manifold.
(5) Remove orifice filter (if equipped) from
hydraulic manifold.
(6) If debris is present in orifice filter, replace
orifice filter.
(7) Remove orifice screw from hydraulic
manifold.
(8) If debris is present in orifice screw, clean
orifice screw with compressed air.

NOTE
If no orifice filter was previously installed,
orifice filter will be installed at this time.
(9) Install orifice screw and orifice filter in
hydraulic manifold.
(10) Position CAB TILT valve and knob on
hydraulic manifold with screw.
(11) Tighten screw to 5-15 lb-in. (1-2 N·m).
(12) Close hydraulic manifold cover and
install pin.
Cont. on page 2-2414.3.

Change 1 2-2414.1/(2-2414.2 Blank)

 TM 9-2320-366-20-3

Cont. from page 2-2414.1.

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (13) through (25) on
hydraulic manifolds installed on vehicles
S/N 7559 and higher or on vehicles where
hydraulic manifolds have two valves on
left side.
(13) Remove pin from hydraulic manifold cover
and lower cover.
(14) Cycle FUNCTION SELECT knob through all
settings.
(15) Cycle CAB TILT knob through both
selector settings.
(16) Remove nut, knob, spring, spacer,
retainer ring, and rubber sleeve from
CAB TILT valve.
(17) Remove CAB TILT valve from hydraulic
manifold.
(18) Remove orifice filter from hydraulic manifold.
(19) If debris is present in orifice filter, replace
orifice filter.
(20) Remove orifice screw from hydraulic
manifold.
(21) If debris is present in orifice screw, clean
orifice screw with compressed air.
(22) Install orifice screw and orifice filter in
hydraulic manifold.
(23) Install CAB TILT valve in hydraulic
manifold.
(24) Install rubber sleeve, retainer ring,
spacer, spring, knob, and nut on
hydraulic manifold.
(25) Close hydraulic manifold cover and
install pin.

Change 1 2-2414.3
TM 9-2320-366-20-3

z1. CAB DOES NOT RAISE (CONT)

KNOWN INFO TEST OPTIONS

2.
Visual Inspection
Air/hydraulic power unit oil
level OK. REASON FOR QUESTION
Air/hydraulic power unit primed. Is cab hydraulic latch If cab hydraulic latch is not
Hydraulic and air hoses OK. adjusted properly? adjusted properly, cab hydraulic
Air tanks charged. latch is faulty.
Hydraulic oil filter OK.
Other hydraulic manifold
functions OK.
Orifice filter OK.
Orifice screw OK.
NO
POSSIBLE PROBLEMS
Faulty cab hydraulic latch.
Faulty hydraulic manifold CAB
TILT valve.
Faulty cab hydraulic cylinder.

YES Adjust cab hydraulic latch (para 19-7).

2-2414.4 Change 1
 TM 9-2320-366-20-3

(1) Start engine and charge air tanks

(TM 9-2320-366-10-1).
(2) Position CAB TILT knob to RAISE.
(3) Position FUNCTION SELECT knob to CAB
TILT.
(4) Check to see if cab hydraulic latch indicator
button is in the unlatched position.
(5) If cab hydraulic latch indicator button does
not unlatch, adjust cab hydraulic latch
(para 19-7).

Change 1 2-2414.5
TM 9-2320-366-20-3

z1. CAB DOES NOT RAISE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
3. on following page.
Pressure Test or
Air/hydraulic power unit oil
Is 2,500-4,000 psi STE/ICE-R Test #51
level OK.
Air/hydraulic power unit primed. (17,237-27,580 kPa) REASON FOR QUESTION
Hydraulic and air hoses OK. present at CAB RAISE If 2,500-4,000 psi (17,237-
Air tanks charged. output port? 27,580 kPa) is not present,
Hydraulic oil filter OK. hydraulic manifold CAB TILT
Other hydraulic manifold valve is faulty. If 2,500-4,000
functions OK. psi (17,237-27,580 kPa) is
Orifice filter OK. present, cab hydraulic cylinder
Orifice screw OK. is faulty.
Cab hydraulic latch OK.
NO
POSSIBLE PROBLEMS
Faulty hydraulic manifold CAB
TILT valve.
Faulty cab hydraulic cylinder.
Repair hydraulic manifold
YES
CAB TILT valve (para 19-4).

Replace cab hydraulic cylinder (para 19-11).

2-2414.6 Change 1
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

PRESSURE TEST

(1) Position drain pan under cab hydraulic

cylinder.
(2) Disconnect CAB RAISE pressure hose
from cab hydraulic cylinder output port.
(3) Connect STE/ICE-R to CAB RAISE pressure
hose.
(4) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(5) Position CAB TILT knob to RAISE.
(6) Position FUNCTION SELECT knob
to CAB TILT.
(7) Push and hold PUMP plunger button
and perform STE-ICE-R Test #51
(TM 9-4910-571-12&P).
(8) If pressure is not 2,500-4,000 psi (17,237-
27,580 kPa), repair hydraulic manifold
CAB TILT valve (para 19-4).
(9) If pressure is 2,500-4,000 psi (17,237-
27,580 kPa), replace cab hydraulic
cylinder (para 19-11).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Disconnect STE/ICE-R from pressure
hose.
(12) Connect pressure hose to cab hydraulic
cylinder output port.

Change 1 2-2414.7
TM 9-2320-366-20-3

z2. CAB DOES NOT LOWER

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-232-366-10-1). STE/ICE-R (Item 41, Appendix C)
Pan, Drain (Item 24, Appendix C)
Personnel Required Goggles, Industrial (Item 15, Appendix C)
(2) Transmitter, Pressure (Item 1, Appendix J)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Material/Parts Key, Socket Head Screw (Item 38.1, Appendix B)
Rag, Wiping (Item 50, Appendix D)
Filter Element, Fluid (Item 21.1, Appendix G) References
TM 9-4910-571-12&P

NOTE
On vehicles S/N 0001 through 7558, the hydraulic manifold,
P/N 12420621, was not originally equipped with an orifice
filter. Orifice filter, P/N 117073098-000, however, may have
been installed during previous maintenance to the hydraulic
manifold.

START

KNOWN INFO TEST OPTIONS

1.
Visual Inspection
Air/hydraulic power unit
oil level OK. Is orifice screw or orifice REASON FOR QUESTION
Air/hydraulic power unit filter (if equipped) free of If orifice screw and/or orifice
primed. debris? filter (if equipped) is clogged,
Hydraulic and air hoses orifice screw and/or orifice
OK. filter is faulty.
Air tanks charged.
Hydraulic oil filter OK.
Other hydraulic manifold NO
functions OK.
POSSIBLE PROBLEMS
Debris in orifice filter (if
equipped).
Clean orifice screw and/or replace
Debris in orifice screw. YES
orifice filter (if equipped).
Faulty hydraulic manifold CAB
TILT valve.
Faulty cab hydraulic cylinder.

2-2414.8 Change 1
 TM 9-2320-366-20-3

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (1) through (12) on
hydraulic manifolds installed on vehicles
S/N 001 through 7558.
(1) Remove pin from hydraulic manifold cover
and lower cover.
(2) Cycle FUNCTION SELECT knob through all
settings.
(3) Cycle CAB TILT knob through both
selector settings.
(4) Remove screw, knob, and CAB TILT valve
from hydraulic manifold.
(5) Remove orifice filter (if equipped) from
hydraulic manifold.
(6) If debris is present in orifice filter, replace
orifice filter.
(7) Remove orifice screw from hydraulic
manifold.
(8) If debris is present in orifice screw, clean
orifice screw with compressed air.
NOTE
If no orifice filter was previously installed,
orifice filter will be installed at this time.
(9) Install orifice screw and orifice filter in
hydraulic manifold.
(10) Position CAB TILT valve and knob on
hydraulic manifold with screw.
(11) Tighten screw to 5-15 lb-in. (1-2 N·m).
(12) Close hydraulic manifold cover and
install pin.

Cont. on page 2-2414.11.

Change 1 2-2414.9/(2-2414.10 Blank)

 TM 9-2320-366-20-3

Cont. from page 2-2414.9.

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should
be removed immediately. Failure to
comply may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (13) through (25) on
hydraulic manifolds installed on vehicles
S/N 7559 and higher or on vehicles where
hydraulic manifolds have two valves on
left side.
(13) Remove pin from hydraulic manifold cover
and lower cover.
(14) Cycle FUNCTION SELECT knob through all
settings.
(15) Cycle CAB TILT knob through both
selector settings.
(16) Remove nut, knob, spring, spacer,
retainer ring, and rubber sleeve from
CAB TILT valve.
(17) Remove CAB TILT valve from hydraulic
manifold.
(18) Remove orifice filter from hydraulic manifold.
(19) If debris is present in orifice filter, replace
orifice filter.
(20) Remove orifice screw from hydraulic
manifold.
(21) If debris is present in orifice screw, clean
orifice screw with compressed air.
(22) Install orifice screw and orifice filter in
hydraulic manifold.
(23) Install CAB TILT valve in hydraulic
manifold.
(24) Install rubber sleeve, retainer ring,
spacer, spring, knob, and nut on
hydraulic manifold.
(25) Close hydraulic manifold cover and
install pin.

Change 1 2-2414.11
TM 9-2320-366-20-3

z2. CAB DOES NOT LOWER (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Pressure Test or
Air/hydraulic power unit oil
Is 2,500-4,000 psi STE/ICE-R Test #51
level OK.
Air/hydraulic power unit primed. (17,237-27,580 kPa) REASON FOR QUESTION
Hydraulic and air hoses OK. present at CAB LOWER If 2,500-4,000 psi (17,237-
Air tanks charged. output port? 27,580 kPa) is not present,
Hydraulic oil filter OK. hydraulic manifold CAB TILT
Other hydraulic manifold valve is faulty. If 2,500-4,000
functions OK. psi (17,237-27,580 kPa) is
Orifice filter OK. present, cab hydraulic cylinder
Orifice screw OK. is faulty.
POSSIBLE PROBLEMS
NO
Faulty hydraulic manifold CAB
TILT valve.
Faulty cab hydraulic cylinder.

Repair hydraulic manifold CAB TILT

YES
valve (para 19-4).

Replace cab hydraulic cylinder (para 19-11).

2-2414.12 Change 1
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

PRESSURE TEST

(1) Position drain pan under cab hydraulic

cylinder.
(2) Disconnect CAB LOWER pressure hose
from cab hydraulic cylinder output port.
(3) Connect STE/ICE-R to CAB LOWER pressure
hose.
(4) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(5) Position CAB TILT knob to LOWER.
(6) Position FUNCTION SELECT knob
to CAB TILT.
(7) Push and hold PUMP plunger button
and perform STE-ICE-R Test #51
(TM 9-4910-571-12&P).
(8) If pressure is not 2,500-4,000 psi (17,237-
27,580 kPa), repair hydraulic manifold
CAB TILT valve (para 19-4).
(9) If pressure is 2,500-4,000 psi (17,237-
27,580 kPa), replace cab hydraulic
cylinder (para 19-11).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Disconnect STE/ICE-R from pressure
hose.
(12) Connect pressure hose to cab hydraulic
cylinder output port.

Change 1 2-2415
TM 9-2320-366-20-3

z3. SPARE TIRE RETAINER DOES NOT RAISE

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-232-366-10-1). STE/ICE-R (Item 41, Appendix C)
Pan, Drain (Item 24, Appendix C)
Personnel Required Goggles, Industrial (Item 15, Appendix C)
(2) Transmitter, Pressure (Item 1, Appendix J)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Material/Parts Key, Socket Head Screw (Item 38.1, Appendix B)
Rag, Wiping (Item 50, Appendix D)
Filter, Element, Fluid (Item 21.1, Appendix G) References
TM 9-4910-571-12&P

NOTE
On vehicles S/N 0001 through 7558, the hydraulic manifold,
P/N 12420621, was not originally equipped with an orifice
filter. Orifice filter, P/N 117073098-000, however, may have
been installed during previous maintenance to the hydraulic
manifold.

START

KNOWN INFO TEST OPTIONS

1.
Visual Inspection
Air/hydraulic power unit
oil level OK. Is orifice screw or orifice REASON FOR QUESTION
Air/hydraulic power unit filter (if equipped) free of If orifice screw and/or orifice
primed. debris? filter (if equipped) is clogged,
Hydraulic and air hoses orifice screw and/or orifice
OK. filter is faulty.
Air tanks charged.
Hydraulic oil filter OK.
Other hydraulic manifold
functions OK. NO

POSSIBLE PROBLEMS
Debris in orifice filter (if
equipped).
Debris in orifice screw. Clean orifice screw and/or replace
YES
Faulty hydraulic manifold orifice filter (if equipped).
SPARE TIRE valve.
Faulty spare tire retainer
cylinder.

2-2416 Change 1
 TM 9-2320-366-20-3

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (1) through (12) on
hydraulic manifolds installed on vehicles
S/N 001 through 7558.
(1) Remove pin from hydraulic manifold cover
and raise cover.
(2) Cycle FUNCTION SELECT knob through all
settings.
(3) Cycle SPARE TIRE knob through both
selector settings.
(4) Remove screw, knob, and SPARE TIRE
valve from hydraulic manifold.
(5) Remove orifice filter (if equipped) from
hydraulic manifold.
(6) If debris is present in orifice filter, replace
orifice filter.
(7) Remove orifice screw from hydraulic
manifold.
(8) If debris is present in orifice screw, clean
orifice screw with compressed air.
NOTE
If no orifice filter was previously installed,
orifice filter will be installed at this time.
(9) Install orifice screw and orifice filter in
hydraulic manifold.
(10) Position SPARE TIRE valve and knob on
hydraulic manifold with screw.
(11) Tighten screw to 5-15 lb-in. (1-2 N·m).
(12) Close hydraulic manifold cover and
install pin.

Cont. on page 2-2416.3.

Change 1 2-2416.1/(2-2416.2 Blank)

 TM 9-2320-366-20-3

Cont. from page 2-2416.1.

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (13) through (25) on hydraulic
manifolds installed on vehicles S/N 7559
and higher or on vehicles where hydraulic
manifolds have two valves on left side.

(13) Remove pin from hydraulic manifold cover

and raise cover.
(14) Cycle FUNCTION SELECT knob through all
settings.
(15) Cycle SPARE TIRE knob through both
selector settings.
(16) Remove nut, knob, spring, spacer,
retainer ring, and rubber sleeve from
SPARE TIRE valve.
(17) Remove SPARE TIRE valve from hydraulic
manifold.
(18) Remove orifice filter from hydraulic manifold.
(19) If debris is present in orifice filter, replace
orifice filter.
(20) Remove orifice screw from hydraulic
manifold.
(21) If debris is present in orifice screw, clean
orifice screw with compressed air.
(22) Install orifice screw and orifice filter in
hydraulic manifold.
(23) Install SPARE TIRE valve in hydraulic
manifold.
(24) Install rubber sleeve, retainer ring,
spacer, spring, knob, and nut on
hydraulic manifold.
(25) Close hydraulic manifold cover and
install pin.

Change 1 2-2416.3
TM 9-2320-366-20-3

z3. SPARE TIRE RETAINER DOES NOT RAISE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Pressure Test or
Air/hydraulic power unit oil
Is 2,500-4,000 psi STE/ICE-R Test #51
level OK.
Air/hydraulic power unit primed. (17,237-27,580 kPa) REASON FOR QUESTION
Hydraulic and air hoses OK. present at SPARE EXT If 2,500-4,000 psi (17,237-
Air tanks charged. port? 27,580 kPa) is not present,
Hydraulic oil filter OK. hydraulic manifold SPARE TIRE
Other hydraulic manifold valve is faulty. If 2,500-
functions OK. 4,000 psi (17,237-27,580
Orifice filter OK. kPa) is present, spare tire
Orifice screw OK. retainer cylinder is faulty.
POSSIBLE PROBLEMS
NO
Faulty hydraulic manifold
SPARE TIRE valve.
Faulty spare tire retainer
cylinder.
Repair hydraulic manifold
YES
SPARE TIRE valve (para 19-4).

Replace spare tire retainer cylinder (para 14-9 or 14-10).

2-2416.4 Change 1
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

PRESSURE TEST

(1) Position drain pan under spare tire retainer

cylinder.
(2) Disconnect SPARE EXT pressure hose
from spare tire retainer cylinder port.
(3) Connect STE/ICE-R to SPARE EXT pressure
hose.
(4) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(5) Position SPARE TIRE knob to RAISE.
(6) Position FUNCTION SELECT knob
to SPARE TIRE.
(7) Push and hold PUMP plunger button
and perform STE-ICE-R Test #51
(TM 9-4910-571-12&P).
(8) If pressure is not 2,500-4,000 psi (17,237-
27,580 kPa), repair hydraulic manifold
SPARE TIRE valve (para 19-4).
(9) If pressure is 2,500-4,000 psi (17,237-
27,580 kPa), replace spare tire retainer
cylinder (para 14-9 or 14-10).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Disconnect STE/ICE-R from pressure
hose.
(12) Connect pressure hose to spare tire retainer
cylinder port.

Change 1 2-2416.5
TM 9-2320-366-20-3

z4. SPARE TIRE RETAINER DOES NOT LOWER

INITIAL SETUP

Equipment Condition Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-232-366-10-1). STE/ICE-R (Item 41, Appendix C)
Pan, Drain (Item 24, Appendix C)
Personnel Required Goggles, Industrial (Item 15, Appendix C)
(2) Transducer, 10,000 PSI (Item 1, Appendix J)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Material/Parts Key, Socket Head Screw (Item 38.1, Appendix B)
Rag, Wiping (Item 50, Appendix D)
Filter Element, Fluid (Item 21.1, Appendix G) References
TM 9-4910-571-12&P

NOTE
On vehicles S/N 0001 through 7558, the hydraulic manifold,
P/N 12420621, was not originally equipped with an orifice
filter. Orifice filter, P/N 117073098-000, however, may have
been installed during previous maintenance to the hydraulic
manifold.

START

KNOWN INFO TEST OPTIONS

1.
Visual Inspection
Air/hydraulic power unit
oil level OK. Is orifice screw or orifice REASON FOR QUESTION
Air/hydraulic power unit filter (if equipped) free of If orifice screw and/or orifice
primed. debris? filter (if equipped) is clogged,
Hydraulic and air hoses orifice screw and/or orifice
OK. filter is faulty.
Air tanks charged.
Hydraulic oil filter OK.
Other hydraulic manifold NO
functions OK.
POSSIBLE PROBLEMS
Debris in orifice filter (if
equipped). Clean orifice screw and/or replace
Debris in orifice screw. YES
orifice filter (if equipped).
Faulty hydraulic manifold
SPARE TIRE valve.
Faulty spare tire retainer
cylinder.

2-2416.6 Change 1
 TM 9-2320-366-20-3

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (1) through (12) on
hydraulic manifolds installed on vehicles
S/N 001 through 7558.
(1) Remove pin from hydraulic manifold cover
and lower cover.
(2) Cycle FUNCTION SELECT knob through all
settings.
(3) Cycle SPARE TIRE knob through both
selector settings.
(4) Remove screw, knob, and SPARE TIRE
valve from hydraulic manifold.
(5) Remove orifice filter (if equipped) from
hydraulic manifold.
(6) If debris is present in orifice filter, replace
orifice filter.
(7) Remove orifice screw from hydraulic
manifold.
(8) If debris is present in orifice screw, clean
orifice screw with compressed air.
NOTE
If no orifice filter was previously installed,
orifice filter will be installed at this time.
(9) Install orifice screw and orifice filter in
hydraulic manifold.
(10) Position SPARE TIRE valve and knob on
hydraulic manifold with screw.
(11) Tighten screw to 5-15 lb-in. (1-2 N·m).
(12) Close hydraulic manifold cover and
install pin.
Cont. on page 2-2416.9.

Change 1 2-2416.7/(2-2416.8 Blank)

 TM 9-2320-366-20-3

Cont. from page 2-2416.7.

WARNING
Drop hydraulic pressure to zero before
disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

Compressed air used for cleaning purposes

will not exceed 30 psi (270 kPa). Use
only with effective chip guarding and
personal protective equipment (goggles,
shields, gloves, etc.). Failure to comply
may result in injury to personnel.
NOTE
Perform steps (13) through (25) on
hydraulic manifolds installed on vehicles
S/N 7559 and higher or on vehicles where
hydraulic manifolds have two valves on
left side.
(13) Remove pin from hydraulic manifold cover
and lower cover.
(14) Cycle FUNCTION SELECT knob through all
settings.
(15) Cycle SPARE TIRE knob through both
selector settings.
(16) Remove nut, knob, spring, spacer,
retainer ring, and rubber sleeve from
SPARE TIRE valve.
(17) Remove SPARE TIRE valve from hydraulic
manifold.
(18) Remove orifice filter from hydraulic manifold.
(19) If debris is present in orifice filter, replace
orifice filter.
(20) Remove orifice screw from hydraulic
manifold.
(21) If debris is present in orifice screw, clean
orifice screw with compressed air.
(22) Install orifice screw and orifice filter in
hydraulic manifold.
(23) Install SPARE TIRE valve in hydraulic
manifold.
(24) Install rubber sleeve, retainer ring,
spacer, spring, knob, and nut on
hydraulic manifold.
(25) Close hydraulic manifold cover and
install pin.

Change 1 2-2416.9
TM 9-2320-366-20-3

z4. SPARE TIRE RETAINER DOES NOT LOWER (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Pressure Test or
Air/hydraulic power unit oil
Is 2,500-4,000 psi STE/ICE-R Test #51
level OK.
Air/hydraulic power unit primed. (17,237-27,580 kPa) REASON FOR QUESTION
Hydraulic and air hoses OK. present at SPARE RET If 2,500-4,000 psi (17,237-
Air tanks charged. port? 27,580 kPa) is not present,
Hydraulic oil filter OK. hydraulic manifold SPARE TIRE
Other hydraulic manifold valve is faulty. If 2,500-
functions OK. 4,000 psi (17,237-27,580
Orifice filter OK. kPa) is present, spare tire
Orifice screw OK. retainer cylinder is faulty.
POSSIBLE PROBLEMS
Faulty hydraulic manifold
SPARE TIRE valve.
Faulty spare tire retainer NO
cylinder.

Repair hydraulic manifold

YES
SPARE TIRE valve (para 19-4).

Replace spare tire retainer

cylinder (para 14-9 or 14-10).

2-2416.10 Change 1
 TM 9-2320-366-20-3

WARNING

Drop hydraulic pressure to zero before

disconnecting any hydraulic hoses. Failure
to comply may result in injury to
personnel.

Hydraulic fluid (MIL-H-5606) is TOXIC.

Wear protective goggles and gloves; use
only in well ventilated area; avoid contact
with skin, eyes, and clothes. Skin and
clothing that come into contact with
hydraulic fluid should be washed
immediately. Saturated clothing should be
removed immediately. Failure to comply
may result in injury to personnel.

PRESSURE TEST

(1) Position drain pan under spare tire retainer

cylinder.
(2) Disconnect SPARE RET pressure hose
from spare tire retainer cylinder port.
(3) Connect STE/ICE-R to SPARE RET pressure
hose.
(4) Start engine and charge air tanks
(TM 9-2320-366-10-1).
(5) Position SPARE TIRE knob to LOWER.
(6) Position FUNCTION SELECT knob
to SPARE TIRE.
(7) Push and hold PUMP plunger button
and perform STE-ICE-R Test #51
(TM 9-4910-571-12&P).
(8) If pressure is not 2,500-4,000 psi (17,237-
27,580 kPa), repair hydraulic manifold
SPARE TIRE valve (para 19-4).
(9) If pressure is 2,500-4,000 psi (17,237-
27,580 kPa), replace spare tire retainer
cylinder (para 14-9 or 14-10).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Disconnect STE/ICE-R from pressure
hose.
(12) Connect pressure hose to spare tire retainer
cylinder port.

Change 1 2-2417/(2-2418 Blank)

 TM 9-2320-366-20-3

2-37. M1089 AIR SYSTEM TROUBLESHOOTING

This paragraph covers M1089 Air System Troubleshooting. The M1089 Air System Fault Index, Table 2-65, lists faults
for the M1089 air system of the vehicle.

Table 2-65. M1089 Air System Fault Index

Fault No. Description Page

aa1. M1089 LH or RH 30K Winch Does Not Pay-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2420

aa2. Main Winch LH FreeSpool Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2422
aa3. Main Winch RH FreeSpool Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2426
aa4. Main Winch LH and RH FreeSpool(s) Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2428
aa5. M1089 LH or RH 30K Winch Cable Drum Tensioner Does Not Operate . . . . . . . . . . . . . . . . . . 2-2430
aa6. One Wrecker Function Does Not Operate From Wrecker Remote Control . . . . . . . . . . . . . . . . 2-2432

Change 1 2-2419
TM 9-2320-366-20-3

aa1. M1089 LH OR RH 30K WINCH DOES NOT PAY-IN

INTIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-2320-366-10-1). Goggles, Industrial (Item 15, Appendix C)

Personnel Required
(2)

NOTE
Perform Electrical System Troubleshooting e138A.
M1089 LH or RH 30K Winch Does Not Pay-In
prior to beginning this task.

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Hydraulic tank oil level OK. Air Pressure Test
MAIN WINCH LH and RH
Is air pressure present at
FREESPOOL switches to OFF. REASON FOR QUESTION
LH/RH 30K winch freespool
MAN WINCH LH FREESPOOL If air pressure is not present,
input 90 degree fitting?
switch OK. perform Wrecker Hydraulic
MAN WINCH RH FREESPOOL System Troubleshooting. If air
switch OK. pressure is present, 30K winch
POSSIBLE PROBLEMS pneumatic manifold solenoid is
faulty.
Faulty 30K winch pneumatic
manifold solenoid valve.
NO
Faulty wrecker hydraulic
system.

Perform Wrecker Hydraulic System

Troubleshooting task w4. M1089 LH 30K
YES
Winch Does Not Operate or W9. M1089
30K RH Winch Does Not Operate.

Replace 30K winch pneumatic manifold

solenoid valve (refer to Table 65.1. 30K Winch
Freespool Solenoid Valves (para 17-29).

2-2420 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from releases of high pressure
air. Failure to comply may result in injury to
personnel.

AIR PRESSURE TEST

NOTE
LH and RH air hose are removed the same
way. LH hose shown.

(1) Disconnect air hose from LH/RH 30K winch

freespool input 90 degree fitting.
(2) Start engine (TM 9-2320-366-10-1).
(3) If air pressure is not present at air hose,
perform Wrecker Hydraulic System
Troubleshooting task w4. M1089 LH 30K
Winch Does Not Operate or w9. M1089 RH
30K Winch Does Not Operate.
(4) If air pressure is present at air hose, replace
30K winch pneumatic manifold solenoid
valve (refer to Table 65.1. 30K Winch
Freespool Solenoid Valves) (para 17-29).
(5) Shut down engine (TM 9-2320-366-10-1).
(6) Connect air hose to LH/RH 30K winch free
spool input 90 degree fitting.

Table 65.1. 30K Winch Freespool Solenoid Valves

30K Winch Solenoid

LH L19
RH L17

Change 1 2-2421
TM 9-2320-366-20-3

aa2. MAIN WINCH LH FREESPOOL DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320- 366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-2320-366-10-1). STE/ICE-R (Item 41, Appendix C)
M1089 30K Winch Pneumatic Test Adapter
Personnel Required (Item 25, Appendix E)
(2) Goggles, Industrial (Item 15, Appendix C)

References
TM 9-4910-571-12&P
NOTE
Perform Electrical System Troubleshooting
task e140. Main Winch LH or RH Freespool
Switch Does Not Operate prior to beginning
this task.

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Air Pressure Test
LH 30K winch operates.
STE/ICE-R Test #50
STATION SELECTOR switch to Is 75-120 PSI REASON FOR QUESTION
WRECKER CONTROL PANEL. (518-837 kPa) present at
MODE SELECTOR SWITCH to pneumatic manifold solenoid If 75-120 PSI (518-827 kPa) is
NORMAL. L19 port 1? not present, 30K winch
MAIN WINCH LH SPEED pneumatic manifold is faulty.
switch operates.
RH 30K winch freespools.
MAIN WINCH LH FREESPOOL
switch OK.
M1089 control panel wiring
harness OK. NO
Terminal block jumper OK.

POSSIBLE PROBLEMS
Faulty 30K winch pnuematic
Repair 30K winch pneumatic
manifold solenoid L19.
YES solenoid or replace solenoid L19
Faulty air hose.
(para 17-29).
Faulty LH 30K winch
assembly.

2-2422 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection piont prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Open LH and RH catwalks.
(2) Disconnect air hose from pneumatic
manifold solenoid L19 port 1.
(3) Remove tube nipple from M1089 30K
winch pneumatic test adapter.
(4) Connect M1089 30K winch pneumatic test
adapter on pneumatic manifold solenoid
L19 port 1.
(5) Install STE/ICE-R 0-1000 PSI transducer on
M1089 30K winch pneumatic test adapter.
(6) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(7) Position MAIN WINCH LH FREESPOOL
switch to ON.
(8) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(9) If 75-120 PSI (518-827 kPa) is not present,
repair 30K winch pneumatic solenoid or
replace solenoid L19 (para 17-29).
(10) Shutdown engine (TM 9-2320-366-10-1).
(11) Drain air tanks (TM 9-2320-366-10-1).
(12) Position MAIN WINCH LH FREESPOOL
switch to OFF.
(13) Disconnect M1089 30K winch pneumatic
test adapter from pneumatic solenoid L19
port 1.
(14) Connect air hose to pneumatic solenoid
L19 port 1.
(15) Close LH and RH catwalks.

Change 1 2-2423
TM 9-2320-366-20-3

aa2. MAIN WINCH LH FREESPOOL DOES NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Air Pressure Test
LH 30K winch operates. STE/ICE-R Test #50
STATION SELECTOR switch to Is 75-120 PSI REASON FOR QUESTION
WRECKER CONTROL PANEL. (518-837 kPa) present at LH
MODE SELECTOR SWITCH to 30K winch freespool input If 75-120 PSI (518-827 kPa) is
NORMAL. 90 degree fitting? not present, air hose is faulty.
MAIN WINCH LH SPEED If 75-120 PSI (518-827 kPa) is
switch operates. present, LH 30K winch
RH 30K winch freespools. assembly is faulty.
MAIN WINCH LH FREESPOOL
switch OK.
M1089 control panel wiring
harness OK. NO
Terminal block jumper OK.
30K winch pneumatic manifold
solenoid L19 OK.

POSSIBLE PROBLEMS
YES Replace air hose (para 23-5).
Faulty air hose.
Faulty LH 30K winch
assembly.

Notify DS Maintenance, LH 30K

winch assembly is faulty.

2-2424 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection piont prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Disconnect air hose from LH 30K winch
freespool input 90 degree fitting.
(2) Install tube nipple on M1089 30K winch
pneumatic test adapter.
(3) Connect air hose to M1089 30K winch
pneumatic test adapter.
(4) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(5) Position MAIN WINCH LH FREESPOOL
switch to ON.
(6) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(7) If 75-120 PSI (518-827 kPa) is not present,
replace air hose (para 23-5).
(8) If 75-120 PSI (518-827 kPa) is present,
notify DS Maintenance, LH 30K winch
assembly is faulty.
(9) Shutdown engine (TM 9-2320-366-10-1).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Position MAIN WINCH LH FREESPOOL
switch to OFF.
(12) Remove STE/ICE-R 0-1000 PSI transducer
from test adapter.
(13) Disconnect air hose from M1089 30K
winch pneumatic test adapter.
(14) Connect air hose to LH 30K winch free
spool 90 degree fitting.

Change 1 2-2425
TM 9-2320-366-20-3

aa3. MAIN WINCH RH FREESPOOL DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320- 366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-2320-366-10-1). STE/ICE-R (Item 41, Appendix C)
M1089 30K Winch Pneumatic Test Adapter
Personnel Required (Item 25, Appendix E)
(2) Goggles, Industrial (Item 15, Appendix C)

References
TM 9-4910-571-12&P
NOTE
Perform Electrical System Troubleshooting
task e140. Main Winch LH or RH Freespool
Switch Does Not Operate prior to beginning
this task.

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Air Pressure Test
RH 30K winch operates.
STE/ICE-R Test #50
STATION SELECTOR switch to Is 75-120 PSI REASON FOR QUESTION
WRECKER CONTROL PANEL. (518-837 kPa) present at
MODE SELECTOR SWITCH to pneumatic manifold solenoid If 75-120 PSI (518-827 kPa) is
NORMAL. L17 port 1? not present, 30K winch
MAIN WINCH LH SPEED pneumatic manifold is faulty.
switch operates.
LH 30K winch freespools.
MAIN WINCH RH FREESPOOL
switch OK.
M1089 control panel wiring
harness OK. NO
Terminal block jumper OK.

POSSIBLE PROBLEMS

Faulty 30K winch pneumatic Repair 30K winch pneumatic

manifold solenoid L17. YES solenoid or replace solenoid L17
Faulty air hose. (para 17-29).
Faulty RH 30K winch
assembly.

2-2426 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Open LH and RH catwalks.
(2) Disconnect air hose from pneumatic
manifold solenoid L17 port 1.
(3) Remove tube nipple from M1089 30K
winch pneumatic test adapter.
(4) Connect M1089 30K winch pneumatic test
adapter on pneumatic manifold solenoid
L17 port 1.
(5) Install STE/ICE-R 0-1000 PSI transducer on
M1089 30K winch pneumatic test adapter.
(6) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(7) Position MAIN WINCH RH FREESPOOL
switch to ON.
(8) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(9) If 75-120 PSI (518-827 kPa) is not present,
repair 30K winch pneumatic solenoid or
replace solenoid L17 (para 17-29).
(10)) Shutdown engine (TM 9-2320-366-10-1).
(11) Drain air tanks (TM 9-2320-366-10-1).
(12) Position MAIN WINCH RH FREESPOOL
switch to OFF.
(13) Disconnect M1089 30K winch pneumatic
test adapter from pneumatic solenoid L19
port 1.
(14) Connect air hose to pneumatic solenoid
L17 port 1.
(15) Close LH and RH catwalks.

Change 1 2-2426.1
 TM 9-2320-366-20-3

aa3. MAIN WINCH RH FREESPOOL DOES NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Air Pressure Test
RH 30K winch operates. STE/ICE-R Test #50
STATION SELECTOR switch to Is 75-120 PSI REASON FOR QUESTION
WRECKER CONTROL PANEL. (518-837 kPa) present at
MODE SELECTOR SWITCH to RH 30K winch freespool If 75-120 PSI (518-827 kPa) is
NORMAL. input 90 degree fitting? not present, air hose is faulty.
MAIN WINCH RH SPEED If 75-120 PSI (518-827 kPa) is
switch operates. present, RH 30K winch
LH 30K winch freespools. assembly is faulty.
MAIN WINCH RH FREESPOOL
switch OK.
M1089 control panel wiring
harness OK. NO
Teminal block jumper OK.
30K winch pneumatic manifold
solenid L17 OK.

POSSIBLE PROBLEMS
YES Replace air hose (para 23-5).
Faulty air hose.
Faulty RH 30K winch
assembly.

Notify DS Maintenance, RH 30K

winch assembly is faulty.

2-2426.2 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection piont prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Disconnect air hose from RH 30K winch
freespool input 90 degree fitting.
(2) Install tube nipple on M1089 30K winch
pnematic test adapter.
(3) Connect air hose to M1089 30K winch
pneumatic test adapter.
(4) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(5) Position MAIN WINCH RH FREESPOOL
switch to ON.
(6) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(7) If 75-120 PSI (518-827 kPa) is not present,
replace air hose (para 23-5).
(8) If 75-120 PSI (518-827 kPa) is present,
notify DS Maintenance, RH 30K winch
assembly is faulty.
(9) Shutdown engine (TM 9-2320-366-10-1).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Positon MAIN WINCH RH FREESPOOL
switch to OFF.
(12) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch pneumatic test
adapter.
(13) Disconnect air hose from M1089 30K
winch pneumatic test adapter.
(14) Connect air hose to RH 30K winch free
spool 90 degree fitting.

Change 1 2-2427
TM 9-2320-366-20-3

aa4. MAIN WINCH LH AND RH FREESPOOLS DO NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320- 366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-2320-366-10-1). STE/ICE-R (Item 41, Appendix C)
M1089 30K Winch Pneumatic Test Adapter
Personnel Required (Item 25, Appendix E)
(2) M1089 30K Winch Test Adapter
(Item 7, Appendix E)
References Goggles, Industrial (Item 15, Appendix C)
TM 9-4910-571-12&P
Material/Parts
Tape, Antiseizing (Item 66, Appendix D)

NOTE
Perform Electrical System Troubleshooting task
e140. Main Winch LH or RH Freespool Switch
Does Not Operate prior to beginning
this task.

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
LH and RH 30K winches Air Pressure Test
operates. STE/ICE-R Test #50
Is 75-120 PSI REASON FOR QUESTION
STATION SELECTOR switch to (518-837 kPa) present at
WRECKER CONTROL PANEL. input tee fitting on pressure This question eliminates
MODE SELECTOR SWITCH to regulator valve? possible problems and
NORMAL. determines where
MAIN WINCH LH and RH troubleshooting continues.
SPEED switch operates.
Terminal block jumper OK.
POSSIBLE PROBLEMS
Faulty pressure protection NO
valve.
Faulty air hose.
Faulty M1089 30K winch
manifold assembly.
Faulty M1089 30K winch
pneumatic manifold assembly. YES Go to step 5 of this fault.

2-2428 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Open LH and RH catwalks.
(2) Disconnect input air hose from input tee
fitting on pressure regulator.
(3) Connect input air hose to M1089 30K
winch pneumatic test adapter.
(4) Install STE/ICE-R 0-1000 PSI transducer on
M1089 30K winch pneumatic test adapter.
(5) Start engine (TM 9-2320-366-10-1).
(6) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(7) If 75-120 PSI (518-827 kPa) is not present,
go to step 5 of this fault.
(8) Shut down engine (TM 9-2320-366-10-1).
(9) Drain air tanks (TM 9-2320-366-10-1).
(10) Disconnect input air hose from M1089 30K
winch pneumatic test adapter.

Change 1 2-2428.1
TM 9-2320-366-20-3

aa4. MAIN WINCH LH AND RH FREESPOOLS DO NOT OPERATE (CONT)

NOTE
Ensure that pressure regulator valve is fully
open by lifting knob and turning clockwise.

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Air Pressure Test
LH and RH 30K winches
STE/ICE-R Test #50
operates. Is 75-120 PSI
STATION SELECTOR switch to REASON FOR QUESTION
(518-827 kPa) present
WRECKER CONTROL PANEL. through M1089 30K winch If 75-120 PSI (518-827 kPa) is
MODE SELECTOR SWITCH to pneumatic manifold? not present, M1089 30K winch
NORMAL. pneumatic manifold is faulty.
MAIN WINCH LH and RH
SPEED switch operates.
Terminal block jumper OK.
Pressure protection valve OK.
POSSIBLE PROBLEMS
NO
Faulty air hose.
Faulty M1089 30K winch
manifold assembly.
Faulty M1089 30K winch
pneumatic manifold assembly. Repair or replace M1089 30K winch
YES
pneumatic manifold (para 17-29).

2-2428.2 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch pneumatic tester.
(2) Connect M1089 30K winch test adapter to
input tee fitting.
(3) Install STE/ICE-R 0-1000 PSI transducer in
M1089 30K winch test adapter.
(4) Connect input air hose to M1089 30K
winch test adapter.
(5) Disconnect air hose from input tee fitting.
(6) Remove tube nipple from M1089 30K
winch pneumatic test adapter.
(7) Connect M1089 30K winch pneumatic test
adapter to input tee fitting.

NOTE
Apply antiseizing tape to first two to five
threads of plug prior to installation.

(8) Install plug in M1089 30K winch pneumatic

test adapter.
(9) Start engine (TM9-2320-366-10-1) and
allow vehicle to build air pressure.
(10) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(11) If 75-120 PSI (518-827 kPa) is not present,
repair or replace M1089 30K winch
pneumatic manifold (para 17-29).
(12) Shut down engine (TM 902320-366-10-1).
(13) Drain air tanks (TM9-2320-366-10-1).
(14) Remove plug from M1089 30K winch
pneumatic test adapter.
(15) Disconnect M1089 30K winch pneumatic test
adapter from input tee fitting.
(16) Install tube nipple on 30K winch pneumatic
test adapter.
(17) Connect air hose to input tee fitting.
(18) Disconnect input air hose from M1089 30K
winch test adapter.
(19) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch test adapter.
(20) Disconnect M1089 30K winch test adapter
from input tee fitting.
(21) Connect input air hose to input tee fitting.

Change 1 2-2428.3
TM 9-2320-366-20-3

aa4. MAIN WINCH LH AND RH FREESPOOLS DO NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
3. on following page.
Air Pressure Test
LH and RH 30K winches
STE/ICE-R Test #50
operates. Is 75-120 PSI
STATION SELECTOR switch to REASON FOR QUESTION
(518-827 kPa) present at
WRECKER CONTROL PANEL. If 75-120 PSI (518-827 kPa) is
input fitting of M1089 30K
MODE SELECTOR SWITCH to not present, air hose is faulty.
winch manifold assembly?
NORMAL.
MAIN WINCH LH and RH
SPEED switch operates.
Terminal block jumper OK.
Pressure protection valve OK.
POSSIBLE PROBLEMS
NO
Faulty air hose.
Faulty M1089 30K winch
manifold assembly.
Faulty M1089 30K winch
pneumatic manifold assembly.
YES Replace air hose (para 23-5).

2-2428.4 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Remove wrecker control panel top cover
(para 14-4).
(2) Disconnect air hose from input fitting of
30K winch manifold assembly.
(3) Connect air hose to M1089 30K winch
pneumatic test adapter.
(4) Install STE/ICE-R 0-1000 PSI transducer in
M1089 30K winch pneumatic test adapter.
(5) Start engine (TM9-2320-366-10-1) and
allow vehicle to build air pressure.
(6) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(7) If 75-120 PSI (518-827 kPa) is not present,
replace air hose (para 23-5).
(8) Shut down engine (TM 902320-366-10-1).
(9) Drain air tanks (TM9-2320-366-10-1).
(10) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch pneumatic test
adapter.
(11) Disconnect air hose from M1089 30K
winch pneumatic test adapter.

Change 1 2-2428.5
TM 9-2320-366-20-3

aa4. MAIN WINCH LH AND RH FREESPOOLS DO NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
4. on following page.
Air Pressure Test
LH and RH 30K winches
STE/ICE-R Test #50
operates. Is 75-120 PSI
STATION SELECTOR switch to REASON FOR QUESTION
(518-827 kPa) present at
WRECKER CONTROL PANEL. 30K winch manifold If 75-120 PSI (518-827 kPa) is
MODE SELECTOR SWITCH to assembly? not present, M1089 30K winch
NORMAL. manifold assembly is faulty. If
MAIN WINCH LH and RH 75-120 PSI (518-827 kPa) is
SPEED switch operates. present, M1089 30K winch
Terminal block jumper OK. manifold assembly is faulty.
Pressure protection valve OK.
Air hoses OK.
NO
POSSIBLE PROBLEMS
Faulty M1089 30K winch
manifold assembly.
Faulty M1089 30K winch
pneumatic manifold assembly. Notify DS Maintenance to
YES repair or replace M1089 30K
winch manifold assembly.

Repair or replace M1089 30K winch

pneumatic manifold (para 17-29).

2-2428.6 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Connect M1089 30K winch test adapter to
input fitting.
(2) Connect air hose to M1089 30K winch test
adapter.
(3) Install STE/ICE-R 0-1000 PSI transducer in
M1089 30K winch test adapter.
(4) Start engine (TM9-2320-366-10-1) and
allow vehicle to build air pressure.
(5) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(6) If 75-120 PSI (518-827 kPa) is not present,
notify DS Maintenance to repair or replace
M1089 30K winch manifold assembly.
(7) If 75-120 PSI (518-827 kPa) is present,
repair or replace M1089 30K winch
pneumatic manifold assembly (para 17-29).
(8) Shut down engine (TM 902320-366-10-1).
(9) Drain air tanks (TM9-2320-366-10-1).
(10) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch test adapter.
(11) Disconnect air hose from M1089 30K
winch test adapter.
(12) Disconnect M1089 30K winch test adapter
from input fitting.
(13) Connect air hose to input fitting on M1089
30K winch manifold assembly.
(14) Close LH and RH catwalks.
(15) Install wrecker control panel top cover
(para 14-4).

Change 1 2-2428.7
TM 9-2320-366-20-3

aa4. MAIN WINCH LH AND RH FREESPOOLS DO NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
5. on following page.
LH and RH 30K winches Air Pressure Test
operates. STE/ICE-R Test #50
Is 75-120 PSI REASON FOR QUESTION
STATION SELECTOR switch to (518-827 kPa) present at
WRECKER CONTROL PANEL. 90 degree fitting of pressure If 75-120 PSI (518-827 kPa) is
MODE SELECTOR SWITCH to protection valve? not present, pressure
NORMAL. protection valve is faulty. If
MAIN WINCH LH and RH 75-120 PSI (518-827 kPa) is
SPEED switch operates. present, air hose is faulty.
Terminal block jumper OK.
POSSIBLE PROBLEMS
Faulty pressure protection
NO
valve.
Faulty air hose.

Replace pressure protection

YES
valve (para 11-29).

Replace air hose (para 23-5).

2-2428.8 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Disconnect air hose from 90 degree fitting
of pressure protection valve.
(2) Remove tube nipple from M1089 30K
winch pneumatic test adapter.
(3) Connect M1089 30K winch pneumatic test
adapter to 90 degree fitting of pressure
protection valve.
(4) Start engine (TM9-2320-366-10-1) and
allow vehicle to build air pressure.
(5) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(6) If 75-120 PSI (518-827 kPa) is not present,
replace pressure protection valve
(para 11-29).
(7) If 75-120 PSI (518-827 kPa) is present,
replace air hose (para 23-5).
(8) Shut down engine (TM 902320-366-10-1).
(9) Drain air tanks (TM9-2320-366-10-1).
(10) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch pneumatic test
adapter.
(11) Disconnect M1089 30K winch pneumatic
test adapter from 90 degree fitting of
pressure protection valve.
(12) Connect air hose to 90 degree fitting of
pressure protection valve.
(13) Connect input air hose to input tee fitting.
(14) Close LH and RH catwalks.
(15) Install tube nipple on 30K winch
pneumatic test adapter.

Change 1 2-2429
TM 9-2320-366-20-3

aa5. M1089 LH OR RH 30K WINCH CABLE DRUM TENSIONER DOES NOT OPERATE

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Air tanks drained (TM 9-2320-366-10-1). STE/ICE-R (Item 41, Appendix C)
M1089 control panel covers removed (para 17-20) M1089 30K Winch Pneumatic Test Adapter
(RH side). (Item 25, Appendix E)
Goggles, Industrial (Item 15, Appendix C)
Personnel Required Nut, Self-Locking (2) (Item 133, Appendix G)
(2) Sealing Compound (Item 58, Appendix D)

References
TM 9-4910-571-12&P

NOTE
M1089 LH and RH 30K winch cable drum
tensioners are tested the same way. LH
side shown.

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Main winch LH/RH freespools. Air Pressure Test
Is 55-65 PSI (380-448 kPa) STE/ICE-R Test #50
POSSIBLE PROBLEMS
present at output 90 degree
Faulty M1089 LH/RH 30K REASON FOR QUESTION
fitting of shuttle valve?
winch cable tensioner. This question eliminates
Faulty 30K winch pneumatic possible problems and
manifold solenoid L8/L4. determines where
Faulty M1089 LH/RH 30K troubleshooting continues.
winch pneumatic valve
assembly.
Faulty air hose. NO

YES Go to step 3 of this fault.

2-2430 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.

AIR PRESSURE TEST

(1) Open LH and RH catwalks.

(2) Disconnect air hose from output 90 degree
fitting of shuttle valve.
(3) Remove tube nipple from M1089 30K
winch pneumatic test adapter.
(4) Connect M1089 30K winch pneumatic
test adapter to output 90 degree fitting of
shuttle valve.
(5) Install STE/ICE-R 0-1000 PSI transducer on
M1089 30K winch pneumatic test adapter.
(6) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(7) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(8) If 55-65 PSI (340-448 kPa) is not present,
go to step 3 of this fault.
(9) Shut down engine (TM 9-2320-366-10-1).
(10) Drain air tanks (TM9-2320-366-10-1).

NOTE
Air pressure trapped in wrecker air
system will be released when
disconnecting M1089 30K winch
pneumatic test adapter from output 90
degree fitting.

(11) Disconnect M1089 30K winch pneumatic

test adapter from output 90 degree
fitting of shuttle valve.
(12) Connect air hose to output 90 degree
fitting of shuttle valve.
(13) Install tube nipple on M1089 30K winch
pneumatic test adapter.

Change 1 2-2430.1
TM 9-2320-366-20-3

aa5. M1089 LH OR RH 30K WINCH CABLE DRUM TENSIONER DOES NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Main winch LH/RH freespools. Air Pressure Test
30K winch pneumatic manifold STE/ICE-R Test #50
solenoid L8/L4 OK. Is 55-65 PSI (380-448 kPa)
M1089 LH/RH 30K winch present at input 90 degree
REASON FOR QUESTION
tensioner pneumatic valve fitting of M1089 LH/RH 30K
assembly OK. winch drum tension If 55-65 PSI (380-448 kPa) is
actuator? not present, air hose is faulty.
POSSIBLE PROBLEMS
If 55-65 PSI (380-448 kPa) is
Faulty M1089 LH/RH 30K present, M1089 LH/RH 30K
winch cable tensioner. winch cable tensioner is faulty.
Faulty air hose.

NO

YES Replace air hose (para 23-5).

Repair or replace M1089 LH/RH 30K

winch cable tensioner (para 17-30).

2-2430.2 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.

AIR PRESSURE TEST

(1) Disconnect air hose from input 90 degree

fitting of M1089 LH/RH 30K winch drum
tension actuator.
(2) Connect air hose to M1089 30K winch
pneumatic test adapter.
(3) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(4) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(5) If 55-65 PSI (380-448 kPa) is not present,
replace air hose (para 23-5).
(6) If 55-65 PSI (380-448 kPa) is present,
repair or replace M1089 LH/RH 30K winch
cable tensioner (para 17-30).
(7) Shut down engine (TM 9-2320-366-10-1).
(8) Drain air tanks (TM9-2320-366-10-1).

NOTE
Air pressure trapped in wrecker air
system will be released when
disconnecting air hose from M1089
30K winch pneumatic test adapter.

(9) Disconnect air hose from M1089 30K

winch pneumatic test adapter.
(10) Connect air hose to input 90 degree fitting
of M1089 LH/RH 30K winch drum tension
actuator.
(11) Close LH and RH catwalks.

NOTE
Perform step (12) for M1089 RH 30K
winch cable drum tensioner.

(12) Install M1089 control panel covers

(para 17-20).

Change 1 2-2430.3
TM 9-2320-366-20-3

aa5. M1089 LH OR RH 30K WINCH CABLE DRUM TENSIONER DOES NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
3. on following page.
Main winch LH/RH freespools. Air Pressure Test
Is 75-120 PSI STE/ICE-R Test #50
POSSIBLE PROBLEMS (518-827 kPa) present at
Faulty 30K winch pneumatic pneumatic manifold (refer to REASON FOR QUESTION
manifold solenoid L8/L4. Table 2-65.2. 30K Winch
Pneumatic Manifold Drum If 75-120 PSI (518-827 kPa) is
Faulty M1089 LH/RH 30K
Tensioner Solenoids) port 1? not present, 30K winch
winch pneumatic valve
pneumatic manifold solenoid
assembly.
L8/L4 is faulty.
Faulty air hose.

NO

Repair M1089 30K winch pneumatic

manifold solenoid or replace solenoid (refer to
YES
Table 2-65.2. 30K Winch Pneumatic Manifold
Drum Tensioner Solenoids) (para 17-29).

2-2430.4 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.

AIR PRESSURE TEST

(1) Disconnect air hose from pneumatic
manifold (refer to Table 2-65.2. 30K
Winch Pneumatic Manifold Drum Tensioner
Solenoids) solenoid port 1.
(2) Remove tube nipple from M1089 30K
winch pneumatic test adapter.
(3) Connect M1089 30K winch pneumatic
test adapter to pneumatic manifold
(refer to Table 2-65.2. 30K Winch
Pneumatic Manifold Drum Tensioner
Solenoids) solenoid port 1.
(4) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(5) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(6) If 75-120 PSI (518-827 kPa) is not present,
repair M1089 30K winch pneumatic
manifold solenoid or replace solenoid
(refer to Table 2-65.2. 30K Winch
Pneumatic Manifold Drum Tensioner
Solenoids) (para 17-29).
(7) Shut down engine (TM 9-2320-366-10-1).
(8) Drain air tanks (TM9-2320-366-10-1).

NOTE
Air pressure trapped in wrecker air
system will be released when
disconnecting M1089 30K winch
pneumatic test adapter from solenoid
port 1.

(9) Disconnect M1089 30K winch pneumatic

test adapter from pneumatic manifold (refer
to Table 2-65.2. 30K Winch Pneumatic
Manifold Drum Tensioner Solenoids)
solenoid port 1.
(10) Connect air hose to pneumatic manifold
(refer to Table 2-65.2. 30K Winch
Pneumatic Manifold Drum Tensioner
Solenoids) solenoid port 1.
(11) Install tube nipple on M1089 30K winch
pneumatic test adapter.

Table 2-65.2. 30K Winch Pneumatic Manifold

Drum Tensioner Solenoids

Side Solenoid
LH L8
RH L4

Change 1 2-2430.5
TM 9-2320-366-20-3

aa5. M1089 LH OR RH 30K WINCH CABLE DRUM TENSIONER DOES NOT OPERATE (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
4. on following page.
Main winch LH/RH freespools. Air Pressure Test
30K winch pneumatic manifold Is 75-120 PSI STE/ICE-R Test #50
solenoid L8/L4 OK. (518-827 kPa) present at
REASON FOR QUESTION
input 90 degree fitting of
POSSIBLE PROBLEMS regulator valve?
If 75-120 PSI (518-827 kPa) is
Faulty M1089 LH/RH 30K not present, air hose is faulty.
winch pneumatic valve
assembly.
Faulty air hose.

NO

YES Replace air hose (para 23-5).

2-2430.6 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.

AIR PRESSURE TEST

NOTE
Tag air hose and connection point prior
to disconnecting.

(1) Disconnect input air hose from input 90

degree fitting of regulator valve.
(2) Connect input air hose to M1089 30K
winch pneumatic test adapter.
(3) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(4) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(5) If 75-120 PSI (518-827 kPa) is not present,
replace air hose (para 23-5).
(6) Shut down engine (TM 9-2320-366-10-1).
(7) Drain air tanks (TM9-2320-366-10-1).

NOTE
Air pressure trapped in wrecker air
system will be released when
disconnecting input air hose from M1089
30K winch pneumatic test adapter.

(8) Disconnect input air hose from M1089 30K

winch pneumatic test adapter.
(9) Remove STE/ICE-R 0-1000 PSI transducer
from M1089 30K winch pneumatic test
adapter.

Change 1 2-2430.7
TM 9-2320-366-20-3

aa5. M1089 LH OR RH 30K WINCH CABLE DRUM TENSIONER DOES NOT OPERATE (CONT)

KNOWN INFO TEST OPTIONS

5.
Main winch LH/RH freespools. Air Pressure Test
30K winch pneumatic manifold Is 55-65 PSI (380-440 kPa) STE/ICE-R Test #50
solenoid L8/L4 OK. present at output 90 degree
Air hoses OK. REASON FOR QUESTION
fitting of regulator valve?

POSSIBLE PROBLEMS If 55-65 PSI (380-440 kPa) is

not present, regulator valve is
Faulty M1089 LH/RH 30K faulty. If 55-65 PSI
winch pneumatic valve (380-440 kPa) is present,
assembly. shuttle valve is faulty.

NO

YES Replace regulator valve (para 17-30).

Replace shuttle valve (para 17-13).

2-2430.8 Change 1
 TM 9-2320-366-20-3

AIR PRESSURE TEST AIR PRESSURE TEST (Cont)

NOTE (26) Remove STE/ICE-R 0-1000 PSI transducer

Tag air hoses and connection points prior from output port of regulator valve.
to disconnecting. (27) Apply sealing compuond to threads of pipe
nipple.
(1) Disconnect air hose from adapter fitting on (28) Install regulating valve on pipe nipple.
shuttle valve. (29) Install 30K winch tension Pneumatic
(2) Disconnect air hose from 90 degree fitting valve assembly (para 17-30).
on shuttle valve. (30) Close LH and RH catwalks.
(3) Remove two self-locking nuts, washers,
screws, and shuttle valve from bulkhead.
Discard self-locking nuts.
(4) Position shuttle valve in vise.
(5) Remove regulator valve from pipe nipple.
(6) Install STE/ICE-R 0-1000 PSI pressure
transducer in output port of regulator valve.
(7) Connect input air hose to input 90 degree
fitting of regulator valve.
(8) Start engine (TM 9-2320-366-10-1) and
allow vehicle to build air pressure.
(9) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(10) If 55-65 PSI (380-440 kPa) is not present,
perform step (18) through (22).
(11) If 55-65 PSI (380-440 kPa) is present,
replace shuttle valve (para 17-30).
(12) Shut down engine (TM 9-2320-366-10-1).
(13) Drain air tanks (TM 9-2320-366-10-1).
(14) Disconnect input air hose from output 90
degree fitting of regulator valve.
(15) Remove STE/ICE-R 0-1000 PSI transducer
from output port of regulator valve.
(16) Close LH and RH catwalks.
NOTE
Perform step (17) for M1089 RH 30K
winch cable drum tensioner.
(17) Install M1089 control panel covers
(para 17-20).
(18) Pull out and turn knob on regulator valve
fully counter clockwise.
(19) Pull out and turn knob on regulator valve
clockwise until STE/ICE-R shows between
55-65 PSI (380-440 kPa).
(20) If 55-65 PSI (380-440 kPa) is present after
adjustment, perform steps (23) through (30).
(21) If 55-65 PSI (380-440 kPa) is still not present
after adjustment, replace regulator valve
(para 17-30).
(22) Perform steps (12) through (17).
(23) Shut down engine (TM 9-2320-366-10-1).
(24) Drain air tanks (TM 9-2320-366-10-1).
(25) Disconnect input air hose from input 90
degree fitting of regulator valve.

Change 1 2-2431
TM 9-2320-366-20-3

aa6. ONE WRECKER FUNCTION DOES NOT OPERATE FROM WRECKER REMOTE CONTROL

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Top control panel cover removed STE/ICE-R (Item 41, Appendix C)
(para 17-20). Multimeter, Digital (Item 22, Appendix C)
Front middle and lower panel covers M1089 Solenoid Test Adapter (Item 8, Appendix E)
removed (para 17-20). Goggles, Industrial (Item 15, Appendix C)
Air tanks drained (TM 9-2320-366-10-1).
References
Personnel Required TM 9-4910-571-12&P
(2)

START

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
1. on following page.
Circuit breaker CB50 OK. Air Pressure Test
Hydraulic functions OK. STE/ICE-R Test #50
Is 75 to 120 psi (517 to
STATION SELECTOR switch to REASON FOR QUESTION
827 kPa) present at
REMOTE CONTROL. solenoid valve output? If air pressure at solenoid valve
MODE SELECTOR SWITCH to output is not present, solenoid
NORMAL valve assembly is faulty.
Air system OK.
Electrical functions OK.
POSSIBLE PROBLEMS
Faulty solenoid valve NO
assembly.
Faulty air hose.
Faulty upper or lower valve
assemblies.
YES Notify DS Maintenance.

2-2432 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting.

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Disconnect air hose from solenoid valve
listed in Table 2-66. Wrecker Function
Solenoid Valves and Actuators.
(2) Install test adapter on solenoid valve.
(3) Install STE/ICE-R 0-1000 psi transducer
on test adapter.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position WRECKER REMOTE CONTROL
switch listed in Table 2-66. Wrecker
Function Solenoid Valve.
(6) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(7) If 75 to 120 psi (517 to 827 kPa) is not
present, notify DS Maintenance.
(8) Shut down engine (TM 9-2320-366-10-1).
(9) Drain air tanks (TM 9-2320-366-10-1).
(10) Remove STE/ICE-R and test adapter from
solenoid valve.
(11) Install air hose on solenoid valve.

Table 2-66. Wrecker Function Solenoid Valves and Actuators

Wrecker Remote Upper or Lower

Actuator and
Function Control Switch Valve Actuator
Solenoid Valve
Position Air Hose Position
Underlift Fold Up Up L18 Lower Front
Underlift Fold Down Down L15 Lower Rear
Stinger In In L16 Lower Front
Stinger Out Out L13 Lower Rear
Underlift Up Up L14 Lower Front
Underlift Down Down L11 Lower Rear
Main Winch LH In In L6 Upper Front
Main Winch LH Out Out L5 Upper Rear
Main Winch RH In In L2 Lower Front
Main Winch RH Out Out L1 Lower Rear

Change 1 2-2432.1
TM 9-2320-366-20-3

aa6. ONE WRECKER FUNCTION DOES NOT OPERATE FROM WRECKER REMOTE
CONTROL (CONT)

WARNING
Read WARNING
KNOWN INFO TEST OPTIONS
2. on following page.
Circuit breaker CB50 OK. Air Pressure Test
Hydraulic functions OK. STE/ICE-R Test #50
Is 75 to 120 psi (517 to
STATION SELECTOR switch to REASON FOR QUESTION
827 kPa) present at
REMOTE CONTROL. actuator end of air hose? If air pressure is not present,
MODE SELECTOR SWITCH to air hose is faulty.
NORMAL.
Air system OK.
Electrical functions OK.
Solenoid valve assembly OK.
POSSIBLE PROBLEMS
NO
Faulty air hose.
Faulty upper or lower valve
assemblies.

YES Replace air hose (para 23-5).

Notify DS Maintenance.

2-2432.2 Change 1
 TM 9-2320-366-20-3

WARNING

Wear protective goggles to protect against

possible injury from release of high pressure
air. Failure to comply may result in injury to
personnel.
NOTE
Tag air hose and connection point prior to
disconnecting.

AIR PRESSURE TEST STE/ICE-R TEST #50

(1) Disconnect air hose from actuator listed in

Table 2-66. Wrecker Function Solenoid
Valves and Actuators.
(2) Install test adapter on solenoid valve.
(3) Install STE/ICE-R 0-1000 psi transducer on
test adapter.
(4) Start engine (TM 9-2320-366-10-1).
(5) Position WRECKER REMOTE CONTROL
switch listed in Table 2-67. Wrecker
Function Actuator.
(6) Perform STE/ICE-R Test #50 and note
reading on STE/ICE-R.
(7) If 75 to 120 psi (517 to 827 kPa) is not
present, replace air hose (para 23-5).
(8) If 75 to 120 psi (517 to 827 kPa) is
present, notify DS Maintenance.
(9) Shut down engine (TM 9-2320-366-10-1).
(10) Drain air tanks (TM 9-2320-366-10-1).
(11) Remove STE/ICE-R and test adapter from
solenoid valve.
(12) Install air hose on actuator.
(13) Install front middle and lower panel covers
(para 17-20).
(14) Install top control panel cover
(para 17-20).

Change 1 2-2433/(2-2434 Blank)

 TM 9-2320-366-20-3

2-38. FRAME TROUBLESHOOTING

This paragraph covers Frame Troubleshooting. The Frame Fault Index, Table 2-68, lists faults for the frame of the
vehicle.

Table 2-68. Frame Fault Index

Fault No. Description Page

ab1. Tires Continue to Wear After Front End Alignment and/or Vehicle Drives Sideways
Down Road . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2436

2-2435
TM 9-2320-366-20-3

ab1. TIRES CONTINUE TO WEAR AFTER FRONT END ALIGNMENT

AND/OR VEHICLE DRIVES SIDEWAYS DOWN ROAD
INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)

Personnel Required
(4)

START

KNOWN INFO TEST OPTIONS

1.
Tire pressure OK. Visual inspection
POSSIBLE PROBLEMS REASON FOR QUESTION
Does frame rail pass
Damaged frame rail. If damage is visible on
visual inspection for
Improper toe-in. frame rail(s), frame rail
damage?
is faulty.

NO

Notify DS Maintenance.
YES

KNOWN INFO TEST OPTIONS

2.
Tire pressure OK. Refer to para 13-7.
POSSIBLE PROBLEMS REASON FOR QUESTION
Is front end aligned
Improper toe-in. If front end is not aligned
properly?
Damaged frame rail. properly, tires will
continue to wear.

NO

Align front end

YES
(para 13-5).

2-2436
 TM 9-2320-366-20-3

Inspect frame rails and cross members for

visible damage. If frame rail(s) and/or cross
member(s) show any evidence of damage or
bends, notify DS Maintenance.

Perform front end alignment and verify

proper toe-in (para 13-5).

2-2437
TM 9-2320-366-20-3

ab1. TIRES CONTINUE TO WEAR AFTER FRONT END ALIGNMENT AND/OR VEHICLE DRIVES SIDEWAYS
DOWN ROAD (CONT)

KNOWN INFO TEST OPTIONS

3.
Tire pressure OK. Road Test
Front end aligned properly. REASON FOR QUESTION
POSSIBLE PROBLEMS Does vehicle travel If vehicle does not travel
Damaged frame rail. in a straight line? in a straight line, frame
rail(s) is faulty.

NO

Notify DS Maintenance.
YES

Fault corrected.

2-2438
 TM 9-2320-366-20-3

ROAD TEST
(1) Road test vehicle with additional vehicle
following.
(2) Have following vehicle monitor path of lead
vehicle.
(3) If front of vehicle can be seen while in direct
line of rear of vehicle, notify DS Maintenance.

2-2439/(2-2440 Blank)
 TM 9-2320-366-20-3

Section V. MAINTENANCE PROCEDURES

2-39. MAINTENANCE INTRODUCTION

This section provides general procedures to be followed for the Unit Maintenance level as specified in the Maintenance
Allocation Chart (MAC). When a special procedure is used, the detailed procedure will be in the section covering that
component.

2-40. GROUND HANDLING

a. Towing. Two towing eyes are located at front and two located at rear of vehicle.

b. Parking. Parking brakes are designed to hold GVW on a minimum of 7-9 percent grade, pointing either uphill or
downhill per Federal Motor Carrier Safety Regulation 393.41.

c. Mooring and Transporting. For forward, aft, lateral and upward movements, vehicle has four tiedown rings. Refer
to TM 9-2320-366-10-2 for mooring condition and tiedown locations.

d. Hoisting. Sling assemblies and towing eyes used for hoisting are found on the vehicle.

2-41. GENERAL REMOVAL INSTRUCTIONS

a. Work Required. Remove parts if repair or replacement is required. Do not disassemble a component any further
than needed.

b. Preparation. Before removal of any electrical, hydraulic, or air system components, ensure system component is
not energized or pressurized. Disconnect battery ground cables. Relieve air system pressure. Before removal of
fasteners (nuts, locknuts) remove any paint on threads to prevent binding of fastener.

c. Identification. To ease assembly and installation, tag and mark shims, connectors, wires and mating ends of lines
before disconnecting them. Identify similar parts to ensure correct assembly.

d. Position of Valves. Before removing valve handles, mark or diagram their positions when open and closed. This
will help during assembly.

e. Tire Removal. Before removing any tires, position jackstands under axles, walking beams or frame. This will
secure the vehicle for safe tire removal.

f. Location. Before removing cable ties, cushion clamps, hoses, tubing, wiring, etc., note the location, position and
routing to ensure correct assembly.

2-2441
TM 9-2320-366-20-3

2-41. GENERAL REMOVAL INSTRUCTIONS (CONT)

g. Data Plate Removal.

WARNING

Wear appropriate eye protection when removing rivets. Failure to comply may
result in injury to personnel.

CAUTION

Use appropriate size drill bit when removing rivets. Failure to comply may cause
damage to equipment.

Remove rivets and data plate from vehicle.

h. Rivnut Removal.

WARNING

Wear appropriate eye protection when removing rivets. Failure to comply may
result in injury to personnel.

CAUTION

Use appropriate size drill bit when removing rivets. Failure to comply may cause
damage to equipment.

Remove rivets and rivnut from vehicle.

2-42. GENERAL DISASSEMBLY INSTRUCTIONS

a. Cleanliness. Work area must be as clean as possible to prevent contamination to components.

CAUTION

Self-locking fasteners that are loosened must be replaced, not tightened.

b. Locking Parts. Replace all lockwashers, cotter pins and self-locking nuts at time of reassembly.

c. Expendable Parts. All gaskets, packings, and seals removed during repair must be discarded and replaced with
new parts.

d. Removing Seals. Be sure all traces of oil, gaskets, and sealants are removed from components. When possible,
use wood or plastic probes and scrapers to prevent damage to machined surfaces.

2-2442
 TM 9-2320-366-20-3

CAUTION

Do not use tape to close off fuel or oil openings. Sticky surface of tape can mix with
fuel and oil and cause engine malfunctions.

e. Parts Protection. To keep dust, dirt, moisture, and other objects out of internal parts of systems or components,
cap or tape all open tubes, hoses, air lines, fittings and component openings as soon as part is removed. Wrap all
removed parts in clean paper or dip parts in preservation oil.

2-43. GENERAL CLEANING INSTRUCTIONS

WARNING

• Dry Cleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles
and gloves; use only in well ventilated area; avoid contact with skin, eyes, and
clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke
when using solvent; the flashpoint for Type I Dry Cleaning Solvent is 100 degrees F
(38 degrees C) and for Type II is 130 degrees F (50 degrees C). Failure to comply
may result in serious injury or death to personnel.

• If personnel become dizzy while using Dry Cleaning Solvent, immediately get fresh
air and medical help. If solvent contacts skin or clothes, flush with cold water. If
solvent contacts eyes, immediately flush eyes with water and get immediate medical
attention. Failure to comply may result in injury to personnel.

• Never use fuel to clean parts. Fuel is highly flammable. Serious injury or death
could result if fuel ignites during cleaning.

a. Cleaning Solvents. Use only approved cleaning solvents to clean parts. Dry Cleaning Solvent P-D-680 (Item 65,
Appendix D) is commonly used. Always work in a well-ventilated area.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc). Failure to comply may result in injury to personnel.

b. Removing Deposits. Soak parts in Dry Cleaning Solvent P-D-680 (Item 65, Appendix D), and wash away deposits
by flushing or spraying. When necessary, brush with a soft bristle brush (not wire) moistened in solvent. Use
compressed air to dry parts, except bearings, after cleaning. Bearings must drip and air dry.

c. Tools. Do not use wire brushes, abrasive wheels, or compounds to clean parts unless specifically approved in the
detailed procedures. Parts may be scratched or altered and may weaken a highly stressed part.

d. Ball and Roller Bearings. When cleaning ball or roller bearings, place them in a basket and suspend them in a
container of Dry Cleaning Solvent P-D-680 (Item 65, Appendix D). If needed, use a brush to remove caked grease,
chips, etc. Avoid rotating bearing before solid particles are removed to prevent damaging races and balls. When
bearings have been cleaned, coat them lightly with lubricating oil (Item 42, Appendix D) to remove solvent.

2-2443
TM 9-2320-366-20-3

2-43. GENERAL CLEANING INSTRUCTIONS (CONT)

CAUTION

Do not clean tires, lubricant seals, rubber hoses, or electrical components with solvent
mixture. Failure to comply may result in damage to equipment.

e. Rubber Parts. Do not clean preformed packings or other rubber parts in Dry Cleaning Solvent. Wipe parts clean
with a dry wiping rag (Item 50, Appendix D).

WARNING

Steam cleaning creates hazardous noise levels and severe burn potential. Eye,
skin, and ear protection is required. Failure to comply may result in injury to
personnel.

CAUTION

Steam cleaning may cause water to enter the transmission Electronic Control Unit
(ECU) connector. Failure to dry off connector after steam cleaning may result in bad
ECU codes.

f. Exterior Parts. Steam clean all exterior parts thoroughly before removing. This will make inspection and
disassembly easier.

WARNING

Solvents used with a spray gun must be used in a spray booth with filter. Face
shield must be used by personnel operating spray gun. Failure to comply may
result in injury to personnel.

g. Engine, Cab, and Body. Use a spray gun and solvent mixture for cleaning exterior of engine, cab, and body. Allow
mixture to remain on item surface for 10 minutes before rinsing. Rinse with hot water under 80 to 120 psi (550 to 830
kPa), if available. An ordinary garden hose with nozzle may be used if other equipment is not available. Rinse
thoroughly.

CAUTION

To prevent corrosion, parts should be dipped in rust preventive within two hours of
degreasing. Failure to comply may result in damage to equipment.

h. Degreasing Machine. A degreasing machine may be used to remove heavy grease and oil from metal parts.

2-2444
 TM 9-2320-366-20-3

WARNING

• Dry Cleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles
and gloves; use only in well ventilated area; avoid contact with skin, eyes, and
clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke
when using solvent; the flashpoint for Type I Dry Cleaning Solvent is 100 degrees F
(38 degrees C) and for Type II is 130 degrees F (50 degrees C). Failure to comply
may result in serious injury or death to personnel.

• If personnel become dizzy while using Dry Cleaning Solvent, immediately get fresh
air and medical help. If solvent contacts skin or clothes, flush with cold water. If
solvent contacts eyes, immediately flush eyes with water and get immediate medical
attention. Failure to comply may result in injury to personnel.

• Never use fuel to clean parts. Fuel is highly flammable. Serious injury or death
could result if fuel ignites during cleaning.

i. Passages. After degreasing, check all oil passages and cavities for dirt or blockage before coating with lubricating
oil (Item 42, Appendix D). Run a thin, flexible wire through oil passages to make sure they are not clogged. Use a
pressure spray gun and Dry Cleaning Solvent P-D-680 (Item 65, Appendix D) to clean dirty passages.

j. Electrical Parts. Electrical parts; such as coils, junction blocks, and switches; should not be soaked or sprayed
with cleaning solutions. Clean these parts with a clean wiping rag (Item 50, Appendix D) moistened with Dry Cleaning
Solvent P-D-680 (Item 65, Appendix D).

CAUTION

Do not use soap or alkalies for cleaning tank interiors. Failure to comply may result
in damage to equipment.

k. Fuel Tank. Pay special attention to all warnings and cautions when working on vehicle fuel tank. Fuel tanks should
be flushed, using a spray gun and Dry Cleaning Solvent P-D-680 (Item 65, Appendix D).

WARNING

Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and
rubber gloves and do not smoke when performing maintenance on batteries.
Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent
clothing being damaged.

l. Battery. Exterior surfaces of the electrical system and battery should be cleaned with a weak solution of baking
soda and water. Apply solution with a bristle brush to remove any corrosion. Pay special attention to all warnings and
cautions when working on batteries.

m. Hydraulic System. When cleaning hydraulic system parts use Dry Cleaning Solvent P-D-680 (Item 65, Appendix
D). Clean and dry parts thoroughly to make sure no residue remains. If a coating of preservative is required before
assembly, apply a light film of lubricating oil (Item 42, Appendix D).

2-2445
TM 9-2320-366-20-3

2-44. GENERAL INSPECTION INSTRUCTIONS

a. Cleaning. Clean all parts before inspection. Check for defects such as physical distortion, wear, cracks, and pitting.

b. Sealing Surfaces. Inspect all surfaces in contact with gaskets, packings, or seals for nicks and burrs. If any defect
is found, remove it before assembly.

c. Bearings. Inspect bearings for rusted or pitted balls, races, or separators. Inspect balls and races for brinelling,
abrasion, and serious discoloration. The following are conditions for bearing rejection:

(1) Cuts or grooves parallel to ball or roller rotation.

(2) Fatigue pits (not minor machine marks or scratches).

(3) Cracks.

d. Gears and Splined Shafts. Inspect gears and splined shafts for wear, pittings, rolling, peening, scoring, burning,
brinnelling and fatigue cracks.

e. Tubing and Hoses. Inspect all hose surfaces for broken or frayed fabric. Check for breaks caused by sharp kinks
or contact with other parts of the vehicle. Inspect copper tubing lines for kinks. Inspect fitting threads and mating
surfaces for damage. Replace any defective part. After assembly and during initial vehicle operation period, check for
leaks.

f. Electrical Parts. Inspect all wiring harnesses and cable assemblies for broken, chafed, or burned wiring. Inspect
all terminal connectors for loose connections and broken parts.

g. Metal Parts. Visually inspect all castings and weldments for cracks. Parts that carry a great load should receive
magnetic particle inspection. Critical non-ferrous parts may be inspected with fluorescent penetrant.

h. Drain Plugs. When removing drain plugs from transmission, engine, hydraulic system components, or axle
differential and planetary hubs, check amount of sediment on plugs. Accumulations of grit or fine metal particles may
indicate actual or potential component failure. A few fine particles are normal. This inspection helps to determine if there
are defective parts prior to internal inspection of the component and to predict degradation of the equipment.

2-45. GENERAL REPAIR INSTRUCTIONS

a. Burrs. Remove burrs from surface teeth with a fine-cut file or crocus cloth.

b. Exterior Parts. Chassis and exterior painted parts may be resurfaced when paint is damaged, or where parts have
been repaired (TB 43-0242).

NOTE

Polished and machined steel parts not protected by cadmium, tin, copper, or other
plating or surface treatment require protection. Bare metal parts must be free of
moisture when protective coating is applied.

c. Protecting Parts. Protect bare steel surfaces from rust when not actually undergoing repair work. Dip parts in, or
spray them with, corrosion preventive compound (Item 18, Appendix D). Aluminum parts may require protection in
atmospheres having a high salt content.

2-2446
 TM 9-2320-366-20-3

d. Screws, Nuts and Fittings. Replace any screw, nut, or fitting with damaged threads. Inspect tapped holes for
thread damage. If cross-threading is evident retap the hole for the next oversize screw or stud. If the retapping will
weaken the part, or if the cost of the part makes retapping impractical, replace the part. Chasing the threads with proper
size tap or die may be adequate.

e. Stud Installation. When installing studs use a proper driver. A worn stud driver may damage the end thread. Then
a chasing die must be used before a nut can be screwed on. This procedure will remove cadmium plating and allow
corrosion. Before installing a stud, inspect the hole for chips. Blow out foreign matter and start stud by hand. Before
final insertion, coat threads with a film of antiseize compound (Item 13, Appendix D). Install stud to proper "setting
height", which is the total projecting length.

f. Dents. Straighten minor body dents by tapping with a soft-faced hammer while using a wooden block backing.

g. Sheet Metal Repair. Repair minor skin cracks by installing patches.

h. Wire Repair. Replace all broken, worn, or burned electrical wiring. Wires with several broken strands must be
replaced. Broken strands will increase the resistance of the wire and impair efficiency of electrical components,
especially the ignition system. Wire numbers must be permanently identified on any new wiring.

i. Repair of Wires with Female Sockets. Strip insulation from wire to equal depth of terminal well. Slide shell and
sleeve over wire insulation. Insert wire into terminal well. Crimp terminal well on wire. Slide sleeve and shell over
terminal.

j. Repair of Wires with Male Plugs. Strip insulation from wire to equal depth of terminal well. Slide shell over wire
insulation. Insert wire into terminal well. Crimp terminal well on wire. Place slotted washer over crimped terminal well.
Slide shell over slotted washer and terminal.

k. Repair of Wires with Terminals of Various Configurations. Strip insulation from wire to equal depth of terminal
well. Slide insulator over insulation. Insert wire into terminal well. Crimp terminal well on wire. Slide insulator over
crimped terminal well.

l. Repair of Cables with Multiple Conductor Receptacle Connectors. Remove insulation sleeving from cable.
Discard insulation sleeving. Extract electrical contact from receptacle body. Strip insulation from wire to equal depth
of well in electrical contact. Position insulation sleeving on cable. Crimp electrical contact on wire. Install electrical
contact in receptacle body. Heat shrink insulation sleeving.

m. Repair of Cables with Multiple Conductor Plug Connectors. Remove insulation sleeving from cable. Discard
insulation sleeving. Extract electrical contact from plug body. Strip insulation from wire to equal depth of well in
electrical contact. Position insulation sleeving on cable. Crimp electrical contact on wire. Install electrical contact in
plug body. Heat shrink insulation sleeving.

n. Repair of Cables with Multiple Conductor Mate-N-Lock Series Connectors. Remove electrical contact from
connector body. Strip insulation equal to depth of well on electrical contact. Position wire end in electrical contact.
Crimp electrical contact on wire end. Install electrical contact in connector body. Remove electrical contact from
connector body. Strip insulation equal to depth of well on electrical contact. Position wire end in electrical contact.
Crimp electrical contact on wire end. Install electrical contact in connector body.

o. Repair of Cables with Multi-Conductor Metri-Pack Series Connectors. Extract electrical contact from connector
body. Strip insulation from wire to equal depth of well in electrical contact. Crimp electrical contact on wire. Install
electrical contact in connector body.

p. Repair of Cables with Multi-Conductor Sure-Seal Series Plug and Receptacle Connectors. Remove insulation
sleeving from connector body. Discard insulation sleeving. Extract electrical contact from connector body. Strip
insulation from wire to equal depth of well in electrical contact. Position insulation sleeving on cable. Crimp electrical
contact in connector body. Heat shrink insulation sleeving.

Change 1 2-2446.1/(2-2446.2 Blank)

 TM 9-2320-366-20-3

q. Repair of Cables with MIL-SPEC Solder-Type Terminal Connectors. Loosen two retaining screws on cable
clamp. Remove cable clamp from connector body. Desolder wire from electrical contact. Remove wire from electrical
contact. Strip insulation from wire to equal depth of well in electrical contact. Position wire in electrical contact. Solder
wire to electrical contact. Install cable clamp on connector body with two retaining screws.

2-46. GENERAL ASSEMBLY INSTRUCTIONS

a. Preparation. Remove protective grease coatings from new parts before installation.

b. Preformed Packing Installation. Lubricate all preformed packings with a thin coat of lubricating oil (Item 42,
Appendix D) before installing. To install a preformed packing, first clean the groove, then stretch packing and place into
position. Place component on flat surface and uniformly press packing into position.

c. Pipe Joints and Fittings. Use antiseize compound (Item 13, Appendix D) or antiseizing tape (Item 66, Appendix
D) to join pipes and fittings.

d. Oil Seals. Coat oil seals evenly with oil or grease before installing. Install oil seals with seal lip facing toward
lubricant, applying an even force to outer edge of seal. If oil seals are to be installed over keyed or splined shafts, use
a guide to prevent sharp edge of keyway or splines from cutting the leather or neoprene seal. Construct guides of very
thin gauge sheet metal and shape to the required diameter. Make certain guide edges are not sharp and are bent
slightly inward so they do not cut the seal.

e. Bearings and Shafts. When mounting bearings on shafts always apply force to the inner races. When mounting
bearings into housing always apply the force to the outer race.

f. Bearing Lubrication. Lubricate bearings before assembly with lubricant used in the related housing or container
to provide the first run-in until lubricant from the system can reach the bearings.

WARNING

On direct contact, uncured silicone sealant irritates eyes. In case of contact,

flush eyes with water and seek medical attention. In case of skin contact, wipe
off and flush with water. Failure to comply may result in injury to personnel.

g. Silicone Sealant. Silicone sealant is often used instead of a gasket to seal mating parts. The mating parts must
be clean, dry, and free of oil or grease for proper adhesion. After silicone sealant has been applied, the mating parts
must be assembled immediately. Silicone sealant starts to set-up in 15 minutes and takes 24 hours to completely dry.
Excess silicone sealant should be wiped off after assembling the mating parts.

Change 1 2-2447
TM 9-2320-366-20-3

2-46. GENERAL ASSEMBLY INSTRUCTIONS (CONT)

h. Gaskets. Remove all traces of previous gasket and sealant before installing new gasket. Coat both sides of gasket
with sealant to provide added sealing.

2-47. GENERAL INSTALLATION INSTRUCTIONS

a. Preparation. When unpacking items, remove all packing material, barrier paper, tape, plastic bags, protective caps
and protective grease coatings. Handle and store removed components carefully.

CAUTION

Use sealing compound sparingly and only on threads. Do not apply compound to hose
connections. Failure to comply may result in damage to equipment.

b. Sealing Compounds. Use only the sealing compounds specified in each maintenance task.

c. Torquing. Tighten bolts, screws, nuts, and fittings as required in each maintenance task or in Appendix F.

d. Identification Tags. Put hoses, tubes, lines, and electrical wiring in place by matching identification tags and
markings on equipment.

e. Hoses, Air Lines and Wiring. After installing hoses, air lines and wiring, ensure that they do not contact moving
parts or component edges. Secure in place, out of the way, with cable ties and cushion clamps.

f. Data Plate Installation.

Install data plate on vehicle with rivets.

g. Rivnut Installation.

Install rivnut on vehicle with rivets.

2-48. PREPARATION FOR STORAGE OR SHIPMENT INTRODUCTION

a. This section gives instructions for making the vehicle ready for shipment or storage.

b. Refer to AR 750-1 for detailed administrative storage instructions.

c. Refer to TB 9-2300-422-20 for security procedures.

2-49. PREPARATION FOR STORAGE OR SHIPMENT

a. Perform Preventive Maintenance Checks and Services (PMCS) listed in Table 2-1.

b. Correct all deficiencies noted during inspection, if facilities are available. If repairs are required, beyond the scope
of Unit Maintenance, refer the deficiencies to Direct Support or General Support Maintenance.

2-2448
 TM 9-2320-366-20-3

2-50. STORAGE MAINTENANCE PROCEDURES

a. Provide access to the vehicle during storage.

CAUTION

Ensure tires are not resting on surfaces containing grease or oil. Failure to comply may
result in damage to equipment.

b. Do not block wheels, but do be sure tires are not resting on surfaces containing grease or oil.

c. Perform complete lubrication in accordance with TM 9-2320-366-10-1 and Appendix H.

d. If possible, store vehicles close together, out of direct sunlight and away from electrical or generating equipment.

e. Ensure the fuel tank contains at least 20 gallons (75.7 liters) of treated fuel. The fuel should be treated with Biobor
J.F. The addition of 3 teaspoons of Biobor to 20 gallons of fuel will provide adequate protection against fungus growth.
When storing a vehicle in freezing conditions, the addition of 3 ounces of isopropyl alcohol to every 20 gallons of diesel
fuel will help prevent fuel-line freeze up.

f. Monthly Storage Maintenance Instructions.

(1) Conduct visual inspection of vehicle. Check lubricant, battery electrolyte, coolant level, and tire pressures.
Correct any discrepancies.

(2) Inspect oil can points. Lubricate if necessary.

(3) Start engine and idle for 10 minutes. After 10 minutes of engine idle, operate engine for 5 minutes at 1500
rpm or until engine water temperature reaches 180 degrees F. Shift transmission slowly through all gear
selector positions. Return transmission to neutral.

(4) Move vehicle 30 feet forward and reverse.

(5) Idle engine 10 minutes before shutdown.

(6) Check grease coating on all chromium plated and unpainted surfaces. If grease was wiped from chromium
plates or unpainted surfaces when vehicle was moved, recoat these surfaces.

g. Quarterly Storage Maintenance Instructions.

(1) Move vehicle at least 1/4 mile. While driving, shift transmission through all gear ranges.

(2) Exercise all auxiliary equipment and winch. While operating winch or crane, lubricate hoist and cables.

h. Yearly Storage Maintenance Instructions.

(1) Clean exterior, engine, and undercarriage. Clean interior of cab. Wash any oil or grease from tires.

(2) Visually inspect vehicle. Check lubricant levels and tire pressures. Correct all discrepancies.

(3) Lubricate chassis, auxiliary equipment, winch, hoist cable, and oil can points.

2-2449/(2-2450 Blank)
 TM 9-2320-366-20-3

CHAPTER 3
ENGINE MAINTENANCE

RESTRICTED MAINTENANCE NOTICE

Units not authorized SC 4910-95-CL-A72 (SHOP EQUIPMENT, COMMON NO. 2) in their T.O.E. may
be unable to perform some of the maintenance tasks described in this chapter. If the required tools
are not authorized, the equipment must be submitted to DS Maintenance for repair.

Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section II. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2. LIFTING PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-3. VALVE COVER AND GASKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-4. ENGINE OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-5. CRANKCASE BREATHER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-6. ENGINE AND TRANSMISSION OIL SAMPLING VALVES REPLACEMENT . . . . . . . . . . . . . . . . . . . . 3-15
3-7. ENGINE OIL FILL TUBE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Section I. INTRODUCTION

3-1. INTRODUCTION

This chapter contains maintenance instructions for replacing engine components authorized by the Maintenance
Allocation Chart (MAC) at the Unit Maintenance level.

Change 1 3-1
TM 9-2320-366-20-3

Section II. MAINTENANCE PROCEDURES

3-2. LIFTING PLATE REPLACEMENT
This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Cab raised (TM 9-2320-366-10-1). Goggles, Industrial (Item 15, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Container (40 qt (38 L) capacity)

WARNING

• Coolant may be very hot and under pressure

from engine operation. Ensure engine is
cool before performing maintenance. Failure
to comply may result in injury to personnel.

• Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

(2) Position container under radiator draincock (3).

(3) Open radiator draincock (3) and drain approximately five

gallons (19 L) of coolant.

(4) Close radiator draincock (3).

3-2
 TM 9-2320-366-20-3

(5) Disconnect air compressor inlet coolant tube (4) from

fitting (5) on thermostat housing (6).

(6) Remove five screws (7), washers (8), and front lifting
plate (9) from engine (10).

(7) Remove four screws (11), washers (12), and rear lifting
plate (13) from engine (10).

3-3
TM 9-2320-366-20-3

3-2. LIFTING PLATE REPLACEMENT (CONT)

b. Installation.

(1) Position rear lifting plate (1) on engine (2) with four
washers (3) and screws (4).

(2) Tighten four screws (4) to 47 lb-ft (64 N·m).

(3) Position front lifting plate (5) on engine (2) with five
washers (6) and screws (7).

(4) Tighten five screws (7) to 47 lb-ft (64 N·m).

(5) Connect air compressor inlet coolant tube (8) to fitting (9)
on thermostat housing (10).

3-4
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check for coolant leaks under vehicle.

(4) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(5) Check coolant level after normal operating temperature

is reached.

(6) Check for coolant leaks under vehicle.

(7) Raise cab (TM 9-2320-366-10-1).

(8) Check around thermostat housing for coolant leaks.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

3-5
TM 9-2320-366-20-3

3-3. VALVE COVER AND GASKET REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Charge air cooler to air inlet elbow tubes/hoses Rag, Wiping (Item 50, Appendix D)
removed (para 4-5). Sealing Compound (Item 59, Appendix D)
Gasket (for valve cover 7W5627) (Item 42,
Tool and Special Tools Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Gasket (for valve cover 119-2960) (Item 28,
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C) Appendix G)
Socket Set, Socket Wrench (Item 36, Appendix C) Adhesive (Item 6, Appendix D)
Screw, Cap (14) (for replacement of valve cover
7W5627 with valve cover 119-2960) (Item 262,
Appendix G)

a. Removal.

NOTE

Position hoses to allow access to valve

cover.

(1) Remove screw (1), washer (2), and clamp (3) from valve
cover (4).

3-6
 TM 9-2320-366-20-3

CAUTION

Area around valve cover must be clean

before removing valve cover from inlet
manifold to prevent contaminants from
entering inlet manifold. Failure to comply
may result in damage to equipment.

(2) Remove 13 screws (5) and washers (6) from valve cover
(4).

CAUTION

Cover inlet manifold with wiping rags after

valve cover is removed to prevent contam-
ination of engine. Failure to comply may
result in damage to equipment.

(3) Remove valve cover (4) from inlet manifold (7).

(4) Remove valve cover gasket (8) from valve cover (4).
Discard gasket.

CAUTION

Engine data plate must remain with original

engine. It contains engine serial number and
other data for this engine. Failure to comply
may result in damage to equipment.

(5) Remove engine data plate (9) from valve cover (4).

3-7
TM 9-2320-366-20-3

3-3. VALVE COVER AND GASKET REPLACEMENT (CONT)

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Install engine data plate (1) on valve cover (2) with
adhesive.

(2) Apply sealing compound between screw holes of valve

cover (2).

(3) Position valve cover gasket (3) on valve cover (2).

NOTE

Vehicle serial numbers 0001 through 3091

were originally equipped with valve cover part
number 7W5627. Vehicle serial num-bers
3092 and higher serial numbers were
originally equipped with valve cover part
number 119-2960. If replacing valve cover
part number 7W5627 with valve cover part
number 119-2960, it will be necessary to use
the longer screws.

(4) Position valve cover (2) on inlet manifold (4) with 13

washers (5) and screws (6).

3-8
 TM 9-2320-366-20-3

(5) Position clamp (7) on valve cover (2) with washer (8)
and screw (9).

(6) Tighten 13 screws (6) and screw (9) to 84-132 lb-in. (9-
15 N·m) in sequence shown.

c. Follow-On Maintenance.

(1) Install charge air cooler to air inlet elbow tubes/hoses

(para 4-5).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Raise cab (TM 9-2320-366-10-1).

(5) Check for oil leaks around valve cover gasket.

(6) Lower cab (TM 9-2320-366-10-1).

(7) Shut down engine (TM 9-2320-366-10-1).

End of Task.

3-9
TM 9-2320-366-20-3

3-4. ENGINE OIL FILTER REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Oil, Lubricating, OE/HDO 15W/40 (Item 44, Appendix
Cab raised (TM 9-2320-366-10-1). D)
Filter, Oil (Item 23, Appendix G)
Tools and Special Tools Packing, Preformed (Item 203, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Wrench, Strap, Adjustable (Item 57, Appendix
C)
Container (40 qt (38 L) capacity)

WARNING

• Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to
personnel.

• Do not remove oil filter while engine

is hot. Failure to comply may result in
injury to personnel.

a. Removal.

(1) Position container under oil pan (1).

(2) Remove oil pan plug (2) from oil pan (1).

(3) Remove preformed packing (3) from oil pan drain

plug (2). Discard preformed packing.

3-10 Change 2
 TM 9-2320-366-20-3

(4) Remove oil filter (4) from oil filter base (5). Discard oil
filter.

b. Installation.

(1) Install preformed packing (1) on oil pan drain plug (2).

(2) Install oil pan drain plug (2) in oil pan (3).

(3) Apply a thin coat of lubricating oil to oil filter gasket (4).

(4) Install oil filter (5) on oil filter base (6), hand tight.

3-11
TM 9-2320-366-20-3

3-4. ENGINE OIL FILTER REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Add oil to engine (Appendix H).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Check for oil leaks under vehicle.

(4) Start engine (TM 9-2320-366-10-1).

(5) Raise cab (TM 9-2320-366-10-1).

(6) Check for oil leaks around oil filter and oil pan drain plug.

(7) Check engine oil level (TM 9-2320-366-10-2); if low, add

oil (Appendix H).

(8) Lower cab (TM 9-2320-366-10-1).

(9) Shut down engine (TM 9-2320-366-10-1).

End of Task.

3-12
 TM 9-2320-366-20-3

3-5. CRANKCASE BREATHER REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Rag, Wiping (Item 50, Appendix D)
Cab raised (TM 9-2320-366-10-1). Packing, Preformed (Item 207, Appendix G)
Oil, Lubricating, OE/HDO 30 (Item 45, Appendix
Tools and Special Tools D)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 35, Appendix C)

a. Removal.

CAUTION

Wipe around fuel filter base before removing

crankcase breather housing. Failure to
comply may result in damage to equipment.

(1) Loosen hose clamp (1) on hose (2).

(2) Remove hose (2) from crankcase breather housing (3).

(3) Remove screw (4) and washer (5) from crankcase

breather housing (3).

(4) Remove crankcase breather housing (3) from fuel filter

base (6).

(5) Remove preformed packing (7) from fuel filter base (6).
Discard preformed packing.

3-13
TM 9-2320-366-20-3

3-5. CRANKCASE BREATHER REPLACEMENT (CONT)

b. Installation.

(1) Apply a thin coat of lubricating oil to both sides of

preformed packing (1).

(2) Install preformed packing (1) on fuel filter base (2).

(3) Position crankcase breather housing (3) on fuel filter

base (2) with washer (4) and screw (5).

(4) Tighten screw (5) to 96-144 lb-in. (11-16 N·m).

(5) Position hose (6) on crankcase breather housing (3) with

clamp (7).

(6) Tighten clamp (7) to 35-45 lb-in. (4-5 N·m).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check for oil leaks under vehicle.

(4) Raise cab (TM 9-2320-366-10-1).

(5) Check for oil leaks around breather housing gasket.

(6) Lower cab (TM 9-2320-366-10-1).

(7) Shut down engine (TM 9-2320-366-10-1).

End of Task.

3-14
 TM 9-2320-366-20-3

3-6. ENGINE AND TRANSMISSION OIL SAMPLING VALVES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 20, Appendix D)
Packing, Preformed (Item 186, Appendix G)
Tools and Special Tools Antiseize Compound (Item 58, Appendix D)
Goggles, Industrial (Item 15, Appendix C)
Pan, Drain (Item 24, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Wrench Set, Socket (Item 51, Appendix C)

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

a. Removal.

(1) Position drain pan under transmission oil sampling valve

(1) and engine oil sampling valve (2).

NOTE

Tag hoses and connection points prior to

disconnecting.

(2) Disconnect transmission oil sampling hose (3) from

transmission oil sampling valve (1).

(3) Disconnect engine oil sampling hose (4) from engine oil
sampling valve (2).

(4) Remove nut (5) and transmission oil sampling valve (1)
from bracket (6).

(5) Remove nut (7) and engine oil sampling valve (2) from
bracket (6).

Change 1 3-15
TM 9-2320-366-20-3

3-6. ENGINE AND TRANSMISSION SAMPLING VALVE REPLACEMENT (CONT)

(6) Remove transmission oil sampling hose (3) from 45-

degree fitting (8).

NOTE

• Note orientation of fitting prior to removal.

• Perform steps (7) and (8) on vehicles equipped

with transmission oil cooler tubes.

(7) Remove 45-degree fitting (8) from transmission oil cooler

tube (9).

(8) Remove preformed packing (10) from 45-degree fitting

(8). Discard preformed packing.

NOTE

Perform step (9) on vehicles equipped with

transmission oil cooler hoses.

(9) Remove 45-degree fitting (8) from transmission oil cooler

hose (9).

(10) Remove engine oil sampling hose (4) from adapter (11).

(11) Remove adapter (11) from 90-degree fitting (12).

3-16 Change 1
 TM 9-2320-366-20-3

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of adapter (1).

(2) Install adapter (1) on 90-degree fitting (2).

(3) Install engine oil sampling hose (3) on adapter (1).

NOTE

Perform steps (4) and (5) on vehicles

equipped with transmission oil cooler tubes.

(4) Install preformed packing (4) on 45-degree fitting (5).

(5) Install 45-degree fitting (5) in transmission oil cooler tube

(6).

NOTE

Perform step (5.1) and (5.2) on vehicles

equipped with transmission oil cooler hoses.

(5.1) Apply antiseize compound to threads of 45-degree fitting

(5).

(5.2) Install 45-degree fitting (5) in transmission oil cooler hose

(6).

(6) Install transmission oil sampling hose (7) on 45-degree

fitting (5).

Change 1 3-17
TM 9-2320-366-20-3

3-6. ENGINE AND TRANSMISSION SAMPLING VALVE REPLACEMENT (CONT)

(7) Position engine oil sampling valve (8) on bracket (9) with
nut (10).

(8) Position transmission oil sampling valve (11) on bracket

(9) with nut (12).

(9) Tighten nuts (10 and 12) to 67 lb-in. (8 N·m).

(10) Install engine oil sampling hose (3) on engine oil

sampling valve (8).

(11) Install transmission oil sampling hose (7) on transmission

oil sampling valve (11).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Check for oil leaks under vehicle.

(3) Start engine (TM 9-2320-366-10-1).

(4) Raise cab (TM 9-2320-366-10-1).

(5) Check for oil leaks around transmission and engine oil
sampling hoses and valves.

(6) Lower cab (TM 9-2320-366-10-1).

(7) Shut down engine (TM 9-2320-366-10-1).

End of Task.

3-18
 TM 9-2320-366-20-3

3-7. ENGINE OIL FILL TUBE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Engine shut down (TM 9-2320-366-10-1). Wrench, Torque, 0-200 lb-in. (Item 59, Appendix
Cab raised (TM 9-2320-366-10-1). C)
Transmission oil fill tube removed (Para 8-22). Socket Set, Socket Wrench (Item 36, Appendix
C)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C) Materials/Parts
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Nut, Self-Locking (2) (all models except
Screwdriver Attachment, Socket Wrench (Item 61, M1093/M1094) (Item 167, Appendix G)
Appendix B) Nut, Self-Locking (M1093/M1094) (Item 167,
Appendix G)

a. Removal.

(1) Remove cap (1) from engine oil fill tube (2).

NOTE

Perform steps (2) and (3) on all models

except M1093/M1094.

(2) Remove self-locking nut (3), washer (4), engine oil fill
tube (2), screw (5), and washer (6) from radiator
overflow tank bracket (7). Discard self-locking nut.

(3) Remove self-locking nut (8), washer (9), engine oil fill
tube (2), screw (10), and washer (11) from front lifting
beam (12). Discard self-locking nut.

3-19
TM 9-2320-366-20-3

3-7. ENGINE OIL FILL TUBE REPLACEMENT (CONT)

NOTE

Perform step (4) on M1093/M1094.

(4) Remove self-locking nut (3), washer (4), engine oil fill
tube (2), screw (13), washer (6), and spacer (14) from
radiator overflow tank bracket (7). Discard self-locking
nut.

(5) Loosen clamp (15) on engine oil fill hose (16).

(6) Remove engine oil fill tube (2) from engine oil fill hose
(16).

b. Installation.

(1) Position engine oil fill tube (1) in engine oil fill hose (2)
with clamp (3).

(2) Tighten clamp (3) to 24-48 lb-in. (3-5 N·m).

3-20 Change 1
 TM 9-2320-366-20-3

NOTE

Perform steps (3) and (4) on M1093/ M1094.

(3) Position engine oil fill tube (1) on radiator overflow tank
bracket (4) with spacer (5), washer (6), screw (7),
washer (8), and self-locking nut (9).

(4) Tighten self-locking nut (9) to 22-26 lb-ft (29-35 N·m).

NOTE

Perform steps (5) through (7) on all models

except M1093/M1094.

(5) Position engine oil fill tube (1) on front lifting beam (10)
with washer (11), screw (12), washer (13), and self-
locking nut (14).

(6) Position engine oil fill tube (1) on radiator overflow tank
bracket (4) with washer (6), screw (15), washer (8), and
self-locking nut (9).

(7) Tighten self-locking nuts (9 and 14) to 22-26 lb-ft (29-35

N·m).

(8) Install cap (16) on engine oil fill tube (1).

c. Follow-On Maintenance.

(1) Install transmission oil fill tube (para 8-22).

(2) Lower cab (TM 9-2320-366-10-1).

End of Task.

Change 1 3-21/(3-22 Blank)

 TM 9-2320-366-20-3

CHAPTER 4
FUEL SYSTEM MAINTENANCE

RESTRICTED MAINTENANCE NOTICE

Units not authorized SC 4910-95-CL-A72 (SHOP EQUIPMENT, COMMON NO. 2) in their T.O.E. may
be unable to perform some of the maintenance tasks described in this chapter. If the required tools
are not authorized, the equipment must be submitted to DS Maintenance for repair.

Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Section II. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND PARTICLE
EXTRACTION TUBE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3. FUEL PRESSURE REGULATING VALVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-4. TURBOCHARGER TO CHARGE AIR COOLER TUBE AND HOSES REPLACEMENT . . . . . . . . . . . 4-28
4-5. CHARGE AIR COOLER TO AIR INLET ELBOW TUBES AND HOSES REPLACEMENT . . . . . . . . . 4-31
4-6. FUEL RATIO CONTROL TUBE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-7. ORIFICE TUBE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4-8. FUEL TANK AND BRACKETS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-9. FUEL HOSES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4-10. FUEL FILTER TUBES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
4-11. FUEL SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-12. GOVERNOR LINKAGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4-13. FUEL/WATER SEPARATOR AND FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-14. FUEL FILTER AND FILTER BASE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-15. ETHER STARTING AID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
4-16. THROTTLE POSITION SENSOR (TPS) CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . 4-85
4-17. HAND THROTTLE LEVER REPLACEMENT/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
4-18. THROTTLE CONTROL CABLE REPLACEMENT/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
4-19. THROTTLE CONTROL THREADED ROD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4-20. THROTTLE CONTROL LEVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
4-21. ACCELERATOR PEDAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
4-22. CHECKING AND STENCILING HIGH/LOW HAND THROTTLE POSITIONS . . . . . . . . . . . . . . . . . 4-104

Section I. INTRODUCTION

4-1. INTRODUCTION

This chapter contains maintenance instructions for replacing, repairing, and adjusting fuel system components
authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.

Change 1 4-1
TM 9-2320-366-20-3

Section II. MAINTENANCE PROCEDURES

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT
This task covers:

a. Intake Air Cleaner Filter Element Removal g. M1093/M1094 Intake Air Cleaner Assembly
b. Intake Air Cleaner Filter Element Installation Installation
c. Intake Air Cleaner Assembly Removal (All Models h. Intake Air Cleaner Assembly Installation (All
Except M1093/M1094) Models Except M1093/M1094)
d. M1093/M1094 Intake Air Cleaner Assembly Removal i. Particle Extraction Tube Removal
e. Intake Air Cleaner Disassembly j. Particle Extraction Tube Installation
f. Intake Air Cleaner Assembly k. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Engine shut down (TM 9-2320-366-10-1). Wrench, Torque, 0-200 lb-in. (Item 59,
Cab raised (TM 9-2320-366-10-1). Appendix C)
Batteries disconnected (para 7-57).
Chemical detection unit removed, if equipped (TM 3- Materials/Parts
6665-225-12). Rag, Wiping (Item 50, Appendix D)
Transmission oil fill tube removed (M1093/M1094) (para Gasket (Item 31, Appendix G)
8-22). Filter Element (Item 21, Appendix G)
Washer, Spring (2) (Item 291, Appendix G)
Tools and Special Tools Nut, Self-Locking (3) (Item 156, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (3) (M1093/M1094) (Item
Wrench, Torque, 0-175 lb-ft (Item 59, Appendix C) 150, Appendix G)
Crowfoot Attachment, Socket Wrench (Item 6, Appendix Nut, Self-Locking (3) (all models except
B) M1093/M1094) (Item 157, Appendix G)
Screwdriver Attachment, Socket Wrench (Item 61,
Appendix B) References
Socket Set, Socket Wrench (Item 36, Appendix C) TM 3-6665-225-12
FM 3-4
FM 3-5

WARNING

After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters shall be handled
with extreme caution. Unprotected personnel may experience serious injury or death if residual
toxic agents or radioactive materials are present. If vehicle is exposed to chemical or biological
agents, servicing personnel shall wear protective mask, hood, protective overgarments, and
chemical protective gloves and boots in accordance with FM-3-4. All contaminated air filters
shall be placed in double-lined plastic bags and moved swiftly to a segregation area away from
the worksite. The same procedure applies for radioactive dust contamination. The Company
NBC team should measure radiation prior to filter removal to determine extent of safety
procedures required per the NBC Annex to the unit Standard Operating Procedures (SOP). The
segregation area in which the contaminated air filters are temporarily stored shall be marked
with appropriate NBC placards. Final disposal of contaminated air filters shall be in accordance
with local SOP. Decontamination operation shall be in accordance with FM-3-5 and local SOP.
Failure to comply may result in serious injury or death to personnel.

4-2
 TM 9-2320-366-20-3

a. Intake Air Cleaner Filter Element Removal.

(1) Unlatch three clasps (1) on cover (2).

(2) Remove cover (2) from intake air cleaner housing (3).

(3) Loosen wingnut (4) and remove filter element (5) from
intake air cleaner housing (3). Discard filter element.

b. Intake Air Cleaner Filter Element Installation.

NOTE

Wipe inside of intake air cleaner housing with

damp wiping rag.

(1) Position filter element (1) in intake air cleaner housing

(2).

CAUTION

Tighten wingnut securely to prevent air leakage

around air cleaner filter element. Do not
overtighten. Failure to comply may result in
damage to equipment.

(2) Tighten wingnut (3) on filter element (1).

(3) Install cover (4) on intake air cleaner housing (2) with
three clasps (5).

4-3
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

c. Intake Air Cleaner Assembly Removal (All Models

Except M1093/M1094).

(1) Remove dust cap (1) from connector J106 (2).

(2) Remove nut (3), dust cap lanyard (4), and connector
J106 (2) from chemical detector mounting bracket (5).

(3) Remove four screws (6) and washers (7) from chemical
detector mounting bracket (5).

(4) Disconnect air filter restriction gauge hose (8) from air
flow sensor (9).

(5) Loosen clamp (10) on particle extraction hose (11).

(6) Remove particle extraction hose (11) from adapter (12).

(7) Loosen clamp (13) on air compressor intake hose (14).

(8) Remove air compressor intake hose (14) from intake air
cleaner boot (15).

4-4
 TM 9-2320-366-20-3

(9) Loosen clamp (16) on turbocharger intake hose (17).

(10) Remove turbocharger intake hose (17) from intake air

cleaner boot (15).

(11) Remove two nuts (18), washers (19), lockwashers (19.1),

and screws (20) from bracket (21). Discard lockwashers.

(12) Remove two screws (22), washers (23), and bracket (21)
from engine inlet manifold (24).

Change 1 4-5
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(13) Loosen clamp (25) on turbocharger inlet coupling (26).

(14) Remove turbocharger tube (27) from turbocharger inlet

coupling (26).

(15) Loosen clamp (28) on turbocharger inlet coupling (26).

CAUTION

Cover turbocharger inlet with wiping rags

after removing turbocharger inlet coupling.
Failure to comply may result in damage to
equipment.

(16) Remove turbocharger inlet coupling (26) from

turbocharger (29).

(17) Loosen clamp (30) on turbocharger intake hose (17).

(18) Remove turbocharger intake hose (17) from turbocharger

tube (27).

4-6
 TM 9-2320-366-20-3

(19) Remove screw (31) and washer (32) from resilient mount
(33).

(20) Remove three self-locking nuts (34) and screws (35)

from mounting brackets (36). Discard self-locking nuts.

(21) Remove intake air cleaner assembly (37) from three

mounting brackets (36) and resilient mount (33).

(22) Remove screw (38), washer (39), and resilient mount

(33) from mounting bracket (36).

d. M1093/M1094 Intake Air Cleaner Assembly Removal.

(1) Remove dust cap (1) from connector J106 (2).

(2) Remove nut (3), dust cap lanyard (4), and connector
J106 (2) from chemical detector mounting bracket (5).

(3) Remove four screws (6) and washers (7) from chemical
detector mounting bracket (5).

(4) Disconnect air filter restriction gauge hose (8) from air
flow sensor (9).

4-7
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(5) Loosen clamp (10) on particle extraction hose (11).

(6) Remove particle extraction hose (11) from adapter (12).

(7) Loosen clamp (13) on air compressor intake hose (14).

(8) Remove air compressor intake hose (14) from intake air
cleaner boot (15).

(9) Loosen clamp (16) on turbocharger intake hose (17).

(10) Remove turbocharger intake hose (17) from intake air

cleaner boot (15).

4-8
 TM 9-2320-366-20-3

(11) Remove two nuts (18), washers (19), lockwashers (19.1),

and screws (20) from bracket (21). Discard lockwashers.

(12) Remove two screws (22), washers (23), and bracket (21)
from engine inlet manifold (24).

(13) Loosen clamp (25) on turbocharger inlet coupling (26).

(14) Remove turbocharger tube (27) from turbocharger inlet

coupling (26).

(15) Loosen clamp (28) on turbocharger inlet coupling (26).

CAUTION

Cover turbocharger inlet with wiping rags

after removing turbocharger inlet coupling.
Failure to comply may result in damage to
equipment.

(16) Remove turbocharger inlet coupling (26) from

turbocharger (29).

Change 1 4-9
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(17) Loosen clamp (30) on turbocharger intake hose (17).

(18) Remove turbocharger intake hose (17) from turbocharger

tube (27).

(19) Remove screw (31) and washer (32) from resilient mount
(33).

(20) Remove three self-locking nuts (34) and screws (35)

from mounting brackets (36). Discard self-locking nuts.

(21) Remove intake air cleaner assembly (37) from mounting

brackets (36) and resilient mount (33).

(22) Remove screw (38), washer (39), and resilient mount

(33) from mounting bracket (36).

4-10
 TM 9-2320-366-20-3

e. Intake Air Cleaner Disassembly.

(1) Remove air flow sensor (1) from pipe coupling (2).

(2) Remove pipe coupling (2) from intake air cleaner

housing (3).

(3) Loosen clamp (4) on intake air cleaner boot (5).

(4) Remove intake air cleaner boot (5) from intake air
cleaner housing (3).

(5) Loosen clamp (6) on intake air cleaner boot (5).

(6) Remove adapter (7) from intake air cleaner boot (5).

(7) Loosen clamp (8) on air intake hood (9).

(8) Remove air intake hood (9) from air intake adapter (10).

NOTE

• Vehicles may be equipped with air intake

adapters PN 12420527, PN 12421274, or PN
12421380. If air intake adapter PN 12420527 or
PN 12421274 is damaged, replace with intake
adapter PN 12421380 and clamp PN 12421379-
001.

• Perform step (9) on vehicles equipped with air

intake adapter PN 12420572.

(9) Remove self-locking nut (11), screw (11.1), and clamp

(11.2) from air intake adapter (10). Discard self-locking
nut.

Change 1 4-10.1
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

NOTE

Perform step (10) on vehicles equipped with

air intake adapter PN 12421274.

(10) Remove self-locking nut (11) and screw (11.1) from band
(11.2). Discard self-locking nut.

NOTE

Perform step (10.1) on vehicles equipped

with air intake adapter PN 12421380.

(10.1) Remove self-locking nut (11) and clamp (11.2) from air
intake adapter (10). Discard self-locking nut.

(10.2) Remove air intake adapter (10) from intake air cleaner
housing (3).

(11) Loosen clamp (12) on resilient mount (13).

(12) Remove resilient mount (13) from intake air cleaner

housing (3).

(13) Loosen clamp (14) on resilient mount (13).

(14) Remove adapter (15) from resilient mount (13).

4-10.2 Change 1
 TM 9-2320-366-20-3

(15) Remove pin (16), air shutter (17), and gasket (18) from
intake air cleaner housing (3). Discard gasket.

f. Intake Air Cleaner Assembly.

(1) Install gasket (1), air shutter (2), and pin (3) in intake air
cleaner housing (4).

(2) Install adapter (5) on resilient mount (6) with clamp (7).

(3) Install resilient mount (6) on intake air cleaner housing

(4) with clamp (8).

4-11
 TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(4) Position air intake adapter (9) on intake air cleaner

housing (4).

NOTE

Perform steps (5) and (5.1) on vehicles

equipped with air intake adapter PN
12421380.

(5) Position clamp (10) on air intake adapter (9) with self-
locking nut (10.1).

(5.1) Tighten self-locking nut (10.1) to 6-8 lb-ft (10-11 N·m).

NOTE

Perform steps (5.2) and (5.3) on vehicles

equipped with air intake adapter PN
12421274.

(5.2) Position screw (10.2) and self-locking nut (10.1) on band

(10).

(5.3) Tighten self-locking nut (10.1) to 33-39 lb-ft (44-54 N·m).

NOTE

Perform steps (5.4) and (5.5) on vehicles

equipped with air intake adapter PN
12420572.

(5.4) Position clamp (10) on air intake adapter (9) with screw
(10.2) and self-locking nut (10.1).

(5.5) Tighten self-locking nut (10.1) to 33-39 lb-ft (44-54 N·m).

4-12 Change 1
 TM 9-2320-366-20-3

(6) Position air intake hood (11) on air intake adapter (9)
with clamp (12).

(7) Tighten clamp (12) to 72-96 lb-in. (8-11 N·m).

(8) Install adapter (13) in intake air cleaner boot (14) with
clamp (15).

(9) Position intake air cleaner boot (14) on intake air cleaner
housing (4) with clamp (16).

(10) Tighten clamp (16) to 36-48 lb-in. (4-5 N·m).

(11) Install pipe coupling (17) in intake air cleaner housing

(4).

(12) Install air flow sensor (18) in pipe coupling (17).

g. M1093/M1094 Intake Air Cleaner Assembly Installation.

(1) Position washer (1), screw (2), and resilient mount (3) on
mounting bracket (4).

(2) Tighten screw (2) to 40-46 lb-ft (54-62 N·m).

Change 1 4-13
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(3) Position intake air cleaner assembly (5) on mounting

brackets (4).

(4) Position washer (6) and screw (7) in resilient mount (3).

(5) Position three screws (8) and self-locking nuts (9) in

mounting brackets (4).

(6) Tighten screw (7) to 40-52 lb-ft (54-70 N·m).

(7) Tighten three self-locking nuts (9) to 40-52 lb-ft (54-70

N·m).

(8) Position turbocharger intake hose (10) on turbocharger

tube (11) with clamp (12).

(9) Tighten clamp (12) to 36-48 lb-in. (4-5 N·m).

CAUTION

Distance between front edge of air duct and

alternator fan shroud must be no less than
0.5 in. (1.27 cm). Failure to comply may
result in damage to equipment.

(10) Position air duct (13) on turbocharger (14) with clamp

(15).

(11) Tighten clamp (15) to 21-25 lb-in. (2-3 N·m).

(12) Position turbocharger tube (11) in air duct (13) with

clamp (16).

(13) Tighten clamp (16) to 36-48 lb-in. (4-5 N·m).

4-14
 TM 9-2320-366-20-3

(14) Position bracket (17) on engine inlet manifold (18) with

two washers (19) and screws (20).

(15) Tighten two screws (20) to 15-25 lb-ft (20-34 N·m).

(16) Position intake tube (21) on bracket (17) with two

lockwashers (22), screws (23), washers (23.1) and nuts
(23.2).

(17) Tighten two nuts (23.2) to 22-26 lb-ft (29-35 N·m).

(18) Position turbocharger intake hose (10) on intake air

cleaner boot (24) with clamp (25).

(19) Tighten clamp (25) to 36-48 lb-in. (4-5 N·m).

Change 1 4-15
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(20) Position air compressor intake hose (26) on intake air

cleaner boot (24) with clamp (27).

(21) Tighten clamp (27) to 36-48 lb-in. (4-5 N·m).

(22) Position particle extraction hose (28) on adapter (29)

with clamp (30).

(23) Tighten clamp (30) to 36-48 lb-in. (4-5 N·m).

(24) Connect air filter restriction gauge hose (31) to air flow
sensor (32).

(25) Install connector J106 (33) and dust cap lanyard (34) on
chemical detector mounting bracket (35) with nut (36).

(26) Install dust cap (37) on connector J106 (33).

(27) Install four washers (38) and screws (39) in chemical

detector mounting bracket (35).

4-16
 TM 9-2320-366-20-3

h. Intake Air Cleaner Assembly Installation (All Models

Except M1093/M1094).

(1) Position washer (1), screw (2), and resilient mount (3) on
mounting bracket (4).

(2) Tighten screw (2) to 40-52 lb-ft (54-70 N·m).

(3) Position intake air cleaner housing (5) on mounting

brackets (4).

(4) Position washer (6) and screw (7) in resilient mount (3).

(5) Position three screws (8) and self-locking nuts (9) in

mounting brackets (4).

(6) Tighten screw (7) to 50-52 lb-ft (54-70 N·m).

(7) Tighten three self-locking nuts (9) to 43-52 lb-ft (58-70

N·m).

(8) Position turbocharger intake hose (10) on turbocharger

tube (11) with clamp (12).

(9) Tighten clamp (12) to 36-48 lb-in. (4-5 N·m).

4-17
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

CAUTION

Distance between front edge of air duct and

alternator fan shroud must be no less than
0.5 in. (1.27 cm). Failure to comply may
result in damage to equipment.

(10) Position air duct (13) on turbocharger (14) with clamp

(15).

(11) Tighten clamp (15) to 21-25 lb-in. (2-3 N·m).

(12) Position turbocharger tube (11) in air duct (13) with

clamp (16).

(13) Tighten clamp (16) to 36-48 lb-in. (4-5 N·m).

(14) Position bracket (17) on engine inlet manifold (18) with

two washers (19) and screws (20).

(15) Tighten two screws (20) to 15-25 lb-ft (20-34 N·m).

(16) Position intake tube (21) on bracket (17) with two

lockwashers (22), screws (23), washers (23.1) and nuts
(23.2).

(17) Tighten two nuts (23.2) to 22-26 lb-ft (29-35 N·m).

4-18 Change 1
 TM 9-2320-366-20-3

(18) Position turbocharger intake hose (10) on intake air

cleaner boot (24) with clamp (25).

(19) Tighten clamp (25) to 36-48 lb-in. (4-5 N·m).

(20) Position air compressor intake hose (26) on intake air

cleaner boot (24) with clamp (27).

(21) Tighten clamp (27) to 36-48 lb-in. (4-5 N·m).

(22) Position particle extraction hose (28) on adapter (29)

with clamp (30).

(23) Tighten clamp (30) to 36-48 lb-in. (4-5 N·m).

4-19
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(24) Connect air filter restriction gauge hose (31) to air flow
sensor (32).

(25) Install connector J106 (33) and dust cap lanyard (34) on
chemical detector mounting bracket (35) with nut (36).

(26) Install dust cap (37) on connector J106 (33).

(27) Install four washers (38) and screws (39) in chemical

detector mounting bracket (35).

i. Particle Extraction Tube Removal.

(1) Loosen clamp (1) on particle extraction hose (2).

(2) Remove particle extraction hose (2) from particle

extraction tube (3).

(3) Remove self-locking nut (4) and screw (5) from bracket
(6). Discard self-locking nut.

(4) Loosen two clamps (7) on particle extraction hose (8).

(5) Remove particle extraction hose (8) from particle

extraction tube (3) and tailpipe (9).

4-20
 TM 9-2320-366-20-3

(6) Remove self-locking nut (10), screw (11), and clamp (12)
from clamp (13). Discard self-locking nut.

(7) Remove self-locking nut (14) from screw (15). Discard

self-locking nut.

CAUTION

Use care when removing particle extraction

tube from vehicle. Failure to comply may
result in damage to equipment.

NOTE

• Step (8) requires the aid of an assistant.

• Remove particle extraction tube toward front of

vehicle.

(8) Remove particle extraction tube (3) from vehicle.

4-21
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

(9) Remove self-locking nut (16), screw (17), bracket (18),

and screw (15) from vehicle. Discard self-locking nut.

j. Particle Extraction Tube Installation.

(1) Position screw (1), bracket (2), screw (3), and self-
locking nut (4) on vehicle.

NOTE

Steps (2) through (5) require the aid of an

assistant.

(2) Tighten self-locking nut (4) to 46-58 lb-ft (62-79 N·m).

CAUTION

Use care when installing particle extraction

tube on vehicle. Failure to comply may result
in damage to equipment.

NOTE

Install particle extraction tube from front of

vehicle.

(3) Position particle extraction tube (5) on vehicle.

(4) Position self-locking nut (6) on screw (1).

(5) Tighten self-locking nut (6) to 46-58 lb-ft (62-79 N·m).

4-22
 TM 9-2320-366-20-3

(6) Position clamp (7) on clamp (8) with screw (9) and self-
locking nut (10).

(7) Tighten self-locking nut (10) to 46-58 lb-ft (62-79 N·m).

(8) Position particle extraction hose (11) on tailpipe (12) and

particle extraction tube (5) with two clamps (13).

(9) Tighten clamp (13) to 36-48 lb-in. (4-5 N·m).

(10) Position screw (14) and self-locking nut (15) on bracket

(16).

(11) Tighten self-locking nut (15) to 46-58 lb-ft (62-79 N·m).

(12) Position particle extraction hose (17) on particle

extraction tube (5) with clamp (18).

(13) Tighten clamp (18) to 36-48 lb-in. (4-5 N·m).

4-23
TM 9-2320-366-20-3

4-2. INTAKE AIR CLEANER FILTER ELEMENT, AIR CLEANER ASSEMBLY, AND
PARTICLE EXTRACTION TUBE REPLACEMENT (CONT)

k. Follow-On Maintenance.

(1) Install transmission oil fill tube (M1093/M1094) (para 8-

22).

(2) Install chemical detection unit, if equipped (TM 3-6665-

225-12).

(3) Connect batteries (para 7-57).

(4) Lower cab (TM 9-2320-366-10-1).

(5) Start engine (TM 9-2320-366-10-1).

(6) Check for air leaks around hose and tube connections.

(7) Check AIR FILTER RESTRICTION GAUGE (TM 9-2320-

366-10-1).

(8) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-24
 TM 9-2320-366-20-3

4-3. FUEL PRESSURE REGULATING VALVE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Packing, Preformed (Item 210, Appendix G)
Cab raised (TM 9-2320-366-10-1). Packing, Preformed (Item 203, Appendix G)
Packing, Preformed (Item 200, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Removal.

(1) Disconnect fuel return hose assembly (1) from 90-degree

fitting (2).

(2) Remove 90-degree fitting (2) and preformed packing (3)

from adapter (4). Discard preformed packing.

4-25
TM 9-2320-366-20-3

4-3. FUEL PRESSURE REGULATING VALVE REPLACEMENT (CONT)

(3) Remove adapter (4) and preformed packing (5) from

tube assembly (6). Discard preformed packing.

(4) Remove spring (7) from tube assembly (6).

(5) Remove fuel pressure regulating valve (8) and preformed

packing (9) from tube assembly (6). Discard preformed
packing.

b. Installation.

(1) Install preformed packing (1) and fuel pressure regulating

valve (2) in tube assembly (3).

(2) Install spring (4) in tube assembly (3).

(3) Install preformed packing (5) and adapter (6) in tube

assembly (3).

(4) Install preformed packing (7) and 90-degree fitting (8) in

adapter (6).

(5) Connect fuel return hose assembly (9) to 90-degree

fitting (8).

4-26
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Raise cab (TM 9-2320-366-10-1).

(4) Check for fuel leaks around regulating valve.

(5) Check that engine runs smoothly at low idle speed.

(6) Check that engine runs smoothly at high idle speed.

(7) Lower cab (TM 9-2320-366-10-1).

(8) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-27
TM 9-2320-366-20-3

4-4. TURBOCHARGER TO CHARGE AIR COOLER TUBE AND HOSES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Cap and Plug Set (Item 14, Appendix D)
Cab raised (TM 9-2320-366-10-1).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C)

a. Removal.

NOTE

Note position of clamps prior to removal.

(1) Loosen two hose clamps (1) and hose clamps (2) on
turbocharger to charge air cooler tube (3).

(2) Remove turbocharger to charge air cooler tube (3) from

charge air cooler (4) and turbocharger (5).

CAUTION

Cap or plug turbocharger outlet and charge

air cooler inlet to prevent contamination of
engine intake air system. Failure to comply
may result in damage to equipment.

(3) Cap or plug turbocharger outlet (6) and charge air cooler
inlet (4).

4-28
 TM 9-2320-366-20-3

(4) Remove two clamps (1) and hose (7) from turbocharger
to charge air cooler tube (3).

(5) Remove two clamps (2) and hose (8) from turbocharger
to charge air cooler tube (3).

b. Installation.

(1) Position hose (1) on turbocharger to charge air cooler

tube (2) with two clamps (3).

(2) Position hose (4) on turbocharger to charge air cooler

tube (2) with two clamps (5).

(3) Remove caps or plugs from turbocharger outlet (6) and

charge air cooler inlet (7).

CAUTION

Clamps at charge air cooler end of

turbocharger to charge air cooler tube must
be oriented as noted in removal. Failure to
comply may result in damage to equipment.

(4) Position turbocharger to charge air cooler tube (2) on

charge air cooler (7) and turbocharger (8).

(5) Tighten two hose clamps (3) and hoses clamps (5) to
90-100 lb-in. (10-11 N·m).

4-29
TM 9-2320-366-20-3

4-4. TURBOCHARGER TO CHARGE AIR COOLER TUBE AND HOSES REPLACEMENT

(CONT)

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Raise cab (TM 9-2320-366-10-1).

(4) Check for air leaks around turbocharger to charge air

cooler tube.

(5) Lower cab (TM 9-2320-366-10-1).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-30
 TM 9-2320-366-20-3

4-5. CHARGE AIR COOLER TO AIR INLET ELBOW TUBES AND HOSES
REPLACEMENT
This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Engine shut down (TM 9-2320-366-10-1). Socket Set, Socket Wrench (Item 36, Appendix C)
Cab raised (TM 9-2320-366-10-1). Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C) Materials/Parts
Screwdriver Attachment, Socket Wrench (Item Nut, Self-Locking (2) (Item 154, Appendix G)
61, Appendix B)

a. Removal.

(1) Remove two self-locking nuts (1), screws (2), and upper
charge air tube bracket (3) from lower charge air tube
bracket (4). Discard self-locking nuts.

NOTE

Inner and outer charge air cooler to air inlet

elbow tubes are removed the same way.
Outer charge air cooler to air inlet elbow tube
shown.

(2) Loosen clamp (5) on hose (6).

(3) Disconnect hose (6) from air inlet elbow (7).

4-31
TM 9-2320-366-20-3

4-5. CHARGE AIR COOLER TO AIR INLET ELBOW TUBES AND HOSES
REPLACEMENT (CONT)

NOTE

Note position of clamps prior to removal.

(4) Loosen three clamps (8) on hose (9).

(5) Remove charge air cooler to air inlet elbow tube (10)
from hose (9).

(6) Remove hose (9) from charge air cooler (11).

NOTE

Vehicle serial numbers 0001 through 3091

were originally equipped with a lower charge
air tube bracket (part number 12421172).
Vehicle serial numbers 3092 and higher were
originally equipped with a lower charge air
tube bracket (part number 12421172-001).
Perform steps (7) and (8) on vehicle serial
numbers 0001 through 3091 that have not
previously had a valve cover or lower charge
air tube bracket replaced.

(7) Remove screw (12) and washer (13) from lower charge
air tube bracket (4).

(8) Remove screw (14), washer (15), and lower charge air
tube bracket (4) from duct manifold (16).

4-32
 TM 9-2320-366-20-3

NOTE

Perform steps (9) through (11) on vehicle

serial numbers 3091 and higher, and vehicle
serial numbers 0001 through 3091 that have
previously had a valve cover or lower charge
air tube bracket replaced.

(9) Remove screw (12) and washer (13) from lower charge
air tube bracket (17).

(10) Remove screw (18), washer (19), and clamp (20) from
lower charge air tube bracket (17).

(11) Remove screw (21), washer (22) and lower charge air
tube bracket (17) from air inlet elbow (23).

(12) Loosen clamp (24) on hose (6).

(13) Remove hose (6) from charge air cooler to air inlet elbow
tube (10).

b. Installation.

(1) Position hose (1) on charge air cooler to air inlet elbow
tube (2) with clamp (3).

4-33
TM 9-2320-366-20-3

4-5. CHARGE AIR COOLER TO AIR INLET ELBOW TUBES AND HOSES
REPLACEMENT (CONT)

NOTE

Perform steps (2) through (5) on vehicle

serial numbers 3091 and higher, and vehicle
serial numbers 0001 through 3091 that have
previously had a valve cover or lower charge
air tube bracket replaced.

(2) Position lower charge air tube bracket (4) on air inlet
elbow (5) with washer (6) and screw (7).

(3) Position clamp (8), washer (9), and screw (10) in lower
charge air tube bracket (4).

(4) Position washer (11) and screw (12) in lower charge air
tube bracket (4).

(5) Tighten screw (7), screw (10), and screw (12) to 15-25
lb-ft (20-34 N·m).

NOTE

Perform steps (6) through (8) on vehicle

serial numbers 0001 through 3091 that have
not previously had a valve cover or lower
charge air tube bracket replaced.

(6) Position lower charge air tube bracket (13) on duct

manifold (14) with washer (15) and screw (16).

(7) Position washer (17) and screw (18) in lower charge air
tube bracket (13).

(8) Tighten screws (16 and 18) to 15-25 lb-ft (20-34 N·m).

4-34
 TM 9-2320-366-20-3

NOTE

Inner and outer charge air cooler to air inlet

elbow tubes are installed the same way.
Outer charge air cooler to air inlet elbow tube
shown.

(9) Position hose (19) on charge air cooler (20) with three
clamps (21).

(10) Position charge air cooler to air inlet elbow tube (2) in
hose (19).

CAUTION

Clamps at charge air cooler end of charge air

cooler to air inlet elbow tube must be
oriented with screw vertical. Failure to
comply will cause interference with bottom of
cab.

(11) Tighten three clamps (21) to 90-100 lb-in. (7-8 N·m).

CAUTION

All clamps on engine air intake path must be

positioned and tightened correctly. Failure to
comply may allow foreign matter into engine air
intake and result in engine failure.

(12) Position hose (1) on air inlet elbow (5) with clamp (22).

(13) Tighten clamps (3 and 22) to 90-100 lb-in. (7-18 N·m).

4-35
TM 9-2320-366-20-3

4-5. CHARGE AIR COOLER TO AIR INLET ELBOW TUBES AND HOSES
REPLACEMENT (CONT)

(14) Position upper charge air tube bracket (23) on lower

charge air tube bracket (4) with two screws (24) and self-
locking nuts (25).

(15) Tighten two self-locking nuts (25) to 20-26 lb-ft (27-35

N·m).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Raise cab (TM 9-2320-366-10-1).

(4) Check around charge air cooler to air inlet elbow tubes
and hoses for air leaks.

(5) Lower cab (TM 9-2320-366-10-1).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-36
 TM 9-2320-366-20-3

4-6. FUEL RATIO CONTROL TUBE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Packing, Preformed (2) (Item 206, Appendix G)
Cab raised (TM 9-2320-366-10-1). Packing, Preformed (2) (Item 204, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Removal.

(1) Remove screw (1), washer (2), and loop clamp (3) from
pressure regulating orifice (4).

(2) Disconnect fuel ratio control tube (5) from adapter (6).

(3) Remove preformed packing (7) from adapter (6).

Discard preformed packing.

(4) Remove adapter (6) from inlet manifold (8).

(5) Remove preformed packing (9) from adapter (6). Discard

preformed packing.

4-37
TM 9-2320-366-20-3

4-6. FUEL RATIO CONTROL TUBE REPLACEMENT (CONT)

(6) Remove fuel ratio control tube (5) from adapter (10).

(7) Remove preformed packing (11) from adapter (10).

Discard preformed packing.

(8) Remove adapter (10) from fuel governor (12).

(9) Remove preformed packing (13) from adapter (10).

Discard preformed packing.

b. Installation.

(1) Install preformed packing (1) on adapter (2).

(2) Install adapter (2) in fuel governor (3).

(3) Install preformed packing (4) in adapter (2).

(4) Connect fuel ratio control tube (5) to adapter (2).

(5) Install preformed packing (6) on adapter (7).

(6) Install adapter (7) in inlet manifold (8).

(7) Install preformed packing (9) on adapter (7).

(8) Install fuel ratio control tube (5) on adapter (7).

(9) Position loop clamp (10), washer (11), and screw (12) in
pressure regulating orifice (13).

(10) Tighten screw (12) to 15-25 lb-ft (20-34 N·m).

4-38
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Raise cab (TM 9-2320-366-10-1).

(4) Check for fuel leaks around fuel ratio control tube.

(5) Check that engine runs smoothly at low idle speed.

(6) Check that engine runs smoothly at high idle speed.

(7) Lower cab (TM 9-2320-366-10-1).

(8) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-39
TM 9-2320-366-20-3

4-7. ORIFICE TUBE ASSEMBLY REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Cab raised (TM 9-2320-366-10-1). Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Fuel pressure regulating valve removed
(para 4-3). Materials/Parts
Fuel ratio control tube removed (para 4-6). Packing, Preformed (Item 209, Appendix G)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Removal.

(1) Remove two screws (1) and washers (2) from orifice
tube assembly (3).

(2) Remove screw (4), orifice tube assembly (3), and

preformed packing (5) from cylinder head (6). Discard
preformed packing.

b. Installation.

(1) Position preformed packing (5) on cylinder head (6).

(2) Position orifice tube assembly (3) on cylinder head (6)

with screw (4).

(3) Position two washers (2) and screws (1) in orifice tube
assembly (3).

(4) Tighten screw (4) to 15-25 lb-ft (20-34 N·m).

(5) Tighten two screws (1) to 33-47 lb-ft (45-64 N·m).

4-40
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Install fuel ratio control tube (para 4-6).

(2) Install fuel pressure regulating valve (para 4-3).

(3) Lower cab (TM 9-2320-366-10-1).

(4) Start engine (TM 9-2320-366-10-1).

(5) Raise cab (TM 9-2320-366-10-1).

(6) Check for fuel leaks around fuel ratio control tube and
orifice tube assembly.

(7) Check that engine runs smoothly at low idle speed.

(8) Check that engine runs smoothly at high idle speed.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-41
TM 9-2320-366-20-3

4-8. FUEL TANK AND BRACKETS REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Rag, Wiping (Item 50, Appendix D)
Dispenser, Pressure Sensitive Adhesive Tape
Tools and Special Tools (Item 20, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Ties, Cable, Plastic (Item 69, Appendix D)
Container (60 Gal (227 L) capacity) Sealing Compound (Item 56, Appendix D)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Primer, Sealing Compound (Item 49, Appendix
Wrench, Torque, 0-600 lb-ft (Item 60, Appendix C) D)
Socket Set, Impact (Item 33, Appendix C) Packing, Preformed (Item 216, Appendix G)
Wrench, Torque. 0-200 lb-in. (Item 59, Appendix C) Nut, Self-Locking (2) (Item 156, Appendix G)
Nut, Self-Locking (8) (Item 161, Appendix G)

Personnel Required
(2)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Removal.

NOTE

Remove plastic cable ties as required.

(1) Disconnect connector clamp (1) from fuel level sending

unit connector (2).

(2) Disconnect fuel level sending unit connector (2) from

connector P82 (3).

(3) Position container under fuel tank (4).

(4) Remove drain plug (5) from fuel tank (4) and drain fuel.

4-42 Change 1
 TM 9-2320-366-20-3

NOTE

Tag fuel hoses and connection points prior to

disconnecting.

(5) Disconnect fuel hose (6) from 90-degree pickup tube

fitting (7).

(6) Disconnect fuel hose (8) from 90-degree return fitting (9).

(7) Disconnect fuel hose (10) from relief valve (11).

(8) Remove four nuts (12) from two straps (13).

(9) Move two straps (13) away from fuel tank (4).

NOTE

Step (10) requires the aid of an assistant.

(10) Remove fuel tank (4) from support brackets (14 and 15).

(11) Remove relief valve (11) from fuel tank (4).

(12) Remove 90-degree pickup tube fitting (7) from fuel tank
(4).

(13) Remove 90-degree return fitting (9) from fuel tank (4).

(14) Remove five screws (16), fuel level sending unit (17),
and preformed packing (18) from fuel tank (4). Discard
preformed packing.

(15) Deleted.

Change 1 4-43
TM 9-2320-366-20-3

4-8. FUEL TANK AND BRACKETS REPLACEMENT (CONT)

(16) Remove fuel tank insulators (20 and 21) from support
brackets (14 and 15).

(17) Remove two bolts (22) and straps (13) from support
brackets (14 and 15).

(18) Remove two insulator straps (23) from straps (13).

(19) Remove four self-locking nuts (24), bolts (25), two plates
(26), and support bracket (14) from frame rail (27).
Discard self-locking nuts.

(20) Remove two self-locking nuts (28), washers (29), and

screws (30) from support bracket (15). Discard self-
locking nuts.

(21) Remove self-locking nut (31) and bolt (32) from support
bracket (15). Discard self-locking nut.

4-44
 TM 9-2320-366-20-3

(22) Remove self-locking nut (33) and bolt (34) from support
bracket (15). Discard self-locking nut.

(23) Remove two self-locking nuts (35), bolts (36), plate (37),
and support bracket (15) from frame rail (27). Discard
self-locking nuts.

b. Installation.

(1) Position support bracket (1) on frame rail (2) with plate
(3), two bolts (4), and self-locking nuts (5).

(2) Position bolt (6) and self-locking nut (7) in support

bracket (1).

(3) Position bolt (8) and self-locking nut (9) in support

bracket (1).

NOTE

Step (4) requires the aid of an assistant.

(4) Tighten two self-locking nuts (5), and self-locking nuts (7

and 9) to 197-237 lb-ft (267-321 N·m).

(5) Position two screws (10), washers (11), and self-locking

nuts (12) in support bracket (1).

(6) Tighten two self-locking nuts (12) to 42-52 lb-ft (57-70

N·m).

Change 1 4-45
TM 9-2320-366-20-3

4-8. FUEL TANK AND BRACKETS REPLACEMENT (CONT)

(7) Position support bracket (13) on frame rail (2) with two
plates (14), four bolts (15), and self-locking nuts (16).

NOTE

Step (8) requires the aid of an assistant.

(8) Tighten four self-locking nuts (16) to 197-237 lb-ft (267-

321 N·m).

(9) Install two insulator straps (17) on straps (18).

(10) Position two straps (18) on support brackets (1 and 13)

with bolts (19).

(11) Tighten two bolts (19) to 76-94 lb-ft (103-127 N·m).

(12) Install fuel tank insulators (20 and 21) on support

brackets (1 and 13).

4-46
 TM 9-2320-366-20-3

(13) Deleted.

(14) Deleted.

(15) Deleted.

(16) Deleted.

(17) Position preformed packing (25) and fuel level sending

unit (26) in fuel tank (23) with five screws (27).

(17.1) Tighten five screws (27) to 20-24 lb-in. (2-3 N·m).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(18) Apply sealing compound primer to threads of 90-degree

return fitting (28), 90-degree pickup tube fitting (29), and
relief valve (30).

(19) Apply sealing compound to threads of 90-degree return

fitting (28), 90-degree pickup tube fitting (29), and relief
valve (30).

(20) Install 90-degree return fitting (28) in fuel tank (23).

(21) Install 90-degree pickup tube fitting (29) in fuel tank (23).

(22) Install relief valve (30) in fuel tank (23).

Change 1 4-47
TM 9-2320-366-20-3

4-8. FUEL TANK AND BRACKETS REPLACEMENT (CONT)

NOTE

Step (23) requires the aid of an assistant.

(23) Install fuel tank (23) on support brackets (1 and 13) with
straps (18).

(24) Position two nuts (31) on two straps (18).

(25) Tighten two nuts (31) to 76-94 lb-ft (103-127 N·m).

(26) Install two nuts (32) on two straps (18).

NOTE

Install plastic cable ties as required.

(27) Connect fuel hose (33) to relief valve (30).

(28) Connect fuel hose (34) to 90-degree return fitting (28).

(29) Connect fuel hose (35) to 90-degree pickup tube fitting

(29).

4-48
 TM 9-2320-366-20-3

(30) Install drain plug (36) in fuel tank (23).

(31) Connect fuel level sending unit connector (37) to

connector P82 (38).

(32) Connect connector clamp (39) to fuel level sending unit

connector (37).

c. Follow-On Maintenance.

(1) Fill fuel tank (TM 9-2320-366-10-1).

(2) Bleed fuel system (para 4-11).

(3) Check for fuel leaks around hoses and fittings.

(4) Connect batteries (para 7-57).

(5) Start engine (TM 9-2320-366-10-1).

(6) Check for fuel leaks around hoses and fittings.

(7) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-49
TM 9-2320-366-20-3

4-9. FUEL HOSES REPLACEMENT

This task covers:

a. Fuel Supply Hose Removal f. Fuel Return Hose Installation

b. Fuel Supply Hose Installation g. Fuel Tank Vent Hose Removal
c. Fuel Transfer Hose Removal h. Fuel Tank Vent Hose Installation
d. Fuel Transfer Hose Installation i. Follow-On Maintenance
e. Fuel Return Hose Removal

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Batteries disconnected (para 7-57). Wrench, Torque, 0-175 lb-ft (Item 58, Appendix
Cab raised (TM 9-2320-366-10-1). C)
Spare tire lowered (TM 9-2320-366-10-2).
Materials/Parts
Tools and Special Tools Ties, Cable, Plastic (Item 69, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (Item 150, Appendix G)
Pan, Drain (Item 24, Appendix C) Nut, Self-Locking (Item 156, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Fuel Supply Hose Removal.

(1) Disconnect fuel supply hose assembly (1) from 90-

degree fitting (2).

4-50
 TM 9-2320-366-20-3

NOTE

• Remove plastic cable ties as required.

• Perform steps (2) and (3) on vehicle serial

number 3092 and higher, and vehicle serial
numbers 0001 through 3091 that have
previously had a spare tire retainer or fuel hose
replaced.

(2) Remove self-locking nut (3), screw (4), and clamp (5)
from spare tire retainer (6). Discard self-locking nut.

(3) Remove fuel supply hose assembly (1) from clamp (5).

(4) Remove self-locking nut (7), screw (8), and clamp (9)
from spare tire retainer (6). Discard self-locking nut.

(5) Remove fuel supply hose assembly (1) from clamp (9).

(6) Remove fuel supply hose assembly (1) from 90-degree

fuel pickup tube fitting (10).

4-51
TM 9-2320-366-20-3

4-9. FUEL HOSES REPLACEMENT (CONT)

b. Fuel Supply Hose Installation.

(1) Install fuel supply hose assembly (1) on 90-degree fuel

pickup tube fitting (2).

(2) Install fuel supply hose assembly (1) in clamp (3).

(3) Position clamp (3) on spare tire retainer (4) with screw
(5) and self-locking nut (6).

(4) Tighten self-locking nut (6) to 87-107 lb-in. (10-12 N·m).

(5) Install fuel supply hose assembly (1) in clamp (7).

(6) Position clamp (7) on spare tire retainer (4) with screw
(8) and self-locking nut (9).

(7) Tighten self-locking nut (9) to 43-52 lb-ft (58-71 N·m).

4-52
 TM 9-2320-366-20-3

NOTE

Install plastic cable ties as required.

(8) Connect fuel supply hose assembly (1) to 90-degree

fitting (10).

c. Fuel Transfer Hose Removal.

(1) Disconnect fuel transfer hose assembly (1) from

fuel/water separator (2).

(2) Remove fuel transfer hose assembly (1) from 90-degree

fitting (3).

4-53
TM 9-2320-366-20-3

4-9. FUEL HOSES REPLACEMENT (CONT)

d. Fuel Transfer Hose Installation.

(1) Install fuel transfer hose assembly (1) on 90-degree

fitting (2).

(2) Connect fuel transfer hose assembly (1) to fuel/water

separator (3).

e. Fuel Return Hose Removal.

(1) Disconnect fuel return hose assembly (1) from 90-degree

fitting (2).

4-54
 TM 9-2320-366-20-3

NOTE

• Remove plastic cable ties as required.

• Perform steps (2) and (3) on vehicle serial

number 3092 and higher, and vehicle serial
numbers 0001 through 3091 that have
previously had a spare tire retainer or fuel hose
replaced.

(2) Remove self-locking nut (3), screw (4), and clamp (5)
from spare tire retainer (6). Discard self-locking nut.

(3) Remove fuel return hose assembly (1) from clamp (5).

(4) Remove self-locking nut (7), screw (8), and clamp (9)
from spare tire retainer (6). Discard self-locking nut.

(5) Remove fuel return hose assembly (1) from clamp (9).

(6) Remove fuel return hose assembly (1) from 90-degree

return fitting (10).

4-55
TM 9-2320-366-20-3

4-9. FUEL HOSES REPLACEMENT (CONT)

f. Fuel Return Hose Installation.

(1) Install fuel return hose assembly (1) on 90-degree return

fitting (2).

(2) Install fuel return hose assembly (1) in clamp (3).

(3) Position clamp (3) on spare tire retainer (4) with screw
(5) and self-locking nut (6).

(4) Tighten self-locking nut (6) to 87-107 lb-in. (10-12 N·m).

(5) Install fuel return hose assembly (1) in clamp (7).

(6) Position clamp (7) on spare tire retainer (4) with screw
(8) and self-locking nut (9).

(7) Tighten self-locking nut (9) to 43-52 lb-ft (58-71 N·m).

4-56
 TM 9-2320-366-20-3

NOTE

Install plastic cable ties as required.

(8) Connect fuel return hose assembly (1) to 90-degree

fitting (10).

g. Fuel Tank Vent Hose Removal.

NOTE

Remove plastic cable ties as required.

(1) Remove self-locking nut (1), screw (2), and clamp (3)
from spare tire retainer (4). Discard self-locking nut.

(2) Remove fuel tank vent hose (5) from clamp (3).

(3) Remove fuel tank vent hose (5) from relief valve (6).

(4) Remove adapter (7) from fuel tank vent hose (5).

4-57
TM 9-2320-366-20-3

4-9. FUEL HOSES REPLACEMENT (CONT)

h. Fuel Tank Vent Hose Installation.

(1) Install adapter (1) in fuel tank vent hose (2).

(2) Install fuel tank vent hose (2) on relief valve (3).

NOTE

Install plastic cable ties as required.

(3) Form a 180-degree bend in fuel tank vent hose (2).

CAUTION

Use care when installing fuel tank vent hose

in clamp so that fuel tank vent hose is not
pinched or crimped. Failure to comply may
result in damage to equipment.

(4) Install fuel tank vent hose (2) in clamp (4).

(5) Position clamp (4) on spare tire retainer (5) with screw
(6) and self-locking nut (7).

(6) Tighten self-locking nut (7) to 87-107 lb-in. (10-12 N·m).

4-58
 TM 9-2320-366-20-3

i. Follow-On Maintenance.

(1) Bleed fuel system (para 4-11).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Connect batteries (para 7-57).

(4) Start engine (TM 9-2320-366-10-1).

(5) Raise cab (TM 9-2320-366-10-1).

(6) Check for fuel leaks around hoses and fittings.

(7) Raise spare tire (TM 9-2320-366-10-2).

(8) Lower cab (TM 9-2320-366-10-1).

(9) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-59
TM 9-2320-366-20-3

4-10. FUEL FILTER TUBES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Packing, Preformed (4) (Item 178, Appendix G)
Batteries disconnected (para 7-57). Packing, Preformed (6) (Item 203, Appendix G)
Sealant, Pipe Teflon (Item 58, Appendix D)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Removal.

(1) Disconnect fuel tube assembly (1) from tee fitting (2).

(2) Remove preformed packing (3) from tee fitting (2).

Discard preformed packing.

(3) Remove fuel tube assembly (1) and 90-degree fitting (4)
from adapter (5).

(4) Remove preformed packing (6) from adapter (5).

Discard preformed packing.

(5) Remove adapter (5) from fuel governor (7).

(6) Remove preformed packing (8) from adapter (5).

Discard preformed packing.

4-60 Change 1
 TM 9-2320-366-20-3

4-10. FUEL FILTER TUBES REPLACEMENT (CONT)

(7) Remove 90-degree fitting (4) from fuel tube assembly

(1).

(8) Remove preformed packing (9) from 90-degree fitting (4).

Discard preformed packing.

(9) Remove screw (10), washer (11), and clip (12) from
cylinder head (13).

(10) Remove clip (12) from fuel tube assembly (14).

(11) Disconnect fuel tube assembly (14) from tee fitting (15).

(12) Remove preformed packing (16) from tee fitting (15).

Discard preformed packing.

4-61
TM 9-2320-366-20-3

(13) Remove fuel tube assembly (14) from 90-degree fitting

(17).

(14) Remove preformed packing (18) from 90-degree fitting

(17). Discard preformed packing.

(15) Remove 90-degree fitting (17) from cylinder head (13).

(16) Remove preformed packing (19) from 90-degree fitting

(17). Discard preformed packing.

(17) Remove plug (20) from adapter (21).

(18) Remove adapter (21) from tee fitting (2).

(19) Remove preformed packing (22) from adapter (21).

Discard preformed packing.

(20) Remove tee fitting (2) from fuel filter base (23).

(21) Remove preformed packing (24) from tee fitting (2).

Discard preformed packing.

4-62
 TM 9-2320-366-20-3

(22) Remove tee fitting (15) from fuel filter base (23).

(23) Remove preformed packing (25) from tee fitting (15).

Discard preformed packing.

b. Installation.

(1) Install preformed packing (1) on tee fitting (2).

(2) Install tee fitting (2) in fuel filter base (3).

(3) Install preformed packing (4) on tee fitting (5).

(4) Install tee fitting (5) in fuel filter base (3).

(5) Install preformed packing (6) on adapter (7).

(6) Install adapter (7) in tee fitting (5).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(6.1) Apply sealing compound to threads of plug (8).

(7) Install plug (8) in adapter (7).

Change 1 4-63
TM 9-2320-366-20-3

(8) Install preformed packing (9) on 90-degree fitting (10).

(9) Install 90-degree fitting (10) in cylinder head (11).

(10) Install preformed packing (12) on 90-degree fitting (10).

(11) Install fuel tube assembly (13) on 90-degree fitting (10).

(12) Install preformed packing (14) on tee fitting (2).

(13) Install fuel tube assembly (13) on tee fitting (2).

4-64
 TM 9-2320-366-20-3

4-10. FUEL FILTER TUBES REPLACEMENT (CONT)

(14) Install clip (15) on fuel tube assembly (13).

(15) Install clip (15) on cylinder head (11) with washer (16)
and screw (17).

(16) Install preformed packing (18) on 90-degree fitting (19).

(17) Install fuel tube assembly (20) on 90-degree fitting (19).

(18) Install preformed packing (21) on adapter (22).

(19) Install adapter (22) in fuel governor (23).

(20) Install preformed packing (24) on adapter (22).

(21) Install 90-degree fitting (19) on adapter (22).

4-65
TM 9-2320-366-20-3

(22) Install preformed packing (25) on tee fitting (5).

(23) Install fuel tube assembly (20) on tee fitting (5).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check for fuel leaks under vehicle.

(5) Raise cab (TM 9-2320-366-10-1).

(6) Check for fuel leaks around tubes and fittings.

(7) Lower cab (TM 9-2320-366-10-1).

(8) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-66
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4-11. FUEL SYSTEM BLEEDING

This task covers:

a. Bleeding b. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Cab raised (TM 9-2320-366-10-1). Pan, Drain (Item 24, Appendix C)

Materials/Parts
Ties, Cable, Plastic (Item 69, Appendix D)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Bleeding.

NOTE

Remove plastic cable ties as required.

(1) Position drain pan below fuel return hose assembly (1).

(2) Disconnect fuel return hose assembly (1) from 90-degree

fitting (2).

(3) Direct fuel return hose assembly (1) into drain pan.

4-67
TM 9-2320-366-20-3

4-11. FUEL SYSTEM BLEEDING (CONT)

(4) Depress button (3) on fuel/water separator (4) as many

times as necessary to get a steady stream of clear fuel.

NOTE

Install plastic cable ties as required.

(5) Connect fuel return hose assembly (1) to 90-degree

fitting (2).

b. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine and allow to run until engine runs smoothly
(TM 9-2320-366-10-1).

(3) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-68
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4-12. GOVERNOR LINKAGE REPLACEMENT

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Pin, Cotter (Item 224, Appendix G)
Cab raised (TM 9-2320-366-10-1). Bushing, Sleeve (Item 6, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Remove cotter pin (1), washer (2), and TPS cable
assembly (3) from stud (4). Discard cotter pin.

(2) Remove clip (5) and throttle control cable (6) from stud
(7).

NOTE

Note position of two springs prior to removal.

(3) Remove springs (8 and 9) from linkage plate (10).

(4) Remove bolt (11), washer (12), and linkage plate (10)
from governor (13).

(5) Remove bolt (14), washer (15), and sensor bracket (16)
from governor (13).

Change 1 4-69
TM 9-2320-366-20-3

4-12. GOVERNOR LINKAGE REPLACEMENT (CONT)

b. Disassembly.

(1) Remove ring spacer (1) from linkage plate (2). Discard
ring spacer.

(2) Remove nut (3), washer (4), and stud (5) from sensor
bracket (6).

c. Assembly.

(1) Install stud (1), washer (2), and nut (3) on sensor bracket
(4).

4-70
 TM 9-2320-366-20-3

(2) Install ring spacer (5) in linkage plate (6).

d. Installation.

(1) Position sensor bracket (1) on governor (2) with washer

(3) and bolt (4).

(2) Tighten bolt (4) to 9 lb-ft (12 N·m).

(3) Position linkage plate (5) on governor (2) with washer (6)
and bolt (7).

(4) Tighten bolt (7) to 20 lb-ft (27 N·m).

(5) Install springs (8 and 9) on linkage plate (5).

(6) Install throttle control cable (10) on stud (11) with clip
(12).

(7) Install TPS cable assembly (13) on stud (14) with washer
(15) and cotter pin (16).

e. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Operate vehicle and check for proper engine operation

(TM 9-2320-366-10-1).

End of Task.

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4-13. FUEL/WATER SEPARATOR AND FILTER REPLACEMENT

This task covers:

a. Filter Removal d. Pump Head Installation

b. Filter Installation e. Follow-On Maintenance
c. Pump Head Removal

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Cloth, Cleaning (Item 16, Appendix D)
Batteries disconnected (para 7-57). Oil, Fuel, Diesel (Item 36 or 37, Appendix D)
Filter Element, Fluid (Item 17, Appendix G)
Tools and Special Tools Packing, Preformed (2) (Item 200, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Filter Removal.

(1) Disconnect connector clamp (1) from fuel/water

separator connector (2).

(2) Disconnect connector P33 (3) from fuel/water separator

connector (2).

(3) Position drain pan under hose (4).

(4) Open drain valve (5) and allow fuel to drain.

(5) Loosen clamp (6) on hose (4).

(6) Remove hose (4) from drain valve (5).

4-72
 TM 9-2320-366-20-3

(7) Remove fluid filter element (7) and bowl assembly (8)
from pump head (9).

(8) Remove bowl assembly (8) from fluid filter element (7).
Discard fluid filter element.

(9) Remove preformed packing (10) from bowl assembly (8).

Discard preformed packing.

(10) Clean debris from valve (11) on bottom of pump head

(9).

b. Filter Installation.

(1) Close drain valve (1).

(2) Install preformed packing (2) on bowl assembly (3).

(3) Install bowl assembly (3) on fluid filter element (4).

(4) Install fluid filter element (4) on pump head (5).

(5) Install hose (6) on drain valve (1) with clamp (7).

(6) Connect connector P33 (8) to fuel/water separator

connector (9).

(7) Connect connector clamp (10) on fuel/water separator

connector (9).

4-73
TM 9-2320-366-20-3

4-13. FUEL/WATER SEPARATOR AND FILTER REPLACEMENT (CONT)

c. Pump Head Removal.

(1) Disconnect fuel transfer hose assembly (1) from adapter

(2).

(2) Remove adapter (2) and preformed packing (3) from

pump head (4). Discard preformed packing.

(3) Disconnect fuel supply hose assembly (5) from 90-

degree fitting (6).

(4) Remove 90-degree fitting (6) and preformed packing (7)

from pump head (4). Discard preformed packing.

(5) Remove two screws (8), washers (9), and pump head (4)
from bracket (10).

d. Pump Head Installation.

(1) Install pump head (1) on bracket (2) with two washers
(3) and screws (4).

4-74
 TM 9-2320-366-20-3

(2) Install preformed packing (5) on 90-degree fitting (6).

(3) Install 90-degree fitting (6) in pump head (1).

(4) Install fuel supply hose assembly (7) on 90-degree fitting

(6).

(5) Install preformed packing (8) on adapter (9).

(6) Install adapter (9) in pump head (1).

(7) Install fuel transfer hose assembly (10) on adapter (9).

e. Follow-On Maintenance.

(1) Bleed fuel system (para 4-11).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Connect batteries (para 7-57).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check for fuel leaks under vehicle.

(6) Raise cab (TM 9-2320-366-10-1).

(7) Check engine compartment for fuel leaks.

(8) Lower cab (TM 9-2320-366-10-1).

(9) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-75
TM 9-2320-366-20-3

4-14. FUEL FILTER AND FILTER BASE REPLACEMENT

This task covers:

a. Filter Removal d. Filter Base Installation

b. Filter Installation e. Follow-On Maintenance
c. Filter Base Removal

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Oil, Fuel, Diesel (Item 36 or 37, Appendix D)
Batteries disconnected (para 7-57). Filter, Fuel (Item 22, Appendix G)
Packing, Preformed (2) (Item 178, Appendix G)
Tools and Special Tools Packing, Preformed (3) (Item 203, Appendix G)
Pan, Drain (Item 24, Appendix C) Packing, Preformed (Item 207, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Gasket, Fuel Filter (Item 44, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C)
Wrench, Strap, Adjustable (Item 57, Appendix C)

WARNING

Diesel fuel is flammable. If fuel is spilled,

clean it up immediately. Failure to comply
may result in serious injury or death to
personnel.

a. Filter Removal.

(1) Position drain pan under filter element (1).

(2) Remove filter element (1) from fuel filter base (2).

4-76
 TM 9-2320-366-20-3

b. Filter Installation.

(1) Coat filter element seal (1) with a light coat of fuel.

(2) Fill filter element (2) with diesel fuel.

(3) Install filter element (2) on fuel filter base (3). Then turn
3/4-turn after filter element touches fuel filter base.

c. Filter Base Removal.

(1) Remove screw (1) and washer (2) from top of crankcase
breather (3).

(2) Remove crankcase breather (3) from fuel filter base (4).

(3) Remove preformed packing (5) from fuel filter base (4).
Discard preformed packing.

(4) Disconnect fuel tube assembly (6) from tee fitting (7).

(5) Remove preformed packing (8) from tee fitting (7).

Discard preformed packing.

4-77
TM 9-2320-366-20-3

4-14. FUEL FILTER AND FILTER BASE REPLACEMENT (CONT)

(6) Remove tee fitting (7) from fuel filter base (4).

(7) Remove preformed packing (9) from tee fitting (7).

Discard preformed packing.

(8) Disconnect fuel tube assembly (10) from tee fitting (11).

(9) Remove preformed packing (12) from tee fitting (11).

Discard preformed packing.

(10) Remove tee fitting (11) from fuel filter base (4).

(11) Remove preformed packing (13) from tee fitting (11).

Discard preformed packing.

(12) Remove four screws (14) and washers (15) from fuel
filter base (4).

(13) Remove fuel filter base (4) and gasket (16) from engine
(17). Discard gasket.

(14) Remove plug (18) from fuel filter base (4).

(15) Remove preformed packing (19) from plug (18). Discard

preformed packing.

4-78
 TM 9-2320-366-20-3

d. Filter Base Installation.

(1) Install preformed packing (1) on plug (2).

(2) Install plug (2) in fuel filter base (3).

(3) Position fuel filter base (3) and gasket (4) on engine (5)
with four washers (6) and screws (7).

(4) Tighten four screws (7) to 96-144 lb-in. (11-16 N·m).

(5) Install preformed packing (8) on tee fitting (9).

(6) Install tee fitting (9) in fuel filter base (3).

(7) Install preformed packing (10) on tee fitting (9).

(8) Connect fuel tube assembly (11) to tee fitting (9).

(9) Install preformed packing (12) on tee fitting (13).

(10) Install tee fitting (13) in fuel filter base (3).

4-79
TM 9-2320-366-20-3

4-14. FUEL FILTER AND FILTER BASE REPLACEMENT (CONT)

(11) Install preformed packing (14) on tee fitting (13).

(12) Connect fuel tube assembly (15) to tee fitting (13).

(13) Apply thin coat of lubricating oil to both sides of

preformed packing (16).

(14) Install preformed packing (16) on top of fuel filter base

(3).

(15) Position crankcase breather (17) on top of fuel filter base

(3) with washer (18) and screw (19).

(16) Tighten screw (19) to 96-144 lb-in. (11-16 N·m).

e. Follow-On Maintenance.

(1) Bleed fuel system (para 4-11).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Connect batteries (para 7-57).

(4) Start engine (TM 9-2320-366-10-1).

4-80
 TM 9-2320-366-20-3

(5) Check for fuel leaks under vehicle.

(6) Raise cab (TM 9-2320-366-10-1).

(7) Check for fuel leaks around fuel filter.

(8) Lower cab (TM 9-2320-366-10-1).

(9) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-81
TM 9-2320-366-20-3

4-15. ETHER STARTING AID REPLACEMENT

This task covers:

a. Ether Cylinder Removal e. Ether Valve Removal

b. Ether Cylinder Installation f . Ether Valve Installation
c. Clamp Removal g. Follow-On Maintenance
d. Clamp Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Gasket (Item 26, Appendix G)
Spare tire lowered (TM 9-2320-366-10-2). Nut, Self-Locking (4) (Item 153, Appendix G)

Tools and Special Tools

Goggles, Industrial (Item 15, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

WARNING

Starting fluid is toxic and highly flamma-

ble. Container is pressurized. NEVER
heat container and NEVER discharge
starting fluid in confined areas or near
open flame. Failure to comply may cause
serious injury or death to personnel.

a. Ether Cylinder Removal.

(1) Remove wingnut (1) from clamp (2).

(2) Remove ether cylinder (3) and gasket (4) from ether
valve (5). Discard gasket.

(3) Remove ether cylinder (3) from clamp (2).

(4) Remove cap (6) from cap retainer (7).

(5) Install cap (6) on ether valve (5).

4-82 Change 1
 TM 9-2320-366-20-3

b. Ether Cylinder Installation.

(1) Remove cap (1) from ether valve (2).

(2) Install cap (2) on cap retainer (3).

(3) Install gasket (4) in ether valve (2).

(4) Position ether cylinder (5) in clamp (6).

(5) Install ether cylinder (5) on ether valve (2).

(6) Install wingnut (7) on clamp (6).

c. Clamp Removal.

Remove two self-locking nuts (1), screws (2), and clamp (3)
from spare tire retainer (4). Discard self-locking nuts.

d. Clamp Installation.

(1) Position clamp (1) on spare tire retainer (2) with two
screws (3) and self-locking nuts (4).

(2) Tighten two self-locking nuts (4) to 25-31 lb-ft (34-42

N·m).

Change 1 4-83
TM 9-2320-366-20-3

4-15. ETHER STARTING AID REPLACEMENT (CONT)

e. Ether Valve Removal.

(1) Disconnect ether tube (1) from ether valve (2).

(2) Disconnect ether valve electrical connector (3) from

connector J93 (4).

(3) Remove two self-locking nuts (5), screws (6), washers

(7), terminal lug TL84 (8), and ether valve (2) from spare
tire retainer (9). Discard self-locking nuts.

f. Ether Valve Installation.

(1) Position ether valve (1) on spare tire retainer (2),

terminal lug TL84 (3), two washers (4), screws (5), and
self-locking nuts (6).

(2) Tighten self-locking nuts (6) to 25-31 lb-ft (34-42 N·m).

(3) Connect ether valve electrical connector (7) to connector

J93 (8).

(4) Connect ether tube (9) to ether valve (1).

g. Follow-On Maintenance.

(1) Raise spare tire (TM 9-2320-366-10-2).

(2) Connect batteries (para 7-57).

(3) Operate ether starting aid (TM 9-2320-366-10-2) and

check for ether leaks.

End of Task.

4-84 Change 1
 TM 9-2320-366-20-3

4-16. THROTTLE POSITION SENSOR (TPS) CABLE ASSEMBLY REPLACEMENT

This task covers:

a. Removal b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Pin, Cotter (Item 224, Appendix G)
Cab raised (TM 9-2320-366-10-1).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Disconnect electrical connector (1) from TPS cable

assembly (2).

(2) Remove three nuts (3), washers (4), screws (5), and
TPS cable assembly (2) from bracket (6).

(3) Remove cotter pin (7) and washer (8) from stud (9).
Discard cotter pin.

(4) Remove TPS cable assembly (2) from stud (9).

(5) Release latch (10) on clamp (11).

(6) Remove TPS cable assembly (2) from clamp (11).

(7) Remove TPS cable assembly (2) from engine.

4-85
TM 9-2320-366-20-3

4-16. THROTTLE POSITION SENSOR (TPS) CABLE ASSEMBLY REPLACEMENT

(CONT)

b. Installation.

(1) Position TPS cable assembly (1) in clamp (2).

(2) Close latch (3) on clamp (2).

(3) Position TPS cable assembly (1) on stud (4).

(4) Install washer (5) and cotter pin (6) on stud (4).

(5) Install TPS cable assembly (1) on bracket (7) with three
screws (8), washers (9) and nuts (10).

(6) Connect electrical connector (11) to TPS cable assembly

(1).

(7) Lower cab (TM 9-2320-366-10-1).

(8) Connect batteries (para 7-57).

NOTE

Wait until Neutral (N) indication appears in

pushbutton shift selector display before
positioning master power switch off.

(9) Position master power switch on and off five times (TM
9-2320-366-10-1).

NOTE

TPS will self-adjust but vehicle will need to be

operated through all gear ranges several
times before correct shifting will be noticed.

(10) Operate vehicle and check for smooth transmission

shifting through all gear ranges (TM 9-2320-366-10-1).

End of Task.

4-86
 TM 9-2320-366-20-3

4-17. HAND THROTTLE LEVER REPLACEMENT/ADJUSTMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation/Adjustment

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Instrument panel assembly removed for access Tool Kit, Genl Mech (Item 46, Appendix C)
(para 7-15). Scale, Weighing (Item 30, Appendix C)

Materials/Parts
Washer, Spring (Item 294, Appendix G)

a. Removal.

Remove nut (1), washer (2), spring washer (3), HAND

THROTTLE lever (4), and friction disk (5) from dashboard
(6). Discard spring washer.

b. Installation/Adjustment.

WARNING

Tab of HAND THROTTLE lever must be

positioned above throttle pivot bar.
Failure to comply may result in injury to
personnel or damage to equipment.

(1) Position friction disk (5), HAND THROTTLE lever (4),

spring washer (3), washer (2), and nut (1) on dashboard
(6).

CAUTION

HAND THROTTLE lever nut must be

tightened so that 9-11 lbs (40-49 N) of force
is required to change position of HAND
THROTTLE lever. Failure to comply may
result in damage to equipment.

(2) Tighten nut (1) on HAND THROTTLE lever (4).

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TM 9-2320-366-20-3

4-17. HAND THROTTLE LEVER REPLACEMENT/ADJUSTMENT (CONT)

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check for smooth operation of HAND THROTTLE lever.

(4) Check high/low HAND THROTTLE lever positions (para

4-22).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-88
 TM 9-2320-366-20-3

4-18. THROTTLE CONTROL CABLE REPLACEMENT/ADJUSTMENT

This task covers:

a. Removal c. Adjustment
b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Grease, Molybdenum Disulfide (Item 24, Appendix D)
Steering wheel removed (para 13-2).
Personnel Required
Tools and Special Tools (2)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Position master power switch to on (TM 9-2320-366-10-

1).

(2) Place wiper blades in the full left position (TM 9-2320-
366-10-1).

(3) Position master power switch to off (TM 9-2320-366-10-

1).

(4) Disconnect batteries (para 7-57).

(5) Remove instrument panel assembly for access (para 7-

15).

WARNING

Retaining rings are under tension and can

act as projectiles when released causing
severe eye injury. Use care when
removing retaining rings. Failure to
comply may result in injury to personnel.

(6) Remove retaining ring (1) and bellcrank (2) from stud (3).

4-89
TM 9-2320-366-20-3

4-18. THROTTLE CONTROL CABLE REPLACEMENT/ADJUSTMENT (CONT)

(7) Remove clip (4) and throttle control cable (5) from stud
(6).

(8) Loosen two nuts (7) with washers (8) on throttle control
cable (5).

(9) Remove throttle control cable (5) from dashboard (9).

(10) Raise cab (TM 9-2320-366-10-1).

(11) Remove throttle control cable (5) and grommet (10) from
cab (11).

(12) Remove clip (12) and throttle control cable (5) from stud
(13).

NOTE

Count threads showing on throttle control cable

ferrule. Record this number prior to removal.

(13) Loosen nut (14) with washers (15) on throttle control

cable (5).

(14) Remove throttle control cable (5) from bracket (16).

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 TM 9-2320-366-20-3

NOTE

Note routing of throttle control cable prior to

removal.

Remove plastic cable ties as required.

(15) Remove throttle control cable (5) from vehicle.

b. Installation.

(1) Position throttle control cable (1) on vehicle.

(2) Position nut (2) on throttle control cable (1) so that same
number of threads are showing on ferrule as was
recorded in removal.

(3) Position throttle control cable (1) in bracket (3) with two
washers (4) and nut (5).

(4) Install throttle control cable (1) on stud (6) with clip (7).

4-91
TM 9-2320-366-20-3

4-18. THROTTLE CONTROL CABLE REPLACEMENT/ADJUSTMENT (CONT)

(5) Position grommet (8) and throttle control cable (1) in cab
(9).

(6) Lower cab (TM 9-2320-366-10-1).

(7) Position throttle control cable (1) in dashboard (10) with

two washers (11) and nuts (12).

(8) Install throttle control cable (1) on stud (13) with clip (14).

(9) Apply grease to stud (15).

WARNING

Retaining rings are under tension and can

act as projectiles when released causing
severe eye injury. Use care when
installing retaining rings. Failure to
comply may result in injury to personnel.

(10) Install bellcrank (16) on stud (15) with retaining ring (17).

4-92
 TM 9-2320-366-20-3

c. Adjustment.

(1) Raise cab (TM 9-2320-366-10-1).

CAUTION

Ensure governor linkage rests against low

idle stop with throttle control cable installed.
Failure to comply may result in damage to
equipment.

NOTE

Perform steps (2) and (3) if governor linkage

does not contact low idle stop with throttle
control cable installed.

(2) Loosen nut (1) on throttle control cable (2) until governor
linkage (3) contacts low idle stop (4).

(3) Tighten nut (5) on throttle control cable (2).

WARNING

Use extreme care when opening cab door

with cab raised. Failure to comply may
result in injury to personnel or damage to
equipment.

CAUTION

Ensure governor linkage contacts high idle stop

with accelerator pedal fully depressed. Failure
to comply may result in damage to equipment.

NOTE

Steps (4) through (7) require the aid of an

assistant.

(4) Depress accelerator pedal (6) to cab floor (7).

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TM 9-2320-366-20-3

4-18. THROTTLE CONTROL CABLE REPLACEMENT/ADJUSTMENT (CONT)

(5) Observe movement of governor linkage (3) to high idle

stop (8).

(6) Release accelerator pedal (6) from cab floor (7).

(7) Observe movement of governor linkage (3) from high idle

stop (8) to low idle stop (4).

4-94
 TM 9-2320-366-20-3

(8) Loosen nut (9) on throttle control cable (2).

(9) Tighten nut (10) on throttle control cable (2).

(10) Perform steps (4) through (9) until freeplay is removed

from throttle control cable (2).

d. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Install instrument panel assembly (para 7-15).

(3) Operate windshield wipers, position wipers stowed (TM

9-2320-366-10-1).

(4) Start engine, check accelerator for smooth operation (TM

9-2320-366-10-1).

(5) Check high/low HAND THROTTLE lever positions (para

4-22).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-95
TM 9-2320-366-20-3

4-19. THROTTLE CONTROL THREADED ROD REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access Grease, Molybdenum Disulfide (Item 24, Appendix D)
(para 7-15).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Remove clip ring (1) from ball seat (2).

(2) Remove ball seat (2) and threaded rod (3) from ball stud
(4).

(3) Remove clip ring (5) from ball seat (6).

(4) Remove ball seat (6) and threaded rod (3) from
accelerator pedal (7).

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 TM 9-2320-366-20-3

(5) Loosen two jam nuts (8) behind ball seats (2 and 6).

(6) Remove ball seats (2 and 6) and two jam nuts (8) from
threaded rod (3).

b. Installation.

(1) Install two jam nuts (1) to bottom of threads on threaded

rod (2).

(2) Install ball seats (3 and 4) on threaded rod (2) until ball
seats contact two jam nuts (1).

(3) Tighten two jam nuts (1) against ball seats (3 and 4).

(4) Apply grease to inside of ball seat (3).

(5) Install ball seat (3) in accelerator pedal (5).

(6) Install clip ring (6) on ball seat (3).

4-97
TM 9-2320-366-20-3

4-19. THROTTLE CONTROL THREADED ROD REPLACEMENT (CONT)

(7) Apply grease to inside of ball seat (4).

(8) Install ball seat (4) on ball stud (7).

(9) Install clip ring (8) on ball seat (4).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Start engine (TM 9-2320-366-10-1).

(3) Depress accelerator pedal and check for smooth

operation.

(4) Check high/low HAND THROTTLE lever positions (para

4-22).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-98
 TM 9-2320-366-20-3

4-20. THROTTLE CONTROL LEVER REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Steering wheel removed (para 13-2). Grease, Molybdenum Disulfide (Item 24, Appendix D)
Washer, Spring (Item 288, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Position master power switch to on (TM 9-2320-366-10-

1).

(2) Place wiper blades in the full left position (TM 9-2320-
366-10-1).

(3) Position master power switch to off (TM 9-2320-366-10-

1).

(4) Disconnect batteries (para 7-57).

(5) Remove instrument panel assembly for access (para 7-

15).

(6) Remove clip ring (1) from ball seat (2).

(7) Remove ball seat (2) with threaded rod (3) from ball stud
(4).

4-99
TM 9-2320-366-20-3

4-20. THROTTLE CONTROL LEVER REPLACEMENT (CONT)

WARNING

Retaining rings are under tension and can

act as projectiles when released causing
sever eye injury. Use care when removing
retaining rings. Failure to comply may
result in injury to personnel.

(8) Remove retaining ring (5) and lever (6) from lever stud
(7).

(9) Remove bushing (8) from lever stud (7).

(10) Remove clip (9) and throttle control cable (10) from stud
(11).

(11) Remove nut (12), spring washer (13), and ball stud (4)
from lever (6). Discard spring washer.

b. Installation.

(1) Install ball stud (1) on lever (2) with spring washer (3)
and nut (4).

(2) Install throttle control cable (5) on stud (6) with clip (7).

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 TM 9-2320-366-20-3

(3) Apply grease to bushing (8) and lever stud (9).

WARNING

Retaining rings are under tension and can

act as projectiles when released causing
severe eye injury. Use care when
removing retaining rings. Failure to
comply may result in injury to personnel.

(4) Install bushing (8) and lever (2) on lever stud (9) with
retaining ring (10).

(5) Apply grease to ball stud (1).

(6) Install ball seat (11) with threaded rod (12) on ball stud
(1).

(7) Install clip ring (13) on ball seat (11).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Start engine (TM 9-2320-366-10-1).

(3) Position windshield wiper control to off (TM 9-2320-366-

10-1).

(4) Depress accelerator pedal and check for smooth

operation.

(5) Check high/low HAND THROTTLE lever positions (para

4-22).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

4-101
TM 9-2320-366-20-3

4-21. ACCELERATOR PEDAL REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Grease, Molybdenum Disulfide (Item 24,
Appendix D)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 35, Appendix C)

a. Removal.

(1) Remove clip ring (1) from ball seat (2).

(2) Remove ball seat (2) and threaded rod (3) from ball stud
(4).

(3) Remove two screws (6), washers (7), and accelerator

pedal (5) from cab floor (8).

b. Installation.

(1) Position accelerator pedal (5) on cab floor (8) with two
washers (7) and screws (6).

(2) Tighten two screws (6) to 72-84 lb-in. (8-10 N·m).

(3) Apply grease to inside of ball seat (2).

(4) Install ball seat (2) and threaded rod (3) on ball stud (4).

(5) Install clip ring (1) on ball seat (2).

c. Follow-On Maintenance.

(1) Start engine (TM 9-2320-366-10-1).

(2) Depress accelerator pedal and check for smooth

operation.

(3) Shut down engine (TM 9-2320-366-10-1).

End of Task.

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 TM 9-2320-366-20-3

4-22. CHECKING AND STENCILING HIGH/LOW HAND THROTTLE POSITIONS

This task covers:

a. Checking High/Low Hand Throttle Positions b. Stenciling High/Low Hand Throttle Positions

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Rubber Stamp Set, Fixed Type (Item 53, Appendix D)
Polyurethane Coating (Item 48, Appendix D)
Tools and Special Tools Ink, Marking Stencil (Item 26, Appendix D)
STE/ICE-R (Item 41, Appendix C) Inking Pad, Rubber Stamp (Item 27, Appendix D)
Gloves, Rubber (Item 13, Appendix C)
Respirator, Air Filter (Item 29, Appendix C) References
TM 9-4910-571-12&P
TB 43-0209

a. Checking High/Low Hand Throttle Positions.

(1) Connect STE/ICE-R to DCA connector (1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Position HAND THROTTLE lever (2) so that upper edge

of lever is even with line below L setting.

NOTE

Acceptable engine RPM with HAND

THROTTLE lever at L setting is 1250-1450
RPM.

(4) Perform STE/ICE-R test #10.

4-103
TM 9-2320-366-20-3

4-22. CHECKING AND STENCILING HIGH/LOW HAND THROTTLE POSITIONS (CONT)

(5) Position HAND THROTTLE lever (2) so that upper edge

of lever is even with line below H setting.

NOTE

Acceptable engine RPM with HAND

THROTTLE lever at H setting is 2000-2200
RPM.

(6) Perform STE/ICE-R test #10.

(7) Perform subparagraph b. Stenciling High/Low Hand

Throttle Positions if engine RPM results from steps (4)
and (6) are not within acceptable limits.

b. Stenciling High/Low Hand Throttle Positions.

(1) Paint over old high and low HAND THROTTLE lever
position markings (TB 43-0209).

(2) Connect STE/ICE-R to DCA connector (1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Perform STE/ICE-R test #10.

4-104
 TM 9-2320-366-20-3

(5) Raise engine RPM to 1350 using HAND THROTTLE

lever (2).

(6) Stencil a line even with top edge of HAND THROTTLE

lever (2).

(7) Raise engine RPM to 2100 using HAND THROTTLE

LEVER (2).

(8) Stencil a line even with top edge of HAND THROTTLE

lever (2).

(9) Lower engine RPM to idle using HAND THROTTLE lever

(2).

(10) Shut down engine (TM 9-2320-366-10-1).

(11) Stencil L above lower line.

(12) Stencil H above upper line.

End of Task.

4-105/(4-106 Blank)
 TM 9-2320-366-20-3

CHAPTER 5
EXHAUST SYSTEM MAINTENANCE

RESTRICTED MAINTENANCE NOTICE

Units not authorized SC 4910-95-CL-A72 (SHOP EQUIPMENT, COMMON NO. 2) in their T.O.E. may
be unable to perform some of the maintenance tasks described in this chapter. If the required tools
are not authorized, the equipment must be submitted to DS Maintenance for repair.

Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Section II. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2. MUFFLER AND EXHAUST HEAT SHIELDS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-3. EXHAUST PIPE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-4. TAILPIPE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Section I. INTRODUCTION

5-1. INTRODUCTION

This chapter contains maintenance instructions for replacing exhaust system components authorized by the
Maintenance Allocation Chart (MAC) at the Unit Maintenance level.

Change 1 5-1
TM 9-2320-366-20-3

Section II. MAINTENANCE PROCEDURES

5-2. MUFFLER AND EXHAUST HEAT SHIELDS REPLACEMENT
This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Nut, Self-Locking (2) (Item 157, Appendix G)
Nut, Self-Locking (4) (Item 154, Appendix G)
Tools and Special Tools Nut, Self-Locking (Item 156, Appendix G)
Goggles, Industrial (Item 15, Appendix C) Nut, Self-Locking (2) (Item 129, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (2) (Item 168, Appendix G)
Drill, Electric, Portable (Item 7, Appendix C) Washer, Flat (4) (Item 280, Appendix G)
Drill Set, Twist (Item 6, Appendix C) Screw, Cap (2) (Item 261, Appendix G)
Drill, Twist (Item 8, Appendix C) Grommet, Nonmetallic (6) (Item 52, Appendix
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C) G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C) Personnel Required
(2)

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

Ensure exhaust system is cool before

performing maintenance. Failure to
comply may result in injury to personnel.

Do not operate MTV vehicle with muffler

removed. Toxic exhaust fumes may enter
cab, resulting in serious injury or death to
personnel.

a. Removal.

(1) Remove self-locking nut (1) from clamp (2). Discard self-
locking nut.

(2) Disconnect exhaust pipe (3) from muffler (4).

5-2
 TM 9-2320-366-20-3

(3) Remove self-locking nut (5) from clamp (6). Discard self-
locking nut.

(4) Disconnect tail pipe (7) from muffler (4).

NOTE

Vehicle serial numbers 0001 through 3091,

except M1088 and M1089, were originally
equipped with different mounting hardware
than vehicle serial numbers 3092 and higher
serial numbers. Perform steps (5) through
(7) on vehicle serial numbers 0001 through
3091, except M1088 and M1089, that have
not previously had a muffler replaced.

(5) Remove two screws (8) and washers (9) from muffler
straps (10).

NOTE

Step (6) requires the aid of an assistant.

(6) Remove muffler (4) from two muffler support brackets

(11).

5-3
TM 9-2320-366-20-3

5-2. MUFFLER AND EXHAUST HEAT SHIELDS REPLACEMENT (CONT)

(7) Remove four nuts (12), washers (13), screws (14),

washers (15), and two resilient mounts (16) from muffler
support brackets (11). Discard nuts, washers, screws,
and resilient mounts.

NOTE

• Perform step (8) on M1088/M1089, vehicle

serial numbers 3092 and higher, and vehicles
that have previously had a muffler replaced.

• Step (8) requires the aid of an assistant.

(8) Remove two self-locking nuts (17), washers (18), rubber

grommets (19), screws (20), washers (21), four rubber
grommets (22), and muffler (4) from muffler support
brackets (11). Discard self-locking nuts and rubber
grommets.

5-4
 TM 9-2320-366-20-3

(9) Remove four self-locking nuts (23), screws (24), and

exhaust heat shield (25) from two muffler support
brackets (11). Discard self-locking nuts.

(10) Remove two self-locking nuts (26), screws (27), and

muffler straps (28) from muffler (4). Discard self-locking
nuts.

b. Installation.

NOTE

Perform steps (1) through (5) on vehicle

serial numbers 0001 through 3091, except
M1088 and M1089, that have not previously
had a muffler replaced.

(1) Scribe a line on muffler support bracket (1) 9.7 in. (24.6
cm) out from right frame rail (2).

(2) Scribe a line on muffler support bracket (1) 1.25 in. (3.2
cm) from front edge of front muffler support bracket.

(3) Drill a pilot hole at intersection of lines scribed in steps

(1) and (2).

(4) Enlarge pilot hole to 16.5 mm.

(5) Perform steps (1) through (4) on rear muffler support

bracket.

5-5
TM 9-2320-366-20-3

5-2. MUFFLER AND EXHAUST HEAT SHIELDS REPLACEMENT (CONT)

(6) Position two muffler straps (3) on muffler (4) with two
screws (5) and self-locking nuts (6).

(7) Position exhaust heat shield (7) on two muffler support

brackets (2) with four screws (8) and self-locking nuts
(9).

(8) Tighten four self-locking nuts (9) to 25-29 lb-ft (34-39

N·m).

NOTE

Step (9) requires the aid of an assistant.

(9) Install muffler (4) on two muffler support brackets (2) with
two rubber grommets (10), four rubber grommets (11),
two washers (12), screws (13), washers (14), and self-
locking nuts (15).

5-6
 TM 9-2320-366-20-3

(10) Position tailpipe (16) on muffler (4) with clamp (17).

(11) Position exhaust pipe (18) on muffler (4) with clamp (19)
and self-locking nut (20).

(12) Tighten self-locking nut (20) to 89-109 lb-in. (10-12 N·m).

(13) Tighten two self-locking nuts (6) to 42-52 lb-ft (51-71

N·m).

(14) Position self-locking nut (21) on clamp (17).

(15) Tighten self-locking nut (21) to 89-109 lb-in. (10-12 N·m).

c. Follow-On Maintenance.

(1) Start engine (TM 9-2320-366-10-1).

(2) Check around muffler for exhaust leaks, excessive noise,

and vibration.

(3) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 1 5-7
TM 9-2320-366-20-3

5-3. EXHAUST PIPE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Nut, Self-Locking (4) (Item 156, Appendix G)
Cab raised (TM 9-2320-366-10-1). Nut, Self-Locking (3) (Item 129, Appendix G)

Tools and Special Tools

Goggles, Industrial (Item 15, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C)

WARNING

Ensure exhaust system is cool before

performing maintenance. Failure to
comply may result in injury to personnel.

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

Do not operate vehicle with exhaust pipe

removed. Toxic exhaust fumes may enter
cab, resulting in serious injury or death to
personnel.

a. Removal.

(1) Remove self-locking nut (1) from clamp (2). Discard self-
locking nut.

(2) Disconnect exhaust pipe (3) from muffler (4).

(3) Remove clamp (2) from exhaust pipe (3).

5-8 Change 1
 TM 9-2320-366-20-3

(4) Remove two self-locking nuts (5), screws (6), and loop
clamp half (7) from exhaust bracket (8). Discard self-
locking nut.

(5) Remove two bolts (9) and exhaust bracket (8) from
transmission (10).

(6) Remove self-locking nut (11) from clamp (12). Discard

self-locking nut.

(7) Remove exhaust pipe (3) from exhaust pipe (13).

(8) Remove clamp (12) from exhaust pipe (3).

(9) Remove two self-locking nuts (14), two screws (15), and
loop clamp half (16) from exhaust pipe bracket (17).
Discard self-locking nuts.

5-9
TM 9-2320-366-20-3

5-3. EXHAUST PIPE REPLACEMENT (CONT)

(10) Remove self-locking nut (18) from clamp (19). Discard

self-locking nut.

(11) Remove exhaust pipe (13) from rear of turbocharger

(20).

(12) Remove clamp (19) from exhaust pipe (13).

b. Installation.

(1) Install exhaust pipe (1) and clamp (2) to rear of

turbocharger (3).

(2) Position self-locking nut (4) on clamp (2).

(3) Tighten self-locking nut (4) to 89-109 lb-in. (10-12 N·m).

(4) Position loop clamp half (5) on exhaust pipe bracket (6)
with two screws (7) and self-locking nuts (8).

(5) Tighten two self-locking nuts (8) to 42-52 lb-ft (57-71

N·m).

5-10 Change 1
 TM 9-2320-366-20-3

(6) Position exhaust pipe (9) and clamp (10) on exhaust

pipe (1).

(7) Position self-locking nut (11) on clamp (10).

(8) Tighten self-locking nut (11) to 89-109 lb-in. (10-12 N·m).

(9) Position exhaust bracket (12) on transmission (13) with

two bolts (14).

(10) Tighten two bolts (14) to 44-55 lb-ft (60-75 N·m).

(11) Position loop clamp half (15) on muffler exhaust pipe (9)
with two screws (16) and self-locking nuts (17).

(12) Tighten two self-locking nuts (17) to 42-52 lb-ft (57-71

N·m).

(13) Position exhaust pipe (9) and clamp (18) on muffler (19).

(14) Position self-locking nut (20) on clamp (18).

(15) Tighten self-locking nut (20) to 89-109 lb-in. (10-12 N·m).

Change 1 5-11
TM 9-2320-366-20-3

5-3. EXHAUST PIPE REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check for exhaust leaks, excessive noise, and vibration.

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

5-12
 TM 9-2320-366-20-3

5-4. TAILPIPE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Nut, Self-Locking (4) (Item 156, Appendix G)
Nut, Self-Locking (Item 129, Appendix G)
Tools and Special Tools
Goggles, Industrial (Item 15, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C)

WARNING

Ensure exhaust system is cool before

performing maintenance. Failure to
comply may result in injury to personnel.

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

a. Removal.

(1) Loosen hose clamp (1) on particle extraction hose (2).

(2) Remove particle extraction hose (2) from tailpipe (3).

5-13
TM 9-2320-366-20-3

5-4. TAILPIPE REPLACEMENT (CONT)

(3) Remove self-locking nut (4) from clamp (5). Discard self-
locking nut.

(4) Disconnect tailpipe (3) from muffler (6).

(5) Remove clamp (5) from tailpipe (3).

(6) Remove two self-locking nuts (7), screws (8), and loop
clamp halves (9) from tailpipe (3). Discard self-locking
nuts.

(7) Remove two self-locking nuts (10), screws (11), and

tailpipe bracket (12) from frame (13). Discard self-locking
nuts.

b. Installation.

(1) Position tailpipe bracket (1) on frame (2) with two screws
(3) and self-locking nuts (4).

(2) Tighten two self-locking nuts (4) to 42-52 lb-ft (57-71

N·m).

(3) Position two loop clamp halves (5) and tailpipe (6) on
tailpipe bracket (1) with two screws (7) and self-locking
nuts (8).

5-14 Change 1
 TM 9-2320-366-20-3

(4) Position clamp (9) and tailpipe (6) on muffler (10).

(5) Position self-locking nut (11) on clamp (9).

(6) Tighten self-locking nut (11) to 89-109 lb-in. (10-12 N·m).

(7) Tighten two self-locking nuts (8) to 42-52 lb-ft (57-71

N·m).

(8) Install particle extraction hose (12) on tailpipe (6) with

hose clamp (13).

c. Follow-On Maintenance.

(1) Start engine (TM 9-2320-366-10-1).

(2) Check around muffler and tailpipe for exhaust leaks.

(3) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 1 5-15/(5-16 Blank)

 TM 9-2320-366-20-3

CHAPTER 6
COOLING SYSTEM MAINTENANCE
RESTRICTED MAINTENANCE NOTICE

Units not authorized SC 4910-95-CL-A72 (SHOP EQUIPMENT, COMMON NO. 2) in their T.O.E. may
be unable to perform some of the maintenance tasks described in this chapter. If the required tools
are not authorized, the equipment must be submitted to DS Maintenance for repair.

Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section II. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2. RADIATOR/CHARGE AIR COOLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3. RADIATOR OVERFLOW TANK AND BRACKET REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . 6-7
6-4. RADIATOR FAN SHROUDS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-5. THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-6. THERMOSTAT HOUSING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-7. COOLANT BYPASS TUBE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-8. PERSONNEL HEATER HOSES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-9. UPPER COOLANT TUBE AND HOSES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6-10. LOWER COOLANT HOSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
6-11. AIR COMPRESSOR INLET AND OUTLET COOLANT TUBES REPLACEMENT . . . . . . . . . . . . . . . 6-59
6-12. WATER PUMP AND FITTINGS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
6-13. DRIVE BELT AND TENSION PULLEY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
6-14. ENGINE FAN AND FAN CLUTCH ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

Section I. INTRODUCTION

6-1. INTRODUCTION

This chapter contains maintenance instructions for replacing and repairing cooling system components authorized by
the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.

Change 1 6-1
TM 9-2320-366-20-3

Section II. MAINTENANCE PROCEDURES

6-2. RADIATOR/CHARGE AIR COOLER REPLACEMENT
This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Radiator fan shrouds removed (para 6-4). Antiseize Compound (Item 58, Appendix D)
Lockwasher (6) (Item 95, Appendix G)
Tools and Special Tools Nut, Self-Locking (4) (Item 156, Appendix G)
Goggles, Industrial (Item 15, Appendix C) Grommet, Nonmetallic (Item 53, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Screw, Self-Locking (6) (Item 263, Appendix G)
Sling, Cargo (Item 31, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Personnel Required
Adapter, Socket Wrench (Item 2, Appendix B) (2)

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

a. Removal.

(1) Disconnect air hose (1) from fitting (2).

(2) Remove fitting (2) from fan clutch assembly (3).

6-2 Change 1
 TM 9-2320-366-20-3

NOTE

Perform steps (3) through (6) on vehicles

serial number 8426 and lower that have not
had the fan clutch replaced.

(3) Remove six screws (4), lockwashers (5), and washers

(6) from engine fan (7). Discard lockwashers.

CAUTION

Mark front of engine fan before removing.

Failure to comply may result in damage to
equipment.

(4) Remove engine fan (7) from fan clutch assembly (3).

(5) Remove fan support plate (8) from engine fan (7).

(6) Remove grommet (9) from engine fan (7). Discard

grommet.

NOTE

Perform steps (6.1) and (6.2) on vehicles

serial number 8427 and higher and on
vehicles that have had the fan, clutch
replaced.

(6.1) Remove six nuts (9.1), lockwashers (9.2), and washers

(9.3) from engine fan (9.4). Discard lockwashers.

CAUTION

Mark front of engine fan before removal. Failure to

comply may result in damage to equipment.

(6.2) Remove engine from (9.4) from fan clutch assembly

(9.5).

Change 1 6-3
TM 9-2320-366-20-3

6-2. RADIATOR/CHARGE AIR COOLER REPLACEMENT (CONT)

(7) Remove four self-locking nuts (10) and screws (11) from
radiator mounting brackets (12). Discard self-locking
nuts.

NOTE

• Additional coolant may drain out of radiator

during removal.

• Steps (8) and (9) require the aid of an assistant.

(8) Slide radiator (13) to the rear approximately four inches,

enough to clear left and right cab hinge pins (14).

6-4
 TM 9-2320-366-20-3

WARNING

• Radiator and charge air cooler assembly

weigh approximately 160 lbs (73 Kgs).
Attach a suitable lifting device prior to
removal. Failure to comply may result in
injury to personnel or damage to equipment.

• Cargo sling must be placed under charge air

cooler inlet and outlet ports. Failure to
comply may result in injury to personnel or
damage to equipment.

(9) Remove radiator (13) and charge air cooler (15) from
vehicle.

(10) Remove six screws (16) and charge air cooler (15) from
two radiator mounting brackets (12).

(11) Remove ten screws (17) and two radiator mounting

brackets (12) from radiator (13).

b. Installation.

(1) Position two radiator mounting brackets (1) on radiator

(2) with ten screws (3).

(2) Tighten ten screws (3) to 20-26 lb-ft (27-35 N·m).

(3) Position charge air cooler (4) between two radiator

mounting brackets (1) with six screws (5).

(4) Tighten six screws (5) to 20-26 lb-ft (27-35 N·m).

Change 1 6-4.1
TM 9-2320-366-20-3

6-2. RADIATOR/CHARGE AIR COOLER REPLACEMENT (CONT)

WARNING

• Radiator and charge air cooler assembly

weigh approximately 160 lbs (73 Kgs).
Attach a suitable lifting device prior to
installation. Failure to comply may result in
injury to personnel or damage to equipment.

• Cargo sling must be placed under charge air

cooler inlet port and outlet port. Failure to
comply may result in injury to personnel or
damage to equipment.

CAUTION

Use caution when lowering radiator and charge

air cooler into vehicle. Failure to comply may
result in damage to equipment.

NOTE

Step (5) requires the aid of an assistant.

(5) Position radiator (2) and charge air cooler (4) in vehicle.

(6) Position four screws (6) and self-locking nuts (7) through
frame rails (8) and two radiator mounting brackets (1).

(7) Tighten four self-locking nuts (7) to 42-52 lb-ft (57-71

N·m).

6-4.2 Change 1
 TM 9-2320-366-20-3

CAUTION

Ensure engine fan is positioned with mark

facing forward. Failure to comply may result
in damage to equipment.

NOTE

Perform steps (7.1) through (7.3) on vehicles

serial number 8427 and higher and on
vehicles that have had the fan clutch
replaced.

(7.1) Position engine fan (8.1) on fan clutch assembly (8.2)

with six washers (8.3), lockwashers (8.4) and nuts (8.5).

(7.2) Tighten six nuts (8.5) to 15 lb-ft (20 N·m) in sequence

shown.

(7.3) Re-tighten six nuts (8.5) to 23-29 lb-ft (31-39 N·m) in

sequence shown.

NOTE

Perform steps (8) through (12) on vehicles

serial number 8426 and lower that have not
had fan clutch replaced.

(8) Install grommet (9) on engine fan (10).

(9) Install fan support plate (11) on engine fan (10).

(10) Position engine fan (10) and fan support plate (11) on
fan clutch assembly (12) with six washers (13),
lockwashers (14), and screws (15).

(11) Tighten six screws (15) to 15 lb-ft (20 N·m) in sequence

shown.

(12) Re-tighten six screws (15) to 22-32 lb-ft (30-44 N·m) in

sequence shown.

Change 1 6-5
TM 9-2320-366-20-3

6-2. RADIATOR/CHARGE AIR COOLER REPLACEMENT (CONT)

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(13) Apply antiseize compound to threads of fitting (16).

(14) Install fitting (16) in fan clutch assembly (12).

(15) Connect air hose (17) to fitting (16).

c. Follow-On Maintenance.

Install radiator fan shrouds (para 6-4).

End of Task.

6-6
 TM 9-2320-366-20-3

6-3. RADIATOR OVERFLOW TANK AND BRACKET REPLACEMENT/REPAIR

This task covers:

a. Radiator Overflow Tank Removal e. Radiator Overflow Tank Bracket Removal

b. Radiator Overflow Tank Disassembly f. Radiator Overflow Tank Bracket Installation
c. Radiator Overflow Tank Assembly g. Follow-On Maintenance
d. Radiator Overflow Tank Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Engine shut down (TM 9-2320-366-10-1). Wrench, Torque, 0-200 lb-in. (Item 59,
Cab raised (TM 9-2320-366-10-1). Appendix C)

Tools and Special Tools Materials/Parts

Pan, Drain (Item 24, Appendix C) Antiseize Compound (Item 58, Appendix D)
Goggles, Industrial (Item 15, Appendix C) Antifreeze, Ethylene Glycol, Permanent (Item
Tool Kit, Genl Mech (Item 46, Appendix C) 12, Appendix D)
Screwdriver Attachment, Socket Wrench (Item 48, Nut, Self-Locking (2) (Item 167, Appendix G)
Appendix B) Nut, Self-Locking (3) (Item 156, Appendix G)
Socket Set, Socket Wrench (Item 36, Appendix C) Nut, Self-Locking (Item 152, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

WARNING

Coolant may be very hot and under pressure from engine operation. Ensure engine is
cool before performing maintenance. Failure to comply may result in injury to personnel.

a. Radiator Overflow Tank Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

(2) Position drain pan under radiator draincock (3).

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

(3) Open radiator draincock (3) and drain approximately

three gallons (11 L) of coolant.

(4) Close radiator draincock (3).

(5) Loosen hose clamp (4) on lower coolant hose (5).

(6) Remove lower coolant hose (5) from radiator overflow

tank (2).

Change 1 6-7
TM 9-2320-366-20-3

6-3. RADIATOR OVERFLOW TANK AND BRACKET REPLACEMENT/REPAIR (CONT)

(7) Loosen two hose clamps (6) on upper coolant hoses (7

and 8).

(8) Remove upper coolant hoses (7 and 8) from radiator

overflow tank (2).

(9) Loosen screw (9) and remove clamp (10) from bracket
(11).

(10) Remove radiator overflow tank (2) from bracket (11).

b. Radiator Overflow Tank Disassembly.

NOTE

Perform step (1) on all models except

M1093/M1094.

(1) Remove 90-degree fitting (1) from radiator overflow tank

(2).

NOTE

Perform step (2) on M1093/M1094.

(2) Remove 45-degree fitting (3) from radiator overflow tank

(2).

6-8
 TM 9-2320-366-20-3

(3) Remove two adapters (4) from radiator overflow tank (2).

(4) Remove two sightglasses (5) from radiator overflow tank

(2).

c. Radiator Overflow Tank Assembly.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of two sightglasses

(1) and adapters (2).

(2) Install two sightglasses (1) in radiator overflow tank (3).

(3) Install two adapters (2) in radiator overflow tank (3).

6-9
TM 9-2320-366-20-3

6-3. RADIATOR OVERFLOW TANK AND BRACKET REPLACEMENT/REPAIR (CONT)

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

NOTE

Perform step (4) on M1093/M1094.

(4) Install 45-degree fitting (4) in radiator overflow tank (3).

NOTE

Perform step (5) on all models except

M1093/M1094.

(5) Install 90-degree fitting (5) in radiator overflow tank (3).

d. Radiator Overflow Tank Installation.

NOTE

If replacing radiator overflow tank 12421810

with radiator overflow tanks 12421810-001 or
12421810-002, replace clamp 12421379-004
with clamp 12421379-006.

(1) Position radiator overflow tank (1) on bracket (2) with

clamp (3) and screw (4).

(2) Tighten screw (4) to 108-132 lb-in. (12-15 N·m).

6-10 Change 1
 TM 9-2320-366-20-3

(3) Position two hose clamps (5) and upper coolant hoses
(6 and 7) on radiator overflow tank (1).

(4) Position hose clamp (8) and lower coolant hose (9) on
radiator overflow tank (1).

(5) Tighten two hose clamps (5) and hose clamp (8) to 36-
44 lb-in. (4-5 N·m).

e. Radiator Overflow Tank Bracket Removal.

NOTE

Perform step (1) on all models except

M1093/M1094.

(1) Remove self-locking nut (1), washer (2), screw (3), and
washer (4) from radiator overflow tank bracket (5).
Discard self-locking nut.

NOTE

Perform step (2) on M1093/M1094.

(2) Remove self-locking nut (6), washer (7), screw (8),

washer (9), and spacer (10) from radiator overflow tank
bracket (5). Discard self-locking nut.

Change 1 6-11
TM 9-2320-366-20-3

6-3. RADIATOR OVERFLOW TANK AND BRACKET REPLACEMENT/REPAIR (CONT)

(3) Remove self-locking nut (11), screw (12), and chain (13),
from radiator overflow tank bracket (5). Discard self-
locking nut.

(4) Remove three self-locking nuts (14), bolts (15), and

radiator overflow tank bracket (5) from front lifting
bracket (16). Discard self-locking nuts.

f. Radiator Overflow Tank Bracket Installation.

(1) Position radiator overflow tank bracket (1) on front lifting

bracket (2) with three bolts (3) and self-locking nuts (4).

(2) Tighten three bolts (3) to 44-56 lb-ft (60-76 N·m).

6-12 Change 1
 TM 9-2320-366-20-3

(3) Position chain (5), screw (6) and self-locking nut (7) in
radiator overflow tank bracket (1).

(4) Tighten screw (6) to 22-26 lb-ft (30-35 N·m).

NOTE

Perform steps (5) and (6) on M1093/ M1094.

(5) Position washer (8), screw (9), spacer (10), washer (11),
and self-locking nut (12) in radiator overflow tank bracket
(1).

(6) Tighten self-locking nut (12) to 22-26 lb-ft (30-35 N·m).

NOTE

Perform steps (7) and (8) on all models

except M1093/M1094.

(7) Position washer (13), screw (14), washer (15), and self-
locking nut (16) in radiator overflow tank bracket (1).

(8) Tighten self-locking nut (16) to 22-26 lb-ft (30-35 N·m).

Change 1 6-13
TM 9-2320-366-20-3

6-3. RADIATOR OVERFLOW TANK AND BRACKET REPLACEMENT/REPAIR (CONT)

g. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check for coolant leaks under vehicle.

(5) Check coolant level after normal operating temperature

is reached. Add coolant as needed (TM 9-2320-366-10-
2).

(6) Raise cab (TM 9-2320-366-10-1).

(7) Check for coolant leaks around radiator overflow tank.

(8) Lower cab (TM 9-2320-366-10-1).

(9) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-14
 TM 9-2320-366-20-3

6-4. RADIATOR FAN SHROUDS REPLACEMENT

This task covers:

a. Top Radiator Fan Shroud Removal d. Bottom Radiator Fan Shroud Installation
b. Top Radiator Fan Shroud Installation e. Follow-On Maintenance
c. Bottom Radiator Fan Shroud Removal

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Turbocharger to charge air cooler tube/hoses Tool Kit, Genl Mech (Item 44, Appendix C)
removed (para 4-4). Wrench, Torque, 0-175 lb-ft (Item 57, Appendix C)
Charge air cooler to air inlet elbow tubes/ Wrench, Torque, 0-200 lb-in. (Item 58, Appendix C)
hoses removed (para 4-5). Wrench, Torque, 0-75 lb-in. (Item 86, Appendix B)
Upper coolant tube and hoses removed (para
6-9). Materials/Parts
Nut, Self-Locking (6) (Item 116, Appendix G)
Tools and Special Tools Antifreeze, Ethylene Glycol, Permanent (Item 13,
Goggles, Industrial (Item 15, Appendix C) Appendix D)
Container (52 qt (50 L) capacity) Sealing Compound (Item 58, Appendix D)
Socket Set, Socket Wrench (Item 35, Appendix
C)

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

a. Top Radiator Fan Shroud Removal.

(1) Loosen hose clamp (1) on radiator vent hose (2).

(2) Disconnect radiator vent hose (2) from radiator (3).

(3) Disconnect fan clutch hoses (4 and 5) from 90-degree

fitting (6).

Change 1 6-15
TM 9-2320-366-20-3

6-4. RADIATOR FAN SHROUDS REPLACEMENT (CONT)

(4) Remove three self-locking nuts (7), six washers (8), and
three screws (9) from left side of top radiator fan shroud
(10). Discard self-locking nuts.

(5) Remove screw (11) and washer (12) from left side of top
radiator fan shroud (10).

(6) Remove three self-locking nuts (7), six washers (8),

three screws (9), clamp (13), and fan clutch hose (4)
from right side of top radiator fan shroud (10). Discard
self-locking nuts.

(7) Remove screw (14) and washer (15) from right side of
top radiator fan shroud (10).

(8) Remove top radiator fan shroud (10) from vehicle.

(9) Remove 90-degree fitting (6) from pipe coupling (11).

(10) Remove fitting (12) from pipe coupling (11).

(11) Remove nut (13), washer (14), and pipe coupling (11)
from top radiator fan shroud (10).

6-16 Change 1
 TM 9-2320-366-20-3

b. Top Radiator Fan Shroud Installation.

(1) Install coupling (1) in top radiator fan shroud (2) with
washer (3) and nut (4).

WARNING

Adhesives, solvents, and sealing

compounds can burn easily, can give off
harmful vapors, and are harmful to skin
and clothing. To avoid injury or death,
keep away from open fire and use in a
well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or
clothing, wash immediately with soap and
water. Failure to comply may result in
injury to personnel.

(2) Apply sealing compound to threads of 90-degree fitting

(5) and fitting (6).

(3) Install fitting (6) in pipe coupling (1).

(4) Install 90-degree fitting (5) in pipe coupling (1).

(5) Position top radiator fan shroud (2) on vehicle.

WARNING

Adhesive sealant MIL-S-46163 can damage

your eyes. Wear safety goggles/glasses
when using; avoid contact with eyes. If
sealant contacts eyes, flush eyes with
water and get immediate medical
attention. Failure to comply may result in
injury to personnel.

(6) Apply sealing compound to threads of screw (7).

(7) Position washer (8) and screw (7) on right side of

radiator fan shroud (2).

(8) Tighten screw (7) to 84-108 lb-in. (10-12 N·m).

(9) Position fan clutch hose (9), clamp (10), six washers
(11), three screws (12) and self-locking nuts (13) on right
side of top radiator fan shroud (2).

(10) Tighten three self-locking nuts (13) to 84-108 lb-in. (10-

12 N·m).

Change 1 6-17
TM 9-2320-366-20-3

6-4. RADIATOR FAN SHROUDS REPLACEMENT (CONT)

(11) Apply sealing compound to threads of screw (14).

(12) Install washer (15) and screw (14) on left side of top
radiator fan shroud (2).

(13) Tighten screw (14) to 84-108 lb-in. (10-12 N·m).

(14) Position six washers (11), three screws (12), and self-
locking nuts (13) on left side of top radiator fan shroud
(2).

(15) Tighten three self-locking nuts (13) to 84-108 lb-in. (10-

12 N·m).

(16) Connect fan clutch hoses (9 and 16) to 90-degree fitting

(5).

(17) Install radiator vent hose (17) on radiator (18) with hose
clamp (19).

c. Bottom Radiator Fan Shroud Removal.

(1) Position container under radiator (1).

(2) Remove radiator cap (2) from radiator overflow tank (3).

(3) Open radiator draincock (4) and drain coolant from

radiator (1).

(4) Close radiator draincock (4).

6-18 Change 1
 TM 9-2320-366-20-3

(5) Loosen clamps (5 and 6) on lower coolant hose (7).

(6) Remove lower coolant hose (7) from radiator (1) and
transmission oil cooler (8).

(7) Remove radiator draincock (4) from radiator (1).

(8) Remove three self-locking nuts (9), six washers (10), and
three screws (11) from left side of bottom radiator fan
shroud (12). Discard self-locking nuts.

6-19
TM 9-2320-366-20-3

6-4. RADIATOR FAN SHROUDS REPLACEMENT (CONT)

(9) Remove three self-locking nuts (13), six washers (14),

three screws (15), clamp (16), and fan clutch hose (4)
from right side of bottom radiator fan shroud (12).
Discard self-locking nuts.

(10) Remove two screws (17) and washers (18) from each
side of bottom radiator fan shroud (12).

(11) Remove bottom radiator fan shroud (12) and two engine
airflow baffles (19).

6-20 Change 1
 TM 9-2320-366-20-3

d. Bottom Radiator Fan Shroud Installation.

(1) Position bottom radiator fan shroud (1) in mounting

location.

(2) Position two engine airflow baffles (2) between bottom

radiator fan shroud (1) and radiator (3).

WARNING

Adhesives, solvents, and sealing

compounds can burn easily, can give off
harmful vapors, and are harmful to skin
and clothing. To avoid injury or death,
keep away from open fire and use in a
well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or
clothing, wash immediately with soap and
water. Failure to comply may result in
injury to personnel.

(3) Apply sealing compound to threads of four screws (5).

(4) Position two washers (4) and screws (5) in each side of
bottom radiator fan shroud (1).

Change 1 6-21
TM 9-2320-366-20-3

6-4. RADIATOR FAN SHROUDS REPLACEMENT (CONT)

(5) Position six washers (6), three screws (7), and self-
locking nuts (8) on left side of bottom radiator fan shroud
(1).

(6) Tighten three self-locking nuts (8) to 84-108 lb-in. (10-12

N·m).

(7) Position six washers (9), three screws (10), self-locking

nuts (11), fan clutch hose (12), and clamp (13) on right
side of bottom radiator fan shroud (1).

(8) Tighten three self-locking nuts (11) to 84-108 lb-in. (10-

12 N·m).

(9) Tighten two screws (5) on each side of bottom radiator

fan shroud (1) to 84-108 lb-in (10-12 N·m).

6-22 Change 1
TM 9-2320-366-20-3

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(10) Apply antiseize compound to threads of radiator

draincock (14).

(11) Install radiator draincock (14) in radiator (3).

(12) Loosen two screws (15) in clamps (16) as far as possible

without disengaging screws from D-nuts (17).

(13) Unhook clamp tabs (18) from tab windows (19).

CAUTION

• Clamp tongue must be started in clamp groove.

Failure to comply may result in damage to
equipment.

• Position clamps so that screws will be toward

center of vehicle and angled down.

(14) Position two clamps (16) on lower coolant hose (20).

Change 1 6-23
TM 9-2320-366-20-3

6-4. RADIATOR FAN SHROUDS REPLACEMENT (CONT)

(15) Install lower coolant hose (20) between radiator (3) and
transmission oil cooler (21).

(16) Engage as many clamp tabs (18) as possible in tab

windows (19) allowing little or no play between clamps
(16) and lower coolant hose (20).

(17) Tighten two clamps (16) to 12-18 lb-in. (1-2 N·m).

NOTE

Minimum allowable gap on clamp is 0.2 in. (5

mm). If gap is less than 0.2 in. (5 mm),
remove and re-install clamp.

(18) Measure gap on two clamps (16).

e. Follow-On Maintenance.

(1) Install upper coolant tube and hoses (para 6-9).

(2) Install charge air cooler to air inlet elbow tubes/hoses

(para 4-5).

(3) Install turbocharger to charge air cooler tube/hoses (para

4-4).

(4) Add coolant to radiator overflow tank (TM 9-2320-365-

10).

(5) Check for coolant leaks under vehicle.

(6) Start engine (TM 9-2320-365-10).

(7) Check for coolant leaks under vehicle.

6-24 Change 1
 TM 9-2320-366-20-3

(8) Check coolant level after normal operating temperature

is reached. Add coolant as required.

(9) Install radiator cap on radiator overflow tank.

(10) Check for coolant leaks under vehicle.

(11) Raise cab (TM 9-2320-365-10).

(12) Check for coolant leaks in engine compartment.

(13) Check to make sure engine fan does not contact fan
shroud.

(14) Lower cab (TM 9-2320-365-10).

(15) Shut down engine (TM 9-2320-365-10).

End of Task.

Change 1 6-24.1/(6-24.2 Blank)

 TM 9-2320-366-20-3

6-5. THERMOSTAT REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Engine shut down (TM 9-2320-366-10-1). Goggles, Industrial (Item 15, Appendix C)
Cab raised (TM 9-2320-366-10-1). Gloves, Rubber (Item 13, Appendix C)

Tools and Special Tools Materials/Parts

Tool Kit, Genl Mech (Item 46, Appendix C) Adhesive (Item 5, Appendix D)
Pan, Drain (Item 24, Appendix C) Gasket and Preformed Packing Set (Item 43.1,
Appendix G)

a. Removal.

(1) Position drain pan under thermostat housing (1).

(2) Remove two screws (2) and washers (3) from outlet
housing (4).

(3) Remove outlet housing (4) from thermostat housing (1).

(4) Remove thermostat (5) from thermostat housing (1).

(5) Remove thermostat gasket (6) from thermostat housing

(1). Discard thermostat gasket.

(6) Remove thermostat gasket debris from outlet housing (4)

and thermostat housing (1).

Change 1 6-25
TM 9-2320-366-20-3

6-5. THERMOSTAT REPLACEMENT (CONT)

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply adhesive to thermostat housing surface (1).

(2) Position thermostat gasket (2) on thermostat housing (1).

(3) Install thermostat (3) with long end up.

(4) Apply adhesive to outlet housing (4) mating surface.

(5) Install outlet housing (4) on thermostat housing (1) with

two washers (5) and screws (6).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(3) Check for coolant leaks under vehicle.

(4) Start engine (TM 9-2320-366-10-1).

(5) Check coolant level after normal operating temperature

is reached. Add coolant as required (TM 9-2320-366-10-
2).

(6) Raise cab (TM 9-2320-366-10-1).

6-26
 TM 9-2320-366-20-3

(7) Check thermostat housing for coolant leaks.

(8) Install radiator cap on radiator overflow tank.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-27
TM 9-2320-366-20-3

6-6. THERMOSTAT HOUSING REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Thermostat removed (para 6-5). Antiseize Compound (Item 58, Appendix D)
Antifreeze, Ethylene Glycol, Permanent (Item 12,
Tools and Special Tools Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Adhesive (Item 5, Appendix D)
Pan, Drain (Item 24, Appendix C) Packing, Preformed (Item 201, Appendix G)
Goggles, Industrial (Item 15, Appendix C)
Gloves, Rubber (Item 13, Appendix C)

a. Removal.

(1) Position drain pan under thermostat housing (1).

(2) Disconnect heater tube (2) from fitting (3).

(3) Loosen hose clamp (4) on radiator fill hose (5).

(4) Disconnect radiator fill hose (5) from fitting (6).

(5) Disconnect connector clamp (7) from water temperature

transducer connector (8).

(6) Disconnect water temperature transducer connector (8)

from connector P41 (9).

(7) Remove water temperature transducer (10) from tee

fitting (11).

(8) Disconnect connector clamp (12) from water temperature

light switch connector (13).

(9) Disconnect water temperature light switch connector (13)

from connector P37 (14).

(10) Remove water temperature light switch (15) from

thermostat housing (1).

6-28 Change 1
 TM 9-2320-366-20-3

(11) Loosen hose clamp (16) on transmission oil cooler hose

(17).

(12) Disconnect transmission oil cooler hose (17) from

thermostat housing (1).

(13) Disconnect compressor inlet coolant tube (18) from 90-

degree fitting (19).

(14) Remove two screws (20) from thermostat housing (1).

(15) Remove thermostat housing (1) and gasket (21) from

engine block (22). Discard gasket.

(16) Remove 90-degree fitting (19) from thermostat housing

(1).

(17) Remove preformed packing (23) from 90-degree fitting

(19). Discard preformed packing.

(18) Remove gasket debris from thermostat housing (1).

(19) Remove tee fitting (11) from thermostat housing (1).

(20) Remove fitting (6) from tee fitting (11).

(21) Remove fitting (24) from thermostat housing (1).

6-29
TM 9-2320-366-20-3

6-6. THERMOSTAT HOUSING REPLACEMENT (CONT)

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash with soap
and water. Failure to comply may result
in injury to personnel.

(1) Apply adhesive to threads of tee fitting (1) and fittings (2

and 3).

(2) Install fitting (2) in tee fitting (1).

(3) Install tee fitting (1) in thermostat housing (4).

(4) Install fitting (3) in thermostat housing (4).

(5) Install preformed packing (5) on 90-degree fitting (6).

(6) Install 90-degree fitting (6) in thermostat housing (4).

(7) Apply adhesive to surfaces of thermostat housing (4) and

engine block (7).

(8) Position gasket (8) on engine block (7).

(9) Install thermostat housing (4) on engine block (7) with

two screws (9).

6-30
 TM 9-2320-366-20-3

(10) Connect compressor inlet coolant tube (10) to 90-degree

fitting (6).

(11) Install transmission oil cooler hose (11) on thermostat

housing (4) with hose clamp (12).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash with soap
and water. Failure to comply may result
in injury to personnel.

(12) Apply antiseize compound to threads of water

temperature light switch (13).

(13) Install water temperature light switch (13) in thermostat

housing (4).

(14) Connect water temperature light switch connector (14) to

connector P37 (15).

(15) Connect connector clamp (16) on water temperature light

switch connector (14).

6-31
TM 9-2320-366-20-3

6-6. THERMOSTAT HOUSING REPLACEMENT (CONT)

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash with soap
and water. Failure to comply may result
in injury to personnel.

(16) Apply antiseize compound to threads of water temp-

erature transducer (17).

(17) Install water temperature transducer (17) in tee fitting (1).

(18) Connect water temperature transducer connector (18) to

connector P41 (19).

(19) Connect connector clamp (20) on water temperature

transducer connector (18).

(20) Install radiator fill hose (21) on fitting (2) with hose clamp
(22).

(21) Connect heater tube (23) to fitting (2).

c. Follow-On Maintenance.

(1) Install thermostat (para 6-5).

(2) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(3) Lower cab (TM 9-2320-366-10-1).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check for coolant leaks under vehicle.

(6) Check coolant level after normal operating temperature

is reached. Add coolant as required (TM 9-2320-366-10-
2).

(7) Check for coolant leaks under vehicle.

6-32
 TM 9-2320-366-20-3

(8) Raise cab (TM 9-2320-366-10-1).

(9) Check for coolant leaks at thermostat housing.

(10) Lower cab (TM 9-2320-366-10-1).

(11) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-33
TM 9-2320-366-20-3

6-7. COOLANT BYPASS TUBE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Antiseize Compound (Item 58, Appendix D)
Cab raised (TM 9-2320-366-10-1). Antifreeze, Ethylene Glycol, Permanent (Item 12,
Batteries disconnected (para 7-57). Appendix D)
Nut, Self-Locking (Item 128, Appendix G)
Tools and Special Tools
Goggles, Industrial (Item 15, Appendix C)
Container (52 qt (50 L) capacity)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

WARNING

• Coolant may be very hot and under pressure

from engine operation. Ensure engine is
cool before performing maintenance. Failure
to comply may result in injury to personnel.

• Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

(2) Position container under radiator (3).

(3) Open radiator draincock (4) and drain coolant.

(4) Close radiator draincock (4).

6-34 Change 1
 TM 9-2320-366-20-3

(5) Remove self-locking nut (5), washer (6), screw (7), and
clamp (8) from bracket (9). Discard self-locking nut.

(6) Remove clamp (8) from coolant bypass tube (10).

(7) Disconnect connector clamp (11) from ether sensor

connector (12).

(8) Disconnect ether sensor connector (12) from connector

P42 (13).

(9) Loosen two clamps (14) on coolant hose (15).

(10) Remove coolant hose (15) and flow restrictor (16) from
transmission oil cooler (17).

(11) Remove coolant hose (15) and two clamps (14) from
coolant bypass tube (10).

6-35
TM 9-2320-366-20-3

6-7. COOLANT BYPASS TUBE REPLACEMENT (CONT)

(12) Loosen two clamps (18) on coolant hose (19).

(13) Remove coolant bypass tube (10) from coolant hose

(19).

(14) Remove coolant hose (19) from thermostat housing (20).

(15) Remove ether sensor (21) from coolant bypass tube

(10).

6-36
 TM 9-2320-366-20-3

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of ether sensor (1).

(2) Install ether sensor (1) in coolant bypass tube (2).

NOTE

Both coolant hoses are assembled the same

way. Only one shown.

(3) Loosen two screws (3) in clamps (4) and clamps (5) as
far as possible without disengaging screws from D-nuts
(6).

(4) Unhook clamp tabs (7) from tab windows (8).

6-37
TM 9-2320-366-20-3

6-7. COOLANT BYPASS TUBE REPLACEMENT (CONT)

CAUTION

Clamp tongue must be started in clamp

groove. Failure to comply may result in
damage to equipment.

(5) Position two clamps (4) on coolant hose (9).

(6) Position two clamps (5) on coolant hose (10).

(7) Position coolant hose (9) on thermostat housing (11).

(8) Position coolant bypass tube (2) in coolant hose (9).

(9) Engage as many clamp tabs (7) as possible in tab

windows (8) allowing little or no play between two
clamps (4) and coolant hose (9).

6-38
 TM 9-2320-366-20-3

(10) Position coolant hose (10) on coolant bypass tube (2).

(11) Position flow restrictor (12) and coolant hose (10) on

transmission oil cooler (13).

(12) Engage as many clamp tabs (7) as possible in tab

windows (8) allowing little or no play between two
clamps (5) and coolant hose (10).

(13) Tighten two clamps (5) to 12-18 lb-in. (1-2 N·m).

(14) Tighten two clamps (4) to 12-18 lb-in. (1-2 N·m).

NOTE

Minimum allowable gap on clamp is 0.2 in. (5

mm). If gap is less than 0.2 in. (5 mm),
remove and re-install clamp.

(15) Measure gap on two clamps (5).

Change 1 6-39
TM 9-2320-366-20-3

6-7. COOLANT BYPASS TUBE REPLACEMENT (CONT)

(16) Measure gap on two clamps (4).

(17) Install clamp (14) on coolant bypass tube (2).

(18) Install clamp (14) on bracket (15) with screw (16),

washer (17), and self-locking nut (18).

(19) Connect connector P42 (19) to ether sensor connector

(20).

(20) Connect connector clamp (21) on ether sensor connector

(20).

6-40
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(3) Lower cab (TM 9-2320-366-10-1).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check for coolant leaks under vehicle.

(6) Check coolant level after normal operating temperature

is reached. Add coolant as required (TM 9-2320-366-10-
2).

(7) Install radiator cap on radiator overflow tank.

(8) Check for coolant leaks under vehicle.

(9) Raise cab (TM 9-2320-366-10-1).

(10) Check around transmission oil cooler, thermostat, and

coolant bypass tube for coolant leaks.

(11) Lower cab (TM 9-2320-366-10-1).

(12) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-41
TM 9-2320-366-20-3

6-8. PERSONNEL HEATER HOSES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools (Cont)

Engine shut down (TM 9-2320-366-10-1). Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Tools and Special Tools Socket Set, Socket Wrench (Item 36, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Container (10 gal (38 L) capacity) Materials/Parts
Tool Kit, Genl Mech (Item 46, Appendix C) Ties, Cable, Plastic (Item 69, Appendix D)

WARNING

Coolant may be very hot and under

pressure from engine operation. Ensure
engine is cool before performing
maintenance. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

(2) Position container under radiator draincock (3).

(3) Open radiator draincock (3) and drain approximately five

gallons (19 L) of coolant.

(4) Close radiator draincock (3).

6-42
 TM 9-2320-366-20-3

NOTE

Remove plastic cable ties as required.

(5) Remove two screws (4) and washers (5) from front grille
(6).

(6) Remove screw (7) and washer (8) from front grille (6).

(7) Remove front grille (6) from cab (9).

(8) Loosen clamp (10) on heater inlet hose (11).

(9) Remove heater inlet hose (11) from supply fitting (12).

(10) Loosen clamp (13) on heater outlet hose (14).

(11) Remove heater outlet hose (14) from return fitting (15).

(12) Raise cab (TM 9-2320-366-10-1).

(13) Loosen clamp (16) on heater inlet hose (11).

(14) Remove heater inlet hose (11) from supply tube (17).

6-43
TM 9-2320-366-20-3

6-8. PERSONNEL HEATER HOSES REPLACEMENT (CONT)

(15) Loosen clamp (18) on heater outlet hose (14).

(16) Remove heater outlet hose (14) from return fitting (19).

b. Installation.

(1) Loosen four screws (1) in clamps (2) as far as possible

without disengaging screws from D-nuts (3).

(2) Unhook clamp tabs (4) from tab windows (5).

CAUTION

Clamp tongue must be started in clamp

groove. Failure to comply may result in
damage to equipment.

(3) Position two clamps (2) on heater outlet hose (6).

(4) Position two clamps (2) on heater inlet hose (7).

6-44
 TM 9-2320-366-20-3

(5) Position heater outlet hose (6) on return fitting (8).

(6) Engage as many clamp tabs (4) as possible in tab

windows (5) allowing little or no play between clamp (2)
and heater outlet hose (6).

(7) Tighten clamp (2) to 12-18 lb-in. (1-2 N·m).

(8) Position heater inlet hose (7) on supply tube (9).

(9) Engage as many clamp tabs (4) as possible in tab

windows (5) allowing little or no play between clamp (2)
and heater inlet hose (7).

(10) Tighten clamp (2) to 12-18 lb-in. (1-2 N·m).

6-45
TM 9-2320-366-20-3

6-8. PERSONNEL HEATER HOSES REPLACEMENT (CONT)

(11) Lower cab (TM 9-2320-366-10-1).

NOTE

Heater outlet hose is marked with an

arrow pointing down.

(12) Position heater outlet hose (6) on return fitting (10).

NOTE

Heater inlet hose is marked with an arrow

pointing up.

(13) Position heater inlet hose (7) on supply fitting (11).

(14) Engage as many clamp tabs (4) as possible in tab

windows (5) allowing little or no play between
clamps (2) and heater outlet hose (6) and heater
inlet hose (7).

(15) Tighten two clamps (2) to 8-9 lb-in. (1 N•m).

(16) Raise cab (TM 9-2320-366-10-1).

NOTE

Minimum allowable gap on clamp is 0.1 in.

(0.3 cm). If gap is less than 0.1 in. (0.3
cm), remove and re-install clamp

(17) Measure gap on two clamps (2).

6-46 Change 2
 TM 9-2320-366-20-3

(18) Measure gap on clamp (2).

(19) Measure gap on clamp (2).

(20) Lower cab (TM 9-2320-366-10-1).

(21) Position front grille (12) on cab (13) with washer (14)
and screw (15).

(22) Position two washers (16) and screws (17) in front grille
(12).

(23) Tighten screw (15) to 48-60 lb-in. (5-7 N·m).

(24) Tighten two screws (17) to 24 lb-in. (3 N·m).

6-47
TM 9-2320-366-20-3

6-8. PERSONNEL HEATER HOSES REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Start engine (TM 9-2320-366-10-1).

(3) Operate personnel heater (TM 9-2320-366-10-1).

(4) Raise cab (TM 9-2320-366-10-1).

(5) Check for coolant leaks around hoses and fittings.

(6) Lower cab (TM 9-2320-366-10-1).

(7) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-48
 TM 9-2320-366-20-3

6-9. UPPER COOLANT TUBE AND HOSES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Antiseize Compound (Item 58, Appendix D)
Cab raised (TM 9-2320-366-10-1). Antifreeze, Ethylene Glycol, Permanent (Item 12,
Batteries disconnected (para 7-57). Appendix D)

Tools and Special Tools

Pan, Drain (Item 24, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

WARNING

Coolant may be very hot and under

pressure from engine operation. Ensure
engine is cool before performing
maintenance. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

(2) Position drain pan under radiator (3).

(3) Open radiator draincock (4) and drain approximately one

gallon of coolant.

(4) Close radiator draincock (4).

Change 1 6-49
TM 9-2320-366-20-3

6-9. UPPER COOLANT TUBE AND HOSES REPLACEMENT (CONT)

(5) Disconnect connector clamp (5) from water temp-erature

switch electrical connector (6).

(6) Disconnect water temperature switch electrical conn-

ector (6) from connector P36 (7).

(7) Remove water temperature switch (8) from upper coolant

tube (9).

(8) Loosen four hose clamps (10) on coolant hoses (11 and
12).

(9) Slide coolant hose (11) completely onto upper coolant

tube (9).

(10) Remove upper coolant tube (9) from vehicle.

(11) Remove coolant hose (12) from radiator (3).

6-50
 TM 9-2320-366-20-3

(12) Remove coolant hose (11) from upper coolant tube (9).

(13) Remove four clamps (10) from coolant hoses (11 and
12).

b. Installation.

NOTE

Both coolant hoses are assembled the same

way. One coolant hose shown.

(1) Loosen two screws (1) in clamps (2) as far as possible

without disengaging screws from D-nuts (3).

(2) Unhook clamp tabs (4) from tab windows (5).

6-51
TM 9-2320-366-20-3

6-9. UPPER COOLANT TUBE AND HOSES REPLACEMENT (CONT)

CAUTION

Clamp tongue must be started in clamp

groove. Failure to comply may result in
damage to equipment.

(3) Position two clamps (2) on coolant hose (6).

(4) Perform steps (1) through (3) on coolant hose (7).

(5) Position coolant hose (6) on upper coolant tube (8).

(6) Position coolant hose (7) on radiator (9).

6-52
 TM 9-2320-366-20-3

(7) Position upper coolant tube (8) between coolant hose (7)
and thermostat housing (10).

(8) Slide coolant hose (6) onto thermostat housing (10).

(9) Engage as many clamp tabs (4) as possible in tab

windows (5) allowing little or no play between four
clamps and two coolant hoses (6 and 7).

(10) Tighten four clamps (2) to 12-18 lb-in. (1-2 N·m).

NOTE

Minimum allowable gap on clamp is 0.2 in. (5

mm). If gap is less than 0.2 in. (5 mm),
remove and re-install clamp.

(11) Measure gap on four clamps (2).

Change 1 6-53
TM 9-2320-366-20-3

6-9. UPPER COOLANT TUBE AND HOSES REPLACEMENT (CONT)

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(12) Apply antiseize compound to threads of water

temperature switch (11).

(13) Install water temperature switch (11) in upper coolant

tube (8).

(14) Connect water temperature switch electrical connector

(12) to connector P36 (13).

(15) Connect connector clamp (14) on water temperature

switch electrical connector (12).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check for coolant leaks under vehicle.

(5) Remove radiator cap from radiator overflow tank.

(6) Check coolant level after normal operating temperature

is reached. Add coolant as required (TM 9-2320-366-10-
2).

(7) Install radiator cap on radiator overflow tank.

(8) Raise cab (TM 9-2320-366-10-1).

(9) Check for coolant leaks around hoses and fittings.

(10) Lower cab (TM 9-2320-366-10-1).

(11) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-54
 TM 9-2320-366-20-3

6-10. LOWER COOLANT HOSE REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Antifreeze, Ethylene Glycol, Permanent
(Item 12, Appendix D)
Tools and Special Tools
Goggles, Industrial (Item 15, Appendix C)
Container (52 qt (50 L) capacity)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

WARNING

Coolant may be very hot and under

pressure from engine operation. Ensure
engine is cool before performing
maintenance. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

(2) Position container under radiator draincock (3).

(3) Open radiator draincock (3) and drain coolant.

(4) Close radiator draincock (3).

6-55
TM 9-2320-366-20-3

6-10. LOWER COOLANT HOSE REPLACEMENT (CONT)

(5) Loosen two clamps (4) on lower coolant hose (5).

(6) Remove lower coolant hose (5) from radiator (6) and
transmission oil cooler (7).

b. Installation.

(1) Loosen two screws (1) in clamps (2) as far as possible

without disengaging screws from D-nuts (3).

(2) Unhook clamp tabs (4) from tab windows (5).

6-56
 TM 9-2320-366-20-3

CAUTION

• Clamp tongue must be started in clamp groove.

Failure to comply may result in damage to
equipment.

• Position clamps so that screws will be toward

center of vehicle and angled down.

(3) Position two clamps (2) on lower coolant hose (6).

(4) Install lower coolant hose (6) between radiator (7) and
transmission oil cooler (8).

(5) Engage as many clamp tabs (4) as possible in tab

windows (5) allowing little or no play between clamp and
lower coolant hose (6).

(6) Tighten two clamps (2) to 12-18 lb-in. (1-2 N·m).

NOTE

Minimum allowable gap on clamp is 0.2 in.

(0.5 cm). If gap is less than 0.2 in. (0.5 cm),
remove and re-install clamp.

(7) Measure gap on two clamps (2).

6-57
TM 9-2320-366-20-3

6-10. LOWER COOLANT HOSE REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Install radiator cap on radiator overflow tank.

(3) Start engine (TM 9-2320-366-10-1).

(4) Check for coolant leaks around lower coolant hose.

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-58
 TM 9-2320-366-20-3

6-11. AIR COMPRESSOR INLET AND OUTLET COOLANT TUBES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Engine shut down (TM 9-2320-366-10-1). Antifreeze, Ethylene Glycol, Permanent (Item 12,
Cab raised (TM 9-2320-366-10-1). Appendix D)

Tools and Special Tools

Pan, Drain (Item 24, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Position drain pan under air compressor (1).

(2) Disconnect air compressor inlet coolant tube (2) from air
compressor (1).

(3) Disconnect air compressor inlet coolant tube (2) from

water pump (3).

(4) Remove air compressor inlet coolant tube (2) from

vehicle.

6-59
TM 9-2320-366-20-3

6-11. AIR COMPRESSOR INLET AND OUTLET COOLANT TUBES REPLACEMENT

(CONT)

(5) Disconnect air compressor outlet coolant tube (4) from

air compressor (1).

(6) Disconnect air compressor outlet coolant tube (4) from

thermostat housing (5).

(7) Remove air compressor outlet coolant tube (4) from

vehicle.

b. Installation.

(1) Connect air compressor outlet coolant tube (1) to

thermostat housing (2).

6-60
 TM 9-2320-366-20-3

(2) Connect air compressor outlet coolant tube (1) to air

compressor (3).

(3) Connect air compressor inlet coolant tube (4) to water

pump (5).

(4) Connect air compressor inlet coolant tube (4) to air

compressor (3).

6-61
TM 9-2320-366-20-3

6-11. AIR COMPRESSOR INLET AND OUTLET COOLANT TUBES REPLACEMENT

(CONT)

c. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check for coolant leaks under vehicle.

(5) Check coolant level after normal operating temperature

is reached. Add coolant as needed (TM 9-2320-366-10-
2).

(6) Install radiator cap on radiator overflow tank.

(7) Raise cab (TM 9-2320-366-10-1).

(8) Check for coolant leaks around coolant lines and fittings.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-62
 TM 9-2320-366-20-3

6-12. WATER PUMP AND FITTINGS REPLACEMENT

This task covers:

a. Water Pump Removal c. Fittings Removal

b. Water Pump Installation d. Fittings Installation
e. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Materials/Parts

100 amp alternator removed, if equipped (para 7-2). Antifreeze, Ethylene Glycol, Permanent (Item 12,
200 amp alternator removed, if equipped (para 20-45). Appendix D)
Alternator brackets removed (para 7-4). Packing, Preformed (Item 195, Appendix G)
Packing, Preformed (Item 214, Appendix G)
Tools and Special Tools Packing, Preformed (3) (Item 205, Appendix G)
Goggles, Industrial (Item 15, Appendix C) Packing, Preformed (2) (Item 202, Appendix G)
Container (52 qt (50 L) capacity)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)
Wrench, Adjustable, Automotive (Item 53, Appendix C)
Gage, Belt Tension (Item 19, Appendix B)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel

a. Water Pump Removal.

(1) Position container under radiator (1).

(2) Remove radiator cap (2) from radiator overflow tank

(3).

(3) Open radiator draincock (4) and drain coolant.

(4) Close radiator draincock (4).

Change 2 6-63
TM 9-2320-366-20-3

6-12. WATER PUMP AND FITTINGS REPLACEMENT (CONT)

(5) Disconnect heater supply tube (5) from fitting (6).

(6) Remove 45-degree fitting (6) and preformed packing (7)

from water pump (8). Discard preformed packing.

(7) Loosen two clamps (9).

(8) Remove coolant hose (10) from water pump (8).

(9) Disconnect coolant tubes (11 and 12) from water pump
(8).

NOTE

Note position and size of washers prior to

removal.

(10) Remove two screws (13), washers (14), and drive

belt/tension pulley (15) from engine (16).

(11) Remove water pump drive belt (17) from water pump (8).

6-64
 TM 9-2320-366-20-3

(12) Remove four screws (18) from water pump (8).

(13) Remove water pump (8) and preformed packings (19

and 20) from engine (16). Discard preformed packings.

b. Water Pump Installation.

(1) Install preformed packings (1 and 2) in water pump (3).

(2) Position water pump (3) on engine (4) with four screws
(5).

(3) Tighten four screws (5) to 33-47 lb-ft (45-64 N·m).

6-65
TM 9-2320-366-20-3

6-12. WATER PUMP AND FITTINGS REPLACEMENT (CONT)

(4) Position drive belt/tension pulley (6) on engine (4) with

two washers (7) and screws (8).

(5) Install water pump drive belt (9) on water pump (3) and
drive belt/tension pulley (6).

NOTE

Use square hole in drive belt/tension pulley to

apply and maintain tension on drive belt while
adjusting belt tension.

(6) Adjust water pump drive belt (9) with drive belt/tension
pulley (6) as follows:

a. New belt (less than 30 minutes running time) 115-

125 lb (512-556 N).

b. Used belt 80-100 lb (356-444 N).

(7) Tighten two screws (8) to 35 lb-ft (47 N·m).

(8) Connect coolant tubes (10 and 11) to water pump (3).

6-66
 TM 9-2320-366-20-3

(9) Loosen two screws (12) in clamps (13) as far as possible

without disengaging screws from D-nuts (14).

(10) Unhook clamp tabs (15) from tab windows (16).

CAUTION

• Clamp tongue must be started in clamp groove.

Failure to comply may result in damage to
equipment.

• Position clamps with screw heads facing forward

so they do not interfere with alternator mount.

(11) Position coolant hose (17) on water pump (3).

(12) Position two clamps (13) on coolant hose (17).

(13) Engage as many clamp tabs (15) as possible in tab

windows (16) allowing little or no play between clamp
and coolant hose (17).

(14) Tighten two clamps (13) to 13-17 lb-in. (2 N·m).

NOTE

Minimum allowable gap on clamp is 0.2 in. (5

mm). If gap is less than 0.2 in. (5 mm),
remove and re-install clamp.

(15) Measure gap on two clamps (13).

(16) Install preformed packing (18) and 45-degree fitting (19)

in water pump (3).

(17) Connect heater supply tube (20) to 45-degree fitting (3).

Change 1 6-67
TM 9-2320-366-20-3

6-12. WATER PUMP AND FITTINGS REPLACEMENT (CONT)

c. Fittings Removal.

(1) Remove plug (1) and preformed packing (2) from water
pump (3). Discard preformed packing.

(2) Remove connector (4) and preformed packing (5) from

water pump (3). Discard preformed packing.

(3) Remove fitting (6) and preformed packing (7) from pipe
bushing (8). Discard preformed packing.

(4) Remove pipe bushing (8) and preformed packing (9)

from water pump (3). Discard preformed packing.

d. Fittings Installation.

(1) Install preformed packing (1) on pipe bushing (2).

(2) Install pipe bushing (2) in water pump (3).

(3) Install preformed packing (4) on fitting (5).

(4) Install fitting (5) in pipe bushing (2).

(5) Install preformed packing (6) on connector (7).

(6) Install connector (7) in water pump (3).

(7) Install preformed packing (8) on plug (9).

(8) Install plug (9) in water pump (3).

6-68
 TM 9-2320-366-20-3

e. Follow-On Maintenance.

(1) Install alternator bracket assembly (para 7-4).

(2) Install alternator (para 7-2 or 20-45).

(3) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(4) Lower cab (TM 9-2320-366-10-1).

(5) Start engine (TM 9-2320-366-10-1).

(6) Check for coolant leaks under vehicle.

(7) Check coolant level after normal operating temperature

is reached. Add coolant as required (TM 9-2320-366-10-
2).

(8) Raise cab (TM 9-2320-366-10-1).

(9) Check for coolant leaks around water pump.

(10) Lower cab (TM 9-2320-366-10-1).

(11) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-69
TM 9-2320-366-20-3

6-13. DRIVE BELT AND TENSION PULLEY REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Top radiator fan shroud removed (para 6-4). Antiseize Compound (Item 58, Appendix D)
Lockwasher (6) (Item 95, Appendix G)
Tools and Special Tools Screw, Self-Locking (6) (Item 263, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Grommet, Nonmetallic (Item 53, Appendix G)
Gage, Belt Tension (Item 19, Appendix B)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

a. Removal.

CAUTION

Mark front of engine fan before removing.

Failure to comply may result in damage to
equipment.

(1) Remove air hose (1) from fitting (2) on fan clutch
assembly (3).

(2) Remove fitting (2) from fan clutch assembly (3).

NOTE

Perform steps (3) through (6) on vehicles

serial number 8426 and lower that have not
had the fan clutch replaced.

(3) Remove six screws (4), lockwashers (5), and

washers (6) from engine fan (7). Discard
lockwashers and screws.

(4) Remove engine fan (7) from fan clutch assembly (3).

(5) Remove fan support plate (8) from engine fan (7).

(6) Remove grommet (9) from engine fan (7). Discard

grommet.
6-70 Change 2
 TM 9-2320-366-20-3

NOTE

Perform steps (6.1) and (6.2) on vehicles

serial number 8427 and higher and vehicles
that have previously had the fan clutch
replaced.

(6.1) Remove six nuts (9.1), lockwashers (9.2), and washers

(9.3) from engine fan (9.4). Discard lockwashers.

(6.2) Remove engine fan (9.4) from fan clutch assembly (9.5).

(7) Loosen two screws (10) from front of engine block (11).

(8) Release alternator belts (12) tension by moving tension

bracket (13) up.

(9) Remove two alternator belts (12) from engine (14).

(10) Remove two screws (15), washers (16), and tension

pulley (17) from engine (14).

(11) Remove drive belt (18) from water pump pulley (19) and
pulley damper (20).

Change 1 6-71
TM 9-2320-366-20-3

6-13. DRIVE BELT AND TENSION PULLEY REPLACEMENT (CONT)

b. Installation.

(1) Install drive belt (1) on pulley damper (2) and water
pump pulley (3).

(2) Position tension pulley (4) on engine (5) with two

washers (6) and screws (7).

NOTE

Use square hole in drive belt/tension pulley to

apply and maintain tension on drive belt while
adjusting belt tension.

(3) Adjust water pump drive belt with drive belt/tension

pulley (4) as follows:

(a) New belt (less than 30 minutes running time) 115-

125 lb (512-556 N).

(b) Used belt 80-100 lb (356-444 N).

(4) Tighten two screws (7) to 35 lb-ft (47 N m).

6-72
 TM 9-2320-366-20-3

(5) Install two alternator belts (8) onto engine (5).

NOTE

Use square hole in drive belt/tension bracket to

apply and maintain tension on alternator belts
while adjusting belt tension.

(6) Adjust alternator belts with tension bracket (9) as follows:

(a) New belt (less than 30 minutes running time) 115-

125 lb (512-556 N).

(b) Used belt 80-100 lb (356-444 N).

(7) Tighten screw (10).

(8) Tighten screw (11) to 47 lb-ft (64 N m).

CAUTION

Ensure engine fan is positioned with mark facing

forward. Failure to comply may result in
damage to equipment.

NOTE

Perform steps (8.1) through (8.3) on vehicles

serial number 8427 and higher.

(8.1) Position engine fan (11.1) on fan clutch assembly (11.2)

with six washers, lockwashers

(8.2) Tighten six nuts (11.5) to 15 lb-ft (20 N·m) in sequence

shown.

(8.3) Re-tighten six nuts (11.5) to 23-29 lb-ft (31-39 N·m) in

sequence shown.

Change 1 6-72.1/(6-72.2 Blank)

 TM 9-2320-366-20-3

NOTE

Perform steps (9) through (13) on vehicles

serial numbers 8426 and lower that have not
had fan clutch replaced.

(9) Install grommet (12) on engine fan (13).

(10) Install fan support plate (14) on engine fan (13).

(11) Position engine fan (13) and fan support plate (14) on
fan clutch assembly (15) with six washers (16),
lockwashers (17), and screws (18).

(12) Tighten six screws (18) to 15 lb-ft (20 N·m) in sequence

shown.

(13) Re-tighten six screws (18) to 22-32 lb-ft (30-44 N·m) in

sequence shown.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(14) Apply antiseize compound to threads of fitting (19).

(15) Install fitting (19) on fan clutch assembly (15).

(16) Connect air hose (20) to fitting (19).

c. Follow-On Maintenance.

Install top radiator fan shroud (para 6-4).

End of Task.

Change 1 6-73
TM 9-2320-366-20-3

6-14. ENGINE FAN AND FAN CLUTCH ASSEMBLY REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Top radiator fan shroud removed (para 6-4). Antiseize Compound (Item 13, Appendix D)
Lockwasher (6) (Item 95, Appendix G)
Tools and Special Tools Screw, Self-Locking (6) (Item 263, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Adapter, Socket Wrench (Item 2, Appendix B)

a. Removal.

(1) Disconnect air hose (1) from fitting (2) on fan clutch
assembly (3).

(2) Remove fitting (2) from fan clutch assembly (3).

6-74 Change 1
 TM 9-2320-366-20-3

NOTE

Perform steps (3) through (8) on vehicles

serial number 8426 and lower that have not
had the fan clutch replaced.

(3) Remove six screws (4), lockwashers (5), and washers

(6) from engine fan (7). Discard lockwashers and
screws.

(4) Remove fan support plate (8) from engine fan (7).

(5) Remove grommet (9) from engine fan (7). Discard

grommet.

CAUTION

Mark front of engine fan before removal.

Failure to comply may result in damage to
equipment.

(6) Remove engine fan (7) from fan clutch assembly (3).

(7) Remove spacer plate (10) from fan clutch assembly (3).

Change 1 6-75
TM 9-2320-366-20-3

6-14. ENGINE FAN AND FAN CLUTCH ASSEMBLY REPLACEMENT (CONT)

NOTE

Perform steps (8) and (8.1) on vehicles serial

number 8427 and higher and on vehicles that
have had the fan clutch replaced.

(8) Remove six nuts (10.1), lockwashers (10.2), and

washers (10.3) from engine fan (10.4). Discard
lockwashers.

CAUTION

Mark front of engine fan before removal. Failure

to comply may result in damage to equipment.

(8.1) Remove engine fan (10.4) from fan clutch assembly

(10.5).

NOTE

• Application of 30 psi (207 kPa) air pressure to

fan clutch will free rotation of fan clutch and
allow removal of fan clutch screws.

• Both fan clutches are removed the same way.

Fan clutch without studs shown.

(8.2) Install fitting (2) in fan clutch assembly (3).

(9) Apply 30 psi (207 kPa) air pressure to fitting (2).

(10) Turn fan clutch assembly (3) until bolts (11) are visible
through fan clutch access holes (12).

(11) Remove six bolts (11) from pulley damper (13).

(12) Remove fan clutch assembly (3) from pulley damper

(13).

6-76 Change 1
 TM 9-2320-366-20-3

b. Installation.

NOTE

Discard fan clutch assembly PN 1090-08000-

03 and replace with fan clutch assembly PN
1090-08000-01.

(1) Position bolt (1) through hole (1.1) in fan clutch assembly
(2).

(2) Position fan clutch assembly (2) on pulley damper (3).

(3) Position five bolts (1) on fan clutch assembly (2).

(4) Tighten six bolts (1) to 42-52 lb-ft (57-71 N m).

CAUTION

Ensure engine fan is positioned with mark

facing forward. Failure to comply may result
in damage to equipment.

NOTE

Discard engine fan PN 4035-41393-74 and

replace with engine fan PN 12421972.

(5) Position engine fan (4) on fan clutch assembly (2) with
six washers (5), lockwashers (6), and nuts (7).

(6) Tighten six nuts (7) to 15 lb-ft (20 N·m) in sequence

shown.

(7) Re-tighten six nuts (7) to 23-29 lb-ft (31-39 N·m) in

sequence shown.

Change 1 6-77
TM 9-2320-366-20-3

6-14. ENGINE FAN AND FAN CLUTCH ASSEMBLY REPLACEMENT (CONT)

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(8) Apply antiseize compound to threads of fitting (8).

(9) Install fitting (8) in fan clutch assembly (2).

(10) Connect air hose (9) to fitting (8).

c. Follow-On Maintenance.

(1) Install top radiator fan shroud (para 6-4).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check for coolant leaks under vehicle.

(5) Raise cab (TM 9-2320-366-10-1).

(6) Check for coolant leaks around radiator.

(7) Lower cab (TM 9-2320-366-10-1).

(8) Shut down engine (TM 9-2320-366-10-1).

End of Task.

6-78 Change 1
 TM 9-2320-366-20-3

CHAPTER 7
ELECTRICAL SYSTEM MAINTENANCE

RESTRICTED MAINTENANCE NOTICE

Units not authorized SC 4910-95-CL-A72 (SHOP EQUIPMENT, COMMON NO. 2) in their T.O.E. may
be unable to perform some of the maintenance tasks described in this chapter. If the required tools
are not authorized, the equipment must be submitted to DS Maintenance for repair.

Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Section II. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-2. 100 AMP ALTERNATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-3. ALTERNATOR BELTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-4. ALTERNATOR BRACKETS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-5. 100 AMP VOLTAGE REGULATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-6. AUXILIARY STARTER SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-7. STARTING MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7-8. AUXILIARY PANEL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7-9. CIRCUIT BREAKER, DIODE, AND RELAY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . 7-39
7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . 7-64
7-12. DIMMER SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-13. WTEC II TRANSMISSION ECU PUSHBUTTON SHIFT SELECTOR (TEPSS)
DIMMER MODULE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
7-14. ELECTRICAL GAGES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
7-16. LIGHTED INDICATOR DISPLAY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
7-17. MAIN LIGHT SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
7-18. ROCKER SWITCHES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-114
7-19. START INHIBIT PUSHBUTTON SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119
7-20. STARTER PUSHBUTTON SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
7-21. TACHOMETER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
7-22. COOLANT TEMPERATURE LIGHT SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124
7-23. M1090/M1094 DUMP BODY SWITCH REPLACEMENT/ADJUSTMENT . . . . . . . . . . . . . . . . . . . 7-127
7-24. FAN AND DIFFERENTIAL LOCK SOLENOIDS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-131
7-25. FLASHER UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134
7-26. TURN SIGNAL SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-135
7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . 7-138
7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 7-159
7-29. SHUNT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-180
7-30. 100 AMP REVERSE POLARITY RELAY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-184
7-31. FREQUENCY ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-188
7-32. CRANE REMOTE CONTROL BOX REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-190
7-33. M1089 TERMINAL BOARD ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-198
7-34. M1089 WRECKER CONTROL PANEL TOGGLE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . 7-202
7-35. M1089 WRECKER REMOTE CONTROL BOX REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-207
7-36. BACKUP LIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-211
7-37. BLACKOUT DRIVE LIGHT REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217
7-38. CLEARANCE AND MARKER LIGHT ASSEMBLIES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-219
7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 7-225
7-40. COMPOSITE FRONT LIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . . 7-233
7-41. HEADLIGHT AND HOUSING REPLACEMENT/REPAIR/ADJUSTMENT . . . . . . . . . . . . . . . . . . . 7-236
7-42. M1088/M1089 STATIONARY WORKLIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . 7-240

Change 1 7-1
TM 9-2320-366-20-3

7-43. AUDIBLE ALARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-242

7-44. AIR PRESSURE TRANSMITTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-244
7-45. COOLANT TEMPERATURE GAGE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-246
7-46. ENGINE SPEED SENSOR REPLACEMENT/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-248
7-47. ETHER SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-251
7-48. OIL PRESSURE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-254
7-49. OIL PRESSURE TRANSDUCER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-256
7-50. WATER TEMPERATURE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258
7-51. M1084/M1086 JACK CYLINDER PROXIMITY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . 7-261
7-52. TRANSMISSION ENGINE SPEED SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264
7-53. HORN AND BRACKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-266
7-54. BATTERY TESTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-269
7-55. BATTERY/BATTERY CABLES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-274
7-56. BATTERY BOX REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-282
7-57. DISCONNECTING/CONNECTING BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-288
7-58. AUXILIARY PANEL CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-291
7-59. CHEMICAL ALARM KIT CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-293
7-60. CENTRAL TIRE INFLATION SYSTEM (CTIS) CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . 7-294
7-61. LEFT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY REPLACEMENT . . . . . . . 7-296
7-62. M1093/M1094 CAB CLEARANCE AND MARKER LIGHTS LOWER CABLE ASSEMBLY
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-303
7-63. M1093/M1094 CAB CLEARANCE AND MARKER LIGHTS UPPER CABLE ASSEMBLY
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-306
7-64. RIGHT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY REPLACEMENT . . . . . . 7-310
7-65. STE/ICE-R CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-317
7-66. CAB CLEARANCE MARKER LIGHTS CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . 7-320
7-67. WINDSHIELD WASHER PUMP ELECTROMAGNETIC INTERFERENCE (EMI) CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-325
7-68. WINDSHIELD WIPER ELECTROMAGNETIC INTERFERENCE (EMI) CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-328
7-69. WINDSHIELD WIPER ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-330
7-70. NATO POWER CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-331
7-71. ALTERNATOR GROUND STRAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-334
7-72. 100 AMP ALTERNATOR TO REVERSE POLARITY RELAY 12 VDC CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-336
7-73. 100 AMP ALTERNATOR TO REVERSE POLARITY RELAY 24 VDC CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-340
7-74. BATTERY TO 100 AMP REVERSE POLARITY RELAY 12 VDC CABLE REPLACEMENT . . . . . . 7-344
7-75. BATTERY TO 100 AMP REVERSE POLARITY RELAY 24 VDC CABLE REPLACEMENT . . . . . . 7-346
7-76. BATTERY TO SHUNT CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-349
7-77. BATTERY TO STARTER CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-351
7-78. CAB TO CHASSIS GROUND STRAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-355
7-79. M1084/M1086 CRANE POWER CONTROL CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . 7-357

Volume 4

7-80. ENGINE CONTROL CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-365

7-81. FRONT INTERVEHICULAR 12 VDC (7 Pin) CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-376
7-82. FRONT LIGHTS CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-377
7-83. M1089 WRECKER CONTROL PANEL WIRING HARNESS REPLACEMENT . . . . . . . . . . . . . . . 7-389
7-84. M1083/M1084/M1085/M1090/M1092/M1093/M1094/M1096 REAR LIGHTS CABLE
ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-397
7-85. M1084/M1086 BOOM DOWN LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . 7-430
7-86. M1084/M1086 BOOM DOWN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-434
7-87. M1084/M1086 BOOM UP LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . 7-438
7-88. M1084/M1086 BOOM UP SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-442

7-2 Change 1
 TM 9-2320-366-20-3

7-89. M1084/M1086 CONTROL LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . 7-446

7-90. M1084/M1086 CRANE POWER CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-450
7-91. M1084/M1086 HOIST DOWN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-454
7-92. M1084/M1086 HOIST UP LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . 7-458
7-93. M1084/M1086 HOIST UP SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-462
7-94. M1084/M1086 LEFT JACK CYLINDER PROXIMITY SENSOR CABLE REPLACEMENT . . . . . . . 7-466
7-95. M1084/M1086 OVERLOAD LOCKOUT CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-470
7-96. M1084/M1086 REMOTE CONTROL CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-474
7-97. M1084/M1086 RIGHT JACK CYLINDER PROXIMITY SENSOR CABLE REPLACEMENT . . . . . . 7-477
7-98. M1084/M1086 SWING CCW SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 7-481
7-99. M1084/M1086 SWING CW SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-485
7-100. M1084/M1086 SYSTEM SHUTDOWN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . 7-489
7-101. M1084/M1086 TELESCOPE IN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-493
7-102. M1084/M1086 TELESCOPE OUT LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . 7-497
7-103. M1084/M1086 TELESCOPE OUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . 7-501
7-104. M1086/M1088/M1089 REAR LIGHTS CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . 7-505
7-105. M1089 BOOM DOWN LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . 7-534
7-106. M1089 BOOM DOWN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-538
7-107. M1089 BOOM UP LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-542
7-108. M1089 BOOM UP SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-546
7-109. M1089 CONTROL PANEL POWER CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . 7-550
7-110. M1089 CRANE POWER CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-553
7-111. M1089 HOIST DOWN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-558
7-112. M1089 HOIST UP LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-562
7-113. M1089 HOIST UP SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-566
7-114. M1089 HYDRAULIC SYSTEM SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-570
7-115. M1089 LEFT SIDE REMOTE CONTROL CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 7-574
7-116. M1089 OVERLOAD LOCKOUT CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-578
7-117. M1089 REMOTE CONTROL WIRING HARNESS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 7-582
7-118. M1089 RIGHT SIDE REMOTE CONTROL CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-585
7-119. M1089 SWING CCW SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-588
7-120. M1089 SWING CW SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-592
7-121. M1089 TELESCOPE IN SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-596
7-122. M1089 TELESCOPE OUT LOCKOUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . 7-600
7-123. M1089 TELESCOPE OUT SOLENOID CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-604
7-124. M1090/M1094 DUMP CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-608
7-125. M1090/M1094 DUMP POWER CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-612
7-126. POWER DISTRIBUTION PANEL (PDP) TO CAB GROUND CABLE REPLACEMENT . . . . . . . . . 7-619
7-127. POWER TAKE-OFF (PTO) CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-621
7-128. REAR INTERVEHICULAR 12 VDC (7 Pin) CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 7-628
7-129. REAR INTERVEHICULAR 24 VDC (12 Pin) CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-630
7-130. 100 AMP REVERSE POLARITY RELAY TO POWER DISTRIBUTION (PDP) PANEL
12 VDC CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-631
7-131. 100 AMP REVERSE POLARITY RELAY TO POWER DISTRIBUTION (PDP) PANEL
24 VDC CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-637
7-132. START AND CHARGING CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-643
7-133. STARTER TO CHASSIS GROUND CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-658
7-134. STARTER TO SHUNT 24 VDC CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-661
7-135. WINCH CONTROL VALVE CABLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 7-665
7-136. TRANSMISSION AUXILIARY OIL COOLER FAN CABLE ASSEMBLY REPLACEMENT . . . . . . . . 7-670
7-137. WTEC II CAB TRANSMISSION HARNESS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-685
7-138. WTEC III CAB TRANSMISSION HARNESS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-691
7-139. M1088 INTERMEDIATE INTERVEHICULAR 12 VDC (7 PIN) (CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-696

Change 1 7-3
TM 9-2320-366-20-3

7-140. M1088 INTERMEDIATE INTERVEHICULAR 24 VDC (12 PIN) CABLE

REPLACEMENT ...........................................................................................................................7-698
7-141. LOW PRESSURE TRANSMITTER REPLACEMENT ...........................................................................7-700
7-142. M1089 WINCH CONTROL WIRING HARNESS REPLACEMENT..........................................................7-703
7-143. M1084/M1086 JUNCTION BOX MODIFICATION ..................................................................................7-708
7-144. M1089 JUNCTION BOX MODIFICATION.............................................................................................7-715
7-145. M1089 REAR LIGHTS CABLE ASSEMBLY REPLACEMENT ..............................................................7-720
7-146. DUMP SWITCH BRACKET AND JUMPER CABLE REPLACEMENT....................................................7-744

Section I. INTRODUCTION
7-1. INTRODUCTION

This chapter contains maintenance instructions for replacing, repairing, and adjusting electrical components
authorized by the Maintenance Allocation Chart (MAC) at the Unit Maintenance level.

7-4 Change 2
 TM 9-2320-366-20-3

Section II. MAINTENANCE PROCEDURES

7-2. 100 AMP ALTERNATOR REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Alternator belts removed (para 7-3). (Item 20, Appendix D)
Nut, Self-Locking (Item 153, Appendix G)
Tools and Special Tools Tape, Insulation, Electrical (Item 68, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Ties, Cable, Plastic (Item 69, Appendix D)
Vise, Machinist (Item 48, Appendix C)
Caps, Vise Jaw (Item 4, Appendix C) Personnel Required
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) (2)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C)

a. Removal.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Remove screw (1), lockwasher (2), terminal lug TL5

(3), washer (4), and ground strap (5) from alternator
(6).

(2) Position washer (4), lockwasher (2), and screw (1) on

alternator (6).

(3) Lift dust boot (7) on terminal lug TL60 (8).

(4) Remove self-locking nut (9), washer (10), terminal

lug TL60 (8), and two washers(11) from alternator
(6).

(5) Position two washers (11), washer (10), and self-

locking nut (9) on alternator (6).

Change 2 7-5
TM 9-2320-366-20-3

7-2. 100 AMP ALTERNATOR REPLACEMENT (CONT)

(6) Remove screw (13), washer (14), and clamp (15)

from alternator (6).

(7) Lift dust boot (16) on terminal lug TL2 (17).

(8) Remove self-locking nut (18), washer (19), terminal

lugs TL2 (17) and TL6 (21), and two washers (22)
from alternator (6).

(9) Position two washers (22), washer (19), and self-

locking nut (18) on alternator (6).

(10) Lift dust boot (23) on terminal lug TL35 (24).

(11) Remove self-locking nut (25), washer (26), and

terminal lug TL35 (24) from voltage regulator (27).

(12) Position washer (26) and self-locking nut (25) on

voltage regulator (27).

(13) Lift dust boot (28) on terminal lug TL110 (29).

NOTE

Perform steps (14) and (15) on vehicles

equipped with alternator P/N N1506-1
(12420852).

(14) Remove self-locking nut (30), washer (31), and

terminal lug TL110 (29) from voltage regulator (27).

(15) Position washer (31) and self-locking nut (30) on

voltage regulator (27).

7-6 Change 2
 TM 9-2320-366-20-3

(16) Remove nut (32), washer (33), screw (34), and washer
(35) from alternator (6).

(17) Remove self-locking nut (36), screw (37), and washer

(38) from alternator (6). Discard self-locking nut.

WARNING

Alternator weighs approximately 50 lbs

(23 kgs). The aid of an assistant is
required to remove alternator. Failure to
comply may result in injury to personnel.

NOTE

Step (18) requires the aid of an assistant.

(18) Remove alternator (6) from support bracket (39).

CAUTION

Alternator pulley must be positioned in a vise

equipped with vise jaw caps when loosening
self-locking nut. Failure to comply may result
in damage to equipment.

(19) Position pulley (40) in vise.

(20) Loosen self-locking nut (41).

(21) Remove pulley (40) from vise.

(22) Remove self-locking nut (41), washer (42), pulley (40),

and key (43) from alternator (6).

(23) Position washer (42) and self-locking nut (41) on

alternator (6).

7-7
TM 9-2320-366-20-3

7-2. 100 AMP ALTERNATOR REPLACEMENT (CONT)

b. Installation.

(1) Remove self-locking nut (1) and washer (2) from

alternator (3).

(2) Position key (4) and pulley (5) on alternator (3) with
washer (2) and self-locking nut (1).

CAUTION

Alternator pulley must be positioned in a vise

equipped with vise jaw caps when tightening
self-locking nut. Failure to comply may result
in damage to equipment.

(3) Position pulley (5) in vise.

(4) Tighten self-locking nut (1) to 120 lb-ft (163 N m).

(5) Remove pulley (5) from vise.

WARNING

Alternator weighs approximately 50 lbs

(23 kgs). The aid of an assistant is
required to install alternator. Failure to
comply may result in injury to personnel.

NOTE

Step (6) requires the aid of an assistant.

(6) Position alternator (3) on support bracket (6) with washer

(7), screw (8), and self-locking nut (9).

(7) Position washer (10), screw (11), washer (12) and nut
(13) on alternator (3).

(8) Tighten nut (13) to 18-22 lb-ft (24-30 N m).

(9) Tighten self-locking nut (9) to 44-56 lb-ft (60-76 N m).

7-8
 TM 9-2320-366-20-3

NOTE

• Perform step (10) if replacing alternator

P/N N1506-1 (12420852) with alternator
P/N N1509-1 (12422863).

• Install plastic cable ties as required to

terminal lug TL110 and tie wire away from
alternator.

(10) Apply electrical tape to terminal lug TL110 (17).

NOTE

Perform steps (10.1) through (13) on alternator

P/N N1506-1 (12420852).

(10.1) Remove self-locking nut (14) and washer (15) from

voltage regulator (16).

(11) Position terminal lug TL110 (17), washer (15), and

self-locking nut (14) on voltage regulator (16).

(12) Tighten self-locking nut (14) to 20-lb-in. (3 N•m).

(13) Position dust boot (18) on terminal lug TL110 (17).

(14) Remove self-locking nut (19) and washer (20) from

voltage regulator (16).

(15) Position terminal lug TL35 (21), washer (20), and

self-locking nut (19) on voltage regulator (16).

(16) Tighten self-locking nut (19) to 25 lb-in. (3 N•m).

(17) Position dust boot (22) on terminal lug TL35 (21).

(18) Remove self-locking nut (23), washer (24), and two

washers (25) from alternator (3).

(19) Position two washers (25) terminal lugs TL6 (26) and
TL2 (27), washer (24), and self-locking nut (23) on
alternator (3).

(20) Tighten self-locking nut (23) to 80 lb-in. (9 N•m).

(21) Position dust boot (28) on terminal lug TL2 (27).

(22) Position clamp (29), washer (30), and screw (31) on

alternator (3).

(23) Tighten screw (31) to 80 lb-in. (9 N•m).

Change 2 7-9
TM 9-2320-366-20-3

7-2. 100 AMP ALTERNATOR REPLACEMENT (CONT)

(24) Remove self-locking nut (32), washer (33), and two

washers (34) from alternator (3).

(25) Position two washers (34), terminal lug TL60 (35),

washer (33), and self-locking nut (32) on alternator (3).

(26) Tighten self-locking nut (32) to 80 lb-in. (9 N m).

(27) Position dust boot (36) on terminal lug TL60 (35).

(28) Remove screw (37), lockwasher (38), and washer (39)

from alternator (3).

(29) Position ground strap (40), washer (39), and terminal lug
TL5 (41) on alternator (3) with lockwasher (38) and
screw (37).

(30) Tighten screw (37) to 80 lb-in. (9 N m).

c. Follow-On Maintenance.

(1) Install alternator belts (para 7-3).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check alternator operation (TM 9-2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-10 Change 1
 TM 9-2320-366-20-3

7-3. ALTERNATOR BELTS REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Cab raised (TM 9-2320-366-10-1). Gage, Belt Tension (Item 19, Appendix B)
Air tanks drained (TM 9-2320-366-10-1). Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

Personnel Required
(2)

CAUTION

Alternator belts must be replaced as a pair.

Failure to comply may result in damage to
equipment.

a. Removal.

(1) Disconnect air hose (1) from fan clutch (2).

(2) Loosen two screws (3) on front of engine block (4).

(3) Move tension bracket (5) up.

(4) Remove two alternator belts (6) from pulley (7).

Change 1 7-11
TM 9-2320-366-20-3

7-3. ALTERNATOR BELTS REPLACEMENT (CONT)

b. Installation.

(1) Position two alternator belts (1) on pulley (2).

CAUTION

Tension bracket adjustment varies for new or

reinstalled belts. New belts must be adjusted
to 110-130 lbs (489-478 N), reinstalled belts
must be adjusted to 80-100 lbs (356-444 N).
Failure to comply may result in early belt
failures.

NOTE

• Steps (2) and (3) require the aid of an

assistant.

• Use square hole in tension bracket to

apply tension to alternator belts.

(2) Push tension bracket (3) down until belt tension gage
indicates correct tension for new or reinstalled belts (1).

(3) Maintain belt tension and tighten two screws (4).

(4) Connect air hose (5) to fan clutch (6).

7-12
 TM 9-2320-366-20-3

(5) Lower cab (TM 9-2320-366-10-1).

(6) Start engine and run for five minutes.

(7) Shut down engine (TM 9-2320-366-10-1).

(8) Raise cab (TM 9-2320-366-10-1).

NOTE

Check belt tension for proper tension for new

or reinstalled belts.

(9) Loosen one screw (4) and readjust tension bracket (3)
for new or reinstalled belts, as required.

(10) Tighten two screws (4) to 47 lb-ft (64 N·m).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check VOLTS gage for indication of 22-28 volts (TM 9-

2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-13
TM 9-2320-366-20-3

7-4. ALTERNATOR BRACKETS REPLACEMENT

This task covers:

a. Support Brackets Removal c. Belt Take-Up Bracket Removal

b. Support Brackets Installation d. Belt Take-Up Bracket Installation
e. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Material/Parts

100 amp alternator removed, if equipped (para 7-2). Sealing Compound (Item 57, Appendix D)
200 amp alternator removed, if equipped (para 20-45). Nut, Self-Locking (Item 167, Appendix G)

Tools and Special Tools Personnel Required

Goggles, Industrial (Item 15, Appendix C) (2)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Gage, Belt Tension (Item 19, Appendix B)

a. Support Brackets Removal.

NOTE

Note location of different size screws for

installation.

(1) Remove two screws (1), washers (2), and belt adjusting
arm (3) from alternator bracket (4).

7-14
 TM 9-2320-366-20-3

(2) Remove two screws (5) and washers (6) from alternator
support bracket (7).

(3) Remove three screws (8) from alternator bracket (4).

(4) Remove self-locking nut (9) and alternator bracket (4)

from thermostat housing (10). Discard self-locking nut.

(5) Remove two screws (11) and alternator support bracket

(7) from engine block (12).

b. Support Brackets Installation.

(1) Position alternator support bracket (1) on engine block

(2) with two screws (3).

(2) Tighten two screws (3) to 121-147 lb-ft (164-200 N·m).

7-15
TM 9-2320-366-20-3

7-4. ALTERNATOR BRACKETS REPLACEMENT (CONT)

WARNING

Adhesive Sealant MIL-S-46163 can

damage your eyes. Wear safety
goggles/glasses when using; avoid
contact with eyes. If sealant contacts
eyes, flush eyes with water and get
immediate medical attention. Failure to
comply may result in injury to personnel.

(3) Apply sealing compound to threads of three screws (4)

and stud (5).

(4) Position alternator bracket (6) on thermostat housing (7)

with three screws (4).

(5) Install self-locking nut (8) on stud (5).

(6) Tighten three screws (4) to 18-22 lb-ft (24-30 N·m).

(7) Position two washers (9) and screws (10) in alternator bracket (6).

(8) Tighten two screws (10) to 121-147 lb-ft (164-200 N·m).

(9) Position belt adjusting arm (11) on alternator bracket (6)

with two washers (12) and screws (13).

(10) Tighten two screws (13) to 18-22 lb-ft (24-30 N·m).

7-16
 TM 9-2320-366-20-3

c. Belt Take-Up Bracket Removal.

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

(1) Loosen two screws (1) on water pump pulley bracket (2).

(2) Position water pump pulley bracket (2) for access to

three screws (3).

(3) Remove screw (4) and washer (5) from alternator belt
take-up plate (6).

(4) Remove screw (7), washer (8), and alternator belt take-
up plate (6) from alternator belt take-up mounting bracket
(9).

(5) Remove three screws (3) from alternator belt take-up

mounting bracket (9).

(6) Remove two screws (10) and alternator belt take-up

mounting bracket (9) from engine front cover (11).

7-17
TM 9-2320-366-20-3

7-4. ALTERNATOR BRACKETS REPLACEMENT (CONT)

d. Belt Take-Up Bracket Installation.

(1) Position alternator belt take-up mounting bracket (1) on

engine front cover (2) with two screws (3).

(2) Position three screws (4) in engine front cover (2).

(3) Tighten two screws (3) to 121-147 lb-ft (164-200 N·m).

(4) Tighten three screws (4) to 106-130 lb-ft (144-176 N·m).

(5) Install alternator belt take-up plate (5) on alternator belt

take-up mounting bracket (1) with washer (6) and screw
(7).

(6) Install washer (8) and screw (9) in alternator belt take-up
plate (5).

NOTE

• Steps (7) and (8) require the aid of an assistant.

• Use square hole in water pump belt pulley

bracket to apply and maintain tension on water
pump belt while adjusting belt tension.

(7) Adjust tension on water pump belt (10) to 80-100 lbs

(356-444 N).

(8) Tighten two screws (11) to 35 lb-ft (47 N·m).

7-18
 TM 9-2320-366-20-3

e. Follow-On Maintenance.

(1) Install 200 amp alternator, if equipped (para 20-45).

(2) Install 100 amp alternator, if equipped (para 7-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-19
TM 9-2320-366-20-3

7-5. 100 AMP VOLTAGE REGULATOR REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Cab raised (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Lockwasher (2) (Item 104, Appendix G)
Tools and Special Tools Nut, Self-Locking (Item 143, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (Item 144, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C) Sealing Compound (Item 59, Appendix D)
Socket Set, Socket Wrench (Item 34, Appendix C) Tape, Insulation Electrical (Item 68, Appendix D)
Tie, Cable, Plastic (Item 69, Appendix D)

a. Removal.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Lift dust boot (1) on terminal lug TL35 (2).

(2) Remove self-locking nut (3), washer (4), and terminal

lug TL35 (2) from voltage regulator (5). Discard self-
locking nut.

NOTE

Perform steps (3) and (4) on vehicles

equipped with alternator P/N N1506-1
(12420852).

(3) Lift dust boot (6) on terminal lug TL110 (7).

(4) Remove self-locking nut (8), washer (9), and terminal

lug TL110 (7) from voltage regulator (5). Discard
self-locking nut.

7-20 Change 2
 TM 9-2320-366-20-3

(5) Disconnect voltage regulator connector (10) from

voltage regulator (5).

(6) Remove two screws (11), lockwashers (12), and

voltage regulator (5) from alternator (13). Discard
lockwashers.

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply sealing compound to threads of two screws (1).

(2) Position voltage regulator (2) on alternator (3) with two

lockwashers (4) and screws (1).

(3) Tighten two screws (1) to 65 lb-in. (7 N m).

(4) Connect voltage regulator connector (5) to voltage

regulator (2).

7-21
TM 9-2320-366-20-3

7-5. 100 AMP VOLTAGE REGULATOR REPLACEMENT (CONT)

NOTE

• Perform step (5) if replacing alternator

P/N N1506-1 (12420852) with alternator
P/N N1509-1 (12422863).

• Install plastic cable ties to terminal lug

TL110 and tie wire away from alternator.

(5) Apply electrical tape to terminal lug TL110 (6).

NOTE

Perform steps (5.1) through (7) on alternator

N1506-1 (12420852).

(5.1) Cut terminal lug TL110 (6) from engine control cable
assembly wire (6.1)

(6) Remove dust boot (7) from engine control cable

assembly wire (6.1).

(7) Apply electrical tape to engine control cable

assembly wire (6.1) so wire doesn’t interfere with
engine or alternator operations.

(8) Position terminal lug TL35 (10) on voltage regulator

(2) with washer (11), and self-locking nut (12).

(9) Tighten self-locking nut (12) to 25 lb-in. (3 N m).

(10) Position dust boot (13) on terminal lug TL35 (10).

c. Follow-On Maintenance

(1) Lower cab (TM 9-2320-366-10-1).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-22 Change 2
 TM 9-2320-366-20-3

7-6. AUXILIARY STARTER SOLENOID REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 20, Appendix D)
Adhesive (Item 8, Appendix D)
Tools and Special Tools Lockwasher (2) (Item 87, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (2) (Item 89, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C) Nut, Self-Locking (2) (Item 128, Appendix G)
Socket Set, Socket Wrench (Item 36, Appendix C)

a. Removal.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Remove adhesive, two nuts (1), lockwashers (2),

terminal lugs TL9 (3) and TL24 (4) from auxiliary starter
solenoid (5). Discard lockwashers.

(2) Remove adhesive, two nuts (6), lockwashers (7),

terminal lugs TL23 (8) and TL33 (9) from auxiliary starter
solenoid (5). Discard lockwashers.

7-23
TM 9-2320-366-20-3

7-6. AUXILIARY STARTER SOLENOID REPLACEMENT (CONT)

NOTE

Perform steps (3) and (4) on vehicle serial

number 7413 and higher, and vehicle serial
numbers 0001 through 7412 which have
previously had an auxiliary starter solenoid
replaced.

(3) Remove self-locking nut (10), washer (11), and screw

(12) from bracket (13). Discard self-locking nut.

(4) Remove self-locking nut (14), washer (15), clamp (16),

screw (17), and auxiliary starter solenoid (5) from bracket
(13). Discard self-locking nut.

NOTE

Perform step (5) on vehicle serial numbers

0001 through 7412 which have not previously
had an auxiliary starter solenoid replaced.

(5) Remove self-locking nuts (10 and 14), washers (11 and
15), screws (12 and 17), and auxiliary starter solenoid
(5) from bracket (13). Discard self-locking nuts.

b. Installation.

(1) Position auxiliary starter solenoid (1) on bracket (2) with

screw (3), clamp (4), washer (5), and self-locking nut (6).

(2) Position screw (7), washer (8), and self-locking nut (9) in
bracket (2).

(3) Tighten self-locking nuts (6 and 9) to 96-120 lb-in. (11-14

N·m).

7-24
 TM 9-2320-366-20-3

(4) Install terminal lugs TL33 (10) and TL23 (11) on auxiliary
starter solenoid (1) with two lockwashers (12) and nuts
(13).

(5) Install terminal lugs TL24 (14) and TL9 (15) on auxiliary
starter solenoid (1) with two lockwashers (16) and nuts
(17).

WARNING

Adhesives, solvents, and sealing

compounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(6) Apply adhesive on nuts (13 and 17) and terminal lugs
TL33 (10), TL23 (11), TL24 (14), and TL9 (15).

7-25
TM 9-2320-366-20-3

7-6. AUXILIARY STARTER SOLENOID REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-26
 TM 9-2320-366-20-3

7-7. STARTING MOTOR REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Adhesive (Item 8, Appendix D)
Tools and Special Tools Adhesive (Item 9, Appendix D)
Goggles, Industrial (Item 15, Appendix C) Bolt, Machine (3) (Item 2, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Gasket (Item 39, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Splice, Conductor (Item 261, Appendix G)
Sling, Endless (Item 32, Appendix C) Tape, Insulation, Electrical (Item 68, Appendix
Wrench Set, Socket (Item 51, Appendix C) D)
Socket Set, Socket Wrench (Item 34, Appendix C) Insulation, Sleeving, Electrical (Item 28.1,
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C) Appendix D)
Adapter, Socket Wrench (Item 2, Appendix B)
Heater, Gun Type, Electric (Item 24, Appendix B) Personnel Required
Crowfoot Attachment, Socket Wrench (Item 8, Appendix (2)
B)

WARNING

Wear appropriate eye protection when

working under vehicle due to the
possibility of falling debris. Failure to
comply may result in injury to personnel.

a. Removal.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Remove adhesive, nut (1), terminal lugs TL55 (2) and
TL12 (3) from solenoid terminal (4).

(2) Position nut (1) on solenoid terminal (4).

(3) Remove adhesive, nut (5), and terminal lug TL26 (6)
from solenoid terminal (7).

(4) Position nut (5) on solenoid terminal (7).

Change 1 7-27
TM 9-2320-366-20-3

7-7. STARTING MOTOR REPLACEMENT (CONT)

(5) Remove adhesive, nut (8), terminal lugs TL25 (9), TL46
(10), ground strap (11), and terminal lug TL53 (12) from
starting motor terminal (13).

(6) Position nut (8) on starting motor terminal (13).

NOTE

Perform step (7) on vehicles that have not

had connector P81 removed.

(7) Disconnect connector P81 (14) from starting motor

connector (15).

(8) Remove screw (16) from starting motor (17). Discard

screw.

WARNING

Starting motor weighs approximately 60

lbs (27 kgs). Attach a suitable lifting
device prior to removal. Failure to comply
may result in injury to personnel or
damage to equipment.

NOTE

Step (9) requires the aid of an assistant.

(9) Remove two screws (18) and starting motor (17) from
flywheel housing (19). Discard screws.

(10) Remove gasket (20) from starting motor (17). Discard

gasket.

7-28 Change 1
 TM 9-2320-366-20-3

b. Installation.

(1) Deleted.

(2) Deleted.

(3) Deleted.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(4) Apply a bead of adhesive around flange (4) of starting

motor (5).

(5) Install gasket (6) on starting motor (5).

(6) Apply a bead of adhesive around gasket (6).

Change 1 7-29
TM 9-2320-366-20-3

7-7. STARTING MOTOR REPLACEMENT (CONT)

WARNING

Starting motor weighs approximately 60

lbs (27 kgs). Attach a suitable lifting
device prior to installation. Failure to
comply may result in injury to personnel
or damage to equipment.

NOTE

Step (7) requires the aid of an assistant.

(7) Position starting motor (5) in flywheel housing (7) with

two screws (8).

(8) Position screw (9) in starting motor (5).

(9) Tighten two screws (8) and screw (9) to 47 lb-ft (64
N·m).

NOTE

Perform step (10) through (21) on vehicles

that have not had connector P81 removed.

(10) Cut connector P81 (10) from start and charging cable
assembly (11).

(11) Remove band marker (12) from start and charging cable
assembly (11).

NOTE

Remove electrical tape as required.

(12) Remove convoluted tubing (13) from two wires (14 and
15).

(13) Remove insulation sleeving (16) from two wires (14 and
15).

7-30 Change 1
 TM 9-2320-366-20-3

NOTE

Measure wires from body of start and

charging cable assembly.

(14) Cut wire (14) to 3 in. (7.6 cm) in length.

(15) Cut wire (15) to 4 in. (10.2 cm) in length.

(16) Remove 0.38 in. (1 cm) of insulation from two wires (14
and 15).

(17) Cut insulation sleeving (17) 1.5 in. (3.8 cm).

(18) Position insulation sleeving (17) on wire (15).

(19) Install conductor splice (18) on two wires (14 and 15).

(20) Install insulation sleeving (17) on conductor splice (18).

NOTE

Install electrical tape as required.

(21) Install convoluted tubing (13) on two wires (14 and 15).

(22) Deleted.

(23) Remove nut (19) from starting motor terminal (20).

(24) Position terminal lug TL53 (21), ground strap (22),

terminal lugs TL46 (23), and TL25 (24) on starting motor
terminal (20) with nut (19).

(25) Tighten nut (19) to 33-37 lb-ft (45-50 N·m).

WARNING

Adhesives, solvents, and sealing compounds

can burn easily, 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, solvent, or
sealing compound gets on skin or clothing,
wash immediately with soap and water.
Failure to comply may result in injury to
personnel.

(26) Apply adhesive on terminal lug TL53 (21), ground strap

(22), terminal lugs TL46 (23), TL25 (24), nut (19), and
starting motor terminal (20).

Change 1 7-31
TM 9-2320-366-20-3

7-7. STARTING MOTOR REPLACEMENT (CONT)

(27) Remove nut (25) from solenoid terminal (26).

(28) Position terminal lug TL26 (27) on solenoid terminal (26)

with nut (25).

(29) Tighten nut (25) to 31 lb-in. (4 N·m).

(30) Remove nut (28) from solenoid terminal (29).

(31) Position terminal lugs TL12 (30) and TL55 (31) on

solenoid terminal (29) with nut (28).

(32) Tighten nut (28) to 30 lb-ft (41 N·m).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(33) Apply adhesive on terminal lug TL26 (27), solenoid

terminal (26), and nut (25).

(34) Apply adhesive on terminal lugs TL12 (30), TL55 (31),

solenoid terminal (29), and nut (28).

7-32 Change 1
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 1 7-33
TM 9-2320-366-20-3

7-8. AUXILIARY PANEL REPLACEMENT

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
(Item 20, Appendix D)
Tools and Special Tools Decal (Item 11, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (2) (Item 131, Appendix G)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal

(1) Remove six screws (1) from auxiliary panel (2).

(2) Lift auxiliary panel (2) outward from auxiliary panel

housing (3) to gain access.

NOTE

• Tag electrical connectors and connection

points prior to removal.

• All rocker switches are removed the same

way. PTO switch shown

(3) Lift tab (4) on connector P904 (5).

(4) Disconnect connector P904 (5) from PTO switch (6).

(5) Disconnect connector P904A (7) from PTO switch

(6).

7-34 Change 2
 TM 9-2320-366-20-3

(6) Push in two tabs (8) on PTO switch (6).

(7) Remove PTO switch (6) from auxiliary panel (2).

NOTE

Auxiliary panel rocker switches will vary

according to vehicle model.

(8) Perform steps (3) through (7) on remaining rocker

switches.

(9) Disconnect connector clamp (9) from tachometer

connector (10).

(10) Disconnect connector P901 (11) from tachometer

connector (10).

(11) Remove two protective caps (12), self-locking nuts

(13), retaining ring (14), and tachometer (15) from
auxiliary panel (2). Discard self-locking nuts.

(12) Remove auxiliary panel (2) from vehicle.

(13) Remove eight screws (16) from auxiliary panel

housing (3).

(14) Remove auxiliary panel housing (3) from heater

assembly (17).

(15) Remove auxiliary panel cable assembly (18) from

auxiliary panel housing (3).

Change 2 7-34.1/(7-34.2 Blank)

 TM 9-2320-366-20-3

(16) Disconnect connector J925 (19) from connector

P925 (20)

(17) Remove auxiliary cable assembly (18) auxiliary

panel jumper cable assembly (21), and connector
J925 (1) from auxiliary panel housing (3).

b. Disassembly

NOTE

Perform step (1) and (2) on models M1090

and M1094.

(1) Remove four nuts (1), screws (2), ring (3), rubber
shield (4), and ring (5) from auxiliary panel housing
(6).

(2) Remove grommet (7) from auxiliary panel housing

(6).

c. Assembly

NOTE

Perform steps (1) and (2) on models M1090

and M1094.

(1) Install grommet (1) in auxiliary panel (2).

(2) Install ring (3), rubber shield (4), and ring (5)
on auxiliary panel (2) with four screws (6) and
nuts (7).

Change 2 7-35
TM 9-2320-366-20-3

d. Installation.

(1) Install decal (1) on auxiliary panel housing (2).

(2) Route auxiliary panel cable assembly (3) in

auxiliary panel housing (2).

(3) Position auxiliary panel housing (2) on heater

assembly (4) with eight screws (5).

(4) Tighten eight screws (5) to 35-44 lb-in. (4-5 N•m).

NOTE

Perform steps (4.1) and (4.2) on models

M1090 and M1094.

(4.1) Route connector J925 (5.1) auxiliary panel jumper

cable assembly (3) in auxiliary panel housing (2).

(4.2) Connect connector P925 (5.3) to connector J925

(5.1)

(5) Position tachometer (6) in auxiliary panel (7) with

retaining ring (8) and two self-locking nuts (9).

(6) Tighten two self-locking nuts (9) to 9 lb-in. (1 N•m).

(7) Install two protective caps (10) on tachometer (6).

(8) Connect connector P901 (11) to tachometer

connector (12).

(9) Connect connector clamp (13) on tachometer

connector (12).
7-36 Change 2
 TM 9-2320-366-20-3

NOTE

All rocker switches are installed the same

way. PTO switch shown.

(10) Install PTO switch (14) in auxiliary panel (7).

(11) Connect connector P904A (15) to PTO switch (14).

(12) Connect connector P904 (16) to PTO switch (14).

NOTE

Auxiliary panel rocker switches will vary

according to vehicle model.

(13) Perform steps (10) through (12) on remaining

rocker switches.

(14) Position auxiliary panel (7) on auxiliary panel

Housing (2) with six screws (17).

(15) Tighten six screws (17) to 18 lb-in. (2 N•m).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check rocker switches and tachometer operation

(TM9-2320-366-10-1).

End of Task.

Change 2 7-37
TM 9-2320-366-20-3

7-9. CIRCUIT BREAKER, DIODE, AND RELAY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions
Batteries disconnected (para 7-57).
PDP cover removed (para 16-2).

NOTE

All circuit breakers, diodes, and relays are

replaced the same way. Circuit breaker
replacement shown.

a. Removal.

(1) Locate diode, relay, or circuit breaker to be replaced.

NOTE

Refer to Figure 7-1. Power Distribution Panel

(PDP) Circuit Breakers, Diodes, and Relays,
Table 7-1. Power Distribution Panel (PDP)
Relays, and Table 7-1.1 Power Distribution
Panel (PDP) Circuit Breakers for details.

(2) Remove circuit breaker (1) from PDP (2).

Figure 7-1. Power Distribution Panel (PDP) Circuit Breakers, Diodes, and Relays

7-38 Change 1
 TM 9-2320-366-20-3

Table 7-1. Power Distribution Panel (PDP) Relays

Relay VDC Throw Function Remarks

K1 24 VDC SPST Starter Relay

K2 12 VDC SPST Control Power Relay

K6 12 VDC SPST Stop Light Relay

K7 12 VDC SPST Headlight Relay

K8 12 VDC SPDT Headlight LO/HI-Beam Relay

K9 12 VDC SPDT Hazard Flasher Blackout Override Relay

K10 12 VDC SPDT Stop/Hazard Flasher Relay

K11 24 VDC SPDT Alternator Excitation Relay

K12 12 VDC SPST Worklights Relay M1088/M1089

K13 12 VDC SPST Rotating Beacon Relay

K15 24 VDC SPDT Auxiliary Oil Cooler Relay

K19 24 VDC SPDT Start Inhibit Relay

K20 12 VDC SPST Marker Lights Relay

K24 24 VDC SPDT Cranking Lock-Out Relay

K25 Empty WTEC II

K25 24 VDC SPST Reverse Warning Relay WTEC III

K26 24 VDC SPST Neutral Start Relay WTEC III

K26 Empty WTEC II

K27 12 VDC SPST Blackout Stoplight Relay

K28 12 VDC SPST Trailer Rear Marker and Taillight Relay

K29 12 VDC SPST Trailer Blackout Marker Relay

K30 12 VDC SPST 24 VDC Intervehicular Left Rear

Composite Lamp Relay

K31 12 VDC SPST 24 VDC Intervehicular Right Rear

Composite Lamp Relay

K32 24 VDC SPST Horn Relay

K34 Empty WTEC II

K34 24 VDC SPDT Inter-Axle Relay WTEC III

K37 Empty WTEC II

K37 24 VDC SPST PTO Relay WTEC III

K52 12 VDC SPDT CTIS Overspeed Indication Relay

K53 24 VDC SPDT Radio Power

Change 1 7-38.1
TM 9-2320-366-20-3

7-9. CIRCUIT BREAKER, DIODE, AND RELAY REPLACEMENT (CONT)

Table 7-1.1 Power Distribution Panel (PDP) Circuit Breakers

CB Amp Function Reset Remarks

CB20 25 AMP Cab Radio Manual

CB21 15 AMP Air Dryer, Dump Up Indicator Light, Dump Up Indicator Switch, Manual
Frequency Divider, Interaxle Differential Solenoid, and Starter
Pushbutton Switch

CB22 10 AMP Engine Fan Off Switch, Ether Start Solenoid, Ether Start Switch, Manual
Ether Sensor, Fan Solenoid, and Water Temperature Switch (fan)

CB23 15 AMP Personnel Heater Manual

CB30 10 AMP Chemical Alarm, Chemical Detector, and Chemical Detector Manual
Indicator Light

CB35 15 AMP WTEC II TEPSS and WTEC II VIM Manual WTEC II

CB35 15 AMP Empty Manual WTEC III

CB36 20 AMP Horn Manual

CB37 20 AMP Windshield Wiper ECU and Wiper Motor Manual

CB38 20 AMP Rotating Warning Light(s) Manual

CB39 10 AMP 24 VDC Intervehicular Blackout Stoplights Manual

CB40 10 AMP CTIS, CTIS Air Pressure Switch, and CTIS Overspeed Indicator Manual
Light

CB41 15 AMP 24 VDC Intervehicular Clearance and Rear Lights Manual

CB42 10 AMP 24 VDC Intervehicular Blackout Clearance, Left Blackout Marker, Manual
and Right Blackout Marker Lights

CB43 15 AMP 24 VDC Intervehicular Left Turn Light and Stoplight Manual WTEC II

CB43 10 AMP WTEC III Transmission ECU Power Manual WTEC III

CB44 15 AMP 24 VDC Intervehicular Right Turn Light and Stoplight Manual WTEC II

CB44 15 AMP 24 VDC Intervehicular Right and Left Turn Lights and Stoplights Manual WTEC III

CB45 15 AMP Not Used Manual

CB48 20 AMP Not Used Manual

CB49 15 AMP Fuel/Water Separator, PTO Solenoid, PTO Switch, Winch In Manual
Solenoid, Winch In/Out Switch, Winch Out Solenoid, and Winch
Switch

CB50 15 AMP Dump Down Solenoid, Dump Up Solenoid, Dump Up/Down Switch, Manual M1090/M1
Tailgate Release Switch, Tailgate Release Solenoid, Wrecker 094
Control Panel, and Wrecker Remote Control

CB53 15 AMP Material Handling Crane Manual

7-38.2 Change 1
 TM 9-2320-366-20-3

Table 7-1.1 Power Distribution Panel (PDP) Circuit Breakers (CONT)

CB Amp Function Reset Remarks

CB54 8 AMP Blackout Drive Light Manual

CB61 Empty

CB62 Empty

CB63 Empty

CB64 Empty

CB65 8 AMP Front Right and Left Manual

Parking Lights

CB66 8 AMP Front Left, Front Right, Rear LH, and Rear RH Blackout Marker Manual
Lights and WTEC II/WTEC III TPSS Dimmer Module

CB67 25 AMP 12 VDC Intervehicular Marker Light and All Marker Lights Manual

CB68 25 AMP Auxiliary Oil Cooler Fan Motors Manual M1088/M1

089

CB68 20 AMP Auxiliary Oil Cooler Fan Motors Manual All models
except
M1088/M1
089

CB70 20 AMP Circuit Breakers CB54, CB65, CB66, CB74, and CB76, Dimmer Manual
Module, Instrument and Auxiliary Panel Rocker Switch Lights,
Instrument and Auxiliary Panel Gage Lights, Main Light Switch,
Master Power Switch, Personnel Heater Lights, Headlight HI/LO
Switch, and Rotating Warning Light Switch

CB71 15 AMP Hazard Warning Switch, Turn Signal Flasher, and Worklight Switch Manual

CB72 15 AMP Worklights, Blackout Override Switch Manual

CB73 8 AMP Backup Light Manual

CB74 10 AMP Turn Signal Flasher ECU Manual

CB76 15 AMP 12 VDC Intervehicular Left and Right Turn Signals, and Stoplight, Manual
24 VDC Intervehicular Auxiliary, Front Left and Right Turn Signals,
Hazard Warning Switch, Left and Right Blackout Stoplights, Left
and Right Turn Signal Indicators, Rear Right and Left Turn Signals,
Stoplight Switches (A) and (B), and Tractor Stoplight Switch

Change 1 7-38.3
TM 9-2320-366-20-3

7-9. CIRCUIT BREAKER, DIODE, AND RELAY REPLACEMENT (CONT)

Table 7-1.1 Power Distribution Panel (PDP) Circuit Breakers (CONT)

CB Amp Function Reset Remarks

CB77 10 AMP Instrument and Auxiliary Panel Gages, Audible Alarm, Manual
Emergency Brake Indicator Light, Engine Fan Off Indicator,
Engine Fan Off Switch, Engine Oil Pressure Switch, Low
Engine Oil Pressure Sensor,Engine Oil Pressure Switch
Indicator Light, Front and Rear Brake Air Indicator Lights,
Front and Rear Brake Air Indicator Light Switches, Front and
Rear Brake Air Pressure Transmitters, Magnetic Pickup,
Master Stop Indicator Light, Parking Brake Indicator Light,
Parking Brake Switch, PTO Indicator Light, PTO Pressure
Switch, Transmission Temperature Indicator Light, Troop
Transport Alarm Switch, Water Temperature Indicator Light,
Water Temperature Sensor, Water Temperature Switch and
Fuel Level Sensor

CB78 15 AMP Left and Right Headlights Auto

CB79 15 AMP WTEC II 10 AMP Fuse TEPSS, Fuel Solenoid, M1089 Manual WTEC II
Remote Engine Kill Switch, and Start Inhibit Pushbutton
Switch

CB79 15 AMP WTEC III Transmission ECU Power, Fuel Solenoid, M1089 Manual WTEC III
Remote Engine Kill Switch, and Start Inhibit Pushbutton
Switch

CB80 25 AMP 12 VDC Intervehicular Taillight, Left and Right Taillights Manual

b.Installation.

NOTE

Refer to Figure 7-1. Power Distribution Panel

(PDP) Circuit Breakers, Diodes, and Relays,
Table 7-1. Power Distribution Panel (PDP)
Relays, and Table 7-1.1 Power Distribution
Panel (PDP) Circuit Breakers for details.

Install circuit breaker (1) on PDP (2).

c.Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

End of Task.

7-38.4 Change 1
 TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR

This task covers:
a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP
Equipment Conditions Materials/Parts
Windshield wiper motor removed (para 18-4). Dispenser, Pressure Sensitive Adhesive Tape
Personnel heater removed (para 18-9). (Item 20, Appendix D)
Instrument panel assembly removed (para 7-15). Ties, Cable, Plastic (Item 69, Appendix D)
Lockwasher (4) (Item 71, Appendix G)
Tools and Special Tools Lockwasher (6) (Item 93, Appendix G)
Tool Kit, Auto Fuel (Item 43, Appendix C) Lockwasher (2) (Item 84, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (10) (Item 83, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Lockwasher (4) (Item 88, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C) Personnel Required
(2)

a. Removal.

NOTE

Remove plastic cable ties as required.

Tag wires and connection points prior to

disconnecting.

(1) Disconnect steering column switch connector J19 (1)

from connector P19 (2).

(2) Disconnect steering column switch connector P18 (3)

from connector J18 (4).

(3) Disconnect connector J118 (5) from connector P118 (6).

7-39
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(4) Disconnect connector J43 (7) from connector P43 (8).

(5) Disconnect connector J31 (9) from connector P31 (10).

(6) Remove screw (11), washer (12), and clamp (13) from
WTEC II dashboard cable assembly (14).

(7) Disconnect connector PX26 (15) from frequency ECU

connector (16).

(8) Remove two screws (17) and frequency ECU (18) from
left side dashboard (19).

7-40
 TM 9-2320-366-20-3

(9) Remove nut (20), lockwasher (21), and terminal lug

TL151 (22) from front brake air pressure
transmitter terminal G (23). Discard lockwasher.

(10) Remove nut (24), lockwasher (25), and terminal lug

TL157 (26) from front brake air pressure
transmitter terminal WK (27). Discard lockwasher.

(11) Remove nut (28), lockwasher (29), and terminal lug

TL150 (30) from rear brake air pressure transmitter
terminal G (31). Discard lockwasher.

(12) Remove nut (32), lockwasher (33), and terminal lug

TL156 (34) from rear brake air pressure transmitter
terminal WK (35). Discard lockwasher.

(13) Remove two nuts (36), lockwashers (37), and

terminal lugs TL153 (38) and TL152 (39) from rear
stoplight switch (40). Discard lockwashers.

(14) Remove two nuts (41), lockwashers (42), and

terminal lugs TL154 (43) and TL155 (44) from front
stoplight switch (45). Discard lockwashers.

Change 2 7-41
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform steps (15) and (16) on vehicles

equipped with auxiliary panel.

(15) Disconnect connector J912 (46) from connector P912

(47)

(16) Disconnect connector P913 (48) from connector J913

(49).

(17) Remove windshield wiper ECU (50) from PDP (51).

(18) Disconnect terminal lugs TL158 (52) and TL159 (53)

from start inhibit pushbutton switch (54).

(19) Remove spring clip (55) from start inhibit pushbutton

switch (54).

(20) Remove start inhibit pushbutton switch (54) from PDP

(51).

7-42
 TM 9-2320-366-20-3

NOTE

Perform step (21) on vehicles not equipped

with auxiliary panel.

(21) Disconnect connector P912A (56) from connector J912

(46).

(22) Disconnect connector J27 (57) from connector P27 (58).

(23) Disconnect connector J51 (59) from connector P51 (60).

(24) Disconnect connector PX34 (61) from fan solenoid

connector (62).

(25) Disconnect connector PX50 (63) from differential

solenoid connector (64).

(26) Disconnect connector J65 (65) from warning light cable

connector P65 (66).

(27) Disconnect connector P99 (67) from chemical alarm kit

cable connector J99 (68).

(28) Disconnect connector PX20 (69) from flasher module

(70).

(29) Disconnect connector P111 (71) from connector J111

(72).

Change 1 7-43
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(30) Loosen captive screw (73) and disconnect connector

PX33 (74) from WTEC II VIM (75).

NOTE

Perform step (31) on vehicles equipped with

cab radio.

(31) Disconnect connector J78 (76) from connector P78 (77).

NOTE

Perform step (32) on M1088.

(32) Remove two nuts (78), lockwashers (79), and terminal

lugs TL501 (80) and TL502 (81) from terminal studs (82
and 83). Discard lockwashers.

7-44
 TM 9-2320-366-20-3

(33) Disconnect WTEC II TEPSS dimmer module (84) from

connector J7 (85).

(34) Remove screw (86), lockwasher (87), terminal lug TL56

(88), and terminal lug (89) from PDP (51).

(35) Position terminal lug (89) on PDP (51) with lockwasher

(87) and screw (86).

(36) Remove screw (90), lockwasher (91), terminal lug TL41

(92), and four terminal lugs (93) from PDP (51).

(37) Position four terminal lugs (93) on PDP (51) with

lockwasher (91) and screw (90).

7-45
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(38) Remove screw (94), lockwasher (95), terminal lug TL42

(96), and four terminal lugs (97) from PDP (51).

(39) Position four terminal lugs (97) on PDP (51) with

lockwasher (95), and screw (94).

(40) Remove terminal lug TL86 (98) from terminal board TB2
(99) position 4.

(41) Remove two nuts (100), lockwashers (101), washers

(102), cover (103), and two washers (102) from terminal
board TB1 (104).

(42) Remove terminal lug TL74 (105) from terminal board

TB1 (104) position 3.

(43) Remove terminal lug TL73 (106) from terminal board

TB1 (104) position 1.

7-46
 TM 9-2320-366-20-3

(44) Remove terminal lug TL71 (107) from terminal board

TB2 (99) position 2.

(45) Remove terminal lug TL75 (108) from terminal board

TB1 (104) position 2.

(46) Position two washers (102) and cover (103) on terminal

board TB1 (104) with two washers (102), lockwashers
(101), and nuts (100).

(47) Remove terminal lug TL87 (109) from terminal board

TB2 (99) position 6.

(48) Remove terminal lug TL14 (110) from terminal board

TB2 (99) position 12.

NOTE

Step (49) requires the aid of an assistant.

(49) Remove WTEC II dashboard cable assembly (14) from

dashboard (19).

NOTE

• Perform steps (50) and (51) on M1084/

M1086/M1088 and M1089.

• Tag relays and circuit breaker prior to removal.

(50) Remove relay K12 (111) from PDP (51).

(51) Remove circuit breaker CB72 (112) from PDP (51).

(52) Remove relay K15 (113) from PDP (51).

7-47
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(53) Remove circuit breaker CB68 (114) from PDP (51).

(54) Deleted

(55) Deleted

(56) Deleted

b. Disassembly.

NOTE

Tag wires and connection points prior to

removal.

(1) Remove nut (1), lockwasher (2), washer (3), and wire
1603 (4) from terminal board TB2 (5). Discard
lockwasher.

(2) Remove 42 quick disconnect terminals (6) from terminal

board TB2 (5) positions 3, 8, 9, 10, 11, 14, 16, 17, 18,
20, 21, 22, 23, 24, 25, 26, 28, 30, 31, 32, 33, 34, 35, 36,
37, 39, 43, 44, 45, 46, 47, 50, 53, 55, 56, 58, 60, 62, 70,
74, 77, and 79.

(3) Remove two nuts (7), lockwashers (8), screws (9), and
terminal board TB2 (5) from PDP frame (10). Discard
lockwashers.

7-48 Change 1
 TM 9-2320-366-20-3

(4) Remove screw (11), lockwasher (12), and wire 1603 (4)
from PDP frame (10). Discard lockwasher.

(5) Remove two nuts (13), lockwashers (14), washers (15),

cover (16), and two washers (15) from terminal board
TB1 (17). Discard lockwashers.

(6) Remove 40 quick disconnect terminals (18) from terminal

board TB1 (17) positions 5, 9, 11, 19, 20, 22, 23, 24, 26,
27, 28, 29, 30, 31, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,
43, 46, 47, 50, 51, 52, 53, 54, 56, 57, 59, 60, 61, 62, 63,
and 64.

(7) Remove two nuts (19), lockwashers (20), washers (21),

spacers (22), terminal board TB1 (17), two spacers (23),
and screws (24) from PDP frame (10). Discard
lockwashers.

(8) Remove six quick disconnect terminals (25) from

connector PX21 (26).

(9) Push in two locking tabs (27) and remove connector

PX21 (26) from front of PDP frame (10).

7-49
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Tag terminal lugs and connection points prior

to removal.

(10) Remove screw (28), lockwasher (29), and four terminal

lugs (30) from PDP (31). Discard lockwasher.

(11) Remove screw (32), lockwasher (33), and four terminal

lugs (34) from PDP (31). Discard lockwasher.

(12) Remove 94 retaining locks (35) from PDP (31).

(13) Remove 94 terminals (36) from PDP (31).

(14) Remove bus bar X1 (37) from PDP (31).

(15) Remove bus bar X6 (38) from PDP (31).

(16) Remove bus bar X2 (39) from PDP (31).

7-50
 TM 9-2320-366-20-3

(17) Remove 41 retaining locks (40) from PDP (31).

(18) Remove 41 terminals (41) from PDP (31).

(19) Remove six nuts (42), lockwashers (43), screws (44),

washers (45), and PDP (31) from PDP frame (10).
Discard lockwashers.

NOTE

Tag diodes, relays, and circuit breakers prior

to removal.

(20) Remove three diodes (46) from PDP (31).

(21) Remove 20 relays (47) from PDP (31).

(22) Remove 30 circuit breakers (48) from PDP (31).

7-51
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

c. Assembly.

(1) Install 30 circuit breakers (1) on PDP (2).

(2) Install 20 relays (3) on PDP (2).

(3) Install three diodes (4) on PDP (2).

(4) Position PDP (2) on PDP frame (5) with six washers (6),
screws (7), lockwashers (8), and nuts (9).

(5) Tighten six nuts (9) to 46-57 lb-ft (63-77 N·m).

(6) Install 41 terminals (10) on PDP (2).

(7) Install 41 retaining locks (11) on PDP (2).

7-52
 TM 9-2320-366-20-3

(8) Install bus bar X2 (12) on PDP (2).

(9) Install bus bar X6 (13) on PDP (2).

(10) Install bus bar X1 (14) on PDP (2).

(11) Install 94 terminals (15) on PDP (2).

(12) Install 94 retaining locks (16) on PDP (2).

(13) Position four terminal lugs (17) on PDP (2) with

lockwasher (18), and screw (19).

(14) Position four terminal lugs (20) on PDP (2) with

lockwasher (21), and screw (22).

(15) Push in two locking tabs (23) and install connector PX21
(24) through front of PDP frame (5).

(16) Install six quick disconnect terminals (25) in connector

PX21 (24).

7-53
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(17) Install terminal board TB1 (26) on PDP frame (5) with
two screws (27), spacers (28), spacers (29), washers
(30), lockwashers (31), and nuts (32).

(18) Install 40 quick disconnect terminals (33) on terminal

board TB1 (26) positions 5, 9, 11, 19, 20, 22, 23, 24, 26,
27, 28, 29, 30, 31, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,
43, 46, 47, 50, 51, 52, 53, 54, 56, 57, 59, 60, 61, 62, 63,
and 64.

(19) Position two washers (34) and cover (35) on terminal

board TB1 (26) with two washers (34), lockwashers (36),
and nuts (37).

(20) Position wire 1603 (38) on PDP frame (5) with

lockwasher (39), and screw (40).

7-54
 TM 9-2320-366-20-3

(21) Install terminal board TB2 (41) on PDP frame (5) with
two screws (42), lockwashers (43), and nuts (44).

(22) Install 42 quick disconnect terminals (45) on terminal

board TB2 (41) positions 3, 8, 9, 10, 11, 14, 16, 17, 18,
20, 21, 22, 23, 24, 25, 26, 28, 30, 31, 32, 33, 34, 35, 36,
37, 39, 43, 44, 45, 46, 47, 50, 53, 55, 56, 58, 60, 62, 70,
74, 77, and 79.

(23) Position wire 1603 (38) on terminal board TB2 (41) with
washer (46), lockwasher (47), and nut (48).

d. Installation.

(1) Deleted

(2) Deleted

(3) Deleted

(4) Install circuit breaker CB68 (5) on PDP (2).

Change 1 7-55
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(5) Install relay K15 (6) on PDP (2).

NOTE

Perform steps (6) and (7) on M1084/

M1086/M1088 and M1089.

(6) Install circuit breaker CB72 (7) on PDP (2).

(7) Install relay K12 (8) on PDP (2).

NOTE

• Step (8) requires the aid of an assistant.

• Install plastic cable ties as required.

(8) Position WTEC II dashboard cable assembly (9) in

dashboard (10).

(9) Install terminal lug TL14 (11) on terminal board TB2 (12)
position 12.

(10) Install terminal lug TL87 (13) on terminal board TB2 (12)
position 6.

(11) Remove two nuts (14), lockwashers (15), washers (16),

cover (17), and two washers (16) from terminal board
TB1 (18).

(12) Install terminal lug TL75 (19) on terminal board TB1 (18)
position 2.

(13) Install terminal lug TL71 (20) on terminal board TB2 (12)
position 2.

7-56
 TM 9-2320-366-20-3

(14) Install terminal lug TL73 (21) on terminal board TB1 (18)
position 1.

(15) Install terminal lug TL74 (22) on terminal board TB1 (18)
position 3.

(16) Install two washers (16) and cover (17) on terminal

board TB1 (18) with two washers (16), lockwashers (15),
and nuts (14).

(17) Install terminal lug TL86 (23) on terminal board TB2 (12)
position 4.

(18) Remove screw (24), lockwasher (25), and four terminal

lugs (26) from PDP (2).

(19) Position four terminal lugs (26) and terminal lug TL42
(27) on PDP (2) with lockwasher (25), and screw (24).

(20) Tighten screw (24) to 35-45 lb-in. (4-5 N·m).

(21) Remove screw (28), lockwasher (29), and four terminal

lugs (30) from PDP (2).

(22) Position four terminal lugs (30) and terminal lug TL41
(31) on PDP (2) with lockwasher (29) and screw (28).

(23) Tighten screw (28) to 35-45 lb-in. (4-5 N·m).

(24) Remove screw (32), lockwasher (33), and terminal lug

(34) from PDP (2).

(25) Position terminal lug (34) and terminal lug TL56 (35) on
PDP (2) with lockwasher (33) and screw (32).

(26) Tighten screw (32) to 35-45 lb-in. (4-5 N·m).

7-57
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(27) Connect WTEC II TEPSS dimmer module (36) to

connector J7 (37).

NOTE

Perform step (28) on M1088.

(28) Install terminal lugs TL502 (38) and TL501 (39) on

terminal studs (40 and 41) with two lockwashers (42)
and nuts (43).

NOTE

Perform step (29) on vehicles equipped with

cab radio.

(29) Connect connector P78 (44) to connector J78 (45).

7-58
 TM 9-2320-366-20-3

(30) Connect connector PX33 (46) to WTEC II VIM (47).

(31) Tighten captive screw (48) in connector PX33 (46).

(32) Connect connector P111 (49) to connector J111 (50).

(33) Connect connector PX20 (51) to flasher module (52).

(34) Connect connector J99 (53) to chemical alarm kit cable

connector P99 (54).

(35) Connect connector P65 (55) to warning light cable

connector J65 (56).

(36) Connect differential lock solenoid connector (57) to

connector PX50 (58).

(37) Connect fan solenoid connector (59) to connector PX34

(60).

7-59
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(38) Connect connector P51 (61) to connector J51 (62).

(39) Connect connector P27 (63) to connector J27 (64).

NOTE

Perform step (40) on vehicles not equipped

with auxiliary panel.

(40) Connect connector P912A (65) to connector J912 (66).

(41) Position start inhibit pushbutton switch (67) in PDP (2).

(42) Install spring clip (68) on start inhibit pushbutton switch

(67).

(43) Connect terminal lugs TL159 (69) and TL158 (70) to

start inhibit pushbutton switch (67).

(44) Install windshield wiper ECU (71) on PDP (2).

7-60 Change 1
 TM 9-2320-366-20-3

NOTE

Perform steps (45) and (46) on vehicles

equipped with auxiliary panel.

(45) Connect connector P913 (72) to connector J913

(73).

(46) Connect connector P912 (74) to connector J912

(66).

(47) Install terminal lugs TL155 (75) and TL154 (76) on

front stoplight switch (77) with two lockwashers (78)
and nuts (79).

(48) Install terminal lugs TL152 (80) and TL153 (81) on

rear stoplight switch (82) with two lockwashers (83)
and nuts (84).

(49) Install terminal lug TL156 (85) on rear brake air

pressure transmitter terminal WK (86) with
lockwasher (87) and nut (88).

(50) Install terminal lug TL150 (89) on rear brake air

pressure transmitter terminal G (90) with
lockwasher (91) and nut (92).

Change 2 7-61
TM 9-2320-366-20-3

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(51) Install terminal lug TL157 (93) on front brake air

pressure transmitter terminal WK (94) with
lockwasher (95) and nut (96).

(52) Install terminal lug TL151 (97) on front brake air

pressure transmitter terminal G (98) with
lockwasher (99) and nut (100).

(53) Install frequency ECU (101) on left side dashboard

(10) with two screws (102).

(54) Connect connector PX26 (103) to frequency ECU

connector (104).

(55) Position clamp (105) on WTEC II dashboard cable

assembly (9).

(56) Position clamp (105) on dashboard (10) with

washer (106) and screw (107).

(57) Tighten screw (107) to 35-45 lb-in. (4-5 N•m).

7-62 Change 2
 TM 9-2320-366-20-3

(58) Connect connector J31 (108) to connector P31 (109).

(59) Connect connector J43 (110) to connector P43 (111).

(60) Connect connector P118 (112) to connector J118 (113).

(61) Connect steering column switch connector P18 (114) to

connector J18 (115).

(62) Connect steering column switch connector J19 (116) to

connector P19 (117).

e. Follow-On Maintenance.

(1) Install windshield wiper motor (para 18-4).

(2) Install personnel heater (para 18-9).

(3) Install instrument panel assembly (para 7-15).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check instruments operation (TM 9-2320-366-10-1).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-63
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR

This task covers:
a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP
Equipment Conditions Materials/Parts
Windshield wiper motor removed (para 18-4). Dispenser, Pressure Sensitive Adhesive Tape
Personnel heater removed (para 18-9). (Item 20, Appendix D)
Instrument panel assembly removed (para 7-15). Ties, Cable, Plastic (Item 69, Appendix D)
Lockwasher (4) (Item 71, Appendix G)
Tools and Special Tools Lockwasher (6) (Item 93, Appendix G)
Tool Kit, Auto Fuel (Item 43, Appendix C) Lockwasher (2) (Item 84, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (11) (Item 83, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Lockwasher (4) (Item 88, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C) Personnel Required
(2)

a. Removal.

NOTE

Remove plastic cable ties as required.

Tag wires and connection points prior to

disconnecting.

(1) Disconnect steering column switch connector J19 (1)

from connector P19 (2).

(2) Disconnect steering column switch connector P18 (3)

from connector J18 (4).

7-64
 TM 9-2320-366-20-3

(3) Disconnect connector J43 (5) from connector P43 (6).

(4) Disconnect connector J31 (7) from connector P31 (8).

(5) Remove screw (9), washer (10), and clamp (11) from
WTEC III dashboard cable assembly (12).

(6) Disconnect connector PX26 (13) from frequency ECU

connector (14).

(7) Remove two screws (15) and frequency ECU (16) from
left side dashboard (17).

7-65
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(8) Remove nut (18), lockwasher (19), and terminal lug

TL151 (20) from front brake air pressure
transmitter terminal G (21). Discard lockwasher.

(9) Remove nut (22), lockwasher (23), and terminal lug

TL157 (24) from front brake air pressure
transmitter terminal WK (25). Discard lockwasher.

(10) Remove nut (26), lockwasher (27), and terminal lug

TL150 (28) from rear brake air pressure transmitter
terminal G (29). Discard lockwasher.

(11) Remove nut (30), lockwasher (31), and terminal lug

TL156 (32) from rear brake air pressure transmitter
terminal WK (33). Discard lockwasher.

(12) Remove two nuts (34), lockwashers (35), and

terminal lugs TL153 (36) and TL152 (37) from rear
stoplight switch (38). Discard lockwashers.

(13) Remove two nuts (39), lockwashers (40), and

terminal lugs TL154 (41) and TL155 (42) from front
stoplight switch (43). Discard lockwashers.

7-66 Change 2
 TM 9-2320-366-20-3

NOTE

Perform steps (14) and (15) on vehicles

equipped with auxiliary panel.

(14) Disconnect connector J912 (44) from connector P912

(45)

(15) Disconnect connector P913 (46) from connector J913

(47).

(16) Remove windshield wiper ECU (48) from PDP (49).

(17) Disconnect terminal lugs TL158 (50) and TL159 (51)

from start inhibit pushbutton switch (52).

(18) Remove spring clip (53) from start inhibit pushbutton

switch (52).

(19) Remove start inhibit pushbutton switch (52) from PDP

(49).

7-67
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform step (20) on vehicles not equipped

with auxiliary panel.

(20) Disconnect connector P912A (54) from connector J912

(44).

(21) Disconnect connector J27 (55) from connector P27 (56).

(22) Disconnect connector J51 (57) from connector P51 (58).

(23) Disconnect connector PX34 (59) from fan solenoid

connector (60).

(24) Disconnect connector PX50 (61) from differential

solenoid connector (62).

(25) Disconnect connector J65 (63) from warning light cable

connector P65 (64).

(26) Disconnect connector P99 (65) from chemical alarm kit

cable connector J99 (66).

7-68 Change 1
 TM 9-2320-366-20-3

(27) Disconnect connector PX20 (67) from flasher module

(68).

(28) Disconnect connector P111 (69) from connector J111

(70).

(29) Disconnect connector clamp (71) from connector P115

(72).

(30) Disconnect connector P115 (72) from WTEC III

transmission ECU (73).

(31) Disconnect connector clamp (74) from connector P116

(75).

(32) Disconnect connector P116 (75) from WTEC III

transmission ECU (73).

NOTE

Perform step (33) on vehicles equipped with

cab radio.

(33) Disconnect connector J78 (76) from connector P78 (77).

7-69
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform step (34) on M1088.

(34) Remove two nuts (78), lockwashers (79), and terminal

lugs TL501 (80) and TL502 (81) from terminal studs (82
and 83). Discard lockwashers.

(35) Remove screw (84), lockwasher (85), terminal lug TL56

(86), and terminal lug (87) from PDP (49).

(36) Position terminal lug (87) on PDP (49) with lockwasher

(85) and screw (84).

(37) Remove screw (88), lockwasher (89), terminal lug TL41

(90), and four terminal lugs (91) from PDP (49).

(38) Position four terminal lugs (91) on PDP (49) with

lockwasher (89) and screw (88).

(39) Remove screw (92), lockwasher (93), terminal lug TL42

(94), and four terminal lugs (95) from PDP (49).

(40) Position four terminal lugs (95) on PDP (49) with

lockwasher (93), and screw (92).

7-70
 TM 9-2320-366-20-3

(41) Remove terminal lug TL86 (96) from terminal board TB2
(97) position 4.

(42) Remove two nuts (98), lockwashers (99), washers (100),

cover (101), and two washers (100) from terminal board
TB1 (102).

(43) Remove terminal lug TL74 (103) from terminal board

TB1 (102) position 3.

(44) Remove terminal lug TL73 (104) from terminal board

TB1 (102) position 1.

(45) Remove terminal lug TL71 (105) from terminal board

TB2 (97) position 2.

(46) Remove terminal lug TL75 (106) from terminal board

TB1 (102) position 2.

(47) Position two washers (100) and cover (101) on terminal

board TB1 (102) with two washers (100), lockwashers
(99), and nuts (98).

(48) Remove terminal lug TL87 (107) from terminal board

TB2 (97) position 6.

(49) Remove terminal lug TL14 (108) from terminal board

TB2 (97) position 12.

7-71
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(50) Remove nut (109), lockwasher (110), terminal lug TL190

(111), terminal lug TL57 (112), two washers (113), and
screw (114) from dashboard (17). Discard lockwasher.

NOTE

Step (51) requires the aid of an assistant.

(51) Remove WTEC III dashboard cable assembly (12) from

dashboard (17).

NOTE

• Perform steps (52) and (53) on M1084/

M1086/M1088 and M1089.

• Tag relays and circuit breaker prior to removal.

(52) Remove relay K12 (115) from PDP (49).

(53) Remove circuit breaker CB72 (116) from PDP (49).

(54) Remove relay K15 (117) from PDP (49).

7-72
 TM 9-2320-366-20-3

(55) Remove circuit breaker CB68 (118) from PDP (49).

(56) Deleted

(57) Deleted

(58) Deleted

b. Disassembly.

NOTE

Tag wires and connection points prior to

removal.

(1) Remove nut (1), lockwasher (2), washer (3), and wire
1603 (4) from terminal board TB2 (5). Discard
lockwasher.

(2) Remove 46 quick disconnect terminals (6) from terminal

board TB2 (5) positions 3, 8, 9, 10, 11, 13, 14, 15, 16,
17, 18, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 35, 36, 37, 39, 40, 43, 44, 45, 46, 47, 50, 53, 55,
56, 60, 62, 70, 74, 77, and 79.

(3) Remove two nuts (7), lockwashers (8), screws (9), and
terminal board TB2 (5) from PDP frame (10). Discard
lockwashers.

Change 1 7-73
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(4) Remove screw (11), lockwasher (12), and wire 1603 (4)
from PDP frame (10). Discard lockwasher.

(5) Remove two nuts (13), lockwashers (14), washers (15),

cover (16), and two washers (15) from terminal board
TB1 (17). Discard lockwashers.

(6) Remove 38 quick disconnect terminals (18) from terminal

board TB1 (17) positions 5, 11, 20, 23, 24, 26, 27, 28,
29, 30, 31, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 46,
47, 50, 51, 52, 53, 54, 56, 57, 58, 59, 60, 61, 62, 63,
and 64.

(7) Remove two nuts (19), lockwashers (20), washers (21),

spacers (22), terminal board TB1 (17), two spacers (23),
and screws (24) from PDP frame (10). Discard
lockwashers.

(8) Remove six quick disconnect terminals (25) from

connector PX21 (26).

(9) Push in two locking tabs (27) and remove connector

PX21 (26) from front of PDP frame (10).

7-74
 TM 9-2320-366-20-3

NOTE

Tag terminal lugs and connection points prior

to removal.

(10) Remove screw (28), lockwasher (29), and four terminal

lugs (30) from PDP (31). Discard lockwasher.

(11) Remove screw (32), lockwasher (33), and four terminal

lugs (34) from PDP (31). Discard lockwasher.

(12) Remove 94 retaining locks (35) from PDP (31).

(13) Remove 94 terminals (36) from PDP (31).

(14) Remove bus bar X1 (37) from PDP (31).

(15) Remove bus bar X6 (38) from PDP (31).

(16) Remove bus bar X2 (39) from PDP (31).

(17) Remove 41 retaining locks (40) from PDP (31).

(18) Remove 41 terminals (41) from PDP (31).

7-75
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(19) Remove six nuts (42), lockwashers (43), screws (44),

washers (45), and PDP (31) from PDP frame (10).
Discard lockwashers.

NOTE

Tag diodes, relays, and circuit breakers prior

to removal.

(20) Remove three diodes (46) from PDP (31).

(21) Remove 24 relays (47) from PDP (31).

(22) Remove 29 circuit breakers (48) from PDP (31).

c. Assembly.

(1) Install 29 circuit breakers (1) on PDP (2).

(2) Install 24 relays (3) on PDP (2).

(3) Install three diodes (4) on PDP (2).

7-76
 TM 9-2320-366-20-3

(4) Position PDP (2) on PDP frame (5) with six washers (6),
screws (7), lockwashers (8), and nuts (9).

(5) Tighten six nuts (9) to 46-57 lb-ft (63-77 N·m).

(6) Install 41 terminals (10) on PDP (2).

(7) Install 41 retaining locks (11) on PDP (2).

(8) Install bus bar X2 (12) on PDP (2).

(9) Install bus bar X6 (13) on PDP (2).

(10) Install bus bar X1 (14) on PDP (2).

(11) Install 94 terminals (15) on PDP (2).

(12) Install 94 retaining locks (16) on PDP (2).

7-77
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(13) Position four terminal lugs (17) on PDP (2) with

lockwasher (18), and screw (19).

(14) Position four terminal lugs (20) on PDP (2) with

lockwasher (21), and screw (22).

(15) Push in two locking tabs (23) and install connector PX21
(24) through front of PDP frame (5).

(16) Install six quick disconnect terminals (25) in connector

PX21 (24).

(17) Install terminal board TB1 (26) on PDP frame (5) with
two screws (27), spacers (28), spacers (29), washers
(30), lockwashers (31), and nuts (32).

7-78
 TM 9-2320-366-20-3

(18) Install 38 quick disconnect terminals (33) on terminal

board TB1 (26) positions 5, 11, 20, 23, 24, 26, 27, 28,
29, 30, 31, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 46,
47, 50, 51, 52, 53, 54, 56, 57, 58, 59, 60, 61, 62, 63,
and 64.

(19) Position two washers (34) and cover (35) on terminal

board TB1 (26) with two washers (34), lockwashers (36),
and nuts (37).

(20) Position wire 1603 (38) on PDP frame (5) with

lockwasher (39), and screw (40).

(21) Install terminal board TB2 (41) on PDP frame (5) with
two screws (42), lockwashers (43), and nuts (44).

(22) Install 46 quick disconnect terminals (45) on terminal

board TB2 (41) positions 3, 8, 9, 10, 11, 13, 14, 15, 16,
17, 18, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34, 35, 36, 37, 39, 40, 43, 44, 45, 46, 47, 50, 53, 55,
56, 60, 62, 70, 74, 77, and 79.

(23) Position wire 1603 (38) on terminal board TB2 (41) with
washer (46), lockwasher (47), and nut (48).

7-79
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

d. Installation.

(1) Deleted

(2) Deleted

(3) Deleted

(4) Install circuit breaker CB68 (5) on PDP (2).

(5) Install relay K15 (6) on PDP (2).

NOTE

Perform steps (6) and (7) on M1084/

M1086/M1088 and M1089.

(6) Install circuit breaker CB72 (7) on PDP (2).

(7) Install relay K12 (8) on PDP (2).

NOTE

• Step (8) requires the aid of an assistant.

• Install plastic cable ties as required.

(8) Position WTEC III dashboard cable assembly (9) in

dashboard (10).

(9) Install two washers (11), screw (12), terminal lug TL57
(13), terminal lug TL190 (14), lockwasher (15), and nut
(16) on dashboard (10).

7-80 Change 1
 TM 9-2320-366-20-3

(10) Install terminal lug TL14 (17) on terminal board TB2 (18)
position 12.

(11) Install terminal lug TL87 (19) on terminal board TB2 (18)
position 6.

(12) Remove two nuts (20), lockwashers (21), two washers

(22), cover (23), and two washers (22) from terminal
board TB1 (24).

(13) Install terminal lug TL75 (25) on terminal board TB1 (24)
position 2.

(14) Install terminal lug TL71 (26) on terminal board TB2 (18)
position 2.

(15) Install terminal lug TL73 (27) on terminal board TB1 (24)
position 1.

(16) Install terminal lug TL74 (28) on terminal board TB1 (24)
position 3.

(17) Install two washers (22) and cover (23) on terminal

board TB1 (24) with two washers (22), lockwashers (21),
and nuts (20).

(18) Install terminal lug TL86 (29) on terminal board TB2 (18)
position 4.

(19) Remove screw (30), lockwasher (31), and four terminal

lugs (32) from PDP (2).

(20) Position four terminal lugs (32) and terminal lug TL42
(33) on PDP (2) with lockwasher (31), and screw (30).

(21) Tighten screw (30) to 35-45 lb-in. (4-5 N·m).

7-81
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(22) Remove screw (34), lockwasher (35), and four terminal

lugs (36) from PDP (2).

(23) Position four terminal lugs (36) and terminal lug TL41
(37) on PDP (2) with lockwasher (35) and screw (34).

(24) Tighten screw (34) to 35-45 lb-in. (4-5 N·m).

(25) Remove screw (38), lockwasher (39), and terminal lug

(40) from PDP (2).

(26) Position terminal lug (40) and terminal lug TL56 (41) on
PDP (2) with lockwasher (39) and screw (38).

(27) Tighten screw (38) to 35-45 lb-in. (4-5 N·m).

NOTE

Perform step (28) on M1088.

(28) Install terminal lugs TL502 (42) and TL501 (43) on

terminal studs (44 and 45) with two lockwashers (46)
and nuts (47).

NOTE

Perform step (29) on vehicles equipped with

cab radio.

(29) Connect connector P78 (48) to connector J78 (49).

7-82
 TM 9-2320-366-20-3

(30) Connect connector P116 (50) to WTEC III transmission

ECU (51).

(31) Connect connector clamp (52) on connector P116 (50).

(32) Connect connector P115 (53) to WTEC III transmission

ECU (51).

(33) Connect connector clamp (54) on connector P115 (53).

(34) Connect connector P111 (55) to connector J111 (56).

(35) Connect connector PX20 (57) to flasher module (58).

(36) Connect connector J99 (59) to chemical alarm kit cable

connector P99 (60).

(37) Connect connector P65 (61) to warning light cable

connector J65 (62).

(38) Connect differential lock solenoid connector (63) to

connector PX50 (64).

(39) Connect fan solenoid connector (65) to connector PX34

(66).

7-83
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(40) Connect connector P51 (67) to connector J51 (68).

(41) Connect connector P27 (69) to connector J27 (70).

NOTE

Perform step (42) on vehicles not equipped

with auxiliary panel.

(42) Connect connector P912A (71) to connector J912 (72).

(43) Position start inhibit pushbutton switch (73) in PDP (2).

(44) Install spring clip (74) on start inhibit pushbutton switch

(73).

(45) Connect terminal lugs TL159 (75) and TL158 (76) to

start inhibit pushbutton switch (73).

(46) Install windshield wiper ECU (77) on PDP (2).

7-84 Change 1
 TM 9-2320-366-20-3

NOTE

Perform steps (47) and (48) on vehicles

equipped with auxiliary panel.

(47) Connect connector P913 (78) to connector J913

(79).

(48) Connect connector P912 (80) to connector J912

(72).

(49) Install terminal lugs TL155 (81) and TL154 (82) on

front stoplight switch (83) with two lockwashers
(84) and nuts (85).

(50) Install terminal lugs TL152 (86) and TL153 (87) on

rear stoplight switch (88) with two lockwashers (89)
and nuts (90).

(51) Install terminal lug TL156 (91) on rear brake air

pressure transmitter terminal WK (92) with
lockwasher (93) and nut (94).

(52) Install terminal lug TL150 (95) on rear brake air

pressure transmitter terminal G (96) with
lockwasher (97) and nut (98).

Change 2 7-85
TM 9-2320-366-20-3

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR (CONT)

(53) Install terminal lug TL157 (99) on front brake air

pressure transmitter terminal WK (100) with
lockwasher (101) and nut (102).

(54) Install terminal lug TL151 (103) on front brake air

pressure transmitter terminal G (104) with
lockwasher (105) and nut (106).

(55) Install frequency ECU (107) on left side dashboard

(10) with two screws (108).

(56) Connect connector PX26 (109) to frequency ECU

connector (110).

(57) Position clamp (111) on WTEC III dashboard cable

assembly (9).

(58) Position clamp (111) on dashboard (10) with washer

(112) and screw (113).

(59) Tighten screw (113) to 35-45 lb-in. (4-5 N•m).

7-86 Change 2
 TM 9-2320-366-20-3

(60) Connect connector J31 (114) to connector P31 (115).

(61) Connect connector J43 (116) to connector P43 (117).

(62) Connect steering column switch connector P18 (118) to

connector J18 (119).

(63) Connect steering column switch connector J19 (120) to

connector P19 (121).

e. Follow-On Maintenance.

(1) Install windshield wiper motor (para 18-4).

(2) Install personnel heater (para 18-9).

(3) Install instrument panel assembly (para 7-15).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check instruments operation (TM 9-2320-366-10-1).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-87
TM 9-2320-366-20-3

7-12. DIMMER SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Instrument panel assembly removed for access Tool Kit, Genl Mech (Item 46, Appendix C)
(para 7-15).

a. Removal.

(1) Disconnect connector clamp (1) from dimmer switch

connector (2).

(2) Disconnect connector PX24 (3) from dimmer switch

connector (2).

(3) Loosen screw (4) on dimmer switch knob (5).

(4) Remove dimmer switch knob (5) from dimmer switch (6).

(5) Remove nut (7), washer (8), and dimmer switch (6) from
instrument panel assembly (9).

b. Installation.

(1) Install dimmer switch (6) in instrument panel assembly

(9) with washer (8) and nut (7).

(2) Install dimmer switch knob (5) on dimmer switch (6).

(3) Tighten screw (4) on dimmer switch knob (5).

(4) Connect connector PX24 (3) to dimmer switch connector

(2).

(5) Connect connector clamp (1) on dimmer switch

connector (2).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Check dimmer switch operation (TM 9-2320-366-10-1).

End of Task.

7-88
 TM 9-2320-366-20-3

7-13. WTEC II TRANSMISSION ECU PUSHBUTTON SHIFT SELECTOR (TEPSS) DIMMER

MODULE REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
PDP cover removed (para 16-2).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) out to gain access.

NOTE

Remove plastic cable ties as required.

(4) Disconnect connector J7 (5) from WTEC II TEPSS

dimmer module connector (6).

7-89
TM 9-2320-366-20-3

7-13. WTEC II TRANSMISSION ECU PUSHBUTTON SHIFT SELECTOR (TEPSS) DIMMER

MODULE REPLACEMENT (CONT)

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Connect connector J7 (1) to WTEC II TEPSS dimmer

module connector (2).

(2) Install PDP (3) on dashboard (4) with three screws (5).

(3) Install three washers (6) and screws (7) in PDP (3).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

End of Task.

7-90
 TM 9-2320-366-20-3

7-14. ELECTRICAL GAGES REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access (para Ties, Cable, Plastic (Item 69, Appendix D)
7-15). Nut, Self-Locking (2) (Item 133, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

NOTE

All electrical gages are removed the same

way. Speedometer shown.

(1) Disconnect connector clamp (1) from speedometer

connector (2).

NOTE

Remove plastic cable ties as required.

(2) Disconnect connector PX8 (3) from speedometer

connector (2).

NOTE

Note position of speedometer prior to

removal.

(3) Remove two protective caps (4), self-locking nuts (5),

retaining ring (6), and speedometer (7) from instrument
panel assembly (8). Discard self-locking nuts.

7-91
TM 9-2320-366-20-3

7-14. ELECTRICAL GAGES REPLACEMENT (CONT)

b. Installation.

CAUTION

Ensure dipswitch settings are correct.

Failure to comply may result in inaccurate
speedometer readings.

NOTE

Perform steps (1) through (3) on

speedometer.
(1) Remove cover (1) from speedometer (2).

(2) Set dipswitches 3,6,7, and 9 in the down position.

(3) Set dipswitches 1,2,4,5,8, and 10 in the up position.

NOTE

Note position of speedometer prior to

installation.

(4) Position speedometer (2) in instrument panel

assembly (3) with retaining ring (4) and two self
locking nuts (5).

(5) Tighten two self-locking nuts (5) to 9 lb-in. (1 N•m).

(6) Install two protective caps (6) on speedometer (2).

NOTE

Install plastic cable ties as required.

(7) Connect connector PX8 (7) on speedometer

connector (8).

(8) Connect connector clamp (9) on speedometer

connector (8).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Check gage(s) operation (TM 9-2320-366-10-1).

End of Task.

7-92 Change 2
 TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly
INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Steering wheel removed (para 13-2). (Item 20, Appendix D)
Inclinometer removed (para 16-29)
Dump Switch Bracket removed (para 7-146)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46 , Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

NOTE

Perform steps (1) through (4) if removing

instrument panel assembly for access.

(1) Loosen screw (1) in HAND THROTTLE knob (2).

(2) Remove HAND THROTTLE knob (2) from HAND

THROTTLE lever (3).

NOTE

Depending upon pre-conditioned items

removed; configuration of instrument panel
can have from 12 to 16 screw. Configuration
with 16 screws shown.

(3) Remove 16 screws (4) and washers (5) from

instrument panel assembly (6).

(4) Lift instrument panel assembly (6) outward to gain

access.

Change 2 7-93
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Remove plastic cable ties as required.

(5) Disconnect connector PX7 (7) from lighted indicator

display (8).

NOTE

All electrical gages are disconnected the

same way. OIL PRESS gage shown. Refer
to Table 7-1.2 Electrical Gages
Connectors for correct combinations of
gages and connectors.

Table 7-1.2 Electrical Gages Connectors

Electrical Gage Connector Number
FRONT BRAKE AIR PX4
REAR BRAKE AIR PX5
FUEL PX9
Speedometer PX8
OIL PRESS PX6
VOLTS PX10
WATER TEMP PX11

(6) Disconnect connector clamp (9) from OIL PRESS gage

connector (10).

(7) Disconnect connector (11) from OIL PRESS gage

connector (10).

(8) Perform steps (6) and (7) on remaining electrical gages.

7-94 Change 1
 TM 9-2320-366-20-3

NOTE

• Vehicle serial numbers 0002 through 0017, 0019

through 0025, 0027 through 0031, 0033 through
0038, 0040 and 0041, 0043 through 0053, 0055
through 0089, 0091 through 0254, 0256 through
0258, 0260, 0261, 0263 through 2400, and 2402
through 3091 are not equipped with LAMP
TEST switch.

• Vehicle serial numbers 0001 through 1477 were

originally equipped with dashboard cable
assemblies containing two unused connectors
for LAMP TEST switch. Vehicle serial numbers
1478 through 3091 were originally equipped with
dashboard cable assemblies without connectors
for LAMP TEST switch.

• All rocker switches are disconnected the same

way. Hazard lights switch shown. Refer to
Table 7-2. Rocker Switch Connectors for
correct combinations of rocker switches and
connectors.

Table 7-2. Rocker Switch Connectors

Switch Name Connector Number
Radiator Fan Off PX1 and PX1A
LAMP TEST PX2 and PX2A
Ether Start PX13 and PX13A
Master Power PX17 and PX17A
Warning Light PX12 and PX12A
Hazard Lights PX14 and PX14A

(9) Lift tab (12) on connector (13).

(10) Disconnect connector (13) from hazard lights switch (14).

(11) Disconnect connector (15) from hazard lights switch (14).

(12) Perform steps (9) through (11) on remaining rocker

switches.

(13) Disconnect vacuum hose (16) from AIR FILTER

RESTRICTION GAUGE (17).

7-95
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform step (14) on M1084, M1086, M1088,

M1089, M1092, and M1096.

(14) Remove two screws (18) and terminal lugs TL160 (19)
and TL161 (20) from audible alarm (21).

NOTE

Perform step (15) on M1083, M1085, M1090,

M1093, and M1094.

(15) Remove three screws (18) and terminal lugs TL160 (19),
TL161 (20), and TL178 (22) from audible alarm (21).

(16) Remove connector clamp (23) from dimmer switch (24).

(17) Disconnect connector PX24 (25) from dimmer switch

(24).

(18) Disconnect connector PX15 (26) from main light switch

(27).

7-96
 TM 9-2320-366-20-3

(19) Disconnect terminal lugs TL162 (28) and TL163 (29)

from starter pushbutton switch (30).

NOTE

Perform steps (20) through (22) on vehicles

equipped with WTEC II transmission controls.

(20) Disconnect connector J115 (31) from WTEC II TEPSS

(32).

(21) Disconnect connector J114 (33) from WTEC II TEPSS

(32).

(22) Remove screw (34), washer (35) and terminal lug (36)
from instrument panel assembly (6).

NOTE

Perform step (23) on vehicles equipped with

WTEC III transmission controls.

(23) Disconnect connector PX33 (37) from WTEC III TPSS

(38).

(24) Remove instrument panel assembly (6) from dashboard

(39).

7-97
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

b. Disassembly.

NOTE

• All rocker switches are removed the same way.

Radiator fan off switch shown.

• Note position of rocker switches prior to

removal.

(1) Push in two tabs (1) on radiator fan off switch (2).

(2) Remove radiator fan off switch (2) from instrument panel
(3).

(3) Perform steps (1) and (2) on remaining rocker switches.

NOTE

• All electrical gages are removed the same way.

FUEL gage shown.

• Note position of electrical gages prior to

removal.

(4) Remove two protective caps (4), self-locking nuts (5),

retaining ring (6), and FUEL gage (7) from instrument
panel (3). Discard self-locking nuts.

(5) Perform step (4) on remaining electrical gages.

7-98
 TM 9-2320-366-20-3

NOTE

Perform steps (6) and (7) on vehicles

equipped with WTEC II transmission controls.

(6) Remove two screws (8) and washers (9) from mounting
bracket (10).

(7) Remove four screws (11), mounting bracket (10), three

clip nuts (12), and WTEC II TEPSS (13) from instrument
panel (3).

NOTE

Perform steps (8) and (9) on vehicles

equipped with WTEC III transmission
controls.

(8) Remove two nuts (14) brackets (15) from WTEC III
TPSS (16).

(9) Remove WTEC III TPSS (16) from instrument panel (3).

(10) Remove four screws (17) and lighted indicator display

(18) from instrument panel (3).

7-99
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

(11) Remove lock ring (19) and audible alarm (20) from
instrument panel (3).

(12) Remove nut (21), washer (22), and starter pushbutton

switch (23) from instrument panel (3).

(13) Remove two screws (24), faceplate (25) and AIR FILTER
RESTRICTION GAUGE (26) from instrument panel (3).

7-100
 TM 9-2320-366-20-3

(14) Loosen screw (27) on dimmer switch knob (28).

(15) Remove dimmer switch knob (28) from dimmer switch

(29).

(16) Remove nut (30), washer (31), and dimmer switch (29)
from instrument panel (3).

(17) Remove three screws (32) from knobs (33).

(18) Remove three knobs (33) and spacers (34) from main
light switch (35).

(19) Remove four screws (36) and main light switch (35) from
instrument panel (3).

(20) Remove electrical switch cover (37) from instrument

panel (3).

c. Assembly.

(1) Install electrical switch cover (1) in instrument panel (2).

(2) Position main light switch (3) in instrument panel (2) with
four screws (4).

(3) Tighten four screws (4) to 9 lb-in. (1 N·m).

(4) Install three spacers (5) and knobs (6) on main light
switch (3).

(5) Install three screws (7) in knobs (6).

7-101
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

(6) Position dimmer switch (8) in instrument panel (2) with

washer (9) and nut (10).

(7) Tighten nut (10) to 159-195 lb-in. (18-22 N·m).

(8) Install dimmer switch knob (11) on dimmer switch (8).

(9) Tighten screw (12) in dimmer switch knob (11).

(10) Install AIR FILTER RESTRICTION GAUGE (13) and

faceplate (14) on instrument panel (2) with two screws
(15).

(11) Position starter pushbutton switch (16) in instrument

panel (2) with washer (17) and nut (18).

(12) Tighten nut (18) to 57-70 lb-in. (6-8 N·m).

7-102
 TM 9-2320-366-20-3

(13) Install audible alarm (19) in instrument panel (2) with

lock ring (20).

(14) Position lighted indicator display (21) in instrument panel

(2) with four screws (22).

(15) Tighten four screws (22) to 9 lb-in. (1 N·m).

NOTE

Perform steps (16) through (19) on vehicles

equipped with WTEC II transmission controls.

(16) Position WTEC II TEPSS (23) in instrument panel (2)

with three clip nuts (24), mounting bracket (25) and four
screws (26).

(17) Position two screws (27) and washers (28) in mounting

bracket (25).

(18) Tighten four screws (26) to 9 lb-in. (1 N·m).

(19) Tighten two screws (27) to 27-35 lb-in. (3-4 N·m).

7-103
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform steps (20) through (22) on vehicles

equipped with WTEC III transmission
controls.

(20) Install WTEC III TPSS (29) in instrument panel (2).

(21) Position two brackets (30) on rear of WTEC III TPSS

(29) with two nuts (31).

(22) Tighten two nuts (31) to 11-13 lb-in. (1.3-1.5 N·m).

NOTE

All electrical gages are installed the same

way. FUEL gage shown.

(23) Position FUEL gage (32) in instrument panel (2) with

mounting ring (33) and two self-locking nuts (34).

(24) Tighten two self-locking nuts (34) to 9 lb-in. (1 N·m).

(25) Install two protective caps (35) on FUEL gage (32).

(26) Perform steps (23) through (25) on remaining gages.

7-104
 TM 9-2320-366-20-3

NOTE

All rocker switches are installed the same

way. Radiator fan off switch shown.

(27) Install radiator fan off switch (36) in instrument panel (2).

(28) Perform step (27) on remaining rocker switches.

d. Installation.

(1) Position instrument panel assembly (1) on dashboard

(2).

NOTE

Perform steps (2) through (4) on vehicles

equipped with WTEC II transmission controls.

(2) Connect connector J114 (3) to WTEC II TEPSS (4).

(3) Connect connector J115 (5) to WTEC II TEPSS (4).

(4) Install terminal lug (6) on instrument panel assembly (1)

with washer (7) and screw (8).

7-105
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform step (5) on vehicles equipped with

WTEC III transmission controls.

(5) Connect connector PX33 (9) to WTEC III TPSS (10).

(6) Connect terminal lugs TL163 (11) and TL162 (12) to

starter pushbutton switch (13).

(7) Connect connector PX15 (14) to main light switch (15).

(8) Connect connector PX24 (16) to dimmer switch (17).

(9) Connect connector clamp (18) on dimmer switch (17).

7-106
 TM 9-2320-366-20-3

NOTE

Perform step (10) on M1083, M1085, M1090,

M1093, and M1094.

(10) Install terminal lugs TL160 (19), TL161 (20), and TL178
(21) on audible alarm (22) with three screws (23).

NOTE

Perform step (11) on M1084, M1086, M1088,

M1089, M1092, and M1096.

(11) Install terminal lugs TL160 (19) and TL161 (20) on

audible alarm (22) with two screws (23).

7-107
TM 9-2320-366-20-3

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR (CONT)

(12) Connect vacuum hose (24) to AIR FILTER

RESTRICTION GAUGE (25).

NOTE

• Vehicle serial numbers 0002 through 0017, 0019

through 0025, 0027 through 0031, 0033 through
0038, 0040 and 0041, 0043 through 0053, 0055
through 0089, 0091 through 0254, 0256 through
0258, 0260, 0261, 0263 through 2400, and 2402
through 3091 are not equipped with LAMP
TEST switch.

• Vehicle serial numbers 0001 through 1477 were

originally equipped with dashboard cable
assemblies containing two unused connectors
for LAMP TEST switch. Vehicle serial numbers
1478 through 3091 were originally equipped with
dashboard cable assemblies without connectors
for LAMP TEST switch.

• All rocker switches are connected the same

way. Hazard lights switch shown. Refer to
Table 7-2. Rocker Switch Connectors for
correct combinations of rocker switches and
connectors.

(13) Connect connector (26) to hazard lights switch (27).

(14) Connect connector (28) to hazard lights switch (27).

(15) Perform steps (13) and (14) on remaining rocker

switches.

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NOTE

All electrical gages are connected the same

way. OIL PRESS gage shown. Refer to Table
7-1.2 Electrical Gages Connectors for correct
combinations of gages and connectors.

(16) Connect connector (29) to OIL PRESS gage

connector (30).

(17) Connect connector clamp (31) on OIL PRESS gage

connector (30).

(18) Perform steps (16) and (17) on remaining electrical

gages.

(19) Connect connector PX7 (32) to lighted indicator

display (33).

NOTE

Depending upon pre-conditioned items

removed; configuration of the instrument
panel can have from 12 to 16 screws.
Configuration with 6 screws shown.

(20) Position instrument panel assembly (1) on dashboard

(2) with 16 washers (34) and screws (35).

(21) Tighten 16 screws (35) to 24 lb-in. (3 N•m).

(22) Install HAND THROTTLE knob (36) on HAND

THROTTLE lever (37) with screw (38).

e. Follow-On Maintenance.

(1) Install steering wheel (para 13-2).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check operation of instrument panel assembly

switches and gages (TM 9-2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 2 7-109
TM 9-2320-366-20-3

7-16. LIGHTED INDICATOR DISPLAY REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Lamp, Incandescent (Item 65, Appendix G)
Lamp, Incandescent (Item 66, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

(1) Remove four screws (1) and lighted indicator display (2)
from instrument panel assembly (3).

(2) Disconnect connector PX7 (4) from lighted indicator

display (2).

b. Disassembly.

(1) Loosen four captive screws (1) in lamp mounting panel

(2).

(2) Remove lamp mounting panel (2) from lighted indicator

display housing (3).

(3) Remove faulty lamp(s) (4) from printed circuit board (5).
Discard faulty lamp(s).

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 TM 9-2320-366-20-3

c. Assembly.

NOTE

Left turn indicator, right turn indicator, and

high beam indicator are 12 vdc lamps. All
other lamps are 24 vdc.

(1) Install replacement lamp(s) (1) in printed circuit board

(2).

(2) Install lamp mounting panel (3) in lighted indicator

display housing (4).

(3) Tighten four captive screws (5) in lamp mounting panel

(3).

d. Installation.

(1) Connect connector PX7 (1) to lighted indicator display

(2).

(2) Position lighted indicator display (2) in instrument panel

assembly (3) with four screws (4).

(3) Tighten four screws (4) to 9 lb-in. (1 N·m).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check operation of lighted indicator display (TM 9-2320-

366-10-1).

End of Task.

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7-17. MAIN LIGHT SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access (para Ties, Cable, Plastic (Item 69, Appendix D)
7-15).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

(1) Remove three screws (1) from knobs (2).

(2) Remove three knobs (2) and spacers (3) from main light
switch (4).

NOTE

Remove plastic cable ties as required.

(3) Disconnect connector PX15 (5) from main light switch

(4).

(4) Remove four screws (6) and main light switch (4) from
instrument panel assembly (7).

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 TM 9-2320-366-20-3

b. Installation.

(1) Position main light switch (1) in instrument panel

assembly (2) with four screws (3).

(2) Tighten four screws (3) to 11-13 lb-in. (1 N•m).

NOTE

Install plastic cable ties as required.

(3) Connect connector PX15 (4) to main light switch

(1).

(4) Install three spacers (5) and knobs (6) on main light
switch (1).

(5) Install three screws (7) in knobs (6).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Check lighting system operation (TM 9-2320-366-

10-1).

End of Task.

Change 2 7-113
TM 9-2320-366-20-3

7-18. ROCKER SWITCHES REPLACEMENT

This task covers:

a. Instrument Panel Rocker Switch Removal d. Auxiliary Panel Rocker Switch Installation
b. Instrument Panel Rocker Switch Installation e. Follow-On Maintenance
c. Auxiliary Panel Rocker Switch Removal

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access (for Dispenser, Pressure Sensitive Adhesive Tape
instrument panel rocker switches) (para 7-15). (Item 20, Appendix D)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Instrument Panel Rocker Switch Removal.

NOTE

• Vehicle serial numbers 0002 through 0017, 0019

through 0025, 0027 through 0031, 0033 through
0038, 0040, 0041, 0043 through 0053, 0055
through 0089, 0091 through 0254, 0256 through
0258, 0260, 0261, 0263 through 2400, and 2402
through 3091 are not equipped with LAMP
TEST switch.

• All instrument panel rocker switches are

removed the same way. Radiator fan off switch
shown.

• Tag electrical connectors and connection points

prior to disconnecting.

(1) Lift tab (1) on connector PX1 (2).

(2) Disconnect connector PX1 (2) from radiator fan off

switch (3).

(3) Disconnect connector PX1A (4) from radiator fan off

switch (3).

(4) Push in two tabs (5) on radiator fan off switch (3).

(5) Remove radiator fan off switch (3) from instrument panel
assembly (6).

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 TM 9-2320-366-20-3

(6) Remove lamp base (7) from radiator fan off switch (3).

(7) Remove lamp (8) from lamp base (7).

b. Instrument Panel Rocker Switch Installation.

NOTE

All instrument panel rocker switches are

installed the same way. Radiator fan off
switch shown.

(1) Install lamp (1) in lamp base (2).

(2) Install lamp base (2) in radiator fan off switch (3).

(3) Install radiator fan off switch (3) in instrument panel

assembly (4).

(4) Connect connector PX1A (5) to radiator fan off switch

(3).

(5) Connect connector PX1 (6) to radiator fan off switch (3).

7-115
TM 9-2320-366-20-3

7-18. ROCKER SWITCHES REPLACEMENT (CONT)

c. Auxiliary Panel Rocker Switch Removal.

(1) Remove six screws (1) from auxiliary panel (2).

(2) Lift auxiliary panel (2) outward to gain access.

NOTE

• All auxiliary panel rocker switches are removed

the same way. PTO switch shown.

• Tag electrical connectors and connection points

prior to disconnecting.

(3) Lift tab (3) on connector P903 (4).

(4) Disconnect connector P903 (4) from PTO switch (5).

(5) Disconnect connector P903A (6) from PTO switch (5).

(6) Push in two tabs (7) on PTO switch (5).

(7) Remove PTO switch (5) from auxiliary panel (2).

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 TM 9-2320-366-20-3

(8) Remove lamp base (8) from PTO switch (5).

(9) Remove lamp (9) from lamp base (8).

d. Auxiliary Panel Rocker Switch Installation.

NOTE

All auxiliary panel rocker switches are

installed the same way. PTO switch shown.

(1) Install lamp (1) in lamp base (2).

(2) Install lamp base (2) in PTO switch (3).

(3) Install PTO switch (3) in auxiliary panel (4).

(4) Connect connector P903A (5) to PTO switch (3).

(5) Connect connector P903 (6) to PTO switch (3).

7-117
TM 9-2320-366-20-3

7-18. ROCKER SWITCHES REPLACEMENT (CONT)

(6) Position auxiliary panel (4) on auxiliary panel housing (7)

with six screws (8).

(7) Tighten six screws (8) to 18 lb-in. (2 N·m).

e. Follow-On Maintenance.

(1) Install instrument panel assembly (for instrument panel

rocker switches) (para 7-15).

(2) Check rocker switch operation (TM 9-2320-366-10-1).

End of Task.

7-118
 TM 9-2320-366-20-3

7-19. START INHIBIT PUSHBUTTON SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
PDP cover removed (para 16-2). (Item 20, Appendix D)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) outward to gain access.

NOTE

Tag electrical connectors and connection

points prior to disconnecting.

(4) Disconnect terminal lugs TL158 (5) and TL159 (6) from
start inhibit pushbutton switch (7).

(5) Remove spring clip (8) and start inhibit pushbutton

switch (7) from PDP (3).

7-119
TM 9-2320-366-20-3

7-19. START INHIBIT PUSHBUTTON SWITCH REPLACEMENT (CONT)

b. Installation.

(1) Install start inhibit pushbutton switch (1) in PDP (2) with
spring clip (3).

(2) Connect terminal lugs TL159 (4) and TL158 (5) to start
inhibit pushbutton switch (1).

(3) Position PDP (2) on dashboard (6).

(4) Install three screws (7) in PDP (2).

(5) Install three washers (8) and screws (9) in PDP (2).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

End of Task.

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 TM 9-2320-366-20-3

7-20. STARTER PUSHBUTTON SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access (para 7- Dispenser, Pressure Sensitive Adhesive Tape
15). (Item 20, Appendix D)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Disconnect terminal lugs TL162 (1) and TL163 (2) from
starter pushbutton switch (3).

(2) Remove nut (4), washer (5), and starter pushbutton

switch (3) from instrument panel assembly (6).

b. Installation.

(1) Position starter pushbutton switch (3) in instrument panel

assembly (6) with washer (5) and nut (4).

(2) Tighten nut (4) to 57-70 lb-in. (6-8 N·m).

(3) Connect terminal lugs TL163 (2) and TL162 (1) to starter
pushbutton switch (3).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Start engine (TM 9-2320-366-10-1).

(3) Shut down engine (TM 9-2320-366-10-1).

End of Task.

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TM 9-2320-366-20-3

7-21. TACHOMETER REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Nut, Self-Locking (2) (Item 133, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

(1) Remove six screws (1) and auxiliary panel (2) from
auxiliary panel housing (3).

(2) Lift auxiliary panel (2) outward to gain access.

(3) Disconnect connector clamp (4) from tachometer

connector (5).

(4) Disconnect connector P901 (6) from tachometer

connector (5).

(5) Remove two protective caps (7), self-locking nuts (8),

and retaining ring (9) from tachometer (10). Discard self-
locking nuts.

(6) Remove tachometer (10) from auxiliary panel (2).

7-122
 TM 9-2320-366-20-3

b. Installation.

(1) Position tachometer (1) in auxiliary panel (2) with

retaining ring (3) and two self-locking nuts (4).

(2) Tighten two self-locking nuts (4) to 9 lb-in. (1 N·m).

(3) Install two protective caps (5) on tachometer (1).

(4) Connect connector P901 (6) to tachometer connector (7).

(5) Connect connector clamp (8) on tachometer connector

(7).

(6) Position auxiliary panel (2) on auxiliary panel housing (9)

with six screws (10).

(7) Tighten six screws (10) to 18 lb-in. (2 N·m).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check tachometer operation (TM 9-2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-123
TM 9-2320-366-20-3

7-22. COOLANT TEMPERATURE LIGHT SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Antiseize Compound (Item 58, Appendix D)
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
Antifreeze, Ethylene Glycol, Permanent (Item 12,
Tools and Special Tools Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C)
Pan, Drain (Item 24, Appendix C)
Goggles, Industrial (Item 15, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Crowfoot Attachment, Socket Wrench (Item 6,
Appendix B)

WARNING

• Coolant may be very hot and under pressure

from engine operation. Ensure engine is
cool before performing maintenance. Failure
to comply may result in injury to personnel.

• Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

(2) Position container under radiator draincock (3).

(3) Open radiator draincock (3) and drain approximately one

gal (one L) of coolant.

(4) Close radiator draincock (3).

7-124 Change 1
 TM 9-2320-366-20-3

NOTE

Remove plastic cable ties as required.

(5) Disconnect connector clamp (4) from coolant

temperature light switch (5).

(6) Disconnect connector P37 (6) from coolant temperature

light switch (5).

(7) Remove coolant temperature light switch (5) from

thermostat housing (7).

b. Installation.
WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of coolant

temperature light switch (1).

(2) Position coolant temperature light switch (1) in

thermostat housing (2).

(3) Tighten coolant temperature light switch (1) to 20-23 lb-ft

(27-31 N·m).

(4) Connect connector P37 (3) to coolant temperature light

switch (1).

NOTE

Install plastic cable ties as required.

(5) Connect connector clamp (4) on coolant temperature

light switch (1).

7-125
TM 9-2320-366-20-3

7-22. COOLANT TEMPERATURE LIGHT SWITCH REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Connect batteries (para 7-57).

(3) Lower cab (TM 9-2320-366-10-1).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check for coolant leaks under vehicle.

(6) Check coolant level after normal temperature is reached.

Add coolant as required (TM 9-2320-366-10-2).

(7) Raise cab (TM 9-2320-366-10-1).

(8) Check for leaks around coolant temperature light switch.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

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 TM 9-2320-366-20-3

7-23. M1090/M1094 DUMP BODY SWITCH REPLACEMENT/ADJUSTMENT

This task covers:

a. Removal c. Adjustment
b. Installation d. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Materials/Parts

Dump body raised to maintenance position (TM 9- Lockwasher (Item 80, Appendix G)
2320-366-10-1).
Engine shut down (TM 9-2320-366-10-1). Personnel Required
(2)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

a. Removal.

(1) Disconnect connector P25 (1) from dump body switch

connector (2).

(2) Remove nut (3) and washer (4) from dump body switch
(5).

(3) Remove lever (6) from dump body switch (5).

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TM 9-2320-366-20-3

7-23. M1090/M1094 DUMP BODY SWITCH REPLACEMENT/ADJUSTMENT (CONT)

(4) Remove nut (7), lockwasher (8), and dump body switch
(5) from mounting plate (9). Discard lockwasher.

(5) Remove screw (10), washer (11), and mounting plate (9)
from frame (12).

b. Installation.

(1) Position mounting plate (1) on frame (2) with washer (3)
and screw (4).

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 TM 9-2320-366-20-3

(2) Install dump body switch (5) in mounting plate (1) with
lockwasher (6) and nut (7).

CAUTION

Lever must be installed so that it is

approximately level before adjustment.
Failure to comply may result in damage to
equipment.

(3) Install lever (8) on dump body switch (5) with washer (9)
and nut (10).

(4) Connect dump body switch connector (11) to connector

P25 (12).

(5) Lower dump body (TM 9-2320-366-10-1).

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TM 9-2320-366-20-3

7-23. M1090/M1094 DUMP BODY SWITCH REPLACEMENT/ADJUSTMENT (CONT)

c. Adjustment.

WARNING

• Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may
result in injury to personnel.

• Ensure exhaust system is cool before

performing maintenance. Failure to comply
may result in injury to personnel.

(1) Loosen screw (1) in mounting plate (2).

(2) Position master power switch to on (TM 9-2320-366-10-

1).

NOTE

Step (3) requires the aid of an assistant.

(3) Push up on lever (3) until DUMP BODY UP indicator (4)

goes out.

(4) Tighten screw (1).

(5) Position master power switch to off (TM 9-2320-366-10-

1).

d. Follow-On Maintenance.

(1) Raise dump body and check that DUMP BODY UP

indicator is lit (TM 9-2320-366-10-1).

(2) Lower dump body and check that DUMP BODY UP

indicator goes out (TM 9-2320-366-10-1).

(3) Shut down engine (TM 9-2320-366-10-1).

End of Task.

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 TM 9-2320-366-20-3

7-24. FAN AND DIFFERENTIAL LOCK SOLENOIDS REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Air tanks drained (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Kick panel removed (para 16-3).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Disconnect fan solenoid connector (1) from connector

PX34 (2).

(2) Disconnect differential lock solenoid connector (3) from

connector PX50 (4).

NOTE

Tag air hoses and connection points prior to

disconnecting.

(3) Disconnect air hose (5) from 90-degree fitting (6).

(4) Disconnect two air hoses (7) from fittings (8).

(5) Remove four screws (9) and bracket (10) from

dashboard (11).

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TM 9-2320-366-20-3

7-24. FAN AND DIFFERENTIAL LOCK SOLENOIDS REPLACEMENT (CONT)

(6) Remove two screws (12) and bracket (10) from

solenoids (13).

(7) Remove 90-degree fitting (6) from solenoids (13).

(8) Remove two fittings (8) from solenoids (13).

(9) Remove plug (14) from solenoids (13).

b. Installation.
WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of plug (1), two

fittings (2), and 90-degree fitting (3).

(2) Install plug (1) in solenoids (4).

(3) Install two fittings (2) in solenoids (4).

(4) Install 90-degree fitting (3) in solenoids (4).

(5) Install bracket (5) on solenoids (4) with two screws (6).

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 TM 9-2320-366-20-3

(6) Install bracket (5) on dashboard (7) with four screws (8).

(7) Connect two air hoses (9) to fittings (2).

(8) Connect air hose (10) to 90-degree fitting (3).

(9) Connect differential lock solenoid connector (11) to

connector PX50 (12).

(10) Connect fan solenoid connector (13) to connector PX34

(14).

c. Follow-On Maintenance.

(1) Install kick panel (para 16-3).

(2) Connect batteries (para 7-57).

(3) Start engine and allow engine temperature to rise to

normal operating levels (TM 9-2320-366-10-1).

(4) Check operation of fan and differential locks (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-133
TM 9-2320-366-20-3

7-25. FLASHER UNIT REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Batteries disconnected (para 7-57). Tool Kit, Genl Mech (Item 46, Appendix C)
Kick panel removed (para 16-3).

a. Removal.

(1) Remove two screws (1), washers (2), and flasher unit (3)
from dashboard (4).

(2) Disconnect connector PX20 (5) from flasher unit (3).

b. Installation.

(1) Connect connector PX20 (5) to flasher unit (3).

(2) Install flasher unit (3) on dashboard (4) with two washers
(2) and screws (1).

c. Follow-On Maintenance.

(1) Install kick panel (para 16-3).

(2) Connect batteries (para 7-57).

(3) Check turn signal and hazard lights operation (TM 9-

2320-366-10-1).

End of Task.

7-134
 TM 9-2320-366-20-3

7-26. TURN SIGNAL SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access (para Dispenser, Pressure Sensitive Adhesive Tape
7-15). (Item 20, Appendix D)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

Tag connectors and connection points prior

to disconnecting.

(1) Disconnect turn signal switch connectors (1 and 2) from

connectors P18 and J19 (3 and 4).

(2) Remove turn signal switch connectors (1 and 2) through

opening (5) in dashboard (6).

(3) Remove screw (7) and sleeve (8) from steering column
(9).

7-135
TM 9-2320-366-20-3

7-26. TURN SIGNAL SWITCH REPLACEMENT (CONT)

(4) Remove two screws (10), collar half (11), and turn signal
switch (12) from steering column (9).

b. Installation.

(1) Install turn signal switch (1) on steering column (2) with
collar half (3) and two screws (4).

(2) Install sleeve (5) on steering column (2) with screw (6).

7-136
 TM 9-2320-366-20-3

(3) Route turn signal switch connectors (7 and 8) through

opening (9) in dashboard (10).

(4) Connect turn signal switch connectors (7 and 8) to

connectors P18 (11) and J19 (12).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Check operation of turn signal switch (TM 9-2320-366-

10-1).

End of Task.

7-137
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Crane erected (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape (Item 20,
Engine shut down (TM 9-2320-366-10-1). Appendix D)
Batteries disconnected (para 7-57). Insulation Sleeving, Electrical (Item 29, Appendix D)
Varnish, Oil (Item 70, Appendix D)
Tools and Special Tools Ties, Cable, Plastic (Item 69, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Conduit (3) (Item 124, Appendix G)
Goggles, Industrial (Item 15, Appendix C) Nut, Conduit (3) (Item 125, Appendix G)
Drill, Portable, Electric (Item 7, Appendix C) Lockwasher (4) (Item 94, Appendix G)
Drill Set, Twist (Item 6, Appendix C) Lockwasher (10) (Item 91, Appendix G)
Tool Kit, Blind Rivet (Item 44, Appendix C) Lockwasher (12) (Item 92, Appendix G)
Tool Kit, Electrical (Item 45, Appendix C) Rivet, Blind (Item 255, Appendix G)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix Lockwasher (Item 93, Appendix G)
B) Modification Kit, Junction Box (Item 31.1, Appendix D)
Rag, Wiping (Item 50, Appendix D)

a. Removal.

NOTE

Remove plastic cable ties as required.

(1) Loosen four screws (1) on junction box (2).

(2) Open cover (3) on junction box (2).

7-138 Change 1
 TM 9-2320-366-20-3

NOTE

Tag wires and connection points prior to

disconnecting.

(3) Disconnect quick disconnect terminal (4) from ground

strip (5) position 17.

(4) Remove two screws (6) from terminal block (7) positions
6 and 11.

(5) Remove conduit nut (8) and right jack cylinder proximity
sensor cable (9) from junction box (2). Discard conduit
nut.

(6) Disconnect quick disconnect terminal (10) from ground

strip (5) position 14.

(7) Remove three screws (11) from terminal blocks (7) and
(12) positions 6, 25, and 28.

7-139
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(8) Remove four nuts (13), lockwashers (14), screws (15),

and overload lockout cable (16) from junction box (2).
Discard lockwashers.

(9) Disconnect quick disconnect terminal (17) from ground

strip (5) position 18.

(10) Remove three screws (18) from terminal block (7)

positions 3, 4, and 5.

(11) Remove four nuts (19), lockwashers (20), screws (21),

and crane power cable (22) from junction box (2).
Discard lockwashers.

7-140
 TM 9-2320-366-20-3

(12) Disconnect quick disconnect terminal (23) from ground

strip (5) position 16.

(13) Remove screw (24) from terminal block (7) position 10.

(14) Remove conduit nut (25) and left jack cylinder proximity
sensor cable (26) from junction box (2). Discard conduit
nut.

(15) Disconnect quick disconnect terminal (27) from ground

strip (5) position 15.

(16) Remove two screws (28) from terminal block (7)

positions 9 and 14.

(17) Remove ten screws (29) from terminal block (12)

positions 17 through 26.

7-141
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(18) Remove four nuts (30), lockwashers (31), screws (32),

and remote control cable (33) from junction box (2).
Discard lockwashers.

(19) Disconnect four quick disconnect terminals (34) from

ground strip (5) positions 6, 7, 9, and 10.

(20) Remove four screws (35) from terminal block (12)

positions 21 through 24.

(21) Remove conduit nut (36) and hoist up solenoid, hoist

down solenoid, boom up solenoid, and boom down
solenoid cable assembly (37) from junction box (2).
Discard conduit nut.

7-142
 TM 9-2320-366-20-3

(22) Disconnect two quick disconnect terminals (38) from

ground strip (5) positions 2 and 8.

(23) Remove two screws (39) from terminal blocks (7) and
(12) positions 12 and 28.

(24) Remove conduit nut (40) and system shutdown solenoid

and boom up lockout solenoid cable assembly (41) from
junction box (2). Discard conduit nut.

(25) Disconnect four quick disconnect terminals (42) from

ground strip (5) positions 4, 5, 11, and 12.

(26) Remove screw (43) from terminal block (7) position 8.

7-143
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(27) Remove conduit nut (44) and telescope out lockout

solenoid, hoist up lockout solenoid, control lockout
solenoid, and boom down lockout solenoid cable
assembly (45) from junction box (2). Discard conduit
nut.

(28) Disconnect three quick disconnect terminals (46) from

ground strip (5) positions 1, 3, and 13.

(29) Remove five screws (47) from terminal block (12)

positions 17 through 21.

(30) Remove conduit nut (48) and telescope in solenoid,

telescope out solenoid, swing CCW solenoid, and swing
CW solenoid cable assembly (49) from junction box (2).
Discard conduit nut.

7-144
 TM 9-2320-366-20-3

(31) Remove nut (50), terminal lug (51), lockwasher (52), and
washer (53) from mounting stud (54). Discard
lockwasher.

(32) Remove three nuts (50), lockwashers (52), washers (53),

and junction box (2) from mounting studs (54). Discard
lockwashers.

b. Disassembly.

NOTE

Tag wires and connection points prior to

removing.

(1) Disconnect three quick disconnect terminals (1) from

diode assembly (2).

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(2) Remove two rivets (3) and diode assembly (2) from
junction box (4).

7-145
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform steps (3) through (6) on junction

boxes that have not had modification kit
installed.

(3) Unsolder five wires (5) from lockout relay (6).

(4) Unsolder five wires (7) from shutdown relay (8).

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(5) Remove six rivets (9) and brackets (10 and 11) from
junction box (4).

(6) Remove six nuts (12), lockwashers (13), washers (14)

and brackets (10 and 11) from shutdown relay (8) and
lockout relay (6). Discard lockwashers.

7-146 Change 1
TM 9-2320-366-20-3

NOTE

Perform steps (6.1) through (6.4) on junction

boxes that have modification kit installed.

(6.1) Disconnect shutdown relay connector (14.1) from

shutdown relay (14.2).

(6.2) Disconnect lockout relay connector (14.3) from lockout

relay (14.4).

(6.3) Remove nut (14.5), lockwasher (14.6), washer (14.7),

shutdown relay (14.2), lockout relay (14.4) and screw
(14.8) from bracket (14.9). Discard lockwasher.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(6.4) Remove two rivets (14.10) and bracket (14.9) from

junction box (4).

Change 1 7-146.1/(7-146.2 Blank)

 TM 9-2320-366-20-3

(7) Disconnect two quick disconnect terminals (15) from

ground strip (16) positions 19 and 20.

(8) Remove two nuts (17), lockwashers (18), washers (19),

nylon washers (20), screws (21), and ground strip (16)
from junction box (4). Discard lockwashers.

(9) Remove screw (22) and terminal lug (23) from terminal
block (24) position 7.

(10) Remove nut (25), lockwasher (26), washer (27), and

circuit breaker (28) from junction box (4). Discard
lockwasher.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(11) Remove four rivets (29) and panel (30) from junction box
(4).

7-147
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Remove plastic cable ties as required.

(12) Remove seven screws (31) and terminal lugs (32) from
terminal block (22) positions 5, 8, 9, 10, 12, 13 and 14.

(13) Remove screw (33) and terminal lug (34) from terminal
block (22) position 7.

(14) Remove two nuts (35), lockwashers (36), washers (37),

screws (38), decal (39), and terminal block (22) from
bracket (40). Discard lockwashers.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(15) Remove four rivets (41) and bracket (40) from junction
box (4).

7-148
 TM 9-2320-366-20-3

(16) Remove two nuts (42), lockwashers (43), washers (44),

screws (45), decal (46), and terminal block (47) from
bracket (48). Discard lockwashers.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(17) Remove four rivets (49) and bracket (48) from junction
box (4).

c. Assembly.

(1) Install bracket (1) on junction box (2) with four rivets (3).

(2) Install decal (4) and terminal block (5) on bracket (1) with
two screws (6), washers (7), lockwashers (8) and nuts
(9).

(3) Install bracket (10) on junction box (2) with four rivets
(11).

(4) Install decal (12) and terminal block (13) on bracket (10)
with two screws (14), washers (15), lockwashers (16),
and nuts (17).

7-149
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(5) Install terminal lug (18) on terminal block (5) position 7

with screw (19).

(6) Install seven terminal lugs (20) on terminal block (5)

positions 5, 8, 9, 10, 12, 13, and 14 with seven screws
(21).

(7) Install panel (22) on junction box (2) with four rivets (23).

(8) Install circuit breaker (24) on junction box (2) with

washer (25), lockwasher (26), and nut (27).

(9) Tighten nut (27) to 25 lb-in. (3 N·m).

(10) Install terminal lug (28) on terminal block (5) position 7

with screw (29).

7-150
 TM 9-2320-366-20-3

(11) Install ground strip (30) on junction box (2) with two
screws (31), nylon washers (32), washers (33),
lockwashers (34), and nuts (35).

(12) Connect two quick disconnect terminals (36) to

ground strip (30) positions 19 and 20.

NOTE

Perform steps (12.1) through (12.4) on

junction boxes that have had modification kit
installed.

(12.1) Install bracket (36.1) on junction box (2) with two

rivets (36.2).

(12.2) Install lockout relay (36.3) and shutdown relay

(36.4) on bracket (36.5) with screw (36.6), washer
(36.7), lockwasher (36.8), and nut (36.9).

(12.3) Connect lockout relay connector (36.10) to lockout

relay (36.3).

(12.4) Connect shutdown relay connector (36.11) to

shutdown relay (36.4).

Change 2 7-150.1/(7-150.2 Blank)

 TM 9-2320-366-20-3

NOTE

Perform steps (13) through (16) on junction

boxes that have not had modification kit
installed.

(13) Install lockout relay (37) and shutdown relay (38) on

brackets (39 and 40) with six washers (41), lockwashers
(42), and nuts (43).

(14) Install brackets (39 and 40) in junction box (2) with six
rivets (44).

(15) Install shrink tubing (45) over ends of five wires (46) and
solder ends on shutdown relay (38) positions 1 through
5.

(16) Install shrink tubing (45) over ends of five wires (47) and
solder ends on lockout relay (37) positions 1 through 5.

Change 1 7-151
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(17) Install diode assembly (48) on junction box (2) with two
rivets (49).

(18) Connect three quick disconnect terminals (50) to diode

assembly (48).

(19) Apply varnish to three quick disconnect terminals (50).

d. Installation.

(1) Install junction box (1) on mounting stud (2) and three
mounting studs (3) with three washers (4), lockwashers
(5), and nuts (6).

(2) Install washer (4), lockwasher (5), and terminal lug (7) on
mounting stud (2) with nut (6).

(3) Loosen four screws (8) on junction box (1).

(4) Open cover (9) on junction box (1).

(5) Install telescope in solenoid, telescope out solenoid,

swing CCW solenoid, and swing CW solenoid cable
assembly (10) in junction box (1) with conduit nut (11).

7-152
 TM 9-2320-366-20-3

(6) Connect three quick disconnect terminals (12) to ground

strip (13) positions 1, 3, and 13.

(7) Install five terminal lugs (14) on terminal block (15)

positions 17 through 21 with five screws (16).

(8) Install telescope out lockout solenoid, hoist up lockout

solenoid, control lockout solenoid, and boom down
lockout solenoid cable assembly (17) in junction box (1)
with conduit nut (18).

(9) Connect four quick disconnect terminals (19) to ground

strip (13) positions 4, 5, 11, and 12.

(10) Install terminal lug (20) on terminal block (21) position 8

with screw (22).

7-153
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(11) Install system shutdown solenoid and boom up lockout

solenoid cable assembly (24) in junction box (1) conduit
nut (25).

(12) Connect two quick disconnect terminals (26) to ground

strip (13) positions 8 and 2.

(13) Install two terminal lugs (27) on terminal block (15)

position 28 and terminal block (21) position 12 with two
screws (28).

(14) Install hoist up solenoid, hoist down solenoid, boom up

solenoid, and boom down solenoid cable assembly (29)
in junction box (1) with conduit nut (30).

7-154
 TM 9-2320-366-20-3

(15) Connect four quick disconnect terminals (31) to ground

strip (13) positions 6, 7, 9, and 10.

(16) Install four terminal lugs (32) on terminal block (15)

positions 21 through 24 with four screws (33).

(17) Install remote control cable (34) in junction box (1) with
four screws (35), lockwashers (36), and nuts (37).

(18) Connect quick disconnect terminal (38) to ground strip

(13) position 15.

(19) Install 12 terminal lugs (39) on terminal block (15)

positions 17 through 26 and terminal block (21) positions
9 and 14 with 12 screws (40).

7-155
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(20) Install left proximity sensor cable (41) in junction box (1)
with conduit nut (42).

(21) Connect quick disconnect terminal (43) to ground strip

(13) position 16.

(22) Install terminal lug (44) on terminal block (21) position 10

with screw (45).

(23) Install crane power cable (46) in junction box (1) with
four screws (47), lockwashers (48), and nuts (49).

7-156
 TM 9-2320-366-20-3

(24) Connect quick disconnect terminal (50) to ground strip

(13) position 18.

(25) Install three terminal lugs (51) on terminal block (21)

positions 3, 4, and 5 with three screws (52).

(26) Install overload lockout cable (53) in junction box (1) with
four screws (54), lockwashers (55), and nuts (56).

(27) Connect quick disconnect terminal (57) on ground strip

(13) position 14.

(28) Install three terminal lugs (58) on terminal block (15)

position 25 and 28 and terminal block (21) position 6
with three screws (59).

7-157
TM 9-2320-366-20-3

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(29) Install right proximity sensor cable (60) in junction box

(1) with conduit nut (61).

(30) Connect quick disconnect terminal (62) to ground strip

(13) position 17.

(31) Install two terminal lugs (63) on terminal block (21)

position 6 and 11 with two screws (64).

(32) Close cover (9) on junction box (1).

(33) Tighten four screws (8) on junction box (1).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Operate crane and check all crane functions (TM 9-

2320-366-10-1).

End of Task.

7-158
 TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Crane erected (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Engine shut down (TM 9-2320-366-10-1). (Item 20, Appendix D)
Batteries disconnected (para 7-57). Insulation Sleeving, Electrical (Item 29,
Appendix D)
Tools and Special Tools Ties, Cable, Plastic (Item 69, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Varnish, Oil (Item 70, Appendix D)
Goggles, Industrial (Item 15, Appendix C) Adhesive (Item 5, Appendix D)
Drill, Portable, Electric (Item 7, Appendix C) Nut, Conduit (3) (Item 124, Appendix G)
Drill, Set Twist (Item 6, Appendix C) Nut, Conduit (2) (Item 125, Appendix G)
Tool Kit, Blind Rivet (Item 44, Appendix C) Lockwasher (16) (Item 91, Appendix G)
Tool Kit, Electrical (Item 45, Appendix C) Lockwasher (4) (Item 94, Appendix G)
Lockwasher (Item 92, Appendix G)
Rivet, Blind (Item 255, Appendix G)
Lockwasher (Item 93, Appendix G)
Modification Kit, Junction Box (Item 31.1, Appendix D)
Rag, Wiping (Item 50, Appendix D)

a. Removal.

NOTE

Remove plastic cable ties as required.

(1) Loosen four screws (1) on junction box (2).

(2) Open cover (3) on junction box (2).

Change 1 7-159
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Tag wires and connection points prior to

disconnecting.

(3) Remove quick disconnect terminal (4) from ground strip

(5) position 20.

(4) Remove screw (6) from terminal block (7) position 19.

(5) Remove conduit nut (8) and boom down lockout solenoid
cable (9) from junction box (2). Discard conduit nut.

(6) Remove quick disconnect terminal (10) from ground

strip (5) position 3.

(7) Remove three screws (11) from terminal block (7)

positions 1, 17, and 19.

7-160
 TM 9-2320-366-20-3

(8) Remove four nuts (12), lockwashers (13), screws (14)

and overload shutdown system cable (15) from junction
box (2). Discard lockwashers.

(9) Remove quick disconnect terminal (16) from ground strip

(5) position 2.

(10) Remove three screws (17) from terminal block (7)

positions 2, 3, and 4.

(11) Remove four nuts (18), lockwashers (19), screws (20)

and crane power cable (21) from junction box (2).
Discard lockwashers.

7-161
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(12) Remove two quick disconnect terminals (22) from ground

strip (5) positions 14 and 15.

(13) Remove conduit nut (23), telescope out lockout solenoid

and hoist up lockout solenoid cable assembly (24) from
junction box (2). Discard conduit nut.

(14) Remove quick disconnect terminal (25) from ground strip

(5) position 4.

(15) Remove 12 screws (26) from terminal block (7) positions

7 through 18.

7-162
 TM 9-2320-366-20-3

(16) Remove four nuts (27), lockwashers (28), screws (29)

and left side remote control cable (30) from junction box
(2). Discard lockwashers.

(17) Remove four quick disconnect terminals (31) from

ground strip (5) positions 16, 17, 18, and 19.

(18) Remove four screws (32) from terminal block (7)

positions 13 through 16.

(19) Remove conduit nut (33) and hoist up solenoid, hoist

down solenoid, boom up solenoid, and boom down
solenoid cable assembly (34) from junction box (2).
Discard conduit nut.

7-163
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(20) Remove two quick disconnect terminals (35) from ground

strip (5) positions 9 and 10.

(21) Remove screw (36) from terminal block (7) position 5.

(22) Remove conduit nut (37) and hydraulic system solenoid

and boom up lockout solenoid cable assembly (38) from
junction box (2). Discard conduit nut.

(23) Remove four quick disconnect terminals (39) from

ground strip (5) positions 5, 6, 7, and 8.

(24) Remove four screws (40) from terminal block (7)

positions 9 through 12.

7-164
 TM 9-2320-366-20-3

(25) Remove conduit nut (41) and telescope in solenoid,

telescope out solenoid, swing CCW solenoid, and swing
CW solenoid cable assembly (42) from junction box (2).
Discard conduit nut.

(26) Remove quick disconnect terminal (43) from ground strip

(5) position 1.

(27) Remove four nuts (44), lockwashers (45), screws (46)

and right side remote control cable (47) from junction
box (2). Discard lockwashers.

7-165
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(28) Remove four screws (48), lockwashers (49), and

washers (50) from junction box (2). Discard lock-
washers.

(29) Remove junction box assembly (2) from crane.

b. Disassembly.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Remove three quick disconnect terminals (1) from diode

assembly (2).

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(2) Remove two rivets (3) from diode assembly (2).

(3) Remove diode assembly (2) from junction box (4).

7-166
 TM 9-2320-366-20-3

NOTE

Perform steps (4) through (6) on junction

boxes that have not had modification kit
installed.

(4) Unsolder five wires (5) from shutdown relay (6).

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(5) Remove three rivets (7) and bracket (8) from junction
box (4).

(6) Remove three nuts (9), lockwashers (10), washers (11),

and shutdown relay (6) from bracket (8). Discard
lockwashers.

NOTE

Perform steps (6.1) through (6.3) on junction

boxes that have modification kits installed.

(6.1) Disconnect shutdown relay connector (11.1) from

shutdown relay (11.2).

(6.2) Remove nut (11.3), lockwasher (11.4), washer (11.5),

shutdown relay (11.2) and screw (11.6) from bracket
(11.7). Discard lockwasher.

Change 1 7-166.1/(7-166.2 Blank)

 TM 9-2320-366-20-3

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(6.3) Remove two rivets (11.8) and bracket (11.7) from

junction box (4).

(7) Remove quick disconnect terminal (12) from ground strip

(13) position 13.

(8) Remove two nuts (14), lockwashers (15), washers (16),

screws (17), nylon washers (18), and ground strip (13)
from junction box (4). Discard lockwashers.

Change 1 7-167
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(9) Remove four screws (19) from terminal block (20)

positions 1, 2, 5 and 6.

(10) Remove nut (21), lockwasher (22), and lockring (23)

from circuit breaker (24). Discard lockwasher.

(11) Remove circuit breaker (24) from junction box (4).

(12) Remove two screws (25), lockwashers (26), and terminal

lugs (27) from circuit breaker (24). Discard lockwashers.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(13) Remove four rivets (28) and panel (29) from junction box
(4).

7-168
 TM 9-2320-366-20-3

(14) Remove two screws (30) from terminal block (20)

positions 7 and 8.

(15) Remove two nuts (31), lockwashers (32), washers (33),

screws (34), decal (35), and terminal block (20) from
bracket (36). Discard lockwashers.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(16) Remove four rivets (37) and bracket (36) from junction
box (4).

7-169
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

c. Assembly.

(1) Install bracket (1) on junction box (2) with four rivets (3).

(2) Install decal (4) and terminal block (5) on bracket (1) with
two screws (6), washers (7), lockwashers (8), and nuts
(9).

(3) Install two terminal lugs (10) on terminal block (5)

positions 7 and 8 with two screws (11).

(4) Install panel (12) on junction box (2) with four rivets (13).

7-170
 TM 9-2320-366-20-3

(5) Install two terminal lugs (14) on circuit breaker (15) with
two lockwashers (16) and screws (17).

(6) Position circuit breaker (15) in junction box (2) with

lockring (18), lockwasher (19), and nut (20).

(7) Tighten nut (20) to 25 lb-in. (3 N·m).

(8) Install four terminal lugs (21) on terminal block (5)

positions 1, 2, 5 and 6 with four screws (22).

(9) Install ground strip (23) on junction box (2) with two
nylon washers (24), screws (25), washers (26),
lockwashers (27), and nuts (28).

(10) Install quick disconnect terminal (29) in ground strip (23)

position 13.

7-171
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

NOTE

Perform steps (10.1) through (10.3) on

junction boxes that have had modification kit
installed.

(10.1)Install bracket (29.2) on junction box (2) with two

rivets (29.8).

(10.2) Install shutdown relay (29.1) on bracket (29.2) with

screw (29.3), washer (29.4), lockwasher (29.5) and
nut (29.6).

(10.3) Connect shutdown relay connector (29.7) to

shutdown relay (29.1).

7-172 Change 2
 TM 9-2320-366-20-3

NOTE

Perform steps (11) through (14) on junction

boxes that have not had modification kit
installed.

(11) Install shutdown relay (30) on bracket (31) with three

washers (32), lockwashers (33), and nuts (34).

(12) Install bracket (31) on junction box (2) with three rivets
(35).

(13) Install shrink tubing (36) over ends of five wires (37) and
solder ends on shutdown relay (30) positions 1 through
5.

(14) Shrink the tubing over ends of all relay pins.

(15) Install diode assembly (38) on junction box (2) with two
rivets (39).

(16) Connect three quick disconnect terminals (40) on diode

assembly (38).

(17) Apply varnish to quick disconnect terminals (40).

Change 1 7-172.1/(7-172.2 Blank)

 TM 9-2320-366-20-3

d. Installation.

(1) Install junction box (1) on crane with four washers (2),
lockwashers (3), and screws (4).

(2) Loosen four screws (5) on junction box (1).

(3) Open cover (6) on junction box (1).

(4) Install right side remote control cable (7) in junction box
(1) with four screws (8), lockwashers (9), and nuts (10).

(5) Install quick disconnect terminal (11) on ground strip (12)

position 1.

7-173
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(6) Install telescope in solenoid, telescope out solenoid,

swing CCW solenoid, and swing CW solenoid cable
assembly (13) in junction box (1) with conduit nut (14).

(7) Install four quick disconnect terminals (15) on ground

strip (12) positions 5, 6, 7, and 8.

(8) Install four terminal lugs (16) on terminal block (17)

positions 9 through 12 with four screws (18).

(9) Install hydraulic system solenoid and boom up lockout

solenoid cable assembly (19) in junction box (1) with
conduit nut (20).

7-174
 TM 9-2320-366-20-3

(10) Install quick disconnect terminals (21) on ground strip

(12) positions 9 and 10.

(11) Install terminal lug (22) on terminal block (17) position 5

with screw (23).

(12) Install hoist up solenoid, hoist down solenoid, boom up

solenoid, and boom down solenoid cable assembly (24)
in junction box (1) with conduit nut (25).

(13) Install four quick disconnect terminals (26) on ground

strip (12) positions 16, 17, 18, and 19.

(14) Install four terminal lugs (27) on terminal block (17)

positions 13 through 16 with four screws (28).

7-175
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(15) Install left side remote control cable (29) in junction box
(1) with four screws (30), lockwashers (31), and nuts
(32).

(16) Install quick disconnect terminal (33) on ground strip (12)

position 4.

(17) Install terminal lugs (34) on terminal block (17) positions

7 through 18 with 12 screws (35).

(18) Install telescope out lockout solenoid, and hoist up

lockout solenoid cable assembly (36) in junction box (1)
with conduit nut (37).

7-176
 TM 9-2320-366-20-3

(19) Install quick disconnect terminals (38) on ground strip

(12) positions 14 and 15.

(20) Install crane power cable (39) in junction box (1) with
four screws (40), lockwashers (41), and nuts (42).

(21) Install quick disconnect terminal (43) on ground strip (12)

position 2.

(22) Install three terminal lugs (44) on terminal block (17)

positions 2 through 4 with three screws (45).

7-177
TM 9-2320-366-20-3

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR (CONT)

(23) Install overload shutdown system cable (46) in junction

box (1) with four screws (47), lockwashers (48), and nuts
(49).

(24) Install quick disconnect terminal (50) on ground strip (12)

position 3.

(25) Install four terminal lugs (51) on terminal block (17)

positions 1, 17 and 19 with three screws (52).

(26) Install boom down lockout solenoid cable (53) in junction

box (1) with conduit nut (54).

7-178
 TM 9-2320-366-20-3

(27) Install quick disconnect terminal (55) on ground strip (12)

position 20.

(28) Install terminal lug (56) on terminal block (17) position 19

with screw (57).

(29) Close cover (58) on junction box (1).

(30) Tighten four screws (59) on junction box (1).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Operate crane and check all crane functions (TM 9-

2320-366-10-1).

End of Task.

7-179
TM 9-2320-366-20-3

7-29. SHUNT REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Spare tire lowered (TM 9-2320-366-10-2). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Lockwasher (2) (Item 86, Appendix G)
Tools and Special Tools Lockwasher (2) (Item 87, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (2) (Item 150, Appendix G)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

(1) Loosen clamp (1) on air hose (2).

(2) Remove air hose (2) from intake air cleaner boot (3).

NOTE

Tag wires and connection points prior to

disconnecting.

(3) Remove screw (4), lockwasher (5), and terminal lug

TL52 (6) from shunt (7). Discard lockwasher.

(4) Remove screw (8), lockwasher (9), and terminal lug

TL45 (10) from shunt (7). Discard lockwasher.

7-180
 TM 9-2320-366-20-3

(5) Remove screw (11), lockwasher (12), washer (13), and

terminal lug TL51 (14) from shunt (7). Discard
lockwasher.

(6) Remove screw (15), lockwasher (16), washer (17), and

terminal lug TL38 (18) from shunt (7). Discard
lockwasher.

(7) Remove two self-locking nuts (19), screws (20), and

shunt (7) from spare tire retainer (21). Discard self-
locking nuts.

b. Installation.

(1) Install shunt (1) on spare tire retainer (2) with two screws
(3) and self-locking nuts (4).

7-181
TM 9-2320-366-20-3

7-29. SHUNT REPLACEMENT (CONT)

(2) Install terminal lug TL38 (5) on shunt (1) with washer (6),
lockwasher (7), and screw (8).

(3) Install terminal lug TL51 (9) on shunt (1) with washer
(10), lockwasher (11), and screw (12).

(4) Install terminal lug TL45 (13) on shunt (1) with

lockwasher (14) and screw (15).

(5) Install terminal lug TL52 (16) on shunt (1) with

lockwasher (17) and screw (18).

(6) Position air hose (19) on intake air cleanerboot (20) with
clamp (21).

(7) Tighten clamp (21) to 36-48 lb-in. (4-5 N·m).

7-182
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Raise spare tire (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-183
TM 9-2320-366-20-3

7-30. 100 AMP REVERSE POLARITY RELAY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Spare tire lowered (TM 9-2320-366-10-2). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Lockwasher (4) (Item 95, Appendix G)
Tools and Special Tools Washer, Spring (6) (Item 290, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (6) (Item 165, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

NOTE

Tag wires and connection points prior to

disconnecting.

(1) Loosen clamp (1) on intake air cleaner boot (2).

(2) Remove intake air cleaner boot (2) from intake air
cleaner housing (3).

(3) Lift terminal cover (4) on terminal lugs TL61 (5) and
TL47 (6).

(4) Remove nut (7), lockwasher (8) and terminal lugs TL61
(5) and TL47 (6) from 100 amp reverse polarity relay (9).
Discard lockwasher.

(5) Lift dust boot (10) on terminal lug TL44 (11).

(6) Remove nut (12), lockwasher (13), and terminal lug TL44
(11) from 100 amp reverse polarity relay (9). Discard
lockwasher.

7-184
 TM 9-2320-366-20-3

(7) Lift dust boot (14) on terminal lug TL80 (15).

(8) Remove nut (16), lockwasher (17), and terminal lug TL80
(15) from 100 amp reverse polarity relay (9). Discard
lockwasher.

(9) Lift terminal cover (18) on terminal lugs TL1 (19), TL37
(20) and TL36 (21).

(10) Remove nut (22), lockwasher (23), and terminal lugs TL1
(19), TL37 (20), and TL36 (21) from 100 amp reverse
polarity relay (9). Discard lockwasher.

(11) Remove six self-locking nuts (24), spring washers (25),

screws (26), and 100 amp reverse polarity relay (9) from
bracket (27). Discard spring washers and self-locking
nuts.

b. Installation.

(1) Position 100 amp reverse polarity relay (1) on bracket (2)
with six screws (3), spring washers (4), and self-locking
nuts (5).

(2) Tighten six screws (3) to 60-72 lb-in. (7-8 N·m).

7-185
TM 9-2320-366-20-3

7-30. 100 AMP REVERSE POLARITY RELAY REPLACEMENT (CONT)

(3) Position terminal lugs TL36 (6), TL37 (7), and TL1 (8) on
100 amp reverse polarity relay (1) with lockwasher (9)
and nut (10).

(4) Tighten nut (10) to 120-144 lb-in. (14-16 N·m).

(5) Position terminal cover (11) on terminal lugs TL36 (6),

TL37 (7), and TL1 (8).

(6) Position terminal lug TL80 (12) on 100 amp reverse

polarity relay (1) with lockwasher (13) and nut (14).

(7) Tighten nut (14) to 120-144 lb-in. (14-16 N·m).

(8) Position dust boot (15) on terminal lug TL80 (12).

(9) Position terminal lug TL44 (16) on 100 amp reverse

polarity relay (1) with lockwasher (17) and nut (18).

(10) Tighten nut (18) to 120-144 lb-in. (14-16 N·m).

(11) Position dust boot (19) on terminal lug TL44 (16).

(12) Position terminal lug TL47 (20) and TL61 (21) on 100
amp reverse polarity relay (1) with lockwasher (22) and
nut (23).

(13) Tighten nut (23) to 120-144 lb-in. (14-16 N·m).

(14) Position terminal cover (24) on terminal lugs TL47 (20)

and TL61 (21).

7-186
 TM 9-2320-366-20-3

(15) Position intake air cleaner boot (25) on intake air cleaner
housing (26) with clamp (27).

(16) Tighten clamp (27) to 36-48 lb-in. (4-5 N·m).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Raise spare tire (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM

9-2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-187
TM 9-2320-366-20-3

7-31. FREQUENCY ECU REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Instrument panel assembly removed for access (para 7- Tool Kit, Genl Mech (Item 46, Appendix C)
15).

a. Removal.

(1) Disconnect frequency ECU connector (1) from connector

PX26 (2).

(2) Remove two screws (3) and frequency ECU (4) from
bracket (5).

(3) Remove two nuts (6), washers (7), screws (8), washers
(9), and bracket (5) from dashboard (10).

7-188
 TM 9-2320-366-20-3

b. Installation.

(1) Install bracket (1) on dashboard (2) with two washers (3),
screws (4), washers (5), and nuts (6).

(2) Install frequency ECU (7) on bracket (1) with two screws
(8).

(3) Connect frequency ECU connector (9) to connector

PX26 (10).

c. Follow-On Maintenance.

Install instrument panel assembly (para 7-15).

End of Task.

7-189
TM 9-2320-366-20-3

7-32. REMOTE CONTROL UNIT REPAIR

This task covers:

a. Controller Removal e. Harness Removal

b. Controller Installation f. Harness Installation
c. Toggle Switch Removal g. Follow-On Maintenance
d. Toggle Switch Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

MHC remote control unit removed (TM 9-2320-366-10-1 Dispenser, Pressure Sensitive Adhesive Tape
or TM 9-2320-366-10-2). (Item 20, Appendix D)
Adhesive (Item 5, Appendix D)
Tools and Special Tools Nut, Self-Locking (4) (Item 175, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Controller Removal.

NOTE

All four controllers are removed the same

way. Boom Up/Down controller shown.

(1) Remove four self-locking nuts (1) from boom up/down

controller (2). Discard self-locking nuts.

(2) Remove boom up/down controller (2) from REMOTE

CONTROL UNIT (3) until connector (4) is accessible.

(3) Disconnect connector (4) from boom up/down controller

(2).

(4) Remove adhesive from seating surface (5).

(5) Loosen jam nut (6) on boom up/down controller (2).

(6) Remove knob (7) from boom up/down controller (2).

(7) Remove jam nut (6) from boom up/down controller (2).

7-190 Change 1
 TM 9-2320-366-20-3

b. Controller Installation.

NOTE

All four controllers are installed the same

way. Boom Up/Down controller shown.

(1) Install jam nut (1) on boom up/down controller (2).

(2) Install knob (3) on boom up/down controller (2).

(3) Tighten jam nut (1) against knob (3).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(4) Apply adhesive to seating surface (4).

(5) Connect connector (5) to boom up/down controller (2).

(6) Position boom up/down controller (2) in REMOTE

CONTROL UNIT (6).

(7) Apply adhesive to the first 2 to 5 threads of mounting

studs (7).

(8) Position four self-locking nuts (8) on boom up/down

controller (2).

(9) Tighten four self-locking nuts (8) to 14 lb-in. (2 N·m).

NOTE

Adhesive requires 24 hours to cure.

(10) Spread excess adhesive over heads of four self-locking

nuts (8).

Change 1 7-191
TM 9-2320-366-20-3

7-32. REMOTE CONTROL UNIT REPAIR (CONT)

c. Toggle Switch Removal.

NOTE

One controller needs to be removed for

access to toggle switch. Boom Up/Down
controller shown.

(1) Remove four self-locking nuts (1) from boom up/down

controller (2). Discard self-locking nuts.

(2) Remove boom up/down controller (2) from REMOTE

CONTROL UNIT (3) until connector (4) is accessible.

(3) Disconnect connector (4) from boom up/down controller

(2).

(4) Remove adhesive from seating surface (5).

(5) Remove nut (6), nylon washer (7), and switch guard
cover (8) from toggle switch (9).

(6) Remove toggle switch (9) from REMOTE CONTROL

UNIT (3) until four wires (10) are accessible.

NOTE

Tag wires and connection points prior to

disconnecting.

(7) Disconnect four wires (10) from toggle switch (9).

7-192 Change 1
 TM 9-2320-366-20-3

d. Toggle Switch Installation.

(1) Connect four wires (1) to toggle switch (2).

NOTE

Keyway of toggle switch aligns with keyway

slot in mounting hole.

(2) Position toggle switch (2) in mounting hole (3).

(3) Install switch guard cover (4) on toggle switch (2) with
nylon washer (5) and nut (6).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(4) Apply adhesive to seating surface (7).

(5) Connect connector (8) to boom up/down controller (9).

(6) Position boom up/down controller (9) in REMOTE

CONTROL UNIT (10).

Change 1 7-193
TM 9-2320-366-20-3

7-32. REMOTE CONTROL UNIT REPAIR (CONT)

WARNING

Adhesives, solvents, and sealing compounds can burn easily, 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, solvent, or sealing compound gets on skin or clothing, wash immediately with soap
and water. Failure to comply may result in injury to personnel.

(7) Apply adhesive to the first 2 to 5 threads of mounting

studs (11).

(8) Position four self-locking nuts (12) on boom up/down

controller (9).

(9) Tighten four self-locking nuts (12) to 14 lb-in. (2 N·m).

NOTE

Adhesive requires 24 hours to cure.

(10) Spread excess adhesive over heads of four self-locking

nuts (12).

e. Harness Removal.

NOTE

• All four controllers are removed for harness

removal.

• All four controllers are removed the same way.

Boom Up/Down controller shown.

(1) Remove four self-locking nuts (1) from boom up/down

controller (2). Discard self-locking nuts.

(2) Remove boom up/down controller (2) from REMOTE

CONTROL UNIT (3) until connector (4) is accessible.

(3) Disconnect connector (4) from boom up/down controller

(2).

(4) Remove adhesive from seating surface (5).

7-194 Change 1
 TM 9-2320-366-20-3

(5) Remove nut (6), nylon washer (7), and switch guard
cover (8) from toggle switch (9).

(6) Remove toggle switch (9) from REMOTE CONTROL

UNIT (3) until four wires (10) are accessible.

NOTE

Tag wires and connection points prior to

disconnecting.

(7) Disconnect four wires (10) from toggle switch (9).

(8) Disconnect harness ground wire (11) from ground tab

(12).

(9) Remove dust cap (13) from receptacle (14).

(10) Remove nut (15) and washer (16) from receptacle (14).

(11) Remove harness (17) from REMOTE CONTROL UNIT

(3).

Change 1 7-195
TM 9-2320-366-20-3

7-32. REMOTE CONTROL UNIT REPAIR (CONT)

f. Harness Installation.

(1) Position harness (1) in REMOTE CONTROL UNIT (2).

(2) Install receptacle (3) with washer (4) and nut (5) on
REMOTE CONTROL UNIT (2).

(3) Connect harness ground wire (6) to ground tab (7).

(4) Install dust cap (8) on receptacle (3).

(5) Connect four wires (9) to toggle switch (10).

NOTE

Keyway of toggle switch aligns with keyway

slot in mounting hole.

(6) Position toggle switch (10) in mounting hole (11).

(7) Install switch guard cover (12) on toggle switch (10) with
nylon washer (13) and nut (14).

7-196 Change 1
 TM 9-2320-366-20-3

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

NOTE

All four controllers are installed the same

way. Boom Up/Down controller shown.

(8) Apply adhesive to seating surface (15).

(9) Connect connector (16) to boom up/down controller (17).

(10) Position boom up/down controller (17) in REMOTE

CONTROL UNIT (2).

(11) Apply adhesive to the first 2 to 5 threads of mounting

studs (18).

(12) Position four self-locking nuts (19) on boom up/down

controller (17).

(13) Tighten four self-locking nuts (19) to 14 lb-in. (2 N·m).

NOTE

Adhesive requires 24 hours to cure.

(14) Spread excess adhesive over heads of four self-locking

nuts (19).

g. Follow-On Maintenance.

Operate crane using REMOTE CONTROL UNIT (TM 9-

2320-366-10-1 or TM 9-2320-366-10-2).

End of Task.

Change 1 7-197
TM 9-2320-366-20-3

7-33. M1089 TERMINAL BLOCK REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Material/Parts

Engine shut down (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Nut, Self-Locking (2) (Item 133, Appendix G)
Tools and Special Tools Lockwasher (8) (Item 100, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (2) (Item 128, Appendix G)

a. Removal.

(1) Remove two self-locking nuts (1), four washers (2), and
two screws (3) from top cover (4). Discard self-locking
nuts.

(2) Remove eight screws (5), lockwashers (6), washers (7),

and top cover (4) from control panel (8). Discard
lockwashers.

NOTE

• Remove plastic cable ties as required.

• Tag and record wires, terminal block jumpers

and connection points prior to disconnecting.

(3) Loosen screws (9) on top of terminal blocks (10).

(4) Remove wires (11) from top of terminal blocks (10).

(5) Remove five terminal block jumpers (12) from top of

terminal blocks (10).

7-198 Change 1
 TM 9-2320-366-20-3

(6) Remove two self-locking nuts (13), screws (14), washers

(15), and channel (16) from winch assembly (17).
Discard self-locking nuts.

(7) Loosen screws (18) on bottom of terminal blocks (10).

(8) Remove wires (19) from bottom of terminal blocks (10).

Change 1 7-199
TM 9-2320-366-20-3

7-33. M1089 TERMINAL BLOCK REPLACEMENT (CONT)

(9) Loosen screw (20) in two clamps (21).

NOTE

Record position of terminal blocks prior to

removal.

(10) Remove two clamps (21), end cap (22) and 28 terminal
blocks (10) from channel (16).

b. Installation.

(1) Label 28 terminal blocks (1) as recorded in removal.

(2) Position 28 terminal blocks (1), end cap (2) on channel

(3) with two clamps (4).

(3) Tighten screw (5) in two clamps (4).

7-200 Change 1
 TM 9-2320-366-20-3

(4) Position wires (6) on bottom of terminal blocks (1) as

recorded in removal.

(5) Tighten screws (7) on bottom of terminal blocks (1).

(6) Install channel (3) on winch assembly (8) with two

washers (9), screws (10), and self-locking nuts (11).

(7) Position five terminal block jumpers (12) on top of

terminal blocks (1) as recorded in removal.

NOTE

Install plastic cable ties as required.

(8) Position wires (13) on top of terminal blocks (1) as

recorded in removal.

(9) Tighten screws (14) on top of terminal blocks (1).

Change 1 7-200.1/(7-200.2 Blank)

 TM 9-2320-366-20-3

(10) Install top cover (15) on control panel (16) with eight
washers (17), lockwashers (18), and screws (19).

(11) Install four washers (20), two screws (21), and self-
locking nuts (22) in top cover (15).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Operate all wrecker functions and check for proper

operation (TM 9-2320-366-10-1).

End of Task.

Change 1 7-201
TM 9-2320-366-20-3

7-34. M1089 WRECKER CONTROL PANEL TOGGLE SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Material/Parts

Engine shut down (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Batteries disconnected (para 7-57). (Item 20, Appendix D)
Insulation Sleeving, Electrical (Item 29, Appendix
Tools and Special Tools D)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (8) (Item 100, Appendix G)
Tool Kit, Electrical (Item 45, Appendix C) Lockwasher (Item 74, Appendix G)
Heater, Gun Type, Electric (Item 24, Appendix B) Nut, Self-Locking (2) (Item 134, Appendix G)
Splice, Conductor (2) (Item 275, Appendix G)
Splice, Conductor (Item 276, Appendix G)

a. Removal.

NOTE

There are seven toggle switches on the

WRECKER CONTROL PANEL. Steps (1
and 2) apply to all seven toggle switches.

(1) Remove eight screws (1), lockwashers (2), and washers

(3) from control panel top cover (4). Discard
lockwashers.

(2) Remove two self-locking nuts (5), four washers (6), two
screws (7), and control panel top cover (4) from
WRECKER CONTROL PANEL (8). Discard self-locking
nuts.

7-202
 TM 9-2320-366-20-3

NOTE

• Steps (3 and 4) apply only to the MAIN WINCH

LH FREE SPOOL and MAIN WINCH RH FREE
SPOOL toggle switches. MAIN WINCH LH
FREE SPOOL toggle switch shown.

• Tag wires and connection points prior to

disconnecting.

(3) Remove nut (9), lockwasher (10), switch cover (11), nut
(12), tab washer (13), and MAIN WINCH LH FREE
SPOOL toggle switch (14) from WRECKER CONTROL
PANEL (8). Discard lockwasher.

(4) Remove two screws (15) and terminal lugs (16) from
MAIN WINCH LH FREE SPOOL toggle switch (14).

CAUTION

Switch covers contain an integral nut. Do not

attempt to pull switch cover off toggle switch.
Failure to comply will result in damage to
equipment.

NOTE

Steps (5 through 9) apply to the remaining

five toggle switches. Two toggle switches
have three electrical connections, the
remaining three have only two electrical
connections. EMERGENCY SHUTDOWN
toggle switch shown.

(5) Remove switch cover nut (17) and EMERGENCY

SHUTDOWN toggle switch (18) from WRECKER
CONTROL PANEL (8).

7-203
TM 9-2320-366-20-3

7-34. M1089 WRECKER CONTROL PANEL TOGGLE SWITCH REPLACEMENT (CONT)

(6) Disconnect conductor splice (19) from two wires (20).

(7) Remove conductor splice (21) and EMERGENCY

SHUTDOWN toggle switch (18) from wire (22).

(8) Remove conductor splices (19 and 21) from

EMERGENCY SHUTDOWN toggle switch (18). Discard
conductor splices.

b. Installation.

NOTE

Steps (1 through 6) apply to the remaining

five toggle switches. Two toggle switches
have three electrical connections, the
remaining three have only two electrical
connections. EMERGENCY SHUTDOWN
toggle switch shown.

(1) Position insulation sleeving (1) over two wires (2).

(2) Position insulation sleeving (1) over wire (3).

(3) Install conductor splices (4 and 5) on EMERGENCY

SHUTDOWN toggle switch (6).

(4) Install conductor splice (5) on wire (3).

(5) Install conductor splice (4) on two wires (2).

7-204
 TM 9-2320-366-20-3

(6) Install EMERGENCY SHUTDOWN toggle switch (6) in

WRECKER CONTROL PANEL (7) with switch cover nut
(8).

NOTE

Steps (7) and (8) apply only to the MAIN

WINCH LH FREE SPOOL and MAIN WINCH
RH FREE SPOOL toggle switches. MAIN
WINCH LH FREE SPOOL toggle switch
shown.

(7) Install two terminal lugs (9) and screws (10) on MAIN
WINCH LH FREE SPOOL toggle switch (11).

(8) Install MAIN WINCH LH FREE SPOOL toggle switch

(11) in WRECKER CONTROL PANEL (7) with tab
washer (12), nut (13), switch cover (14), lockwasher (15),
and nut (16).

7-205
TM 9-2320-366-20-3

7-34. M1089 WRECKER CONTROL PANEL TOGGLE SWITCH REPLACEMENT (CONT)

(9) Install control panel top cover (17) on WRECKER

CONTROL PANEL (7) with four washers (18), two
screws (19), and self-locking nuts (20).

(10) Install eight washers (21), lockwashers (22), and screws

(23) in control panel top cover (17).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Operate function of toggle switch that was

replaced (TM 9-2320-366-10-1) and check for proper
operation.

End of Task.

7-206
 TM 9-2320-366-20-3

7-35. M1089 WRECKER REMOTE CONTROL REPAIR

This task covers:

a. Disassembly c. Follow-On Maintenance

b. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

REMOTE CONTROL assembly removed (TM 9-2320- Dispenser, Pressure Sensitive Adhesive Tape
366-10-1). (Item 20, Appendix D)
Ties, Cable, Plastic (Item 69, Appendix D)
Tools and Special Tools Insulation Sleeving, Electrical (Item 29,
Tool Kit, Genl Mech (Item 46, Appendix C) Appendix D)
Tool Kit, Electrical (Item 45, Appendix C) Nut, Conduit (Item 123, Appendix G)

a. Disassembly.

(1) Open cover (1) on REMOTE CONTROL (2).

(2) Remove four screws (3), washers (4), and panel (5) from
REMOTE CONTROL (2).

Change 1 7-207
TM 9-2320-366-20-3

7-35. M1089 WRECKER REMOTE CONTROL REPAIR (CONT)

NOTE

• Remove plastic cable ties as required.

• All 8 switches are removed the same way.

UNDERLIFT FOLD switch shown.

(3) Remove switch cover nut (6) and switch (7) from panel
(5).

NOTE

• Cut cable wires at heat shrink when removing

switch.

• Tag wires and connection points prior to

disconnecting.

(4) Remove switch (7) from cable (8).

(5) Perform steps (3) and (4) on remaining seven switches.

(6) Remove conduit nut (9) and cable (8) from remote
control box (2). Discard conduit nut.

(7) Remove seal (10) from adapter (11).

(8) Remove nut (12) from adapter (11).

(9) Remove adapter (11), seal (13), grip (14), and nut (12)
from cable (8).

7-208
 TM 9-2320-366-20-3

b. Assembly.

(1) Position nut (1), grip (2), seal (3), and adapter (4) on
cable (5).

(2) Install seal (6) on adapter (4).

(3) Position cable (5) in remote control box (7).

(4) Position conduit nut (8) on cable (5).

NOTE

Perform steps (5) through (7) for all switches.

(5) Position tubing (9) on switch (10).

(6) Attach switch (10) to cable (5) with splice connector (11).

(7) Shrink tubing (9) over splice connector (11).

(8) Install switch (10) in panel (12) with switch cover nut
(13).

7-209
TM 9-2320-366-20-3

7-35. M1089 WRECKER REMOTE CONTROL REPAIR (CONT)

(9) Install adapter (4) in REMOTE CONTROL (7) with

conduit nut (8).

(10) Install seal (3) and grip (2) on adapter (4) with nut (1).

(11) Install panel (12) on REMOTE CONTROL (7) with four

washers (14) and screws (15).

(12) Close cover (16) on REMOTE CONTROL (7).

c. Follow-On Maintenance.

Test operate wrecker with REMOTE CONTROL (TM 9-

2320-366-10-1).

End of Task.

7-210 Change 1
 TM 9-2320-366-20-3

7-36. BACKUP LIGHT ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. M1088 Backup Light Assembly Removal g. M1083/M1084/M1085/M1086/M1090/M1092/M10

b. M1088 Backup Light Assembly Installation 93/M1094/M1096 Backup Light Assembly
c. M1089 Backup Light Assembly Removal Removal
d. M1089 Backup Light Assembly Installation h. M1083/M1084/M1085/M1086/M1090/M1092/M10
e. Deleted 93/M1094/M1096 Backup Light Assembly
f. Deleted Installation
i. Disassembly
j. Assembly
k. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Lockwasher (2) (Item 96, Appendix G)
Lockwasher (4) (Item 114, Appendix G)
Tools and Special Tools Packing, Preformed (Item 215, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (4) (Item 168, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

a. M1088 Backup Light Assembly Removal.

(1) Disconnect backup light connector (1) from connector

P87 (2).

(2) Remove two screws (3), lockwashers (4), terminal lug

TL17 (5), and backup light assembly (6) from bracket (7).
Discard lockwashers.

b. M1088 Backup Light Assembly Installation.

(1) Position terminal lug TL17 (5), two lockwashers (4),

screws (3), and backup light assembly (6) on bracket (7).

(2) Tighten two screws (3) to 19-24 lb-ft (26-32 N·m).

(3) Connect connector P87 (2) to backup light connector (1).

Change 1 7-211
TM 9-2320-366-20-3

7-36. BACKUP LIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

c. M1089 Backup Light Assembly Removal.

(1) Disconnect backup light connector (1) from connector

P87 (2).

(2) Remove screw (3), lockwasher (4), and terminal lug

TL47 (5) from bracket (6). Discard lockwasher.

(3) Remove screw (7), lockwasher (8), and backup light

assembly (9) from bracket (6). Discard lockwasher.

(4) Remove two self-locking nuts (10), lockwashers (11),

screws (12), and bracket (6) from bracket (13). Discard
lockwashers and self-locking nuts.

d. M1089 Backup Light Assembly Installation.

(1) Position bracket (1) on bracket (2) with two lockwashers

(3), screws (4), and self-locking nuts (5).

(2) Tighten two screws (4) to 35-43 lb-ft (48-58 N·m).

7-212
 TM 9-2320-366-20-3

(3) Position backup light assembly (6) on bracket (1) with

lockwasher (7) and screw (8).

(4) Position terminal lug TL47 (9), lockwasher (10), and

screw (11) in backup light assembly (6).

(5) Tighten screws (8 and 11) to 35-42 lb-ft (48-57 N·m).

(6) Connect backup light connector (12) to connector P87

(13).

e. Deleted

Change 1 7-213
TM 9-2320-366-20-3

7-36. BACKUP LIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

f. Deleted

7-214 Change 1
 TM 9-2320-366-20-3

g. M1083/M1084/M1085/M1086/M1090/M1092/M1093/
M1094/M1096/ Backup Light Assembly Removal.

(1) Disconnect backup light connector (1) from connector

P87 (2).

(2) Remove two screws (3), lockwashers (4), terminal lug

TL17 (5), and backup light assembly (6) from taillight
carrier (7). Discard lockwashers.

h. M1083/M1084/M1085/M1086/M1090/M1092/M1093/
M1094/M1096 Backup Light Assembly Installation.

(1) Position terminal lug TL17 (5), two lockwashers (4),

screws (3), and backup light assembly (6) on taillight
carrier (7).

(2) Tighten two screws (3) to 35-42 lb-ft (48-57 N·m).

(3) Connect backup light connector (1) to connector P87 (2).

i. Disassembly.

(1) Loosen six screws (1) on lens (2).

(2) Remove lens (2) from housing (3).

(3) Remove preformed packing (4) from housing (3).

Discard preformed packing.

(4) Remove two lamps (5) from sockets (6).

Change 1 7-215
TM 9-2320-366-20-3

7-36. BACKUP LIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

j. Assembly.

(1) Install two lamps (1) in sockets (2).

(2) Install preformed packing (3) and lens (4) on housing (5)
with six screws (6).

k. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check backup light operation (TM 9-2320-366-10-1).

End of Task.

7-216
 TM 9-2320-366-20-3

7-37. BLACKOUT DRIVE LIGHT REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Lockwasher (Item 96, Appendix G)
Packing, Preformed (Item 189, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Disconnect connector P17 (1) from blackout drive light

(2).

(2) Remove nut (3), lockwasher (4), washer (5), washer (6),
and terminal lug TL79 (7) from blackout drive light (2).
Discard lockwasher.

(3) Remove blackout drive light (2) from bumper (8).

b. Disassembly.

(1) Loosen three screws (1) on cover (2).

(2) Remove cover (2) and preformed packing (3) from

housing (4). Discard preformed packing.

(3) Remove lamp (5) from socket (6).

7-217
TM 9-2320-366-20-3

7-37. BLACKOUT DRIVE LIGHT REPLACEMENT/REPAIR (CONT)

c. Assembly.

(1) Install lamp (1) in socket (2).

(2) Install preformed packing (3) and cover (4) on housing

(5) with three screws (6).

d. Installation.

(1) Position blackout drive light (1) on bumper (2).

(2) Position terminal lug TL79 (3), washer (4), washer (5),
lockwasher (6), and nut (7) on blackout drive light (1).

(3) Tighten nut (7) to 156-192 lb-in. (18-22 N·m).

(4) Connect connector P17 (8) to back of blackout drive light

(1).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check blackout drive light operation (TM 9-2320-366-10-

1).

End of Task.

7-218
 TM 9-2320-366-20-3

7-38. CLEARANCE AND MARKER LIGHT ASSEMBLIES REPLACEMENT

This task covers:

a. Cab Clearance and Marker Light Removal d. Chassis Clearance and Marker Light Installation
b. Cab Clearance and Marker Light Installation e. Follow-On Maintenance
c. Chassis Clearance and Marker Light Removal

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Adhesive (Item 5, Appendix D)
Lockwasher (2) (Item 82, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Cab Clearance and Marker Light Removal.

NOTE

All cab clearance and marker lights are

removed the same way. Front left marker
light shown.

(1) Remove two screws (1) and lens cover (2) from base
(3).

(2) Remove two clips (4) and lens (5) from lens cover (2).

(3) Remove lamp (6) from socket (7).

(4) Remove four screws (8) from base (3).

Change 1 7-219
TM 9-2320-366-20-3

7-38. CLEARANCE AND MARKER LIGHT ASSEMBLIES REPLACEMENT (CONT)

CAUTION

Do not let wires slip through hole and into

cab structure. If wires slip into cab structure,
vehicle will need further disassembly to
retrieve wires.

(5) Disconnect marker light connector (9) from connector

P50 (10).

(6) Remove nut (11), lockwasher (12), terminal lug (13),

lockwasher (14), base (3), and gasket (15) from vehicle.
Discard lockwashers.

(7) Remove nut (16), and screw (17) from base (3).

b. Cab Clearance and Marker Light Installation.

WARNING

Adhesives, solvents, and sealing compounds

can burn easily, 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, solvent, or
sealing compound gets on skin or clothing,
wash immediately with soap and water.
Failure to comply may result in injury to
personnel.

(1) Apply adhesive to threads of screw (1).

(2) Install screw (1) in base (2) with nut (3).

NOTE

Clearance and marker lights originally come

with cork gaskets. Discard cork gaskets and
replace with rubber gaskets PN 12421469.

(3) Install gasket (4) on base (2).

(4) Connect marker light connector (5) to connector P50 (6).

(5) Install lockwasher (7), terminal lug (8), lockwasher (9),

and nut (10) on back of base (2).

7-220 Change 1
 TM 9-2320-366-20-3

(6) Install base (2) on vehicle with four screws (11).

(7) Install lamp (12) in socket (13).

(8) Install lens (14) in lens cover (15) with two clips (16).

(9) Install lens cover (15) on base (2) with two screws (17).

c. Chassis Clearance and Marker Light Removal.

NOTE

All chassis clearance and marker lights are

removed the same way. Right rear marker
light shown.

(1) Remove two screws (1) and lens cover (2) from base
(3).

(2) Remove two clips (4) and lens (5) from lens cover (2).

7-221
TM 9-2320-366-20-3

7-38. CLEARANCE AND MARKER LIGHT ASSEMBLIES REPLACEMENT (CONT)

(3) Remove lamp (6) from socket (7).

(4) Disconnect marker light connector (8) from connector

P54 (9).

(5) Remove nut (10), lockwasher (11), terminal lug (12), and
lockwasher (13) from screw (14). Discard lockwashers.

NOTE

Perform step (6) on three center clearance

lights on all models except M1084/M1086
and M1089.

(6) Remove four nuts (15), washers (16), screws (17),

washers (18), base (3), and gasket (19) from vehicle.

NOTE

Perform step (7) on three center clearance

lights on M1084/M1086 and M1089.

(7) Remove four nuts (15), washers (16), screws (17), base
(3), and gasket (19) from vehicle.

(8) Remove nut (20) and screw (14) from base (3).

7-222 Change 1
 TM 9-2320-366-20-3

d. Chassis Clearance and Marker Light Installation.

WARNING

Adhesives, solvents, and sealing compounds

can burn easily, 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, solvent, or
sealing compound gets on skin or clothing,
wash immediately with soap and water.
Failure to comply may result in injury to
personnel.

(1) Apply adhesive to threads of screw (1).

(2) Install screw (1) in base (2) with nut (3).

NOTE

Clearance and marker lights originally come

with cork gaskets. Discard cork gaskets and
replace with rubber gaskets PN 12421469.

(3) DELETED

NOTE

Perform step (4) on three center clearance

lights on M1084/M1086 and M1089.

(4) Install gasket (4) and base (2) on vehicle with four
screws (5), washers (6), and nuts (7).

NOTE

Perform step (5) on three center clearance

lights on all models except M1084/M1086
and M1089.

(5) Install gasket (4) and base (2) on vehicle with four
washers (8), screws (5), washers (6), and nuts (7).

Change 1 7-223
TM 9-2320-366-20-3

7-38. CLEARANCE AND MARKER LIGHT ASSEMBLIES REPLACEMENT (CONT)

(6) Install lockwasher (9) and terminal lug (10) on screw (1)
with lockwasher (11) and nut (12).

(7) Connect marker light connector (13) to connector P54

(14).

(8) Install lamp (15) in socket (16).

(9) Install lens (17) on lens cover (18) with two clips (19).

(10) Install lens cover (18) on base (2) with two screws (20).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check clearance and marker light operation (TM 9-2320-

366-10-1).

End of Task.

7-224 Change 1
 TM 9-2320-366-20-3

7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. M1088 Composite Taillight Assembly Removal h. Deleted

b. M1088 Composite Taillight Assembly Installation i. Composite Taillight Assembly Removal (All
c. M1089 Composite Taillight Assembly Removal Models Except M1088/M1089)
d. M1089 Composite Taillight Assembly Installation j. Composite Taillight Assembly Installation (All
e. Deleted Models Except M1088/M1089)
f. Deleted k. Disassembly
g. Deleted l. Assembly
m. Follow-On Maintenance

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
(Item 20, Appendix D)
Tools and Special Tools Ties, Cable, Plastic (Item 69, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (2) (Item 96, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Packing, Preformed (Item 191, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Wrench Set, Socket (Item 51, Appendix C)

NOTE

Tag wires and connection points prior to

disconnecting.

Remove plastic cable ties as required.

Right side connectors are P61, P62, P63,

P64, 22-460, 24, 23, 21, and TL 21.

a. M1088 Composite Taillight Assembly Removal.

NOTE

Left and right composite taillights are

removed the same way. Left side shown.

(1) Disconnect connectors P74, P76, P77, P78 (1) from

composite taillight connectors 22-461, 24, 23, 21 (2).

(2) Remove two screws (3), lockwashers (4), terminal lug

TL18 (5), and composite taillight assembly (6) from
vehicle. Discard lockwashers.

Change 1 7-225
TM 9-2320-366-20-3

7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

b. M1088 Composite Taillight Assembly Installation.

NOTE

Left and right composite taillights are installed

the same way. Left side shown.

Install plastic cable ties as required.

(1) Position composite taillight assembly (1) on vehicle with

terminal lug TL18 (2), two lockwashers (3), and screws
(4).

(2) Tighten two screws (4) to 19-24 lb-ft (26-32 N·m).

(3) Connect connectors P74, P76, P77, P78 (5) to

composite taillight connectors 22-461, 24, 23, 21 (6).

c. M1089 Composite Taillight Assembly Removal.

NOTE

Left and right composite taillights are removed

the same way. Left side shown.

(1) Disconnect connectors P74, P76, P77, P78 (1) from

composite taillight connectors 22-461, 24, 23, 21 (2).

(2) Remove two screws (3), lockwashers (4), terminal lugs

TL18 (5), and composite taillight assembly (6) from
vehicle. Discard lockwashers.

7-226 Change 1
 TM 9-2320-366-20-3

d. M1089 Composite Taillight Assembly Installation.

NOTE

• Left and right composite taillights are installed

the same way. Left side shown.

Install plastic cable ties as required.

(1) Position composite taillight assembly (1) on vehicle with

two terminal lugs TL18 (2), lockwashers (3), and screws
(4).

(2) Tighten two screws (4) to 50-60 lb-in. (6-7 N·m).

(3) Connect connectors P74, P76, P77, P78 (5) to

composite taillight connectors 22-461, 24, 23, 21 (6).

e. Deleted.

Change 1 7-227
TM 9-2320-366-20-3

7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

f. Deleted.

g. Deleted.

7-228 Change 1
 TM 9-2320-366-20-3

h. Deleted.

i. Composite Taillight Assembly Removal (All Models

Except M1088/M1089).

NOTE

Left and right composite taillights are

removed the same way. Left side shown.

(1) Remove self-locking nut (1), screw (2), and clamp (3)
from taillight carrier (4). Discard self-locking nut.

(2) Disconnect connectors P74, P76, P77, P78 (5) from

composite taillight connectors 22-461, 24, 23, 21 (6).

(3) Remove two screws (7), lockwashers (8), terminal lug

TL18 (9), and composite taillight assembly (10) from
taillight carrier (4). Discard lockwashers.

Change 1 7-229
TM 9-2320-366-20-3

7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

j. Composite Taillight Assembly Installation (All Models

Except M1088/M1089).

NOTE

• Left and right composite taillights are installed

the same way. Left side shown.

• Install plastic cable ties as required.

(1) Position two lockwashers (1), screws (2), terminal lug

TL18 (3), and composite taillight assembly (4) on taillight
carrier (5).

(2) Tighten two screws (2) to 35-42 lb-ft (48-57 N·m).

(3) Connect connectors P74, P76, P77, P78 (6) to

composite taillight connectors 22-461, 24, 23, 21 (7).

(4) Install clamp (8) on taillight carrier (5) with screw (9) and
self-locking nut (10).

k. Disassembly.

(1) Remove six screws (1), cover (2), and preformed

packing (3) from housing (4). Discard preformed
packing.

(2) Remove two screws (5), bezel (6), lens (7), and retainer
(8) from cover (2).

7-230 Change 1
 TM 9-2320-366-20-3

(3) Remove lamps (9 and 10) from sockets (11 and 12).

(4) Position blackout stoplight lamp (13) for access to socket

(14).

(5) Remove connector (15) from socket (14).

(6) Position blackout marker lamp (16) for access to socket

(17).

(7) Remove connector (18) from socket (17).

l. Assembly.

(1) Install connector (1) in socket (2).

(2) Position blackout marker lamp (3) in connector (1).

(3) Install connector (4) in socket (5).

(4) Install blackout stoplight lamp (6) in connector (4).

(5) Install two lamps (7 and 8) in sockets (9 and 10).

(6) Position retainer (11), lens (12), and bezel (13) on cover
(14) with two screws (15).

(7) Position preformed packing (16) and cover (14) on

housing (17) with six screws (18).

(8) Tighten two screws (15) and six screws (18) to 20-25 lb-
in. (1 N·m).

7-231
TM 9-2320-366-20-3

7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

m. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check operation of taillights (TM 9-2320-366-10-1).

(3) Check operation of blackout lights (TM 9-2320-366-10-1).

(4) Check operation of brake lights (TM 9-2320-366-10-1).

End of Task.

7-232
 TM 9-2320-366-20-3

7-40. COMPOSITE FRONT LIGHT ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 20, Appendix D)
Lockwasher (2) (Item 96, Appendix G)
Tools and Special Tools Packing, Preformed (Item 191, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

NOTE

Both composite front light assemblies are

removed the same way. Left side shown.

Tag wires and connection points prior to

disconnecting.

Connectors for right side are P8, P9 and

P10.

(1) Disconnect connectors P22, P23, and P24 (1) from

composite front light assembly (2).

(2) Remove two screws (3), lockwashers (4), three terminal

lugs (5), and composite front light assembly (2) from
front bumper (6). Discard lockwashers.

7-233
TM 9-2320-366-20-3

7-40. COMPOSITE FRONT LIGHT ASSEMBLY REPLACEMENT/REPAIR (CONT)

b. Disassembly.

(1) Loosen five screws (1) on cover (2).

(2) Remove cover (2) and preformed packing (3) from

housing (4). Discard preformed packing.

(3) Remove lamps (5 and 6) from sockets (7).

(4) Open blackout marker lamp (8).

(5) Remove blackout marker lamp (8) from socket (9).

c. Assembly.

(1) Open blackout marker lamp (1).

(2) Install blackout marker lamp (1) in socket (2).

(3) Install lamps (3 and 4) in sockets (5).

(4) Install preformed packing (6) and cover (7) on housing

(8) with five screws (9).

7-234
 TM 9-2320-366-20-3

d. Installation.

NOTE

Both composite front light assemblies are

installed the same way. Left side shown.

(1) Position composite front light assembly (1) in front

bumper (2).

(2) Position three terminal lugs (3), two lockwashers (4), and
screws (5) on composite front light assembly (1).

(3) Tighten two screws (5) to 156-192 lb-in. (18-22 N·m).

(4) Connect connectors P22, P23, and P24 (6) to composite

front light assembly (1).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check operation of hazard lights, turn signals, park

lights, and blackout marker lights (TM 9-2320-366-10-1).

End of Task.

7-235
TM 9-2320-366-20-3

7-41. HEADLIGHT AND HOUSING REPLACEMENT/REPAIR/ADJUSTMENT

This task covers:

a. Removal d. Installation
b. Disassembly e. Adjustment
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 18, Appendix C)
Grommet, Nonmetallic (3) (Item 55, Appendix
Tools and Special Tools G)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (3) (Item 85, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)
Headlight Adjustment Screen (Item E-6, Appendix E)

a. Removal.

NOTE

• Both headlights are removed the same way.

Left headlight shown.

• Perform steps (1) through (3) to remove lamp

only.

(1) Remove three screws (1) and retaining ring (2) from
housing (3).

(2) Remove lamp (4) from housing (3).

NOTE

• Tag connectors and connection points prior to

disconnecting.

• Connector numbers are the same on left and

right headlights.

(3) Disconnect connectors 18, 91, and 17 (5) from housing

(3).

7-236
 TM 9-2320-366-20-3

NOTE

• Tag connectors and connection points prior to

disconnecting.

• Connectors for right side are P13, P14, and P12.

(4) Disconnect connectors P4, P19, and P20 (6) from

housing (3).

(5) Remove three nuts (7) and housing (3) from bumper (8).

b. Disassembly.

(1) Remove two screws (1) and lens retainer (2) from
housing (3).

(2) Remove three nuts (4), resilient mounts (5), washers (6),
and lockwashers (7) from housing (3). Discard
lockwashers.

(3) Remove three adapters (8) and grommets (9) from

housing (3). Discard grommets.

c. Assembly.

(1) Install three grommets (1) and adapters (2) on housing

(3).

(2) Install three resilient mounts (4) on housing (3) with three
washers (5), lockwashers (6), and nuts (7).

(3) Install lens retainer (8) on housing (3) with three screws
(9).

7-237
TM 9-2320-366-20-3

7-41. HEADLIGHT AND HOUSING REPLACEMENT/REPAIR/ADJUSTMENT (CONT)

d. Installation.

NOTE

Both headlights are installed the same way.

Left headlight shown.

(1) Position housing (1) on bumper (2) with three nuts (3).

(2) Tighten three nuts (3) to 60-72 lb-in. (7-8 N·m).

NOTE

Connectors for right side are P13, P14, and

P12.

(3) Install connectors P20, P19, and P4 (4) to back of

housing (1).

NOTE

• Perform steps (4) through (6) to install lamp

only.

• Connector numbers are the same on left and

right headlights.

(4) Connect connectors 18, 91, and 17 (5) on housing (1).

(5) Install lamp (6) in housing (1).

(6) Install retaining ring (7) on housing (1) with three screws
(8).

(7) Lower cab (TM 9-2320-366-10-1).

7-238
 TM 9-2320-366-20-3

e. Adjustment.

NOTE

Vehicle must be empty when making

headlight adjustment.

(1) Connect batteries (para 7-57).

(2) Position vehicle on level surface with both headlights

approximately 36 in. (91 cm) from headlight adjustment
screen with vertical lines (1) directly in front of bumper
ends (2).

(3) Turn headlights on LOW beam (TM 9-2320-366-10-1).

(4) Observe headlight spots on headlight adjustment screen.

If headlight spots are within squares (3), alignment is
correct.

NOTE

Perform steps (5) and (6) if headlights need

adjusting.

(5) Adjust screw (4) to move headlight spot up or down.

(6) Adjust screw (5) to move headlight spot left or right.

(7) Turn off headlights (TM 9-2320-366-10-1).

End of Task.

7-239
TM 9-2320-366-20-3

7-42. M1088/M1089 STATIONARY WORKLIGHT ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. Removal d. Installation
b. Disassembly e. Follow-On Maintenance
c. Assembly

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Lockwasher (Item 96, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

Left side and right side stationary

worklight assemblies are removed the
same way. Right side shown.

(1) Disconnect worklight connector (1) from connector

P134A (2).

(2) Remove nut (3), lockwasher (4), washer (5) and

worklight assembly (6) from vehicle. Discard
lockwasher.

b. Disassembly.

(1) Remove screw (1) and retaining ring (2) from worklight
assembly (3).

(2) Loosen two screws (4) on back of lamp (5).

(3) Disconnect two terminals (6) from lamp (5).

7-240
 TM 9-2320-366-20-3

c. Assembly.

(1) Install two terminals (1) on lamp (2) with two screws (3).

(2) Install lamp (2) and retaining ring (4) on worklight

assembly (5) with two screws (6).

d. Installation.

NOTE

Left side and right side stationary worklight

assemblies are installed the same way.
Right side shown.

(1) Position worklight assembly (1) in mounting location on

vehicle.

(2) Install washer (2), lockwasher (3) and nut (4) on

worklight assembly (1).

(3) Connect worklight connector (5) to connector P134A (6).

e. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check operation of work light (TM 9-2320-366-10-1).

End of Task.

7-241
TM 9-2320-366-20-3

7-43. AUDIBLE ALARM REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Instrument panel assembly removed for access (para Dispenser, Pressure Sensitive Adhesive Tape
7-15). (Item 20, Appendix D)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Disconnect connector PX7 (1) from lighted indicator

display (2).

7-242 Change 1
 TM 9-2320-366-20-3

(2) Remove lock ring (3) and audible alarm (4) from
instrument panel assembly (5).

NOTE

• Tag wires and connection points prior to

disconnecting.

• Perform step (3) on M1084, M1086, M1088, and

M1089.

(3) Remove two screws (6) and terminal lugs TL161 (7) and
TL160 (8) from audible alarm (4).

NOTE

Perform steps (4) and (5) on all models

except M1084, M1086, M1088, and M1089.

(4) Remove two screws (6) and terminal lugs TL161 (7) and
TL178 (8) from audible alarm (4).

(5) Remove screw (9) and TL160 (10) from audible alarm
(4).

b. Installation.

NOTE

Perform steps (1) and (2) on all models

except M1084, M1086, M1088, and M1089.

(1) Install terminal lug TL160 (1) on audible alarm (2) with
screw (3).

(2) Install terminal lugs TL161 (4) and TL178 (5) on audible
alarm (2) with two screws (6).

NOTE

Perform step (3) on M1084, M1086, M1088,

and M1089.

(3) Install terminal lugs TL160 (5) and TL161 (4) on audible
alarm (2) with two screws (6).

(4) Install audible alarm (2) in instrument panel assembly (7)

with lock ring (8).

Change 1 7-242.1/(7-242.2 Blank)

 TM 9-2320-366-20-3

(5) Connect connector PX7 (9) to lighted indicator display

(10).

c. Follow-On Maintenance.

(1) Install instrument panel assembly (para 7-15).

(2) Check operation of audible alarm (TM 9-2320-366-10-1).

End of Task.

Change 1 7-243
TM 9-2320-366-20-3

7-44. AIR PRESSURE TRANSMITTER REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape (Item
Air tanks drained (TM 9-2320-366-10-1). 20, Appendix D)
Packing, Preformed (Item 191.1, Appendix G)
Tools and Special Tools Lockwasher (2) (Item 71, Appendix G)
Tool Kit, Genl Mech (Item 58, Appendix C)

a. Removal.

• NOTE

• Tag wires and connection points prior to

disconnecting.

• Front brake air pressure transmitter and rear brake

air pressure transmitter are removed the same way.
Rear brake air pressure transmitter shown.

• Terminal lugs on front brake air pressure transmitter

are TL150 for terminal G and TL156 for terminal
WK.

(1) Remove nut (1), lockwasher (2), and terminal lug

TL151 (3) from air pressure transmitter terminal G
(4). Discard lockwasher.

(2) Remove nut (5), lockwasher (6), and terminal lug

TL157 (7) from air pressure transmitter terminal
WK (8).

(3) Remove air pressure transmitter (9) from reducer

(10).

NOTE

Perform the following step on air pressure

transmitters equipped with preformed

(4) Remove preformed packing (11) from air pressure

transmitter (9). Discard preformed packing.

7-244 Change 2
 TM 9-2320-366-20-3

b. Installation.

(1) Install preformed packing (1) on air pressure

transmitter (2).

(2) Install air pressure transmitter (1) in reducer (2).

NOTE

• Front brake air pressure transmitter and rear

brake air pressure transmitter are installed the
same way. Rear brake air pressure
transmitter shown.

• Terminal lugs on front brake air pressure

transmitter are TL150 for terminal G and
TL156 for terminal WK.

(3) Install terminal lug TL157 (4) on air pressure

transmitter terminal WK (5) with lockwasher (6)
and nut (7).

(4) Install terminal lug TL151 (8) on air pressure

transmitter terminal G (8) with lockwasher (10) and
nut (11).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check FRONT BRAKE AIR and REAR BRAKE AIR

pressure gage operation (TM 9-2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 2 7-245
TM 9-2320-366-20-3

7-45. COOLANT TEMPERATURE GAGE SENSOR REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Sealing Compound (Item 58, Appendix D)
Batteries disconnected (para 7-57).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

Perform steps (1) through (3) on coolant

temperature gage sensors equipped with a
connector clamp.

(1) Disconnect connector clamp (1) from coolant

temperature gage sensor (2).

(2) Disconnect connector P41 (3) from coolant temperature

gage sensor (2).

(3) Remove coolant temperature gage sensor (2) from

adapter (4).

NOTE

Perform steps (4) and (5) on coolant

temperature gage sensors not equipped with
a connector clamp.

(4) Disconnect connector P41 (3) from coolant temperature

gage sensor (2).

(5) Remove coolant temperature gage sensor (2) from

adapter (4).

7-246 Change 1
 TM 9-2320-366-20-3

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of coolant

temperature gage sensor (1).

(2) Install coolant temperature gage sensor (1) in adapter

(2).

(3) Connect connector P41 (3) to coolant temperature gage

sensor (1).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check coolant temperature gage operation (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 1 7-247
TM 9-2320-366-20-3

7-46. ENGINE SPEED SENSOR REPLACEMENT/ADJUSTMENT

This task covers:

a. Removal c. Adjustment
b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Ties, Cable, Plastic (Item 69, Appendix D)
Batteries disconnected (para 7-57).
References
Tools and Special Tools TM 9-4910-571-12&P
Tool Kit, Genl Mech (Item 46, Appendix C)
STE/ICE-R (Item 41, Appendix C)

a. Removal.

(1) Disconnect connector clamp (1) from engine speed

sensor connector (2).

(2) Disconnect engine speed sensor connector (2) from

connector P38 (3).

(3) Loosen jam nut (4) on engine speed sensor (5).

(4) Remove engine speed sensor (5) from flywheel housing

(6).

7-248
 TM 9-2320-366-20-3

b. Installation.

(1) Turn engine speed sensor (5) to the right in fly wheel
housing (6) until engine speed sensor contacts fly wheel.

(2) Turn engine speed sensor (5) to the left out of fly wheel
housing (6) two full turns.

(3) Tighten jam nut (4) on engine speed sensor (5).

(4) Connect engine speed sensor connector (2) to connector

P38 (3).

(5) Connect connector clamp (1) on engine speed sensor

connector (2).

c. Adjustment.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Connect batteries (para 7-57).

NOTE

Perform step (3) on vehicles not equipped with

tachometer.

(3) Connect STE/ICE-R to DCA connector (1).

(4) Start engine (TM 9-2320-366-10-1).

NOTE

Perform step (5) on vehicles equipped with

tachometer.

If engine speed is not obtained in steps (5) or

(6), perform steps (7) through (13).

(5) Depress accelerator pedal and check tachometer

operation (TM 9-2320-366-10-1).

NOTE

Perform step (3) on vehicles not equipped with

tachometer.

(6) Perform STE/ICE-R test 10 and verify engine speed (TM

9-4910-571-12&P).

7-249
TM 9-2320-366-20-3

7-46. ENGINE SPEED SENSOR REPLACEMENT/ADJUSTMENT (CONT)

(7) Shut down engine (TM 9-2320-366-10-1).

(8) Raise cab (TM 9-2320-366-10-1).

(9) Loosen jam nut (2) on engine speed sensor (3).

(10) Turn engine speed sensor (3) right one-quarter turn.

(11) Tighten jam nut (2) on engine speed sensor (3).

(12) Lower cab (TM 9-2320-366-10-1).

(13) Repeat steps (4) through (12) to verify engine speed.

(14) If engine speed is not obtained, perform engine

troubleshooting.

(15) Shut down engine (TM 9-2320-366-10-1).

NOTE

Perform step (16) on vehicles not equipped

with tachometer.

(16) Disconnect STE/ICE-R from DCA connector (1).

End of Task.

7-250
 TM 9-2320-366-20-3

7-47. ETHER SENSOR REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions
Cab raised (TM 9-2320-366-10-1). Materials/Parts
Batteries disconnected (para 7-57). Antiseize Compound (Item 13, Appendix D)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

WARNING

• Coolant may be very hot and under pressure

from engine operation. Ensure engine is
cool before performing maintenance. Failure
to comply may result in injury to personnel.

• Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

(2) Position container under radiator draincock (3).

(3) Open radiator draincock (3) and drain approximately one

gallon (one L) of coolant.

(4) Close radiator draincock (3).

7-251
TM 9-2320-366-20-3

7-47. ETHER SENSOR REPLACEMENT (CONT)

(5) Disconnect connector clamp (4) from ether sensor

connector (5).

(6) Disconnect connector P42 (6) from ether sensor

connector (5).

(7) Remove ether sensor (7) from coolant bypass tube (8).

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of ether sensor (1).

(2) Install ether sensor (1) in coolant bypass tube (2).

(3) Connect connector P42 (3) to ether sensor connector

(4).

(4) Connect connector clamp (5) on ether sensor connector

(4).

7-252
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Connect batteries (para 7-57).

(3) Lower cab (TM 9-2320-366-10-1).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check for coolant leaks under vehicle.

(6) Check coolant level after normal temperature is reached.

Add coolant as required (TM 9-2320-366-10-2).

(7) Raise cab (TM 9-2320-366-10-1).

(8) Check for coolant leaks around ether sensor.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-253
TM 9-2320-366-20-3

7-48. OIL PRESSURE SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Antiseize Compound (Item 58, Appendix D)
Batteries disconnected (para 7-57).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Disconnect connector clamp (1) from connector J34 (2).

(2) Disconnect connector P34 (3) from connector J34 (2).

(3) Remove oil pressure switch (4) from fitting (5).

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, can give off
harmful vapors, and are harmful to skin
and clothing. To avoid injury or death,
keep away from open fire and use in a
well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or
clothing, wash immediately with soap and
water. Failure to comply may result in
injury to personnel.

(1) Apply antiseize compound to threads of oil pressure

switch (4).

(2) Install oil pressure switch (4) in fitting (5).

(3) Connect connector P34 (3) to connector J34 (2).

(4) Connect connector clamp (1) on connector J34 (2).

7-254 Change 1
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check that low oil pressure is not indicated (TM 9-

2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-255
TM 9-2320-366-20-3

7-49. OIL PRESSURE TRANSMITTER REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Cab raised (TM 9-2320-366-10-1). Antiseize Compound (Item 58, Appendix D)
Batteries disconnected (para 7-57).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Disconnect connector P32 (1) from oil pressure

transmitter (2).

(2) Remove oil pressure transmitter (2) from fitting (3).

b. Installation.

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water.
Failure to comply may result in injury to
personnel.

(1) Apply antiseize compound to threads of oil

pressure transmitter (2).

(2) Install oil pressure transmitter (2) in fitting (3).

(3) Connect connector P32 (1) to oil pressure transmitter (2).

7-256 Change 2
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check oil pressure gage operation (TM 9-2320-366-10-

1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-257
TM 9-2320-366-20-3

7-50. WATER TEMPERATURE SWITCH REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Tools and Special Tools

Cab raised (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Batteries disconnected (para 7-57). Goggles, Industrial (Item 15, Appendix C)

WARNING

• Coolant may be very hot and under pressure

from engine operation. Ensure engine is
cool before performing maintenance. Failure
to comply may result in injury to personnel.

• Wear appropriate eye protection when

working under vehicle due to the possibility
of falling debris. Failure to comply may
result in injury to personnel.

a. Removal.

(1) Remove radiator cap (1) from radiator overflow tank (2).

(2) Position container under radiator draincock (3).

(3) Open radiator draincock (3) and drain approximately one

gallon (one L) of coolant.

(4) Close radiator draincock (3).

7-258
 TM 9-2320-366-20-3

(5) Disconnect connector clamp (4) from connector P36 (5).

(6) Disconnect water temperature switch connector (6) from

connector P36 (5).

(7) Remove water temperature switch (7) from upper coolant

tube (8).

b. Installation.

(1) Install water temperature switch (1) in upper coolant tube

(2).

(2) Connect connector P36 (3) to water temperature switch

connector (4).

(3) Connect connector clamp (5) on connector P36 (3).

7-259
TM 9-2320-366-20-3

7-50. WATER TEMPERATURE SWITCH REPLACEMENT (CONT)

c. Follow-On Maintenance.

(1) Add coolant to radiator overflow tank (TM 9-2320-366-

10-2).

(2) Connect batteries (para 7-57).

(3) Lower cab (TM 9-2320-366-10-1).

(4) Start engine (TM 9-2320-366-10-1).

(5) Check for coolant leaks under vehicle.

(6) Check coolant level after normal temperature is reached.

Add coolant as required (TM 9-2320-366-10-2).

(7) Raise cab (TM 9-2320-366-10-1).

(8) Check for leaks around water temperature switch.

(9) Lower cab (TM 9-2320-366-10-1).

(10) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-260
 TM 9-2320-366-20-3

7-51. M1084/M1086 JACK CYLINDER PROXIMITY SENSOR REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Jack cylinders lowered (TM 9-2320-366-10-1). Ties, Cable, Plastic (Item 69, Appendix D)
Engine shut down (TM 9-2320-366-10-1).
Personnel Required
Tools and Special Tools (2)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

Remove plastic cable ties as required.

(1) Disconnect connector (1) from proximity sensor

connector (2).

(2) Remove nut (3) from proximity sensor (4).

(3) Remove proximity sensor (4) from mounting bracket (5).

(4) Remove nut (6) from proximity sensor (4).

7-261
TM 9-2320-366-20-3

7-51. M1084/M1086 JACK CYLINDER PROXIMITY SENSOR REPLACEMENT (CONT)

b. Installation.

(1) Position nut (1) approximately 1 1/4 - 1 3/8 in. (3.2 -

3.5 cm) from bottom of proximity sensor (2).

(2) Position proximity sensor (2) in mounting bracket (3) with

nut (4).

(3) Adjust proximity sensor (2) until gap between fitting (5)
and proximity sensor is 3/16 in. (0.5 cm).

(4) Tighten nuts (1 and 4).

NOTE

Install plastic cable ties as required.

(5) Connect proximity sensor connector (6) to connector (7).

7-262
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

Operate MHC and check jack cylinder operation (TM 9-

2320-366-10-1).

End of Task.

7-263
TM 9-2320-366-20-3

7-52. TRANSMISSION ENGINE SPEED SENSOR REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SET-UP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Packing, Preformed (Item 199, Appendix G)

Tools and Special Tools

Goggles, Industrial (Item 15, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

WARNING

Wear eye protection when working under

vehicle due to the possibility of falling
debris. Failure to comply may result in
injury to personnel.

a. Removal.

(1) Disconnect engine speed sensor connector (1) from

transmission engine speed sensor (2).

(2) Remove screw (3), transmission engine speed sensor

bracket (4), and transmission engine speed sensor (2)
from converter housing module (5).

(3) Remove preformed packing (6) from transmission engine

speed sensor (2). Discard preformed packing.

7-264
 TM 9-2320-366-20-3

b. Installation.

(1) Install preformed packing (1) on transmission engine

speed sensor (2).

(2) Position transmission engine speed sensor bracket (3)

and transmission engine speed sensor (2) on converter
housing module (4) with screw (5).

(3) Tighten screw (5) to 22-26 lb-ft (30-35 N·m).

(4) Connect engine speed sensor connector (6) to

transmission engine speed sensor (2).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check for diagnostic codes logged (para 8-4 or 8-5).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-265
TM 9-2320-366-20-3

7-53. HORN AND BRACKET REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
(Item 20, Appendix D)
Tools and Special Tools Lockwasher (2) (Item 71, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Remove two screws (1) and washers (2) from front grille
(3).

(2) Remove screw (4), washer (5), and front grille (3) from
cab (6).

NOTE

Tag connectors and connection points prior

to disconnecting.

(3) Disconnect connectors P5 (7) and P6 (8) from horn (9).

(4) Remove two screws (10), lockwashers (11), strap (12),

and horn (9) from horn bracket (13). Discard
lockwashers.

7-266
 TM 9-2320-366-20-3

(5) Remove two screws (14), washers (15), and horn

bracket (13) from cab (6).

b. Installation.

(1) Install horn bracket (1) on cab (2) with two washers (3)
and screws (4).

(2) Position horn (5) on horn bracket (1) with strap (6), two
lockwashers (7), and screws (8).

(3) Tighten two screws (8) to 96-120 lb-in. (11-14 N·m).

(4) Connect connectors P6 (9) and P5 (10) to horn (5).

7-267
TM 9-2320-366-20-3

7-53. HORN AND BRACKET REPLACEMENT (CONT)

(5) Position front grille (11) on cab (2) with washer (12) and
screw (13).

(6) Position two washers (14) and screws (15) in front grille
(11).

(7) Tighten screw (13) to 48-60 lb-in. (5-7 N·m).

(8) Tighten two screws (15) to 24 lb-in. (3 N·m).

c. Follow-On Maintenance.

Connect batteries (para 7-57).

End of Task.

7-268
 TM 9-2320-366-20-3

7-54. BATTERY TESTER REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Engine shut down (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Battery box cover removed (TM 9-2320-366-10-2). (Item 20, Appendix D)
Grease, Automotive and Artillery (GAA)
Tools and Special Tools (Item 22, Appendix D)
Goggles, Industrial (Item 15, Appendix C) Lockwasher (Item 87, Appendix G)
Apron, Rubber (Item 3, Appendix C)
Gloves, Rubber (Item 13, Appendix C)
Puller, Battery Terminal (Item 28, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)

WARNING

• Remove rings, bracelets, watches, necklaces, and any other jewelry before working around
vehicle. Jewelry can catch on equipment and cause injury or short across electrical circuit
and cause severe burns or electrical shock. Batteries can explode from a spark. Battery acid
is harmful to skin and eyes. Always wear eye protection and rubber gloves when working
with batteries. Failure to comply may result in injury to personnel.

• Negative battery terminals must be disconnected first. Failure to comply may result in
serious injury or death to personnel.

a. Removal.

NOTE

Tag cables and connection points prior to

disconnecting.

(1) Remove nut (1) and lockwasher (2) from battery

ground cable (3). Discard lockwasher.

(2) Deleted.

(3) Remove terminal lugs TL50A (5), TL48 (6), and

battery tester terminal lug (7) from battery ground
cable (3).

Change 2 7-269
TM 9-2320-366-20-3

7-54. BATTERY TESTER REPLACEMENT (CONT)

NOTE

Remove battery terminal covers as required.

(4) Loosen two terminal screws (8) on battery ground

cable (3).

(5) Remove battery ground cable (3) from battery

terminals BT4 E2 (9) and BT3 E2 (10).

(6) Remove nut (11) from battery 24 VDC cable (12).

(7) Deleted.

(8) Remove terminal lug TL49A (14) and battery tester

terminal lug (15) from battery 24 VDC cable (12).

7-270 Change 2
 TM 9-2320-366-20-3

(9) Remove screw (16) and clamp (17) from battery hold-
down bracket (18).

(10) Remove battery tester (19) from spring clip (20).

(11) Remove two screws (21) and spring clip (20) from
battery hold-down bracket (18).

b. Installation.

(1) Install spring clip (1) on battery hold-down bracket (2)

with two screws (3).

(2) Install battery tester (4) in spring clip (1).

(3) Install clamp (5) on battery hold-down bracket (2) with

screw (6).

7-271
TM 9-2320-366-20-3

7-54. BATTERY TESTER REPLACEMENT (CONT)

WARNING

Negative battery terminals must be

connected last. Failure to comply may
result in serious injury or death to
personnel.

(4) Install battery tester terminal lug (7) and terminal

lug TL49A (8) on battery 24 VDC cable (9).

(5) Deleted.

(6) Install nut (11) on battery 24 VDC cable (9).

NOTE

Install battery terminal covers as required.

(7) Install battery ground cable (12) on battery

terminals BT4 E2 (13) and BT3 E2 (14).

(8) Tighten two terminal screws (15) on battery ground

cable (12).

7-272 Change 2
 TM 9-2320-366-20-3

(9) Install battery tester terminal lug (16), and terminal

lugs TL50A (17) and TL48 (18) on battery ground
cable (12).

(10) Deleted.

(11) Install lockwasher (20) and nut (21) on battery

ground cable (12).

(12) Apply grease to all battery terminals.

c. Follow-On Maintenance.

Install battery box cover (TM 9-2320-366-10-2).

End of Task.

Change 2 7-273
TM 9-2320-366-20-3

7-55. BATTERY/BATTERY CABLES REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Engine shut down (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Battery box cover removed (TM 9-2320-366-10-2). (Item 20, Appendix D)
Grease, Automotive and Artillery (GAA)
Tools and Special Tools (Item 22, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (Item 100, Appendix G)
Apron, Rubber (Item 3, Appendix C)
Goggles, Industrial (Item 15, Appendix C) References
Gloves, Rubber (Item 13, Appendix C) TM 9-6140-200-14
Puller, Battery Terminal (Item 28, Appendix C)

a. Removal.

WARNING

• Remove rings, bracelets, watches, necklaces, and any other jewelry before working around vehicle.
Jewelry can catch on equipment and cause injury or short across electrical circuit and cause
severe burns or electrical shock. Batteries can explode from a spark. Battery acid is harmful to
skin and eyes. Always wear eye protection and rubber gloves when working with batteries.
Failure to comply may result in injury to personnel.

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and
do not smoke when performing maintenance on batteries. Injury will result if acid contacts skin
or eyes. Wear rubber apron to prevent clothing being damaged. Failure to comply may result in
injury to personnel.

• Negative battery terminals and battery tester negative terminal lug must be disconnected first.
Failure to comply may result in serious injury or death to personnel.

7-274
 TM 9-2320-366-20-3

NOTE

Tag cables and connection points prior to

disconnecting.

(1) Remove nut (1) and lockwasher (2) from battery ground
cable (3). Discard lockwasher.

(2) Deleted.

(3) Remove terminal lugs TL50A (5), TL48 (6), battery

tester terminal lug (7) and washer (4) from battery
ground cable (3).

NOTE

Remove battery terminal covers as required.

(4) Loosen two terminal screws (8) on battery ground cable

(3).

(5) Remove battery ground cable (3) from battery terminals

BT4 E2 (9) and BT3 E2 (10).

(6) Remove nut (11) and terminal lug TL99 (12) from
battery BT2 to BT4 12 vdc cable (13).

Change 1 7-275
TM 9-2320-366-20-3

7-55. BATTERY/BATTERY CABLES REPLACEMENT (CONT)

(7) Remove nut (14) and terminal lug TL136 (15) from
battery BT2 to BT4 12 vdc cable (13).

(8) Loosen two terminal screws (16) on battery BT4 to BT2

12 vdc cable (13).

(9) Remove battery BT2 to BT4 12 vdc cable (13) from

battery terminals BT4 E1 (17) and BT2 E2 (18).

(10) Loosen two terminal screws (19) on battery BT1 to

BT3 12 vdc cable (20).

(11) Remove battery BT1 to BT3 12 vdc cable (20) from

battery terminals BT1 E2 (21) and BT3 E1 (22).

(12) Remove nut (23) from battery 24 vdc cable (24).

(13) Deleted.

(14) Remove terminal lug TL49A (26) and battery tester

terminal lug (27) from battery 24 vdc cable (24).

7-276 Change 1
 TM 9-2320-366-20-3

(15) Remove nut (28), and terminal lugs TL39 (29) and TL10
(30) from battery 24 vdc cable (24).

(16) Loosen two terminal screws (31) on battery 24 vdc

cable (24).

(17) Remove battery 24 vdc cable (24) from battery terminals

BT1 E1 (32) and BT2 E1 (33).

(17) Remove nut (34) and washer (35) from battery

bracket hold down screw (36).

7-277
TM 9-2320-366-20-3

7-55. BATTERY/BATTERY CABLES REPLACEMENT (CONT)

(18) Remove battery hold down bracket (37) from battery box
(38).

(19) Remove batteries BT3 (39), BT4 (40), BT1 (41), and BT2
(42) from battery box (38).

b. Installation

NOTE

Install battery terminal covers as required.

(1) Position batteries BT1 (1), BT2 (2), BT3 (3), and BT4 (4)
in battery box (5).

(2) Position battery hold down bracket (6) in battery box (5).

(3) Install washer (7) and nut (8) on battery bracket hold
down screw (9).

7-278
 TM 9-2320-366-20-3

(4) Install battery 24 vdc cable (10) on battery terminals BT1

E1 (11) and BT2 E1 (12).

(5) Tighten two terminal screws (13) on battery 24 vdc cable

(10).

(6) Install terminal lugs TL10 (14), TL39 (15) on battery 24

vdc cable (10) with nut (16).

WARNING

Negative battery terminals must be

connected last. Failure to comply may
result in serious injury or death to
personnel.

(7) Install battery tester terminal lug (17) and terminal lug
TL49A (18) on battery 24 vdc cable (10).

(8) Deleted.

(9) Install nut (20) on battery 24 vdc cable (10).

Change 1 7-279
TM 9-2320-366-20-3

7-55. BATTERY/BATTERY CABLES REPLACEMENT (CONT)

(10) Install battery BT1 to BT3 12 vdc cable (21) on battery

terminals BT1 E2 (22) and BT3 E1 (23).

(11) Tighten two terminal screws (24) on battery BT1 to BT3

12 vdc cable (21).

(12) Install battery BT2 to BT4 12 vdc cable (25) on battery

terminals BT4 E1 (26) and BT2 E2 (27).

(13) Tighten two terminal screws (28) on battery BT2 to BT4

12 vdc cable (25).

(14) Install terminal lug TL136 (29) on battery BT2 to BT4 12

vdc cable (25) with nut (30).

(15) Install terminal lug TL99 (31) on battery BT2 to BT4 12

vdc cable (25) with nut (32).

7-280
 TM 9-2320-366-20-3

(16) Install battery ground cable (33) on battery terminals BT4

E2 (34) and BT3 E2 (35).

(17) Tighten two terminal screws (36) on battery ground cable

(33).

(18) Install battery tester terminal lug (37), terminal lugs TL48
(38) and TL50A (39) and washer (40) on battery ground
cable (33).

(19) Deleted.

(20) Install lockwasher (41) and nut (42) on battery ground

cable (33).

(21) Apply grease to all battery terminals.

c. Follow-On Maintenance.

(1) Service batteries (TM 9-6140-200-14).

(2) Install battery box cover (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 1 7-281
TM 9-2320-366-20-3

7-56. BATTERY BOX REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Tools and Special Tools (Cont)
Batteries removed (para 7-55). Wrench, Torque, 0-600 lb-ft (Item 60, Appendix
NATO power cable removed (para 7-70). C)
Wet tank removed (para 23-12). Adapter, Socket Wrench (Item 1, Appendix C)
Secondary and primary air tanks removed (para 11- Socket Set, Socket Wrench (Item 35, Appendix
22). C)

Tools and Special Tools Materials/Parts

Tool Kit, Genl Mech (Item 46, Appendix C) Lockwasher (2) (Item 90, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C) Nut, Self-Locking (4) (Item 161, Appendix G)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C) Washer, Flat (10) (Item 279.1, Appendix G)
Drill, Portable, Electric (Item 7, Appendix C) Tape, Adhesive, Rubber (Item 65.2, Appendix
Drill Set, Twist (Item 6, Appendix C) D)
Goggles, Industrial (Item 15, Appendix C) Rivet, Blind (Item 254.1, Appendix G)
Tool Kit, Blind Rivet (Item 74, Appendix C) Rivet, Blind (Item 254.2, Appendix G)
Socket Set, Socket Wrench (Item 34, Appendix C)
Wrench Set, Socket (Item 51, Appendix C) Personnel Required
(3)

a. Removal.

(1) Remove 16 nuts (1), screws (2), and 32 washers (3)

from battery tray (4).

(2) Remove battery tray (4) from battery box (5).

(3) Deleted.

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(3.1) Remove six rivets (6), washers (6.1), and two latches
(6.2) from battery box (5).

(3.2) Remove six band clamps (6.3) from battery box (5).

7-282 Change 1
 TM 9-2320-366-20-3

(4) Remove two nuts (7), lockwashers (8), and stud (9) from
battery tray (4). Discard lockwashers.

(5) Remove nut (10), screw (11), and washer (12) from
battery box (5).

(5.1) Remove two nuts (13.1), screws (13.2), four washers

(13.3), and stone guard (13) from battery box (5).

NOTE

Step (6) requires the aid of an assistant.

(6) Remove two self-locking nuts (14) and screws (15) from
battery box (5). Discard self-locking nuts.

Change 1 7-283
TM 9-2320-366-20-3

7-56. BATTERY BOX REPLACEMENT (CONT)

WARNING

Battery box weighs approximately 70 lbs

(32 kgs). The aid of two assistants is
required to remove battery box from
vehicle frame. Failure to comply may
result in injury to personnel.

NOTE

Step (7) requires the aid of two assistants.

(7) Remove two self-locking nuts (16), screws (17),

reinforcing plate (18), and battery box (5) from left frame
rail (19). Discard self-locking nuts.

(8) Remove three nuts (20), screws (21), washers (22), and
LH bracket (23) from battery box (5) and bracket (23.1).

(9) Remove six nuts (24), screws (25), washers (26) and
bracket (23.1) from battery box (5).

(10) Deleted.

7-284 Change 1
 TM 9-2320-366-20-3

(11) Remove two nuts (30), screws (31), reinforcing plate

(32), and RH bracket (33) from battery box (5).

WARNING

Wear appropriate eye protection when

removing rivets. Failure to comply may
result in injury to personnel.

(12) Remove four rivets (34), washers (35), strip (36), and
two plates (37) from battery box (5).

(13) Remove adhesive tape (38) from strip (36).

b. Installation.

(1) Cut adhesive tape (1) to 18 1/4 in. (465 mm).

(2) Install adhesive tape (1) on strip (2).

(3) Install two plates (3) and strips (2) on battery box (4)
with four screws (6), washers (5) and nuts (6.1).

Change 1 7-285
TM 9-2320-366-20-3

7-56. BATTERY BOX REPLACEMENT (CONT)

(4) Position RH bracket (7) and reinforcing plate (8) on

battery box (4) with two screws (9) and nuts (10).

(5) Position bracket (10.1), six screws (11), washers (12),

and nuts (13) in battery box (4).

(6) Tighten six nuts (13) to 31-39 lb-ft (42-53 N·m).

(7) Tighten two nuts (10) to 68-78 lb-ft (92-106 N·m).

(8) Deleted.

(9) Position bracket (10.1) and LH bracket (17) on battery

box (4) with three screws (18), washers (19), and nuts
(20).

7-286 Change 1
 TM 9-2320-366-20-3

WARNING

Battery box weighs approximately 70 lbs

(32 kgs). The aid of two assistants is
required to position battery box on vehicle
frame. Failure to comply may result in
injury to personnel.

NOTE

Step (10) requires the aid of two assistants.

(10) Position battery box (4), and reinforcing plate (21) on left
frame rail (22) with two screws (23) and self-locking nuts
(24).

(11) Deleted.

NOTE

Steps (12) and (13) require the aid of an

assistant.

(12) Position two screws (27) and self-locking nuts (28) in

battery box (4).

(13) Tighten screws (23 and 27) to 171-209 lb-ft (232-283

N·m).

(14) Position stone guard (29) on battery box (4) with screw
(30), washer (31), and nut (32).

(14.1) Position two screws (32.1), four washers (32.2), and two
nuts (32.3) in stone guard (29).

(15) Tighten nuts (32, 32.3 and 20) to 31-39 lb-ft (42-53
N·m).

Change 1 7-286.1
TM 9-2320-366-20-3

7-56. BATTERY BOX REPLACEMENT (CONT)

(16) Position stud (33) in battery tray (34) with two

lockwashers (35) and nuts (36).

(17) Tighten two nuts (36) to 81-99 lb-in. (9-11 N·m).

(18) Install two latches (37) on battery box (4) with six screws
(38), lockwashers (39) and nuts (39.1).

(19) Install six band clamps (39.2) in battery box (4).

(20) Position battery tray (34) in battery box (4).

(21) Position 32 washers (40), 16 screws (41) and self-

locking nuts (42) in battery tray (34).

(22) Tighten 16 nuts (42) to 9-11 lb-ft (12-15 N·m).

7-286.2 Change 1
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Deleted.

(2) Deleted.

(3) Install secondary and primary air tanks (para 11-22).

(4) Install wet tank (para 23-12).

(5) Install NATO power cable (para 7-70).

(6) Install batteries (para 7-55).

(7) Start engine (TM 9-2320-366-10-1).

(8) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(9) Shut down engine (TM 9-2320-366-10-1).

End of Task.

Change 1 7-287
TM 9-2320-366-20-3

7-57. DISCONNECTING/CONNECTING BATTERIES

This task covers:
a. Disconnecting c. Follow-On Maintenance
b. Connecting

INITIAL SETUP
Equipment Conditions Tools and Special Tools (Cont)
Engine shut down (TM 9-2320-366-10-1). Tool Kit, Genl Mech (Item 46, Appendix C)
Battery box cover removed (TM 9-2320-366-10-2).
Materials/Parts
Tools and Special Tools Dispenser, Pressure Sensitive Adhesive Tape
Goggles, Industrial (Item 15, Appendix C) (Item 20, Appendix D)
Apron, Rubber (Item 3, Appendix C) Grease, Automotive and Artillery (GAA)
Gloves, Rubber (Item 13, Appendix C) (Item 22, Appendix D)
Puller, Battery Terminal (Item 28, Appendix C) Lockwasher (Item 87, Appendix G)

a. Disconnecting.
WARNING

• Remove rings, bracelets, watches, necklaces, and any other jewelry before working around
vehicle. Jewelry can catch on equipment and cause injury or short across electrical circuit
and cause severs burns or electrical shock. Batteries can explode from a spark. Battery acid
is harmful to skin and eyes. Always wear eye protection when working with batteries.
Failure to comply may result in injury to personnel.

• Negative battery terminals and battery tester negative terminal lug must be disconnected
first. Failure to comply may result in serious injury or death to personnel.

NOTE

Tag battery terminals, terminal lugs, and

connection points prior to disconnecting.

(1) Remove nut (1) and lockwasher (2) from battery 24 VDC
ground cable (3). Discard lockwasher.

(2) Deleted.

(3) Remove terminal lugs TL50A (5), TL48 (6), battery tester
terminal lug (7) and washer (8) from battery 24 VDC
ground cable (3).

7-288 Change 1
 TM 9-2320-366-20-3

(4) Remove nut (9) and terminal lug TL99 (10) from battery
12 VDC cable (11).

b. Connecting.

WARNING

Negative battery terminals must be

connected last. Failure to comply may
result in serious injury or death to
personnel.

(1) Install terminal lug TL99 (1) on battery 12 VDC cable (2)
with nut (3).

(2) Install washer (4) battery tester terminal lug (5), and
terminal lugs TL48 (6) and TL50A (7) on battery 24 VDC
ground cable (8).

(3) Deleted.

(4) Install lockwasher (10) and nut (11) on battery 24 VDC

ground cable (8).

(5) Apply grease to all battery terminals.

Change 1 7-289
TM 9-2320-366-20-3

7-57. DISCONNECTING/CONNECTING BATTERIES (CONT)

c. Follow-On Maintenance.

(1) Install battery box cover (TM 9-2320-366-10-2).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-290
 TM 9-2320-366-20-3

7-58. AUXILIARY PANEL CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Personnel heater removed (para 18-9). Dispenser, Pressure Sensitive Adhesive Tape
(Item 20, Appendix D)
Tools and Special Tools Ties, Cable, Plastic (Item 69, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

• Remove plastic cable ties as required.

• Tag wires and connection points prior to

disconnecting.

(1) Disconnect connector J108 (1) from connector P108 (2).

(2) Disconnect connector J210 (3) from connector P210 (4).

(3) Disconnect connector P913 (5) from connector J913 (6).

(4) Disconnect connector P912 (7) from connector J912 (8).

(5) Remove auxiliary panel cable assembly (9) from

dashboard (10).

7-291
TM 9-2320-366-20-3

7-58. AUXILIARY PANEL CABLE ASSEMBLY REPLACEMENT (CONT)

b. Installation.

(1) Position auxiliary panel cable assembly (1) in dashboard

(2).

(2) Connect connector P913 (3) to connector J913 (4).

(3) Connect connector P912 (5) to connector J912 (6).

NOTE

Install plastic cable ties as required.

(4) Connect connector P108 (7) to connector J108 (8).

(5) Connect connector P210 (9) to connector J210 (10).

c. Follow-On Maintenance.

(1) Install personnel heater (para 18-9).

(2) Check rocker switches and tachometer operation (TM 9-

2320-366-10-1).

End of Task.

7-292
 TM 9-2320-366-20-3

7-59. CHEMICAL ALARM KIT CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
Kick panel removed (para 16-3).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

• Note routing of chemical alarm kit cable prior to

removal.

• Remove plastic cable ties as required.

(1) Disconnect connector J99 (1) from connector P99 (2).

(2) Remove chemical alarm kit cable assembly (3) from

vehicle.

b. Installation.

NOTE

Install plastic cable ties as required.

Connect connector P99 (2) to connector J99 (1) and route

chemical alarm kit cable assembly (3).

c. Follow-On Maintenance.

(1) Install kick panel (para 16-3).

(2) Connect batteries (para 7-57).

End of Task.

7-293
TM 9-2320-366-20-3

7-60. CENTRAL TIRE INFLATION SYSTEM (CTIS) CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
Kick panel removed (para 16-3).
Personnel heater removed (para 18-9).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)

a. Removal.

NOTE

• Note routing of CTIS cable assembly prior to

removal.

• Remove plastic cable ties as required.

(1) Disconnect connector P111 (1) from connector J111 (2).

(2) Disconnect connector P112 (3) from manifold valve

assembly (4).

(3) Disconnect connector P113 (5) from pressure transducer

(6).

(4) Remove CTIS cable assembly (7) from vehicle.

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Position CTIS cable assembly (7) in vehicle.

(2) Connect connector P113 (5) to pressure transducer (6).

(3) Connect connector P112 (3) to manifold valve assembly

(4).

(4) Connect connector P111 (1) to connector J111 (2).

7-294
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Install personnel heater (para 18-9).

(2) Install kick panel (para 16-3).

(3) Connect batteries (para 7-57).

(4) Start engine (TM 9-2320-366-10-1).

(5) Operate vehicle and check CTIS system for proper

operation (TM 9-2320-366-10-1).

(6) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-295
TM 9-2320-366-20-3

7-61. LEFT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
PDP cover removed (para 16-2). Lockwasher (4) (Item 82, Appendix G)
Lockwasher (2) (Item 88, Appendix G)
Tools and Special Tools Gasket (2) (Item 24, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

• Note routing of left-hand door and cab marker

lights cable assembly prior to removal.

• Remove plastic cable ties as required.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) outward to gain access.

(4) Remove two nuts (5), lockwashers (6), washers (7), and
cover (8) from terminal board TB1 (9). Discard
lockwashers.

(5) Disconnect terminal lug TL75 (10) from terminal board

TB1 (9) position 2.

(6) Disconnect terminal lug TL87 (11) from terminal board

TB2 (12) position 6.

7-296 Change 1
 TM 9-2320-366-20-3

(7) Remove two screws (13) and marker lens cover (14)
from marker light (15).

(8) Remove four screws (16) and marker light (15) from cab
(17).

(9) Remove nut (18), lockwasher (19), terminal lug TL133

(20), and lockwasher (21) from marker light (15).
Discard lockwashers.

(10) Disconnect connector P129 (22) from marker light

connector 489 (23).

(11) Remove gasket (24) from marker light (15). Discard

gasket.

Change 1 7-297
TM 9-2320-366-20-3

7-61. LEFT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT (CONT)

(12) Remove two screws (25) and marker lens cover (26)
from marker light (27).

(13) Remove four screws (28) and marker light (27) from door
(29).

(14) Remove nut (30), lockwasher (31), and terminal lug

TL130 (32), and lockwasher (33) from marker light (27).
Discard lockwashers.

(15) Disconnect connector P130 (34) from marker light

connector 489 (35).

(16) Remove gasket (36) from marker light (27). Discard

gasket.

7-298 Change 1
 TM 9-2320-366-20-3

(17) Remove tube protector (37) and left-hand door and cab
marker lights cable assembly (38) from door (29).

(18) Remove left-hand door and cab marker lights cable

assembly (38) from dashboard (39).

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Position left-hand door and cab marker lights cable

assembly (1) in dashboard (2).

(2) Install left-hand door and cab marker lights cable

assembly (1) and tube protector (3) in door (4).

(3) Install gasket (5) on marker light (6).

(4) Connect connector P130 (7) to marker light connector

489 (8).

(5) Install lockwasher (8.1) and terminal lug TL130 (9) on

marker light (6) with lockwasher (10) and nut (11).

Change 1 7-299
TM 9-2320-366-20-3

7-61. LEFT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT (CONT)

(6) Install marker light (6) on door (4) with four screws (12).

(7) Install marker lens cover (13) on marker light (6) with two
screws (14).

(8) Install gasket (15) on marker light (16).

(9) Connect connector P129 (17) to marker light connector

489 (18).

(10) Install lockwasher (18.1) and terminal lug TL133 (19) on

marker light (16) with lockwasher (20) and nut (21).

7-300 Change 1
 TM 9-2320-366-20-3

(11) Install marker light (16) on cab (22) with four screws
(23).

(12) Install marker lens cover (24) on marker light (16) with
two screws (25).

(13) Connect terminal lug TL87 (26) to terminal board TB2

(27) position 6.

(14) Connect terminal lug TL75 (28) to terminal board TB1

(29) position 2.

(15) Install cover (30) on terminal board TB1 (29) with two
washers (31), lockwashers (32), and nuts (33).

7-301
TM 9-2320-366-20-3

7-61. LEFT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT (CONT)

(16) Install PDP (34) on dashboard (2) with three screws (35).

(17) Install three washers (36) and screws (37) in PDP (34).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

(3) Check operation of left-hand door and cab marker lights

(TM 9-2320-366-10-1).

End of Task.

7-302
 TM 9-2320-366-20-3

7-62. M1093/M1094 CAB CLEARANCE AND MARKER LIGHTS LOWER CABLE

ASSEMBLY REPLACEMENT
This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Material/Parts

Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
PDP cover removed (para 16-2). (Item 20, Appendix D)
Lockwasher (2) (Item 88, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) outward to gain access.

NOTE

Tag wires and connection points prior to

disconnecting.

(4) Remove two nuts (5), lockwashers (6), washers (7), and
cover (8) from terminal board TB1 (9). Discard
lockwashers.

(5) Disconnect terminal lug TL74 (10) from terminal board

TB1 (9) position 3.

(6) Disconnect terminal lug TL86 (11) from terminal board

TB2 (12) position 4.

7-303
TM 9-2320-366-20-3

7-62. M1093/M1094 CAB CLEARANCE AND MARKER LIGHTS LOWER CABLE

ASSEMBLY REPLACEMENT (CONT)

(7) Disconnect connector P3 (13) from connector J3 (14).

(8) Remove two screws (15), washers (16), clamps (17),

and M1093/M1094 cab clearance and marker lights
lower cable assembly (18) from cab (19).

(9) Remove two clamps (17) from M1093/M1094 cab

clearance and marker lights lower cable assembly (18).

b. Installation.

(1) Install two clamps (1) on M1093/M1094 cab clearance

and marker lights lower cable assembly (2).

(2) Position M1093/M1094 cab clearance and marker lights

lower cable assembly (2) in cab (3) with two clamps (1),
washers (4), and screws (5).

(3) Tighten two screws (5) to 29-35 lb-in. (3-4 N·m).

(4) Connect connector P3 (6) to connector J3 (7).

(5) Connect terminal lug TL86 (8) to terminal board TB2 (9)
position 4.

(6) Connect terminal lug TL74 (10) to terminal board TB1

(11) position 3.

(7) Install cover (12) on terminal board TB1 (11) with two
washers (13), lockwashers (14), and nuts (15).

7-304
 TM 9-2320-366-20-3

(8) Position PDP (16) on dashboard (17).

(9) Install three screws (18) in PDP (16).

(10) Install three washers (19) and screws (20) in PDP (16).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

(3) Check operation of cab clearance and marker lights (TM

9-2320-366-10-1).

End of Task.

7-305
TM 9-2320-366-20-3

7-63. M1093/M1094 CAB CLEARANCE AND MARKER LIGHTS UPPER CABLE

ASSEMBLY REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Lockwire (Item 30, Appendix D)
Gasket (5) (Item 24, Appendix G)
Tools and Special Tools Lockwasher (10) (Item 82, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-75 lb-in. (Item 90, Appendix B)

a. Removal.

(1) Disconnect connector J3 (1) from connector P3 (2).

NOTE

All M1093/M1094 cab clearance and marker

lights are removed the same way. Upper left
cab marker light shown.

(2) Remove two screws (3) and lens cover (4) from marker
light (5).

7-306 Change 1
 TM 9-2320-366-20-3

(3) Remove four screws (6) and marker light (5) from cab
roof (7).

NOTE

• Wrap mechanics wire on each connector and

terminal lug for ease of installation.

• Refer to Table 7-3. M1093/M1094 Cab

Clearance and Marker Lights Connectors for
combinations of terminal lugs and connectors on
each light.

(4) Remove nut (8), lockwasher (9), terminal lug (10), and
lockwasher (11) from marker light (5). Discard
lockwashers.

(5) Disconnect connector (12) from marker light connector

489 (13).

(6) Remove gasket (14) from marker light (5). Discard

gasket.

Table 7-3. M1093/M1094 Cab Clearance and Marker Lights Connectors

Light Location Connector Terminal lug
Left Side Marker P50 TL27
Left Center Clearance P57 TL22
Center Clearance P60 TL8
Right Center Clearance P59 TL4
Right Side Marker P55 TL3

Change 1 7-307
TM 9-2320-366-20-3

7-63. M1093/M1094 CAB CLEARANCE AND MARKER LIGHTS UPPER CABLE

ASSEMBLY REPLACEMENT (CONT)

(7) Remove M1093/M1094 cab clearance and marker lights

upper cable assembly (15) from cab roof (7).

b. Installation.

NOTE

Transfer mechanics wire to new

M1093/M1094 cab clearance and marker
lights upper cable assembly.

(1) Position M1093/M1094 cab clearance and marker lights

upper cable assembly (1) in cab roof (2).

NOTE

• All M1093/M1094 cab clearance and marker

lights are installed the same way. Upper left
cab marker light shown.

• Refer to Table 7-3. M1093/M1094 Cab

Clearance and Marker Lights Connectors for
combinations of terminal lugs and connectors on
each light.

(2) Install gasket (3) on marker light (4).

(3) Connect connector (5) to marker light connector 489 (6).

(4) Install lockwasher (6.1) and terminal lug (7) on marker

light (4) with lockwasher (8) and nut (9).

7-308 Change 1
 TM 9-2320-366-20-3

(5) Install marker light (4) on cab roof (2) with four screws
(10).

(6) Install lens cover (11) on marker light (4) with two screws
(12).

(7) Connect connector J3 (13) to connector P3 (14).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check operation of cab clearance and marker lights (TM

9-2320-366-10-1).

End of Task.

Change 1 7-309
TM 9-2320-366-20-3

7-64. RIGHT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
PDP cover removed (para 16-2). Lockwasher (4) (Item 82, Appendix G)
Lockwasher (2) (Item 88, Appendix G)
Tools and Special Tools Gasket (2) (Item 24, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

• Note routing of right-hand door and cab marker

lights cable assembly prior to removal.

• Remove plastic cable ties as required.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) outward to gain access.

(4) Remove two nuts (5), lockwashers (6), washers (7), and
cover (8) from terminal board TB1 (9). Discard
lockwashers.

(5) Disconnect terminal lug TL73 (10) from terminal board

TB1 (9) position 1.

(6) Disconnect terminal lug TL71 (11) from terminal board

TB2 (12) position 2.

7-310 Change 1
 TM 9-2320-366-20-3

(7) Remove two screws (13) and marker lens cover (14)
from marker light (15).

(8) Remove four screws (16) and marker light (15) from cab
(17).

(9) Remove nut (18), lockwasher (19), terminal lug TL134

(20), and lockwasher (20.1) from marker light (15).
Discard lockwashers.

(10) Disconnect connector P132 (21) from marker light

connector 489 (22).

(11) Remove gasket (23) from marker light (15). Discard

gasket.

Change 1 7-311
TM 9-2320-366-20-3

7-64. RIGHT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT (CONT)

(12) Remove two screws (24) and marker lens cover (25)
from marker light (26).

(13) Remove four screws (27) and marker light (26) from door
(28).

(14) Remove nut (29), lockwasher (30), terminal lug TL131

(31), and lockwasher (31.1) from marker light (26).
Discard lockwashers.

(15) Disconnect connector P131 (32) from marker light

connector 489 (33).

(16) Remove gasket (34) from marker light (26). Discard

gasket.

7-312 Change 1
 TM 9-2320-366-20-3

(17) Remove tube protector (35) and right-hand door and cab
marker lights cable assembly (36) from door (28).

(18) Remove right-hand door and cab marker lights cable

assembly (36) dashboard (37).

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Position right-hand door and cab marker lights cable

assembly (1) in dashboard (2).

(2) Install right-hand door and cab marker lights cable

assembly (1) and tube protector (3) in door (4).

(3) Install gasket (5) on marker light (6).

(4) Connect connector P131 (7) to marker light connector

489 (8).

(5) Install lockwasher (8.1) and terminal lug TL131 (9) on

marker light (6) with lockwasher (10) and nut (11).

Change 1 7-313
TM 9-2320-366-20-3

7-64. RIGHT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT (CONT)

(6) Install marker light (6) on door (3) with four screws (12).

(7) Install marker lens cover (13) on marker light (6) with two
screws (14).

(8) Install gasket (15) on marker light (16).

(9) Connect connector P132 (17) to marker light connector

489 (18).

(10) Install lockwasher (18.1) and terminal lug TL134 (19) on

marker light (16) with lockwasher (20) and nut (21).

7-314 Change 1
 TM 9-2320-366-20-3

(11) Install marker light (16) on cab (22) with four screws
(23).

(12) Install marker lens cover (24) on marker light (16) with
two screws (25).

(13) Connect terminal lug TL71 (26) to terminal board TB2

(27) position 2.

(14) Connect terminal lug TL73 (28) to terminal board TB1

(29) position 1.

(15) Install cover (30) on terminal board TB1 (29) with two
washers (31), lockwashers (32), and nuts (33).

7-315
TM 9-2320-366-20-3

7-64. RIGHT-HAND DOOR AND CAB MARKER LIGHTS CABLE ASSEMBLY

REPLACEMENT (CONT)

(16) Position PDP (34) on dashboard (2) with three screws

(35).

(17) Deleted.

(18) Install three washers (36) and screws (37) in PDP (34).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

(3) Check operation of right-hand door and cab marker lights

(TM 9-2320-366-10-1).

End of Task.

7-316 Change 1
 TM 9-2320-366-20-3

7-65. STE/ICE-R CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Instrument panel assembly removed for access (para Ties, Cable, Plastic (Item 69, Appendix D)
7-15). Lockwasher (4) (Item 76, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

NOTE

Remove plastic cable ties as required.

(1) Disconnect connector J31X (1) from connector P31X (2).

(2) Disconnect connector J43X (3) from connector P43X (4).

(3) Remove two screws (5) and bracket (6) from cab (7).

7-317
TM 9-2320-366-20-3

7-65. STE/ICE-R CABLE ASSEMBLY REPLACEMENT (CONT)

(4) Remove two screws (8), washers (9), junction box (10),
and STE/ICE-R cable assembly (11) from dashboard
(12).

(5) Remove four nuts (13), lockwashers (14), screws (15),

chain (16), and bracket (6) from STE/ICE-R cable
assembly (11). Discard lockwashers.

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Install bracket (1) on STE/ICE-R cable assembly (2) with

chain (3), four screws (4), lockwashers (5), and nuts (6).

7-318
 TM 9-2320-366-20-3

(2) Position STE/ICE-R cable assembly (2) in dashboard (7).

(3) Install junction box (8) on dashboard (7) with two

washers (9) and screws (10).

(4) Install bracket (1) on cab (11) with two screws (12).

(5) Connect connector J43X (13) to connector P43X (14).

(6) Connect connector J31X (15) to connector P31X (16).

c. Follow-On Maintenance.

Install instrument panel assembly (para 7-15).

End of Task.

7-319
TM 9-2320-366-20-3

7-66. CAB CLEARANCE MARKER LIGHTS CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Lockwire (Item 30, Appendix D)
PDP cover removed (para 16-2). Lockwasher (10) (Item 82, Appendix G)
Lockwasher (2) (Item 88, Appendix G)
Tools and Special Tools Gasket (5) (Item 24, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) outward to gain access.

(4) Remove two nuts (5), lockwashers (6), washers (7), and
cover (8) from terminal board TB1 (9). Discard
lockwashers.

(5) Disconnect terminal lug TL74 (10) from terminal board

TB1 (9) position 3.

(6) Disconnect terminal lug TL86 (11) from terminal board

TB2 (12) position 4.

7-320 Change 1
 TM 9-2320-366-20-3

NOTE

All cab clearance marker lights are removed

the same way. Upper left cab clearance
marker light shown.

(7) Remove two screws (13) and marker lens cover (14)
from marker light (15).

(8) Remove four screws (16) and marker light (15) from cab
(17).

NOTE

• Wrap mechanics wire on each connector and

terminal lug for ease of installation.

• Refer to Table 7-4. Cab Clearance Marker

Light Connectors for combinations of terminal
lugs and connectors on each marker light.

(9) Remove nut (18), lockwasher (19), terminal lug (20), and
lockwasher (20.1) from marker light (15). Discard
lockwashers.

(10) Disconnect connector (21) from marker light connector

489 (22).

(11) Remove gasket (23) from marker light (15). Discard

gasket.

Change 1 7-321
TM 9-2320-366-20-3

7-66. CAB CLEARANCE MARKER LIGHTS CABLE ASSEMBLY REPLACEMENT (CONT)

Table 7-4. Cab Clearance Marker Light Connectors

Marker Light Location Connector Terminal lug

Left Side P50 TL27

Left Center P59 TL4

Center P60 TL8

Right Center P57 TL22

Right Side P55 TL3

(12) Remove eight screws (24), washers (25), clamps (26),

and cab clearance marker lights cable assembly (27)
from cab (17).

(13) Remove eight clamps (26) from cab clearance marker

lights cable assembly (27).

b. Installation.

NOTE

Transfer mechanics wire to new cab

clearance marker lights cable assembly.

(1) Install eight clamps (1) on cab clearance marker lights

cable assembly (2).

(2) Install cab clearance marker lights cable assembly (2) on

cab (3) with eight clamps (1), washers (4), and screws
(5).

7-322
 TM 9-2320-366-20-3

NOTE

• All cab clearance marker lights are installed the

same way. Upper left cab clearance marker
light shown.

• Refer to Table 7-4. Cab Clearance Marker

Light Connectors for combinations of terminal
lugs and connectors on each marker light.

(3) Install gasket (6) on marker light (7).

(4) Connect connector (8) to marker light connector 489 (9).

(5) Install lockwasher (9.1) and terminal lug (10) on marker

light (7) with lockwasher (11) and nut (12).

(6) Install marker light (7) on cab (2) with four screws (13).

(7) Install marker lens cover (14) on marker light (7) with two
screws (15).

Change 1 7-323
TM 9-2320-366-20-3

7-66. CAB CLEARANCE MARKER LIGHTS CABLE ASSEMBLY REPLACEMENT (CONT)

(8) Connect terminal lug TL86 (16) to terminal board TB2

(17) position 4.

(9) Connect terminal lug TL74 (18) to terminal board TB1

(19) position 3.

(10) Install cover (20) on terminal board TB1 (19) with two
washers (21), lockwashers (22), and nuts (23).

(11) Position PDP (24) on dashboard (25).

(12) Install three screws (26) in PDP (24).

(13) Install three washers (27) and screws (28) in PDP (24).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

(3) Check operation of cab clearance marker lights (TM 9-

2320-366-10-1).

End of Task.

7-324
TM 9-2320-366-20-3

7-67. WINDSHIELD WASHER PUMP ELECTROMAGNETIC INTERFERENCE (EMI)

CABLE REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Nut, Self-Locking (Item 167, Appendix G)

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Loosen screw (1) and open cab step tread (2).

(2) Disconnect connector J25 (3) from connector P25 (4).

(3) Disconnect connector P125 (5) from windshield washer

pump (6).

7-325
TM 9-2320-366-20-3

7-67. WINDSHIELD WASHER PUMP ELECTROMAGNETIC INTERFERENCE (EMI)

CABLE REPLACEMENT (CONT)

(4) Remove self-locking nut (7), washer (8), screw (9),

washer (10), terminal lug TL94 (11), and windshield
washer pump EMI cable (12) from box (13). Discard
self-locking nut.

b. Installation.

(1) Position windshield washer pump EMI cable (1) in box

(2).

(2) Install terminal lug TL94 (3) on box (2) with washer (4),
screw (5), washer (6), and self-locking nut (7).

(3) Connect connector P125 (8) to windshield washer pump

(9).

(4) Connect connector P25 (10) to connector J25 (11).

7-326
 TM 9-2320-366-20-3

(5) Close cover (12) and tighten screw (13).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Check operation of windshield washers (TM 9-2320-366-

10-1).

End of Task.

7-327
TM 9-2320-366-20-3

7-68. WINDSHIELD WIPER ELECTROMAGNETIC INTERFERENCE (EMI) CABLE

REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
PDP cover removed (para 16-2).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Remove three screws (1) and washers (2) from PDP (3).

(2) Remove three screws (4) from PDP (3).

(3) Lift PDP (3) outward to gain access.

NOTE

Remove plastic cable ties as required.

(4) Disconnect windshield wiper EMI cable connector PX22

(5) from windshield wiper motor (6).

(5) Disconnect windshield wiper EMI cable connector P2 (7)

from connector J2 (8).

7-328
 TM 9-2320-366-20-3

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Connect windshield wiper EMI cable connector P2 (1) to

connector J2 (2).

(2) Connect windshield wiper EMI cable connector PX22 (3)

to windshield wiper motor (4).

(3) Position PDP (5) on dashboard (6).

(4) Install three screws (7) in PDP (5).

(5) Install three washers (8) and screws (9) in PDP (5).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

(3) Check operation of windshield wipers (TM 9-2320-366-

10-1).

End of Task.

7-329
TM 9-2320-366-20-3

7-69. WINDSHIELD WIPER ECU REPLACEMENT

This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions
Batteries disconnected (para 7-57).
PDP cover removed (para 16-2).

a. Removal.

Remove windshield wiper ECU (1) from PDP (2).

b. Installation.

Install windshield wiper ECU (1) in PDP (2).

c. Follow-On Maintenance.

(1) Install PDP cover (para 16-2).

(2) Connect batteries (para 7-57).

(3) Check operation of windshield wipers (TM 9-2320-366-

10-1).

End of Task.

7-330
 TM 9-2320-366-20-3

7-70. NATO POWER CABLE REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Engine shut down (TM 9-2320-366-10-1). Dispenser, Pressure Sensitive Adhesive Tape
Battery box cover removed (TM 9-2320-366-10-2). (Item 20, Appendix D)
Grease, Automotive and Artillery (GAA) (Item 22,
Tools and Special Tools Appendix D)
Goggles, Industrial (Item 15, Appendix C) Nut, Self-Locking (4) (Item 158, Appendix G)
Gloves, Rubber (Item 13, Appendix C) Lockwasher (Item 87, Appendix G)
Apron, Rubber (Item 3, Appendix C)
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

WARNING

• Remove rings, bracelets, watches, necklaces, and any other jewelry before working around
vehicle. Jewelry can catch on equipment and cause injury or short across electrical circuit and
cause severs burns or electrical shock. Batteries can explode from a spark. Battery acid is
harmful to skin and eyes. Always wear eye protection when working with batteries. Failure to
comply may result in injury to personnel.

• Negative battery terminals and battery tester negative terminal lug must be disconnected first.
Failure to comply may result in serious injury or death to personnel.

NOTE

Tag battery terminals, terminal lugs, and

connection points prior to disconnecting.

(1) Remove nut (1) and lockwasher (2) from battery

ground cable (3). Discard lockwasher.

(2) Deleted.

(3) Remove terminal lugs TL50A (5), TL48 (6), and

battery tester terminal lug (7) from battery ground
cable (3).

Change 2 7-331
TM 9-2320-366-20-3

7-70. NATO POWER CABLE REPLACEMENT (CONT)

(4) Remove nut (8) from battery 24 vdc cable (9).

(5) Deleted.

(6) Remove terminal lug TL49A (11) and battery tester

terminal lug (12) from battery 24 vdc cable (9).

(7) Remove four self-locking nuts (13), washers (14),

screws (15), and eyelet (16) from NATO power
cable (17). Discard self-locking nuts.

(8) Remove NATO power cable (17) and terminal lugs

TL49A (11) and TL50A (5) from bracket (18) and
battery box (19).

b. Installation.

(1) Position terminal lugs TL49A (1) and TL50A (2),

and NATO power cable (3) in bracket (4) and
battery box (5).

(2) Install NATO power cable (3) and eyelet (6) on

bracket (4) with four screws (7), washers (8), and
self-locking nuts (9).

7-332 Change 2
 TM 9-2320-366-20-3

WARNING

Negative battery terminals must be

connected last. Failure to comply may
result in serious injury or death to
personnel.

(3) Install battery tester terminal lug (10) and terminal

lug TL49A (1) on battery 24 vdc cable (11).

(4) Deleted.

(5) Install nut (13) on battery 24 vdc cable (11).

(6) Install battery tester terminal lug (14), and terminal

lugs TL48 (15) and TL50A (2) on battery ground
cable (16).

(7) Deleted.

(8) Install lockwasher (18) and nut (19) on battery

ground cable (16).

(9) Apply grease to all battery terminals.

c. Follow-On Maintenance.

Install battery box cover (TM 9-2320-366-10-2).

End of Task.

Change 2 7-333
TM 9-2320-366-20-3

7-71. ALTERNATOR GROUND STRAP REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Cab raised (TM 9-2320-366-10-1). Lockwasher (Item 103, Appendix G)
Batteries disconnected (para 7-57). Lockwasher (Item 81, Appendix G)
Nut, Self-Locking (Item 158, Appendix G)
Tools and Special Tools
Tool Kit, Genl Mech (Item 46, Appendix C)

a. Removal.

(1) Remove screw (1), lockwasher (2), washer (3), terminal

lug TL5 (4), and ground cable (5) from alternator (6).
Discard lockwasher.

(2) Remove self-locking nut (7), washer (8), ground cable

(5), lockwasher (9), screw (10), and washer (11) from
right frame rail (12). Discard self-locking nut and
lockwasher.

7-334
 TM 9-2320-366-20-3

b. Installation.

(1) Install lockwasher (1) and ground cable (2) on right

frame rail (3) with washer (4), screw (5), washer (6) and
self-locking nut (7).

(2) Install ground cable (2) and terminal lug TL5 (8) on
alternator (9) with washer (10), lockwasher (11), and
screw (12).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Lower cab (TM 9-2320-366-10-1).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-335
TM 9-2320-366-20-3

7-72. 100 AMP ALTERNATOR TO REVERSE POLARITY RELAY 12 VDC CABLE

REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Spare tire lowered (TM 9-2320-366-10-2). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 20, Appendix D)
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
Lockwasher (Item 96, Appendix G)
Tools and Special Tools Nut, Self-Locking (Item 144.1, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Loosen clamp (1) on turbocharger intake hose (2).

(2) Remove turbocharger intake hose (2) from intake air

cleaner boot (3).

(3) Lift terminal cover (4) on terminal lugs TL47 (5) and
TL61 (6).

NOTE

Remove plastic cable ties as required.

(4) Remove nut (7), lockwasher (8), and terminal lugs TL47
(5) and TL61 (6) from reverse polarity relay 12 VDC
LOAD terminal (9). Discard lockwasher.

7-336 Change 1
 TM 9-2320-366-20-3

(5) Lift dust boot (10) on terminal lug TL60 (11).

(6) Remove self-locking nut (12), washer (13), insulation

washer (14), and terminal lug TL60 (11) from alternator
(15). Discard self-locking nut.

(7) Remove dust boot (10) from 100 amp alternator to

reverse polarity relay 12 vdc cable (16).

(8) Remove three screws (17), washers (18), clamps (19),

and 100 amp alternator to reverse polarity relay 12 vdc
cable (16) from engine (20).

(9) Remove three clamps (19) from 100 amp alternator to

reverse polarity relay 12 vdc cable (16).

b. Installation.

(1) Install three clamps (1) on 100 amp alternator to reverse

polarity relay 12 vdc cable (2).

NOTE

Install plastic cable ties as required.

(2) Position 100 amp alternator to reverse polarity relay 12

vdc cable (2) on engine (3) with three clamps (1),
washers (4), and screws (5).

(3) Tighten three screws (5) to 22-27 lb-ft (31-37 N·m).

Change 1 7-337
TM 9-2320-366-20-3

7-72. 100 AMP ALTERNATOR TO REVERSE POLARITY RELAY 12 VDC

CABLE REPLACEMENT (CONT)

(4) Install dust boot (6) on 100 amp alternator to reverse

polarity relay 12 vdc cable (2).

CAUTION

Insulation washer must be installed with flat

side up. Failure to comply may result in
damage to equipment.

(5) Position terminal lug TL60 (7) on alternator (8) with

insulator washer (9), washer (10) and self-locking nut
(11).

(6) Tighten self-locking nut (11) to 40 lb-in. (5 N m).

(7) Position dust boot (6) on terminal lug TL60 (7).

(8) Position terminal lugs TL61 (12) and TL47 (13) on

reverse polarity relay 12 VDC LOAD terminal (14) with
lockwasher (15) and nut (16).

(9) Tighten nut (16) to 120-144 lb-in. (14-16 N·m).

(10) Position terminal cover (17) on terminal lugs TL47 (13)

and TL61 (12).

(11) Position turbocharger intake hose (18) on intake air

cleaner boot (19) with clamp (20).

(12) Tighten clamp (20) to 36-48 lb-in. (4-5 N·m).

7-338
 TM 9-2320-366-20-3

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Raise spare tire (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-339
TM 9-2320-366-20-3

7-73. 100 AMP ALTERNATOR TO REVERSE POLARITY RELAY 24 VDC CABLE

REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Spare tire lowered (TM 9-2320-366-10-2). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 20, Appendix D)
Batteries disconnected (para 7-57). Ties, Cable, Plastic (Item 69, Appendix D)
Lockwasher (Item 96, Appendix G)
Tools and Special Tools Nut, Self-Locking (Item 143, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Loosen clamp (1) on turbocharger intake hose (2).

(2) Remove turbocharger intake hose (2) from intake air

cleaner boot (3).

(3) Lift terminal cover (4) on terminal lugs TL1 (5), TL36 (6),
and TL37 (7).

NOTE

Remove plastic cable ties as required.

(4) Remove nut (8), lockwasher (9), and terminal lugs TL1
(5), TL36 (6), and TL37 (7) from reverse polarity relay 24
VDC LOAD terminal (10). Discard lockwasher.

7-340
 TM 9-2320-366-20-3

(5) Lift dust boot (11) on terminal lugs TL2 (12) and TL6
(13).

(6) Remove self-locking nut (14), washer (15), insulation

washer (16), and terminal lugs TL2 (12) and TL6 (13)
from alternator (17). Discard self-locking nut.

(7) Remove 100 amp alternator to reverse polarity relay 24

vdc cable (18) from dust boot (11).

(8) Remove three screws (19), washers (20), clamps (21),

and 100 amp alternator to reverse polarity relay 24 vdc
cable (18) from engine (22).

(9) Remove three clamps (21) from 100 amp alternator to

reverse polarity relay 24 vdc cable (18).

7-341
TM 9-2320-366-20-3

7-73. 100 AMP ALTERNATOR TO REVERSE POLARITY RELAY 24 VDC CABLE

REPLACEMENT (CONT)

b. Installation.

(1) Install three clamps (1) on 100 amp alternator to reverse

polarity relay 24 vdc cable (2).

NOTE

Install plastic cable ties as required.

(2) Position 100 amp alternator to reverse polarity relay 24

vdc cable (2) on engine (3) with three clamps (1),
washers (4), and screws (5).

(3) Tighten three screws (5) to 22-27 lb-ft (31-37 N·m).

(4) Install 100 amp alternator to reverse polarity relay 24 vdc

cable (2) in dust boot (6).

CAUTION

Insulation washer must be installed with flat

side up. Failure to comply may result in
damage to equipment.

(5) Position terminal lugs TL6 (7) and TL2 (8) on alternator
(9) with insulation washer (10), washer (11) and
self-locking nut (12).

(6) Tighten self-locking nut (12) to 40 lb-in. (5 N·m).

(7) Position dust boot (6) on terminal lugs TL2 (8) and TL6
(7).

7-342
 TM 9-2320-366-20-3

(8) Position terminal lugs TL37 (13), TL36 (14), and TL1
(15) on reverse polarity relay 24 VDC LOAD terminal
(16) with lockwasher (17) and nut (18).

(9) Tighten nut (18) to 120-144 lb-in. (14-16 N·m).

(10) Position terminal cover (19) on terminal lugs TL1 (15),

TL36 (14), and TL37 (13).

(11) Position turbocharger intake hose (20) on intake air

cleaner boot (21) with clamp (22).

(12) Tighten clamp (22) to 36-48 lb-in. (4-5 N·m).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Raise spare tire (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-343
TM 9-2320-366-20-3

7-74. BATTERY TO 100 AMP REVERSE POLARITY RELAY 12 VDC CABLE

REPLACEMENT
This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Spare tire lowered (TM 9-2320-366-10-2). Ties, Cable, Plastic (Item 63, Appendix C)
Cab raised (TM 9-2320-366-10-1). Lockwasher (Item 96, Appendix G)
Batteries disconnected (para 7-57).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Lift terminal cover (1) on terminal lugs TL61 (2) and
TL47 (3).

NOTE

Remove plastic cable ties as required.

(2) Remove nut (4), lockwasher (5), and terminal lugs TL61
(2) and TL47 (3) from 100 amp reverse polarity relay 12
VDC BAT terminal (6). Discard lockwasher.

NOTE

Note routing of 100 amp reverse polarity

relay 12 vdc cable prior to removal.

(3) Remove battery to 100 amp reverse polarity relay 12 vdc

cable (7) from vehicle.

7-344
 TM 9-2320-366-20-3

b. Installation.

NOTE

Install plastic cable ties as required.

(1) Position battery to 100 amp reverse polarity relay 12 vdc

cable (1) on vehicle.

(2) Position terminal lugs TL47 (2) and TL61 (3) on 100 amp
reverse polarity relay 12 VDC BAT terminal (4) with
lockwasher (5) and nut (6).

(3) Tighten nut (6) to 120-144 lb-in. (14-16 N·m).

(4) Position terminal cover (7) on terminal lugs TL47 (2) and
TL61 (3).

c. Follow-On Maintenance.

(1) Raise spare tire (TM 9-2320-366-10-2).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-345
TM 9-2320-366-20-3

7-75. BATTERY TO 100 AMP REVERSE POLARITY RELAY 24 VDC CABLE

REPLACEMENT
This task covers:

a. Removal c. Follow-On Maintenance

b. Installation

INITIAL SETUP

Equipment Conditions Materials/Parts

Spare tire lowered (TM 9-2320-366-10-2). Lockwasher (Item 96, Appendix G)
Cab raised (TM 9-2320-366-10-1).
Batteries disconnected (para 7-57).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 36, Appendix C)
Goggles, Industrial (Item 15, Appendix C)

a. Removal.

WARNING

Remove rings, bracelets, watches, neck-

laces, and any other jewelry before
working around vehicle. Jewelry can
catch on equipment and cause injury or
short across electrical circuit and cause
severe burns or electrical shock.
Batteries can explode from a spark.
Battery acid is harmful to skin and eyes.
Always wear eye protection when working
with batteries. Failure to comply may
result in injury to personnel.

(1) Remove nut (1) and terminal lugs TL39 (2) and TL10 (3)
from battery 24 vdc cable (4).

7-346 Change 1
 TM 9-2320-366-20-3

(2) Loosen clamp (5) on turbocharger intake hose (6).

(3) Remove turbocharger intake hose (6) from intake air

cleaner boot (7).

(4) Lift terminal cover (8) on terminal lugs TL1 (9), TL36
(10), and battery to 100 amp reverse polarity relay 24
vdc cable terminal lug TL37 (11).

(5) Remove nut (12), lockwasher (13), terminal lugs TL1 (9),
TL36 (10), and battery to 100 amp reverse polarity relay
24 vdc cable terminal lug TL37 (11) from 100 amp
reverse polarity relay 24 VDC BAT terminal (14).
Discard lockwasher.

b. Installation.

(1) Position battery to 100 amp reverse polarity relay 24 vdc

cable terminal lug TL37 (1) and terminal lugs TL36 (2)
and TL1 (3) on 100 amp reverse polarity relay 24 VDC
BAT terminal (4) with lockwasher (5) and nut (6).

(2) Tighten nut (6) to 120-144 lb-in. (14-16 N·m).

(3) Position terminal cover (7) on terminal lugs TL1 (3),

TL36 (2), and battery to 100 amp reverse polarity relay
24 vdc cable terminal lug TL37 (1).

7-347
TM 9-2320-366-20-3

7-75. BATTERY TO 100 AMP REVERSE POLARITY RELAY 24 VDC CABLE

REPLACEMENT (CONT)

(4) Position turbocharger intake hose (8) on intake air

cleaner boot (9) with clamp (10).

(5) Tighten clamp (10) to 36-48 lb-in. (4-5 N·m).

(6) Install terminal lugs TL10 (11) and TL39 (12) on battery
24 vdc cable (13) with nut (14).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Raise spare tire (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check VOLTS gage for 24 vdc (TM 9-2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-348
 TM 9-2320-366-20-3

7-76. BATTERY TO SHUNT CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Spare tire lowered (TM 9-2320-366-10-2). Lockwasher (Item 87, Appendix G)
Cab raised (TM 9-2320-366-10-1).
Batteries disconnected (para 7-57).

Tools and Special Tools

Tool Kit, Genl Mech (Item 46, Appendix C)
Wrench, Torque, 0-200 lb-in. (Item 59, Appendix C)
Socket Set, Socket Wrench (Item 34, Appendix C)

a. Removal.

(1) Loosen clamp (1) on turbocharger intake hose (2).

(2) Remove turbocharger intake hose (2) from intake air

cleaner boot (3).

(3) Remove screw (4), lockwasher (5), and terminal lug

TL52 (6) from shunt (7). Discard lockwasher.

7-349
TM 9-2320-366-20-3

7-76. BATTERY TO SHUNT CABLE ASSEMBLY REPLACEMENT (CONT)

b. Installation.

(1) Install terminal lug TL52 (1) on shunt (2) with

lockwasher (3) and screw (4).

(2) Position turbocharger intake hose (5) on intake air

cleaner boot (6) with clamp (7).

(3) Tighten clamp (7) to 36-48 lb-in. (4-5 N·m).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Raise spare tire (TM 9-2320-366-10-2).

(3) Start engine (TM 9-2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-350
 TM 9-2320-366-20-3

7-77. BATTERY TO STARTER CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Cab raised (TM 9-2320-366-10-1). (Item 20, Appendix D)
Ties, Cable, Plastic (Item 69, Appendix D)
Tools and Special Tools Adhesive (Item 8, Appendix D)
Tool Kit, Genl Mech (Item 46, Appendix C) Nut, Self-Locking (2) (Item 150, Appendix G)
Wrench, Torque, 0-175 lb-ft (Item 58, Appendix C)
Personnel Required
(2)

a. Removal.

WARNING

Remove rings, bracelets, watches, neck-

laces, and any other jewelry before
working around vehicle. Jewelry can
catch on equipment and cause injury or
short across electrical circuit and cause
severe burns or electrical shock.
Batteries can explode from a spark.
Battery acid is harmful to skin and eyes.
Always wear eye protection when working
with batteries. Failure to comply may
result in injury to personnel.

NOTE

• Note routing of battery to starter cable assembly

prior to removal.

• Tag wires and connection points prior to

disconnecting.

(1) Remove nut (1) and terminal lugs TL39 (2) and TL10 (3)
from battery 24 vdc cable (4).

7-351
TM 9-2320-366-20-3

7-77. BATTERY TO STARTER CABLE ASSEMBLY REPLACEMENT (CONT)

NOTE

• Both clamps are removed the same way. One

shown.

• Remove plastic cable ties as required.

(2) Remove self-locking nut (5), screw (6), battery to starter

cable assembly (7), and clamp (8) from frame rail (9).
Discard self-locking nut.

NOTE

Step (3) requires the aid of an assistant.

(3) Perform step (2) on remaining clamp.

(4) Remove two clamps (8) from battery to starter cable

assembly (7).

(5) Remove adhesive, nut (10), and terminal lug TL12 (11)
from starter solenoid (12).

7-352 Change 1
 TM 9-2320-366-20-3

b. Installation.

(1) Position terminal lug TL12 (1) on starter solenoid (2) with
nut (3).

(2) Tighten nut (3) to 15-20 lb-ft (20-27 N·m).

WARNING

Adhesives, solvents, and sealing com-

pounds can burn easily, 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, solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water. Failure
to comply may result in injury to
personnel.

(3) Apply adhesive to terminal lug TL12 (1) on starter

solenoid (2).

NOTE

Both clamps are installed the same way.

One shown.

(4) Install two clamps (4) on battery to starter cable

assembly (5).

NOTE

Steps (5) through (7) require

the aid of an assistant.

(5) Position battery to starter cable assembly (5) on frame

rail (6) with clamp (4), screw (7) and self-locking nut (8).

(6) Perform Step (5) on remaining clamp.

NOTE

Install plastic cable ties as required.

(7) Tighten two self-locking nuts (8) to 97-124 lb-in. (11-14

N·m).

Change 1 7-353
TM 9-2320-366-20-3

7-77. BATTERY TO STARTER CABLE ASSEMBLY REPLACEMENT (CONT)

(8) Install terminal lugs TL10 (9) and TL39 (10) on battery
24 vdc cable (11) with nut (12).

c. Follow-On Maintenance.

(1) Lower cab (TM 9-2320-366-10-1).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-354
 TM 9-2320-366-20-3

7-78. CAB TO CHASSIS GROUND STRAP REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Tools and Special Tools (Cont)
Batteries disconnected (para 7-57). Socket Set, Socket Wrench, (Item 35, Appendix C)

Tools and Special Tools Materials/Parts

Tool Kit, Genl Mech (Item 46, Appendix C) Ties, Cable, Plastic (Item 69, Appendix D)
Wrench, Torque, 0-200 lb-in. (Item 58, Appendix C) Nut, Self-Locking (Item 167, Appendix G)
Lockwasher (Item 75, Appendix G)

a. Removal.

NOTE

Remove plastic cable ties as required.

(1) Remove two screws (1) and washers (2) from front grille
(3).

(2) Remove screw (4) and washer (5) from front grille (3).

(3) Remove front grille (3) from cab (6).

(4) Loosen screw (7) in chassis (8) and remove cab to

chassis ground cable (9).

(5) Remove self-locking nut (10), washer (11), cab to

chassis ground cable (9), and lockwasher (12) from stud
(13). Discard self-locking nut and lockwasher.

Change 1 7-355
TM 9-2320-366-20-3

7-78. CAB TO CHASSIS GROUND STRAP REPLACEMENT (CONT)

b. Installation.

(1) Install cab to chassis ground cable (1) on stud (2) with
lockwasher (3), washer (4), and self-locking nut (5).

(2) Position cab to chassis ground cable (1) on chassis (6)

and tighten screw (7).

(3) Position front grille (8) on cab (9) with washer (10) and
screw (11).

(4) Position two washers (12) and screws (13) in front grille
(8).

(5) Tighten screw (11) to 48-60 lb-in. (5-7 N•m).

(6) Tighten two screws (13) to 24 lb-in. (3 N•m).

c. Follow-On Maintenance.

(1) Connect batteries (para 7-57).

(2) Start engine (TM 9-2320-366-10-1).

(3) Check VOLTS gage for charge indication (TM 9-2320-

366-10-1).

(4) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-356
 TM 9-2320-366-20-3

7-79. M1084/M1086 CRANE POWER CONTROL CABLE ASSEMBLY REPLACEMENT

This task covers:
a. Removal c. Follow-On Maintenance
b. Installation

INITIAL SETUP
Equipment Conditions Materials/Parts
Batteries disconnected (para 7-57). Dispenser, Pressure Sensitive Adhesive Tape
Kick panel removed (para 16-3). (Item 20, Appendix D)
Ties, Cable, Plastic (Item 69, Appendix D)
Tools and Special Tools Lockwasher (2) (Item 96, Appendix G)
Tool Kit, Genl Mech (Item 46, Appendix C) Washer, Spring (2) (Item 289, Appendix G)
Washer, Spring (2) (Item 296, Appendix G)
Nut, Self-Locking (19) (Item 154, Appendix G)

a. Removal.

(1) Disconnect connector P171 (1) from crane junction box

connector (2).

NOTE

• Remove plastic cable ties as required.

• Tag terminal lugs and connection points prior to

disconnecting.

(2) Remove screw (3), terminal lugs TL67 (4), TL17 (5),
TL69 (6), and lockwasher (7) from left taillight carrier (8).
Discard lockwasher.

7-357
TM 9-2320-366-20-3

7-79. M1084/M1086 CRANE POWER CONTROL CABLE ASSEMBLY REPLACEMENT

(CONT)

(3) Remove dust cap (9) from connector P135 (10).

(4) Remove nut (11), screw (12), spring washer (13), and
lanyard (14) from left taillight carrier (8). Discard spring
washer.

(5) Remove nut (15), spring washer (16), and connector

P135 (10) from left tail light carrier (8). Discard spring
washer.

(6) Remove screw (17), terminal lugs TL20 (18), TL21 (19),
TL68 (20), and lockwasher (21) from right taillight carrier
(22). Discard lockwasher.

(7) Remove dust cap (23) from connector P136 (24).

(8) Remove nut (25), screw (26), spring washer (27), and
lanyard (28) from worklight connector bracket (29).
Discard spring washer.

(9) Remove nut (30), spring washer (31), and connector

P136 (24) from worklight connector bracket (29).
Discard spring washer.

7-358
 TM 9-2320-366-20-3

(10) Remove 19 self-locking nuts (32), screws (33), and

clamps (34) from right frame rail (35). Discard
self-locking nuts.

(11) Remove crane power control cable assembly (36) from

19 clamps (34).

(12) Disconnect connector P108 (37) from connector J108

(38).

(13) Remove grommet (39) from cab (40).

(14) Remove crane power control cable assembly (29) from

grommet (39).

(15) Remove crane power control cable assembly (29) from

cab (40).

b. Installation.

(1) Route crane power control cable assembly (1) inside cab
(2).

(2) Install crane power control cable assembly (1) in

grommet (3).

(3) Connect connector P108 (4) to connector J108 (5).

7-359
TM 9-2320-366-20-3

7-79. M1084/M1086 CRANE POWER CONTROL CABLE ASSEMBLY REPLACEMENT

(CONT)

(4) Install crane power control cable assembly (1) in 19

clamps (6).

(5) Install 19 clamps (6) on right frame rail (7) with 19

screws (8) and self-locking nuts (9).

(6) Install connector P136 (10) in worklight connector

bracket (11) with spring washer (12) and nut (13).

(7) Install lanyard (14) on worklight connector bracket (11)

with spring washer (15), screw (16), and nut (17).

(8) Install dust cap (18) on connector P136 (10).

(9) Install terminal lugs TL68 (19), TL21 (20), and TL20 (21)
on right taillight carrier (22) with lockwasher (23) and
screw (24).

7-360
 TM 9-2320-366-20-3

(10) Install connector P135 (25) in left taillight carrier (26) with
spring washer (27) and nut (28).

(11) Install lanyard (29) on left taillight carrier (26) with spring
washer (30), screw (31), and nut (32).

(12) Install dust cap (33) on connector P135 (25).

(13) Install terminal lugs TL69 (34), TL17 (35), and TL67 (36)
on left taillight carrier (26) with lockwasher (37) and
screw (38).

(14) Connect crane junction box connector (39) to connector

P171 (40).

c. Follow-On Maintenance.

(1) Install kick panel (para 16-3).

(2) Connect batteries (para 7-57).

(3) Start engine (TM 9-2320-366-10-1).

(4) Check MHC operation (TM 9-2320-366-10-1).

(5) Shut down engine (TM 9-2320-366-10-1).

End of Task.

7-361/(7-362 Blank)
 TM 9-2320-366-20-3

APPENDIX A
REFERENCES

A-1. SCOPE

This appendix lists all forms, field manuals, technical manuals, and other publications referenced in this manual. Those
publications that should be consulted for additional information about vehicle operations are also listed.

A-2. PUBLICATIONS INDEX

The following index should be consulted frequently for latest changes or revisions and for new publications relating to
material covered in this technical manual.

Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Pam 25-30

A-3. FORMS

The following forms pertain to this manual. See DA Pam 25-30 for index of blank forms. See DA Pam 738-750, The
Army Maintenance Management System (TAMMS), for instructions on the use of maintenance forms pertaining to this
material.

Recommended Changes to DA Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2

Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407
Equipment Control Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9
Processing and Deprocessing Record of Shipping, Storage, and Issue of Vehicles and
Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397
Packaging Improvement Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 6
Report of Item Discrepancy (ROID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 364
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 368

A-4. OTHER PUBLICATIONS

The following publications contain information pertinent to the MTV and associated equipment.

a. Safety.

First Aid for Soldiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11

Security of Tactical Wheeled Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-422-20
Safety Inspection and Testing of Lifting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0142

A-1
TM 9-2320-366-20-3

A-4. OTHER PUBLICATIONS (CONT)

b. MTV.

Direct Support and General Support Maintenance Manual for M1083 Series, 5-Ton,
6x6, Medium Tactical Vehicle (MTV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-366-34
Hand Receipt Covering Contents of Components of End Item (COEI), Basic Issue
Items (BII), and Additional Authorization List (AAL), for M1083 Series, 5-Ton,
6x6, Medium Tactical Vehicles (MTV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-366-10-HR
Operator’s Manual for M1083 Series, 5-Ton, 6x6, Medium Tactical Vehicle (MTV) . . . . . . . . . . . TM 9-2320-366-10
Unit, Direct Support, and General Support Repair Parts and Special Tools List for
M1083 Series, 5-Ton, 6x6, Medium Tactical Vehicle (MTV) . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-366-24P
Warranty Program for M1083 Series, 5-Ton, 6x6, Medium Tactical Vehicle (MTV) . . . . . . . . . . . TB 9-2300-366-15

c. General Vehicle Operation.

Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 55-30

Deleted
Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305
Petroleum Tank Vehicle Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-71
Safety Prevention of Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-557
Vehicle Recovery Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 20-22

d. General Maintenance and Repair.

Army Oil Analysis Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... TB 43-0211

Camouflage Pattern Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . FM 5-20
Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Pam 750-33
Color, Marking, and Camouflage Painting of Military Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . ... TB 43-0209
Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... TM 750-254
Corrosion Prevention and Control Including Rustproofing Procedures for Tactical
Vehicles and Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0213
Description, Use, Bonding Techniques, and Properties of Adhesives . . . . . . . . . . . . . . . . . . . . . . . TB ORD 1032
Equipment Improvement Report and Maintenance Digest: TACOM Equipment . . . . . . . . . . . . . . TB 43-0001-39-1
Equipment Improvement Report and Maintenance Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0143
Installation Instructions for Installation Kit, Electronic Equipment,
MK-2700/VRC (NSN 5895-01-421-0814) (EIC: N/A) to Permit Installation
of Radio Set AN/VRC-87/88/90 Series into M1078, M1080, M1081, M1083-
M1086, M1088-M1094 and M1096 Family of Medium Tactical Vehicles . . . . . . . . . . . . . TB 11-5820-890-20-101
Installation Instructions for Installation Kit, Electronic Equipment,
MK-2715/VRC (NSN 5895-01-421-0812) (EIC: N/A) to Permit Installation
of Radio Set AN/VRC-89/91/92 Series into M1078, M1080, M1081, M1083-
M1086, M1088-M1094 and M1096 Family of Medium Tactical Vehicles . . . . . . . . . . . . . . TB 11-5820-890-20-92
Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance Materiel
and Related Materials Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247
Metal Body Repair and Related Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 43-2
Operator’s and Organizational Maintenance Manual for Radio Sets . . . . . . . . . . . . . . . . . . . . TM 11-5820-498-12
Operator’s and Organizational Maintenance Manual Including Repair Parts and
Special Tools List Simplified Test Equipment for Internal Combustion Engines
Reprogrammable (STE/ICE-R) (NSN 4910-01-222-6589) . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-4910-571-12&P
Operator’s Manual, Radio Set, AN/VRC-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 11-5820-401-10-1
Operator’s Manual, Radio Set, AN/VRC-90A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 11-5820-890-10-1
Operator’s, Unit, Direct Support, and General Support Maintenance Manual
for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14

A-2 Change 1
 TM 9-2320-366-20-3

Ordnance Tracked and Wheeled Vehicle Hull and Chassis Wiring, Repair of . . . . . . . . . . . . . . . . . . TB ORD 650
Organizational Care, Maintenance, and Repair of Pneumatic Tires and Inner Tubes . . . . . . . . . TM 9-2610-200-14
Painting Instructions for Field Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139
Purging, Cleaning, and Coating Interior Ferrous and Terne Sheet Vehicle Fuel Tanks . . . . . . . . . . . . . TB 43-0212
Repair of Tents, Canvas, and Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-16
Rigging Techniques, Procedures, and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-125
Use and Care of Hand Tools and Measuring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-243
Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems . . . . . . . . . . . . . . . TB 750-651
Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237

e. Cold Weather Operation.

Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71
Operation and Maintenance of Ordnance Materiel in Cold Weather (0° to -65°F) . . . . . . . . . . . . . . . . . . FM 9-207

f. Decontamination.

Decontamination Operations Facilities & Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 700-4

NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-5
NBC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-4

g. Maintenance of Special Purpose Kits.

Operator and Organizational Maintenance Manual for Chemical Alarm . . . . . . . . . . . . . . . . . . . TM 3-6665-225-12

Operator’s and Unit Maintenance Manual Including Repair Parts and Special Tools
List for Decontaminating Apparatus: M13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-4230-214-12&P
Operator, Organizational, Direct Support, and General Support Maintenance Manual
Including Repair Parts and Special Tools List for Various Machine Gun Mounts . . . . . . . . . . . TM 9-1005-245-14

h. General.

Operator’s Manual (M998 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-280-10

Operator’s Manual (M1008 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-289-10
Operator’s Manual (M35 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-361-10
Operator’s Manual (M939 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-272-10
Principles of Automotive Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-8000
Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use
(US Army Tank-automotive and Armaments Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-6
Route Reconnaissance and Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-36
Soldier’s Manual MOS 88M Motor Transport Operator, Skill Levels 1/2 . . . . . . . . . . . . . . . . . STP 55-88-M12-SM

i. Land, Sea, and Air Shipment.

Airdrop of Supplies and Equipment: Rigging 5-Ton Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-526

Containerization of Military Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTMCTEA Ref 95-55-23
Lifting and Tiedown of U.S. Military Helicopters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTMCTEA Ref 95-55-21
Marine Lifting and Lashing Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTMCTEA Ref 95-55-22
Marine Terminal Lifting Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTMCTEA Pam 56-1

Change 1 A-3
TM 9-2320-366-20-3

A-4. OTHER PUBLICATIONS (CONT)

i. Land, Sea, and Air Shipment (Cont).

Multiservice Helicopter External Air Transport: Basic Operations and Equipment . . . . . . . . . . . . . . . . FM 55-450-3
Multiservice Helicopter External Air Transport: Dual-Point Load Rigging Procedures . . . . . . . . . . . . . FM 55-450-5
Multiservice Helicopter External Air Transport: Single-Point Load Rigging Procedures . . . . . . . . . . . . FM 55-450-4
Standard Characteristics (Dimensions, Weight, and Cube) for Transportability of Military
Vehicles and Other Outsize/Overweight Equipment (in TOE Line Sequence) . . . . . . . . . . . . . . . . . . TB 55-46-1
Tiedown Handbook for Rail Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTMCTEA Pam 55-19
Tiedown Handbook for Truck Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTMCTEA Ref 92-55-20

A-4
 TM 9-2320-366-20-3

APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC)

SECTION I

INTRODUCTION

B-1. The Army Maintenance System MAC.

a.This introduction (Section I) provides a general explanation of all maintenance and repair functions authorized at
various maintenance levels under the standard Army Maintenance System concept.

b.The Maintenance Allocation Chart (MAC) in Section II designates overall authority and responsibility for the
performance of maintenance functions on the identified end item or component. The application of the maintenance
functions to the end item or component will be consistent with the capacities and capabilities of the designated
maintenance levels, which are shown on the MAC in column (4) as:

Unit/FIELD - includes two subcolumns, C (Operator/Crew) and O (Unit) maintenance.

Direct Support/FIELD - includes an F subcolumn.

General Support/SUSTAINMENT - includes an H subcolumn.

Depot/SUSTAINMENT - includes a D subcolumn.

c. Section III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance
function as referenced from Section II.

d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.

B-2. Maintenance Functions. Maintenance functions are limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (e.g. by sight, sound, or feel).

b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an
item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition; e.g. to clean (includes
decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemicals fluids, or gases.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating
characteristics to specified parameters.

e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or Test,

Measurement, and Diagnostic Equipment (TMDE) used in precision measurement. Consists of comparison of two
instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the
accuracy of the instrument being compared.

Change 3 B-1
TM 9-2320-366-20-3

g. Remove/Install. To remove and install the same item when required to perform service or other maintenance
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component
or assembly) in a manner to allow the proper functioning of an equipment or system.

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace " is authorized
by the MAC and assigned maintenance level is shown as the 3d position code of the SMR code.
1 2
i Repair. The application of maintenance services including fault location/troubleshooting , removal/installation, and
3 4
disassembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item
by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly),
end item, or system.

j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely

serviceable/operational condition as required by maintenance standards in appropriate technical publications (i.e.,
DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally
return an item to like new condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new
condition in accordance with original manufacturing standards. Rebuild is the highest degree of material maintenance
applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (e.g.,
hours/miles) considered in classifying Army equipment/components.

B-3. Explanation of Columns in the MAC, Section II.

a Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify
maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly.

b. Column 2, Component/Assembly. Column 2 contains the item names of components , assemblies,

subassemblies, and modules for which maintenance is authorized.

c. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the items listed in Column 2.
(For detailed explanation of these functions, see Paragraph B-2.)

d. Column 4, Maintenance Level. Column 4 specifies each level of maintenance authorized to perform each function
listed in Column 3, by indicating work time required (expressed in man-hours in whole hours or decimals) in the
appropriate subcolumn. This work-time figure represents the active time required to perform that maintenance function at
the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function vary at
different maintenance levels, appropriate work-time figures are to be shown for each level. The work-time figure
represents the average time required to restore an item (assembly, subassembly, component, module, end item, or
system) to a serviceable condition under typical field operating conditions.

1
Services – Inspect, test, service, adjust, align calibrate, and/or replace.

2
Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunction; the
act of isolating a fault within a system or Unit Under Test (UUT).

3
Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded item, to the
level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e.,
identified as maintenance significant).

4
Actions - Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.

B-2
 TM 9-2320-366-20-3

This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location
time, and quality assurance time in addition to the time required to perform the specific tasks identified for the
maintenance functions authorized in the maintenance allocation chart. The symbol designations for the various
maintenance levels are as follows:

C ....................................................................................................................................... Operator or crew maintenance

O ....................................................................................................................................................Unit/Field maintenance
F....................................................................................................................................Direct Support/Field maintenance
L .................................................................................................................................. Specialized Repair Activity (SRA)5
H .................................................................................................................. General Support/Sustainment maintenance
D ....................................................................................................................................Depot/Sustainment maintenance

e. Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, those common tools sets
(not individual tools), common TMDE, and special tools, special TMDE, and special support equipment required to
perform the designated functions. Codes are keyed to tools and test equipment in Section III.

f. Column 6, Remarks. When applicable, this column contains a letter code, in alphabetical order, which is keyed to
the remarks contained in Section IV.

B-4. Explanation of Columns in Tool and Test Equipment Requirements, Section III.

a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the MAC,
Section II column 5.

b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.

c. Column 3, Nomenclature. Name or identification of the tool or test equipment.

d. Column 4, National Stock Number. The National Stock Number of tool or test equipment.

e. Column 5, Tool Number. The manufacturer's part number, model number, or type number.

B-5. Explanation of Columns in Remarks, Section IV.

a. Column 1, Remarks Code. The code recorded in column 6, Section II.

b.Column 2, Remarks. This column lists information pertinent to the maintenance function being performed as
indicated in the MAC, Section II.

5
This maintenance level is not included in Section II, Column (4) of the Maintenance Allocation Chart. Functions to this
level of maintenance are identified by a work-time figure in the "H" column of Section II, Column (4), and an associated
reference code is used in the Remarks column (6). This code is keyed to Section IV, Remarks, and the SRA complete
repair application is explained there.

Change 3 B-3
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
0100 ENGINE ASSEMBLY Inspect 0.1 80
Test 1.5 0.3 80,81
Adjust 3.0 58,62,80,82
Service 0.8 59,61,80
Replace 7.0 19,58,61,63
,80,81
Repair 0.4 1.6 3.3 19,35,36,46
,58,61,62,6
3,80,81
0101 CYLINDER HEAD ASSEMBLY Inspect 0.1 80
Replace 2.0 46,58,61,62
,80
Repair 2.5 58,61,62,63
,64,80,83
0102 CRANKSHAFT Replace 16.0 58,59,62,73
,80
Repair 3.8 16.0 19,35,36,58
,61,62,63,8
0
0103 FLEXPLATE, ENGINE Replace 6.5 58,61,80
Repair 1.0 58,61,80
0104 PISTON ASSEMBLY Replace 9.0 58,59,61,62
,64,80,81
Repair 0.6 80
0105 CAMSHAFT ASSEMBLY Replace 3.1 17,58,59,61
,62,80
Repair 1.2 58,80
0105 ROCKER ARM AND PUSH Replace 2.0 46,61,62,63
RODS ,80
Repair 0.3 59,80
0106 COOLER, ENGINE OIL Replace 1.3 58,80
Repair 0.3 58,80
0108 MANIFOLDS, INLET AND Replace 1.5 58,62,63,80
EXHAUST ,81
0301 INJECTOR ASSEMBLY, FUEL Replace 2.1 46,59,80,82
Adjust 1.6 58,80,81,82
0304 AIR INTAKE SYSTEM Service 0.3
Repair 0.3 48,59,

B-4 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General Tools and Remarks
Group Component/Assembly Maintenance Support Support Equipment Code
Unit Depot
Number Function Ref Code
C O F H D
0304 INTAKE AIR CLEANER Service 0.2
Replace 0.8 6,48,59, 80
Repair 0.4 59,80
0305 TURBOCHARGER Replace 0.8 58,63,80,81
0306 FUEL TANK Inspect 0.1
Replace 1.5 59,61,80
0308 GOVERNOR, ENGINE Replace 1.0 59,62,78,80
SPEED ,81
Repair 0.5 0.7 59,80
0309 FILTER, FUEL/WATER Inspect 0.2
SEPARATOR
Service 0.2 0.3 80
Replace 0.5 59,80
0311 ETHER STARTING AID Replace 0.6 59,61,80
0312 ACCELERATOR/HAND Replace 0.5 59,80
THROTTLE
Adjust 0.2 59,80
0401 EXHAUST MUFFLER/PIPES Inspect 0.1 0.2
Replace 0.9 59,61,80
0501 RADIATOR/CHARGE AIR Inspect 0.1
COOLER
Replace 2.5 2,31,55,
61,80
Service 1.5 61,80
Repair 0.6 2.0 2,31,55,
61,80
0501 RADIATOR OVERFLOW Replace 0.5 48,59,80
TANK
Repair 0.3 80
0502 SHROUD, FAN Replace 1.0 59,61,80,90
0503 HOSES, WATER Replace 0.5 59,61,80,90
0504 PUMP, WATER Replace 0.8 18,59,61,80
,90
0505 CLUTCH, ENGINE FAN Inspect 1.0 59

Replace 1.5 2,55,59, 80

Repair 1.2 58,61,62,63
,80,81

Change 3 B-5
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot

Group Component/Assembly Maintenance C O F H D Tools and Remarks

Number Function Equipment Code
Ref Code
0601 ALTERNATOR, 100 AMP Inspect 0.2
Test 0.5 1.5 61,65,80
Replace 1.0 61,80
Repair 0.2 0.5 40,58,59,61
,65,80,81
0603 STARTING MOTOR, ENGINE Inspect 0.1
Test 0.5 0.5 59,65
Replace 1.5 2,8,59,
61,80
Repair 2.1 54,58,61,62
,78,80
0606 SOLENOID, FUEL SHUTOFF Replace 1.0 62,80,82
0607 CABLE ASSEMBLY, Test 0.5 58
DASHBOARD
Replace 2.9 59,61,78,80
Repair 1.0 0.6 58,59,63,80
0607 DISPLAY, LIGHTED Test 0.3
INDICATOR
Replace 0.5 80,90
Repair 0.3 80
0608 JUNCTION BOX ASSEMBLY, Inspect 0.1
M1084/M1086
Replace 1.5 59,61,80,90
Repair 1.5 59,61,65,80
0608 JUNCTION BOX ASSEMBLY, Inspect 0.1
M1089
Replace 1.5 59,61,80,90
Repair 1.5 59,61,65,80
0609 LIGHT ASSEMBLY, BACKUP Inspect 0.1

Replace 0.8 59,80

Repair 0.3 80
0609 LIGHT, BLACKOUT DRIVE Inspect 0.1
Replace 0.8 59,61,80
Repair 0.5 80
Replace 0.8 59,61,80

B-6 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
0609 TAILLIGHT ASSEMBLY, Inspect 0.1
COMPOSITE
Repair 0.5 80
0609 LIGHT ASSEMBLY, FRONT Inspect 0.1
TURN SIGNAL AND PARK
Replace 0.8 59,61,80
Repair 0.5 80
0609 HEADLIGHT Inspect 0.1
Adjust 0.4
Replace 1.0 59,61,80
0609 WORKLIGHT ASSEMBLY, Inspect 0.1
M1088/M1089 STATIONARY
Replace 0.8 80
Repair 0.3 80
0610 AUDIBLE ALARM Inspect 0.1
Replace 0.6 80
0611 HORN, CAB Inspect 0.1
Replace 0.4 59,80
0612 BOX ASSEMBLY, BATTERY Inspect 0.1
Test 0.5 59,80
Service 0.3 59 A
Replace 1.0 59,61,80
Repair 0.2 65
0613 CABLE ASSEMBLY, LH/RH Inspect 0.1
CAB AND DOOR MARKER
LIGHTS
Replace 0.8 80

Repair 0.7 65
0613 CABLE ASSEMBLY, LOWER, Inspect 0.1
CAB MARKER LIGHTS,
M1093/M1094
Replace 0.6 80,90
Repair 0.5 65
0613 CABLE ASSEMBLY, UPPER, Inspect 0.1
CAB CLEARANCE AND
MARKER LIGHTS,
M1093/M1094
Replace 0.8 80,90
Repair 0.5 65

Change 3 B-7
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Tools and
Group Maintenance Direct General Equipment
Number Function Support Support Ref Code Remarks
Component/Assembly Unit Depot
Code
C O F H D
0613 CABLE ASSEMBLY, Replace 1.0 80
STE/ICE-R
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, CAB Inspect 0.1
CLEARANCE AND
MARKER LIGHTS
Replace 1.2 59,80
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, Replace 0.5 50,80,90
WARNING LIGHT
Repair 0.3 0.5 65
0613 CABLE ASSEMBLY, Replace 0.5 80
WINDSHIELD WASHER
PUMP/EMI
Repair 0.3 65
Repair 0.5 0.5 65
0613 CABLE ASSEMBLY, Inspect 0.1
CRANE POWER
Replace 1.2 80
Repair 0.5 0.5 65
0613 BOX ASSEMBLY, CRANE Test 0.5
REMOTE CONTROL
Repair 0.7 80,90
0613 CABLE ASSEMBLY, Inspect 0.1
ENGINE CONTROL
Replace 2.3 59,80
Repair 0.5 0.5 65
0613 CABLE ASSEMBLY, FRONT Replace 0.8 61,80
INTERVEHICULAR, 12 VDC

0613 CABLE ASSEMBLY, FRONT Replace 2.0 59,61,80,90

LIGHTS
Repair 0.5 0.5 65
0613 CABLE ASSEMBLY, REAR Replace 2.8 59,61,80
LIGHTS
Repair 0.5 0.5 65

0613 CABLE, M1084/M1086 Replace 2.0 59,80

BOOM DOWN LOCKOUT
SOLENOID
Repair 0.5 0.8 65
0613

B-8 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
BOOM DOWN SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 BOOM Replace 2.0 59,80
UP LOCKOUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 BOOM Replace 2.0 59,80
UP SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 Replace 2.0 59,80
CONTROL LOCKOUT
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 CRANE Replace 2.0 59,80
POWER
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 HOIST Replace 2.0 59,80
DOWN SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 HOIST Replace 2.0 59,80
UP LOCKOUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 HOIST Replace 2.0 59,80
UP SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 LEFT Replace 1.0 59,80
JACK CYLINDER PROXIMITY
SENSOR
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 Replace 2.0 59,80
OVERLOAD LOCKOUT
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 Replace 2.0 59,80
REMOTE CONTROL
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 SWING Replace 2.0 59,80
CCW SOLENOID
0613 CABLE, M1084/M1086 SWING Replace 2.0 59,80
CW SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 Replace 2.0 59,80
SYSTEM SHUTDOWN
SOLENOID
Repair 0.5 0.8 65

Change 3 B-9
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
0613 CABLE, M1084/M1086 Replace 2.0 59,80
TELESCOPE IN SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 Replace 2.0 59,80
TELESCOPE OUT LOCKOUT
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1084/M1086 Replace 2.0 59,80
TELESCOPE OUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 BOOM DOWN Replace 2.0 59,80
LOCKOUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 BOOM DOWN Replace 2.0 59,80
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 BOOM UP Replace 2.0 59,80
LOCKOUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 BOOM UP Replace 2.0 59,80
SOLENOID
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, M1089 Replace 2.0 80
CONTROL PANEL POWER
Repair 0.5 0.8 65
0613 CABLE, M1089 CRANE Replace 2.0 59,80
POWER
Repair 0.5 0.8 65
0613 CABLE, M1089 HOIST DOWN Replace 2.0 59,80
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 HOIST UP Replace 2.0 59,80
LOCKOUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 HOIST UP Replace 2.0 59,80
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 HYDRAULIC Replace 2.0 59,80
SYSTEM SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 LEFT SIDE Replace 2.0 59,80
REMOTE CONTROL

B-10 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT

Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
Repair 0.5 0.8 65
0613 CABLE, M1089 OVERLOAD Replace 2.0 59,80
LOCKOUT
Repair 0.5 0.8 65
0613 WIRING HARNESS, M1089 Replace 2.0 80
REMOTE CONTROL
Repair 0.5 0.8 65
0613 CABLE, M1089 RIGHT SIDE Replace 2.0 59,80
REMOTE CONTROL
Repair 0.5 0.8 65
0613 CABLE, M1089 SWING CCW Replace 2.0 59,80
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 SWING CW Replace 2.0 59,80
SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 TELESCOPE Replace 2.0 59,80
IN SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 TELESCOPE Replace 2.0 59,80
OUT LOCKOUT SOLENOID
Repair 0.5 0.8 65
0613 CABLE, M1089 TELESCOPE Replace 2.0 59,80
OUT SOLENOID
Repair 0.5 0.8 65
0613 BOX ASSEMBLY, WRECKER Repair 1.6 59,80
REMOTE CONTROL
0613 CABLE ASSEMBLY, Replace 0.8 59,61,80
M1090/M1094 DUMP
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, Replace 1.2 59,61,80
M1090/M1094 DUMP POWER
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, PTO Replace 1.6 59,61,80
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, REAR Replace 0.6 61,80
INTERVEHICULAR, 24 VDC
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, START Replace 2.0 59,80
AND CHARGING
Repair 0.5 0.8 65

Change 3 B-11
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
0613 CABLE ASSEMBLY, WINCH Replace 1.8 59,61,80
CONTROL VALVE
Repair 0.5 0.8 65
0613 CABLE ASSEMBLY, Replace 1.8 59,61,80
TRANSMISSION AUXILIARY
OIL COOLER FAN
Repair 0.5 65
0705 VEHICLE INTERFACE Replace 0.6 80
MODULE
Repair 0.8 80
0708 TORQUE CONVERTER Adjust 0.9 22,61,62,80
Remove/ 0.8 48,61,62,64
Install ,80
Repair 1.3 34,58,61,62
,64,80
0710 TRANSMISSION Inspect 0.4 80
Service 1.5 59,61,80
Replace 7.0 58,61,62,63
,80,81,87
Repair 0.4 2.7 1.9 3,22,23,
28,29,31,43
,58,59,61,6
2,63,80,81,
87
0710 MODULE, FRONT SUPPORT Remove/ 2.0 58,59,61,62
Install ,63,80
Repair 0.7
0710 MODULE, PLANETARY GEAR Remove/ 2.0 61,62,73,80
(P1) Install
Repair 1.5 61,62,73,80
0710 MODULE, PLANETARY (P2) Remove/ 2.0 3,58,61,
Install 62,63,80
Repair 1.9 3,23,58,
61,62,63,73
,80
0710 PLANETARY CARRIER (P3) Remove/ 2.0 3,58,62, 80
Install
Repair 1.9 3,31,58,
62,80

0710 MODULE, MAIN SHAFT Remove/ 2.0 61,62,80

Install
Repair 0.4 61,62,80

B-12 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
0710 MODULE, CONVERTER Remove/ 4.3 3,58,59,
HOUSING Install 61,62,80
Repair 2.0 3,23,29,
58,59,61,62
,80
0713 CLUTCH ASSEMBLY, Remove/ 2.0 58,59,61,62
C3/C4/C5, TRANSMISSION Install ,80
Repair 1.0 43,58,59,61
,62,80
0713 MODULE, ROTATING Remove/ 2.0 3,58,61,
CLUTCH Install 62,80
Repair 2.4 3,23,28,
58,61,62,
80
0714 VALVE ASSEMBLY, Remove/ 2.0 58,61,62,63
CONTROL MODULE Install ,80,81
Repair 1.0 2.5 61,63,80,81
0714 BODY ASSEMBLY, MAIN Service 1.5 59,61,80
VALVE
Remove/ 2.0 58,61,62,63
Install ,80,81
Repair 1.5 2.5 58,61,62,63
,80,81
0801 MODULE, TRANSFER CASE Adjust 1.0
Remove/ 2.0 25,58,59,61
Install ,62,63,73,7
6,80,81
Repair 1.1 27,31,37,52
,58,59,62,8
0
0802 HOUSING ASSEMBLY, C6 Remove/ 2.0 58,61,62,63
AND C7 CLUTCH Install ,80
Repair 0.8 23,27,30,31
,32,33,58,6
1,62,63,64,
73,80
0802 CONTROL VALVE ASSEMBLY Remove/ 2.0 58,61,63,80
Install ,81
Repair 1.0 58,61,63,80
,81
0804 PUMP ASSEMBLY, OIL Replace 1.0 81
Repair 0.8 81
0900 PROPELLER SHAFT Inspect 0.1

Change 3 B-13
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
Service 0.5 61
Repair 0.6 59,61,80
Replace 0.5 59,61,80
1000 AXLE ASSEMBLY, FRONT Inspect 0.1 0.3 0.7 80
Adjust 1.0 59,81
Service 0.5 61,80
Replace 4.5 58,59,61,
62,63,72,
80
Repair 2.3 2.2 6.0 58,59,61,
62,63,80
1002 CARRIER ASSEMBLY Inspect 0.1 0.1 0.1 80,81
DIFFERENTIAL
Service 0.3 80
Replace 4.6 25,58,59,
61,62,80,
81
Repair 2.7 58,59,61,
62,80,81
1004 STEERING KNUCKLE, AXLE Inspect 0.2
Adjust 2.5 81
Service 0.3 81
Replace 5.1 58,59,61,62
,73,80
1100 AXLE ASSEMBLY, Inspect 0.1 0.4 0.7
INTERMEDIATE
Service 0.8 59,61,80
Replace 4.5 58,59,61,62
,63,80,87
Repair 1.6 6.0 25,58,59,61
,62,69,80
1100 AXLE ASSEMBLY, REAR Inspect 0.1 0.4 0.7
Service 0.8 59,61,80
Replace 4.5 38,58,59,61
,62,80,87
Repair 0.9 6.0 25,58,59,61
,62,80,87,8
8

B-14 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipme Code
nt Ref
1102 CARRIER ASSEMBLY Inspect 0.1 0.1 0.1 80,81
DIFFERENTIAL
INTERMEDIATE AXLE
Service 0.3 80
Replace 4.6 25,58,59,
61,62,69,
80
Repair 2.7 25,58,59,
61,62,63,
69,75,80
1102 CARRIER ASSEMBLY Inspect 0.1 0.1 0.1 80,81
DIFFERENTIAL, REAR AXLE
Service 0.3 80
Replace 4.6 25,58,59,
61,62,80,
81,88
Repair 2.7 25,39,58,
59,61,62,
73,75,80
1202 BRAKE ASSEMBLY, FRONT Inspect 0.1 1.0 61,80,81
AXLE
Adjust 0.4 59,61,80
Repair 1.5 0.5 59,61,80,8
5
1202 BRAKE ASSEMBLY, Inspect 0.1 1.0 61,80,81
INTERMEDIATE AND REAR
AXLE
Adjust 0.4 59,61,80
Repair 1.5 0.5 59,61,80,8
5
1208 AIR DRYER, BRAKE SYSTEM Replace 0.5 59,61,80
Repair 1.0 59,61,80
1209 AIR COMPRESSOR Adjust 0.6 61,80
Replace 1.2 58,62,63,8
0,81
1311 WHEEL ASSEMBLY, Inspect 0.1 59 B
PNEUMATIC TIRE

Replace 1.0 1.2 59,61

Repair 2.0 59,61
1313 TIRE, PNEUMATIC Replace 2.0 59,61
1401 STEERING SYSTEM Inspect 0.2
Adjust 1.0 58,62,80

Change 3 B-15
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipme Code
nt Ref
Repair 1.0 1.5 56,58,59,6
1,62,63,80
,81
1407 STEERING GEAR ASSEMBLY Replace 4.0 58,62,80
1410 PUMP, POWER STEERING Replace 1.5 49,58,61,6
2,80
1411 HOSES, POWER STEERING Replace 0.3 59,61,80,9
0
1413 HYDRAULIC RESERVOIR, Service 0.1 0.5 80
POWER STEERING
Replace 0.8 61,80,90
1501 FRAME ASSEMBLY Inspect 0.1 0.3
Repair 0.8 14.0 58,59,61,6
2,63,80,81
1501 BOOM REST ASSEMBLY, Inspect 0.1
CRANE
Replace 2.0 58,59,61,6
2,80,81,87
Repair 0.7 58,59,61,6
2,80,81,87
1504 RETAINER, SPARE TIRE Inspect 0.1 0.1
Replace 3.0 59,61,80
Repair 0.6 59,61,80
1506 FIFTH WHEEL ASSEMBLY Inspect 0.1
Service 0.5 21,80
Replace 4.0 58,61,62,8
0,81
Repair 2.5 21,58,61,6
2,66,80,81
1601 LEAF SPRING ASSEMBLIES Inspect 0.1 0.2
Service 0.3 59
Replace 2.7 58,59,61,6
2,80,81
1604 SHOCK ABSORBERS Inspect 0.1 0.3
Replace 0.5 59,61,80
1605 STABILIZER BAR, REAR Inspect 0.2
Replace 2.0 59,61,70,8
0
Repair 1.5 59,80
1801 CAB BODY, STANDARD Inspect 0.1

B-16 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipme Code
nt Ref
Replace 60.0 58,59,62,6
3,80,81
Repair 0.6 59,61,80
1801 CAB BODY, AIR DROP Inspect 0.1
Replace 60.0 58,59,62,6
3,80,81
Repair 0.6 59,61,80
1801 CAB DOORS, STANDARD Inspect 0.1
Replace 1.0 57,61,80
Repair 2.7 51,59,80
1801 CAB DOORS, AIR DROP Inspect 0.1
Replace 1.0 57,61,80
Repair 2.7 51,59,80
1801 SUPPORT ASSEMBLY, CAB Inspect 0.1
FRONT
Repair 1.1 59,61,80
Replace 3.0 7,15,59,
61,62,80,
81
1801 SUPPORT ASSEMBLY, CAB Inspect 0.1
REAR
Replace 1.0 59,61,80
Repair 0.8 59,80
1802 WINDSHIELD Replace 0.6 57,61,80
1802 FENDER, VEHICULAR, Inspect 0.1
FRONT
Replace 2.0 59,61,80
Repair 0.5 59,80
1803 ROOF, CAB, M1093/M1094 Replace 1.0 47,52,59,61
,80
1805 STEP ASSEMBLY, CAB Replace 1.0 59,80
Repair 0.7 59,80
1808 TOOL BOX ASSEMBLY Inspect 0.1
Replace 0.5 49,59,61,80
Repair 0.5 59,61,80
1808 STOWAGE BOX, CAB Replace 0.8 59,80
Repair 0.5 59,80
1810 BODY, CARGO, (W/MHC, LWB inspect 0.1
AND LWB W/MHC)
Replace 4.0 58,59,61,62
,80

Change 3 B-17
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
80
Repair 0.5 59,61,80
1810 DUMP BODY ASSEMBLY Inspect 0.1
Repair 0.5 4.0 58,59,61,
62,80
1810 DUMP HYDRAULIC Inspect 0.1
CYLINDER
Replace 1.0 59,62,80
Repair 2.5 59,61,62,80
,89
1810 DUMP TAILGATE ASSEMBLY Inspect 0.1
Replace 1.5 80
Repair 0.8 80
1812 BOX ASSEMBLY, TOOL, Inspect 0.1
M1089
Remove/ 1.0 59,61,80
Install
Repair 0.8 59,61,80
2001 UNDERLIFT ASSEMBLY, Inspect 0.1
M1089
Test 0.5 0.1
Service 0.5 61
Replace 6.0 58,59,61,62
,80,87
Repair 1.0 54,58,59,61
,62,80,81,8
6,87
2001 CROSSBAR ASSEMBLY, Inspect 0.1
M1089
Replace 0.5 58,59,61,62
,80,81,86
Repair 1.0 58,59,61,62
,81,86
2001 LOWER ARM, UNDERLIFT Inspect 0.1
Replace 2.0 58,59,61,62
,80,87
Repair 0.5 58,59,61,62
,80,87
2001 CYLINDER, TELESCOPIC Replace 1.5 59,61,80
LIFT
Repair 1.0 61,62,63,80
2001 STIFFLEG ASSEMBLY Inspect 0.1

B-18 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
Replace 2.0 59,61,62,80
,87
2001 BOOM FRAME, FOLDING, Inspect 0.1
UNDERLIFT
Repair 2.5 61,80
2001 ARM ASSEMBLY, UPPER, Repair 2.5 58,59,61,62
UNDERLIFT ,80
2001 CYLINDER, UNDERLIFT FOLD Replace 0.5 59,61,80,87
Repair 0.5 59,61,62,63
,80
2001 CYLINDER, UNDERLIFT Replace 0.5 59,61,62,80
STINGER ,87
Repair 0.5 58,61,62,63
,68,80,81
2001 WINCH, 15K SELF- Inspect 0.1 4.0
RECOVERY
Service 0.2 61
Replace 1.0 61,62,80
Repair 0.9 61,62,80
2001 MOTOR, HYDRAULIC, SELF- Replace 0.5 59,80
RECOVERY WINCH
2001 MATERIAL HANDLING CRANE Inspect 0.1 0.5 80
(MHC), M1089
Test 0.2 0.3 59
Service 0.5 61
Replace 6.0 59,61,62,80
,87
Repair 0.5 9,58,59,
61,62,80
2001 CYLINDER, LIFT, M1089 MHC Inspect 0.1
Test 0.2 61
Replace 4.0 58,62,80
Repair 2.0 59,61,62,63
,80
2001 CYLINDER, ERECTION, Inspect 0.1
M1089 MHC
Test 0.2 61
Replace 4.0 58,62,80
Repair 2.0 59,61,62,63
,80,81
2001 HOIST ASSEMBLY, M1089 Inspect 0.1
MHC

Change 3 B-19
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level

FIELD SUSTAINMENT
Direct General
Unit Support Support Depot

Group Component/Assembly Maintenance C O F H D Tools and Remarks

Number Function Equipment Code
Ref Code
Test 0.2 61
Replace 6.0 61,62,80
Repair 3.0 59,61,62,80
2001 HYDRAULIC MOTOR, HOIST, Inspect 0.1
M1089 MHC
Test 0.1 59,65
Replace 2.0 59,80
Repair 4.2 58,59,61,62
,63,80
2001 GEAR SET, M1089 MHC Inspect 0.2
Test 0.2 61
Repair 1.7 61,62,80
2001 BOOM ASSEMBLY, M1089 Inspect 0.1
MHC
Test 0.2
Replace 8.0 58,62,80
Repair 2.0 58,61,62,80
2001 CYLINDER, TELESCOPIC, Inspect 0.1
BOOM, M1089 MHC
Test 0.2 61
Replace 6.0 58,61,62,80
Repair 2.0 59,61,62,80
2001 SWING DRIVE ASSEMBLY, Inspect 0.1 0.5
M1089 MHC
Test 0.2 61
Service 0.3
Replace 4.0 59,61,62,80
Repair 4.0 59,61,62,80
2001 MOTOR, ORBIT, HYDRAULIC, Inspect 0.1
M1089 MHC
Test 0.2
Replace 1.0 59,61,62,80
Repair 3.0 59,61,62,63
,80,81

B-20 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
2001 CYLINDER ASSEMBLY, Inspect 0.1
EXTENSION, OUTRIGGER,
M1089 MHC
Test 0.2 61
Replace 3.0 80
Repair 5.0 61,62,80
2001 CYLINDER ASSEMBLY, JACK, Inspect 0.1
M1089 MHC
Test 0.2 61
Replace 3.0 62,80
Repair 5.0 59,61,62,80
2001 VALVE ASSEMBLY, EIGHT- Inspect 0.1
BANK, M1089 MHC
Replace 0.5 58,59,61,80
Repair 2.0 58,59,61,80
2001 WINCH ASSEMBLY, M1089 Inspect 0.1
(30K)
Test 0.5 0.2 63
Replace 9.0 20,59,61,62
,80,81
Repair 0.5 59,61,62,63
,73,80,81
2001 MOTOR ASSEMBLY, DRIVE, Replace 0.5 59,61,62,63
(30K) WINCH ,73,80,81
Repair 8.0 59,61,62,63
,73,80,81
2001 VALVE ASSEMBLY, MAIN, Replace 0.5 61,62,80
UPPER, M1089
Repair 0.5 61,62,80
2001 VALVE ASSEMBLY, MAIN, Replace 0.5 61,62,80
LOWER, M1089
Repair 0.5 61,62,80
2001 VALVE ASSEMBLY, MONO, Replace 1.5 59,61,62,80
M1089 ,87
Repair 1.0 59,61,62,80
,87
2001 MATERIAL HANDLING CRANE Inspect 0.1
MHC), M1084/M1086
Test 0.2 81

Change 3 B-21
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
Service 2.0 61
Replace 4.0 58,59,61,62
,80
Repair 0.5 58,59,61,62
,63,73,80,8
1
2001 CYLINDER, LIFT, Inspect 0.1
M1084/M1086 MHC
Test 2.0 65,81
Replace 2.0 58,59,62,80
Repair 4.0 58,59,62,80
2001 CYLINDER, ERECTION, Inspect 0.1
M1084/M1086 MHC
Test 0.2 65,81
Replace 4.0 58,62,80
Repair 4.0 59,61,63,80
,81
2001 HOIST ASSEMBLY, Inspect 0.1
M1084/M1086 MHC
Test 0.2 65,81
Replace 6.0 61,62,80
Repair 3.5 59,61,62,80
2001 MOTOR, HYDRAULIC, HOIST, Inspect 0.1
M1084/M1086 MHC
Test 0.1 65,81
Replace 2.0 59,80
Repair 4.2 58,59,61,62
,63,80
2001 GEAR SET, M1084/M1086 Inspect 0.2
MHC
Test 0.2
Repair 4.5 61,62,80
2001 CYLINDER, TELESCOPIC, Inspect 0.1
BOOM, M1084/M1086 MHC
Test 0.1 65,81
Replace 2.0 58,61,62,80
Repair 4.0 59,61,62,80

B-22 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
2001 SWING DRIVE ASSEMBLY, Inspect 0.1 0.5 61
M1084/M1086 MHC
Test 0.1 65,81
Service 0.3
Replace 4.0 59,61,62,80
Repair 3.5 4.2 59,61,62,80
2001 MOTOR, ORBIT, HYDRAULIC, Inspect 0.1 61
M1084/M1086 MHC
Test 0.1 65,81
Replace 2.0 59,61,80
Repair 4.2 59,61,63,73
,80,81
2001 VALVE ASSEMBLY, Replace 0.8 59,61,62,80
CONTROL, FOUR WAY,
M1084/M1086 MHC
Repair 1.1 59,61,62,80
2001 VALVE ASSEMBLY, Replace 0.8 59,61,62,80
CONTROL, THREE WAY, ,81
M1084/M1086 MHC
Repair 1.1 59,61,62,80
,81
2001 CYLINDER, JACK, Inspect 0.1
M1084/M1086 MHC
Test 0.2 81
Replace 2.0 62,80
Repair 4.0 59,61,62,80
2004 POWER TAKEOFF Inspect 0.1
ASSEMBLY (PTO)
Replace 1.0 58,59,61,62
,80
Repair 0.8 58,59,61,62
,80
2201 CAB PROTECTOR, Inspect 0.1
M1090/M1094
Replace 2.0 58,80
2202 MOTOR, WIPER, Test 0.5
WINDSHIELD

Replace 1.0 80
2207 HEATER ASSEMBLY, Replace 2.0 59,61,80
PERSONNEL

Change 3 B-23
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
2210 DECALS Inspect 0.1
Replace 1.0 80
2401 POWER UNIT, Inspect 0.1
AIR/HYDRAULIC
Test 0.2
Service 1.0
Replace 3.0 59,61,80
Repair 2.0 59,61,62,71
,80,81
2402 MANIFOLD, HYDRAULIC Inspect 0.1
Test 0.2
Replace 1.5 53,59,61,80
Repair 1.0 53,59,61,80
2406 FILTER, HYDRAULIC Service 0.3 61,80
Replace 0.2 61,80
2407 LATCH, HYDRAULIC, CAB Inspect 0.1
Adjust 0.5 59,61,80
Replace 0.5 59,61,80
2408 RESERVOIR, HYDRAULIC Replace 1.0 59,61,80
Repair 0.5 59,61,80
2408 TANK ASSEMBLY, Inspect 0.1
HYDRAULIC, M1089
Service 2.0 59,61,80
Replace 2.0 6,9,59,
61,80
Repair 0.5 59,61,80
3307 ALTERNATOR KIT, 200 AMP Inspect 0.1 0.2
Test 0.5
Remove/ 2.0 59,61,80
Install
Replace 1.0 59,61,80
Repair 0.5 58,59,62,63
,80
3307 ALTERNATOR, 200 AMP Inspect 0.2
Test 0.5 1.5 61,65,80
Replace 1.0 59,61,80
Repair 0.2 0.5 58,59,62,63
,65,80
3307 CRANE (LMHC), MATERIAL Inspect 0.1 0.1
HANDLING, LIGHT
Replace 0.5 61,78,80

B-24 Change 3
 TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
Repair 0.5
Test 0.5
3307 WEIGHT BLOCK AND WIRE Inspect 0.1
ROPE, LMHC
Replace 0.1 61,80
Repair 0.5 61,80
Test 0.5
3307 WINCH, LMHC Inspect 0.1
Replace 0.5 61,80
Repair 1.0 61,80
Test 0.5
3307 MAST/SWING ASSEMBLY, Inspect 0.1
LMHC
Repair 1.0 61,80
Test 0.5
3307 CONTROL BOX, LMHC Inspect 0.1
Replace 0.1
Repair 0.5 78,80
Test 0.1 0.5
3307 TROOPSEAT KIT Remove/ 1.0
Install
Inspect 0.1
Replace 1.0
Repair 0.5 80
3307 COVER KIT, CARGO SOFT Remove/ 1.5
TOP Install
Inspect 0.1
Replace 2.0
Repair 0.5
3307 WARNING LIGHT ASSEMBLY, Inspect 0.1
AMBER
Repair 0.4 80
Test 0.2
3401 MACHINE GUN RING KIT Inspect 0.1
Remove/ 4.0 58,59,62,
Install 80,81,87
Repair 1.1 10,59,80
3402 MOUNT, SMALL ARMS Inspect 0.1
Replace 0.3 80
3901 WARNING LIGHT ASSEMBLY, Repair 0.8 59,61,80
AMBER, M1089

Change 3 B-25
TM 9-2320-366-20-3

Section II. MAINTENANCE ALLOCATION CHART FOR THE MTV VEHICLE

(1) (2) (3) (4) (5) (6)
Maintenance Level
FIELD SUSTAINMENT
Direct General
Unit Support Support Depot
Group Component/Assembly Maintenance C O F H D Tools and Remarks
Number Function Equipment Code
Ref Code
3903 MAST, WARNING LIGHT, Replace 0.6 59,61,80
AMBER, M1089
3909 CABLE ASSEMBLY, Inspect 0.1
WARNING LIGHT
Replace 0.5 80
4316 AIR HOSE, CTIS Inspect 0.1
Replace 0.4 61,80
4317 VALVE, INVERSION Replace 0.5 61,80
4318 CYLINDER, PNEUMATIC, Replace 0.4 61,80
TAILGATE, M1090/M1094
4321 AIR DRYER Inspect 0.1 0.1
Replace 1.0 59,61,80
Repair 0.6 59,61,80
4702 GAUGE, AIR FILTER Replace 0.5 80
RESTRICTION

Section III. TOOLS AND TEST EQUIPMENT FOR MTV VEHICLES

Tool or Test
Equipment Maintenance Nomenclature National Stock Number Tool Number
REF Code Level
1 O,F ADAPTER, RADIATOR 4910-01-170-4928 J29003-A
2 O ADAPTER, SOCKET WRENCH 5120-00-240-8702 11655788-2
2.1 O BASE, MAGNETIC P5646
3 H BUSHING DRIVER SET 5120-01-391-3541 J35922
4 O CRIMPING TOOL, TERMINAL, HAND 5120-00-165-3912 M22520/1-01
5 O CROWFOOT ATTACHMENT, 5120-00-078-3809 10935497
SOCKET WRENCH
6 O CROWFOOT ATTACHMENT, 5120-00-293-1010 5120-293-1282
SOCKET WRENCH
7 F CROWFOOT ATTACHMENT, 5120-01-074-7557 FCOM19
SOCKET WRENCH
8 O CROWFOOT ATTACHMENT, 5120-01-236-9996 FCOM15
SOCKET WRENCH
9 O CROWFOOT ATTACHMENT, 5120-01-335-1089 FCO28
SOCKET WRENCH
10 O CROWFOOT ATTACHMENT, 5120-01-335-1091 FCO32
SOCKET WRENCH
11 O CROWFOOT ATTACHMENT, 5120-01-335-1119 SCO34
SOCKET WRENCH
12 O CROWFOOT ATTACHMENT, 5120-01-335-1122 SCO40
SOCKET WRENCH

B-26 Change 3
 TM 9-2320-366-20-3

Section III. TOOLS AND TEST EQUIPMENT FOR MTV VEHICLES

Tool or Test
Equipment Maintenance Nomenclature National Stock Number Tool Number
REF Code Level
12.1 O CROWFOOT ATTACHMENT, 5120-01-335-1126 SCO48
SOCKET WRENCH
13 O CROWFOOT ATTACHMENT, 5120-01-335-1153 FCO20
SOCKET WRENCH
14 O CROWFOOT ATTACHMENT, 5120-01-335-1156 FCO26
SOCKET WRENCH
15 F CROWFOOT ATTACHMENT, 5120-01-348-9473 AN8508-19A
SOCKET WRENCH
16 O CUTTER, BOLT 5110-00-224-7057 GGG-C-740
16.1 O DISPENSER, SEALANT 5120-00-061-1283 45RCT
16.2 F DRILL SET, STOPCOLLAR 5133-01-383-7665 1955
17 H DRIVER KIT, BEARING 4910-01-032-3128 8S0602
18 DELETED
19 O,F GAGE, BELT TENSION 6635-01-143-2237 GA-424
20 O,F GAGE, PRESSURE, 0-150 psi 6685-00-474-5721 111T1D05A01
21 O GAGE, PROFILE 5220-01-357-4913 TF-0237
22 F,H GAGE, PROFILE 5220-01-388-1460 J-38548-1
23 H HANDLE, DRIVE 5120-00-377-2259 J8092
24 O HEATER, GUN TYPE, ELECTRIC 4940-00-561-1002 500A
25 F,H HOLDING BAR, PINION 5120-01-166-0573 J3453
25.1 O INDICATOR, DIAL P36491
26 O INSERTER AND REMOVER, 5120-00-915-4588 MS3447-16
ELECTRICAL CONTACT
27 H INSERTER AND REMOVER, SPRING 5120-01-388-3660 J38573
28 H INSERTER AND REMOVER, SPRING 5120-01-388-4436 J35923
29 H INSERTER, BEARING AND BUSHING 5120-01-388-7841 J-38565
30 H INSERTER, BEARING AND BUSHING 5120-01-389-0658 J35921-1
31 H INSERTER, BEARING AND BUSHING 5120-01-390-1104 J 38569
32 H INSERTER, BEARING AND BUSHING 5120-01-390-1105 J 38568-3
33 H INSERTER, BEARING AND BUSHING 5120-01-391-5133 J 38579
34 F,H INSERTER, BEARING AND BUSHING 5120-01-414-7398 J38566
35 F INSERTER, SEAL 5120-01-362-2026 1U7430
36 F INSERTER, SEAL 5120-01-362-2027 1U7598
37 F INSTALLER, SEAL N/A J38574
37.1 F JACK, DOLLY TYPE HYDRAULIC 4910-01-396-5044 TTJ3
38 F JACK, LEVELING SUPPORT, 2590-00-231-7418 10876244
VEHICLE
38.1 O KEY, SOCKET HEAD SCREW 5120-01-355-1670 AWML2.5
38.2 F NOSE ASSEMBLY 99-3307
38.3 O PLIERS, HOG RING STAPLE 5120-01-413-8837 0012
38.4 F LIFTING SADDLE ASSEMBLY TTJ-ZIFA
39 H PULLER KIT, UNIVERSAL 5180-00-089-3660 A57QB
40 F PULLER KIT, UNIVERSAL 5180-01-124-1903 1P3075
41 O REMOVER, ELECTRICAL CONTACT 5120-00-148-9844 MS3448-001B
42 F RIVETER, BLIND, HAND 5120-01-289-4310 HP-2

Change 3 B-27
TM 9-2320-366-20-3

Section III. TOOLS AND TEST EQUIPMENT FOR MTV VEHICLES

Tool or Test
Equipment Maintenance Nomenclature National Stock Number Tool Number
REF Code Level
42.1 F RIVETER, BLIND, PNEUMATIC 5130-01-232-4042 245
43 H RIVETER, YOKE, HAND 5120-01-415-3558 J-39354
44 F SCREWDRIVER ATTACHMENT, 5120-00-601-6934 LAW120A
SOCKET WRENCH
45 O SCREWDRIVER ATTACHMENT, 5120-01-053-4158 FAM5A
SOCKET WRENCH
46 O,F,H SCREWDRIVER ATTACHMENT, 5120-01-055-1308 ANSIB18.3.2M
SOCKET WRENCH
47 O SCREWDRIVER ATTACHMENT, 5120-01-079-8032 SAM8A
SOCKET WRENCH
48 O SCREWDRIVER ATTACHMENT, 5120-01-160-8862 S 6 HBS
SOCKET WRENCH
49 O,F SCREWDRIVER ATTACHMENT, 5120-01-367-3462 SA10A
SOCKET WRENCH
49.1 O,F SCREWDRIVER ATTACHMENT, 5120-01-367-3483 FA5LE
SOCKET WRENCH
50 O,F SCREWDRIVER ATTACHMENT, 5120-01-367-3497 TMP12A
SOCKET WRENCH
51 O SCREWDRIVER ATTACHMENT, 5120-01-367-3519 F23D
SOCKET WRENCH
52 O SCREWDRIVER ATTACHMENT, 5120-01-367-3526 FP24
SOCKET WRENCH
53 O SCREWDRIVER ATTACHMENT, 5120-01-367-3527 FP32A
SOCKET WRENCH
54 F,H SCREWDRIVER ATTACHMENT, 5120-01-367-3536 FTX40A
SOCKET WRENCH
55 O SCREWDRIVER ATTACHMENT, 5120-01-367-3574 GFA8A
SOCKET WRENCH
56 O SEPARATOR, BALL JOINT 5120-01-255-8238 2287
57 F SETTING TOOL, WINDSHIELD 5120-01-316-4995 CRL216
58 O,F SHOP EQUIPMENT, AUTOMOTIVE 4910-00-348-7696 SC4910-95CLA02
VEHICLE
59 O,F,H SHOP EQUIPMENT, AUTOMOTIVE 4910-00-754-0650 SC4910-95CLA72
VEHICLE
60 O SHOP EQUIPMENT, AUTOMOTIVE 4910-00-754-0653 SC4910-95CLA73
VEHICLE
61 O,F,H SHOP EQUIPMENT, AUTOMOTIVE 4910-00-754-0654 SC4910-95CLA74
VEHICLE
62 F,H SHOP EQUIPMENT, AUTOMOTIVE 4910-00-754-0705 SC4910-95CLA31
VEHICLE
63 F,H SHOP EQUIPMENT, AUTOMOTIVE 4910-00-754-0706 SC4910-95CLA62
VEHICLE
64 O,F,H SHOP EQUIPMENT, AUTOMOTIVE 4910-00-754-0707 SC4910-95CLA63
VEHICLE
65 O,F SHOP EQUIPMENT, FUEL AND 4910-00-754-0714 SC4910-95CLA01
ELECTRICAL
66 F SLIDER, SPRING COMPRESSOR 4910-01-165-6015 TF-TUN-J500
67 F SLING, MULTIPLE LEG 3940-00-777-5744 A170

B-28 Change 3
 TM 9-2320-366-20-3

Section III. TOOLS AND TEST EQUIPMENT FOR MTV VEHICLES

Tool or Test
Equipment Maintenance Nomenclature National Stock Number Tool Number
REF Code Level
68 H SOCKET SET, SOCKET WRENCH 5120-01-195-0640 208FA
69 F,H SOCKET, SOCKET WRENCH 5120-01-068-5643 5555M
70 O SOCKET, SOCKET WRENCH 5120-01-161-5907 GLDH382
71 F SOCKET, SOCKET WRENCH 5120-01-335-0784 TW321
72 O SOCKET, SOCKET WRENCH 5120-01-144-5324 ANS 1913A
73 F SOLDERING AND BRAZING OUTFIT, 3439-00-460-7198 SC4940-95-CLB20
RESISTANCE HEATING
74 O SOLDERING IRON, ELECTRIC 3439-01-036-3308 3112-S3-40W
75 H STAND, DIFFERENTIAL CARRIER 4910-01-085-7729 J3409-D
REPAIR
76 H STAND, MAINTENANCE, 4910-00-808-3372 J29109
AUTOMOTIVE ENGINE
77 F TOOL, DISTORTER 5120-01-119-1748 5P-7312
78 O,F TOOL KIT, AUTO FUEL AND 5180-00-754-0655 SC4910-95CLA50
ELECTRICAL SYSTEM REPAIR
79 F TOOL KIT, BODY AND FENDER 5180-00-754-0643 SC5180-90-N34
80 O,F,H TOOL KIT, GENERAL MECHANIC'S 5180-00-177-7033 SC5180-90-CL-N26
81 F,H TOOL KIT, GENERAL MECHANIC'S 5180-00-699-5273 SC5180-90-CL-N05
82 F TOOL KIT, INTERNAL COMBUSTION 5180-01-356-8155 1U6680
ENGINE
83 H TOOL KIT, DIESEL INJECTOR 5180-01-466-3966 143-2099
84 F TOOL OUTFIT, HYDRAULIC 4940-01-036-5784 SC4940-95-CL-B07
85 O TOOL, SPRING REMOVAL 5120-01-360-1918 TV940010
86 F WIRE TWISTER, PLIER 5120-00-542-4171 GGG-W-340
87 F WRENCH SET, CROWFOOT, 5120-00-293-0013 GGG-W-646
RATCHETING
88 F WRENCH SET, SOCKET 5120-00-148-3706 ANSI-B107.5
89 H WRENCH SET, SPANNER 5120-00-215-1882 46D7578
90 O WRENCH, TORQUE, 0-75 LB-IN. 5120-01-112-9532 TQSC6A

Section IV. REMARKS FOR THE MTV VEHICLE

Remarks Code Remarks
A Battery service will be in accordance with TM 9-6140-200-14.
B Repair of tires will be in accordance with TM 9-2610-200-14.

Change 3 B-29/(B-30 Blank)

 TM 9-2320-366-20-3

APPENDIX C
TOOLS IDENTIFICATION LIST

Section I. INTRODUCTION

C-1. INTRODUCTION

This appendix lists common tools, supplements, and special tools/fixtures that are suggested for maintenance tasks
performed at the Unit Maintenance level.

C-2. EXPLANATION OF COLUMNS

a. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative
instructions to identify the item, e.g., "Bar, Pry (Item 1, Appendix C)."

b. Column (2) - Item Name. This column contains the nomenclature for the item.

c. Column (3) - National Stock Number. This is the national stock number assigned to the item which you can use
to requisition it.

d. Column (4) - Part Number. This provides the Government, manufacturer, or vendor part number for the item.

e. Column (5) - Reference. This column contains the shop catalog (SC), technical manual, or other publication
which provides an illustration and description of the item, or lists whether the item is fabricated.

APPENDIX C
Section II. TOOLS IDENTIFICATION LIST
(1) (2) (3) (4) (5)
ITEM NATIONAL
NUMBER ITEM NAME STOCK NUMBER PART NUMBER REFERENCE

1 ADAPTER, SOCKET 5120-00-227-8088 A-A-2172 SC 4910-95-CL-A74

WRENCH
2 ADJUSTING TOOL, BRAKE 5120-01-154-3029 J34061 SC 4910-95-CL-A74
SHOE
3 APRON, RUBBER 8145-00-082-6108 MIL-A-41829 SC 4910-95-CL-A74
4 CAPS, VISE JAW 5120-00-221-1506 GGG-C-137 SC 4910-95-CL-A74
5 DISPENSING PUMP, HAND 4930-00-263-9886 43D15069 SC 4910-95-CL-A74
DRIVEN
6 DRILL SET, TWIST 5130-00-293-0983 58 SC 4910-95-CL-A74
7 DRILL, PORTABLE, 5130-00-293-1849 W-D-661 SC 4910-95-CL-A74
ELECTRIC
8 DRILL, TWIST 5133-01-120-3519 SC 4910-95-CL-A72

C-1
TM 9-2320-366-20-3

Section II. TOOLS IDENTIFICATION LIST (CONT)

(1) (2) (3) (4) (5)
ITEM NATIONAL
NUMBER ITEM NAME STOCK NUMBER PART NUMBER REFERENCE

9 FISHING TOOL, PNEUMATIC 5120-00-516-4220 991 SC 4910-95-CL-A74

TIRE VALVE
10 GAGE, DEPTH, 5210-00-619-4045 445BZ-6RL CTA 50-909
MICROMETER
11 GAGE, TIRE PRESSURE 4910-01-117-2994 955 SC 4910-95-CL-A72
12 GAGE, WHEEL ALIGNMENT 5210-01-223-3701 WA361 SC 4910-95-CL-A72
13 GLOVES, RUBBER 8415-00-641-4601 ZZ-G-381 SC 4910-95-CL-A74
14 GLOVES, WELDER'S 8415-00-268-7859 A-A-50022 SC 4910-95-CL-A72
15 GOGGLES, INDUSTRIAL 4240-00-052-3776 A-A-1110 SC 4910-95-CL-A74
16 GUN, LUBRICATING 4930-00-253-2478 1142 SC 4910-95-CL-A74
17 HAMMER, HAND 5120-00-224-4130 A-A-1292 SC 4910-95-CL-A74
18 HAMMER, HAND 5120-01-065-9037 57-533 SC 4910-95-CL-A72
19 HOSE ASSEMBLY, 4720-00-356-8557 ZZ-H-461 SC 4910-95-CL-A74
NONMETALLIC
20 IRON, TIRE 5120-00-765-8536 T48A SC 4910-95-CL-A74
21 JACK, HYDRAULIC, HAND 5120-00-224-7330 D120 SC 4910-95-CL-A74
22 MULTIMETER, DIGITAL 6625-01-139-2512 T00377 SC 4910-95-CL-A74
23 MULTIPLIER, TORQUE 5120-00-574-9318 292 SC 4910-95-CL-A72
WRENCH
24 PAN, DRAIN 4910-00-387-9592 450 SC 4910-95-CL-A74
25 PAN, WASH 4940-00-617-9859 5582281 SC 4910-95-CL-A72
26 PRESSURE TESTER, 4910-01-170-4929 J24460-01 SC 4910-95-CL-A74
RADIATOR
27 PULLER KIT, MECHANICAL 5120-00-313-9496 1178 SC 4910-95-CL-A74
28 PULLER, BATTERY 5120-00-944-4268 21 SC 4910-95-CL-A74
TERMINAL
29 RESPIRATOR, AIR FILTER 4240-00-022-2524 GGG-M-125/6 SC 4910-95-CL-A72
30 SCALE, WEIGHING 6670-00-254-4634 AAA-S-133 SC 4910-95-CL-A74
31 SLING, CARGO 1670-00-823-5043 63J4261-13 CTA 50-970
32 SLING, ENDLESS 3940-00-675-5003 PD101-96 CTA 50-970
33 SOCKET SET, IMPACT 5120-01-117-0466 4151MMY SC 4910-95-CL-A74
34 SOCKET SET, SOCKET 5120-01-073-2821 217FMY SC 4910-95-CL-A74
WRENCH

C-2 Change 2
 TM 9-2320-366-20-3

Section II. TOOLS IDENTIFICATION LIST (CONT)

(1) (2) (3) (4) (5)
ITEM NATIONAL
NUMBER ITEM NAME STOCK NUMBER PART NUMBER REFERENCE

35 SOCKET SET, SOCKET 5120-01-115-1149 315SIMMY SC 4910-95-CL-A74

WRENCH
36 SOCKET SET, SOCKET 5120-01-117-3876 221FSMY SC 4910-95-CL-A72
WRENCH
37 SOCKET, SOCKET WRENCH 5120-00-181-6813 5530 SC 4910-95-CL-A74
38 SOCKET, SOCKET WRENCH 5120-00-232-5681 1242 SC 4910-95-CL-A74
39 SOCKET, SOCKET WRENCH 5120-00-243-7351 5316 SC 4910-95-CL-A74
40 SOCKET, SOCKET WRENCH 5120-01-112-0581 SIMM190 SC 4910-95-CL-A74
41 STE/ICE-R 4910-01-222-6589 12259266 SC 4910-95-CL-A74
41.1 TEST KIT, RADIATOR 4910-00-728-8227 SC 4910-95-CL-A74
41.2 TAP AND DIE SET 5136-01-119-0005 TDM99117 SC 4910-95-CL-A72
42.3 TAP, THREAD, CUTTING 5136-00-729-5692 B94.9 ½-13 SC 4910-95-CL-A72
UNCHSGH3
42 TESTER, ANTIFREEZE AND 6630-00-105-1418 10425 SC 4910-95-CL-A74
BATTERY
43 TOOL KIT, AUTO FUEL 5180-00-754-0655 SC 5180-95-CL-A50
44 TOOL KIT, BLIND RIVET 5180-01-201-4978 D-100-MIL-1 SC 4910-95-CL-A74
45 TOOL KIT, ELECTRICAL 5180-00-876-9336 7550526 SC 4910-95-CL-A72
46 TOOL KIT, GENERAL 5180-00-177-7033 SC 5180-90-N26
MECHANIC'S
47 TRESTLE, MOTOR VEHICLE 4910-00-251-8013 306 SC 4910-95-CL-A74
MAINTENANCE
48 VISE, MACHINIST 5120-00-293-1439 504M2 SC 4910-95-CL-A74
49 WRENCH SET, SOCKET 5120-00-081-2305 GGG-W-641 SC 4910-95-CL-A74
50 WRENCH SET, SOCKET 5120-00-204-1999 GGG-W-641 SC 4910-95-CL-A74
51 WRENCH SET, SOCKET 5120-00-322-6231 51200017510 SC 4910-95-CL-A74
52 WRENCH, ADJUSTABLE 5120-00-264-3793 2117080 SC 4910-95-CL-A74
53 WRENCH, ADJUSTABLE, 5120-00-449-8083 1B7536 SC 4910-95-CL-A74
AUTOMOTIVE
54 WRENCH, BOX AND OPEN 5120-00-277-8833 1244 SC 4910-95-CL-A74
END
55 WRENCH, BOX AND OPEN 5120-00-277-8834 GGG-W-636 SC 4910-95-CL-A74
END
56 WRENCH, PIPE 5120-00-277-1485 SC 4910-95-CL-A74

Change 2 C-3
TM 9-2320-366-20-3

Section II. TOOLS IDENTIFICATION LIST (CONT)

(1) (2) (3) (4) (5)
ITEM NATIONAL
NUMBER ITEM NAME STOCK NUMBER PART NUMBER REFERENCE

57 WRENCH, STRAP, 5120-00-020-2947 A91C SC 4910-95-CL-A74

ADJUSTABLE
58 WRENCH, TORQUE, 0-175 lb- 5120-00-640-6364 1753LDF SC 4910-95-CL-A74
ft
59 WRENCH, TORQUE, 0-200 lb- 5120-00-853-4538 F2001 SC 4910-95-CL-A72
in.
59.1 WRENCH, TORQUE, 0-300 lb- 5120-00-776-1841 2163993 SC 4910-95-CL-A74
in.
60 WRENCH, TORQUE, 0-600 lb- 5120-00-221-7983 SW130-301 SC 4910-95-CL-A72
ft

C-4 Change 2
 TM 9-2320-366-20-3

APPENDIX D
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

Section I. INTRODUCTION

D-1. SCOPE

This appendix lists expendable and durable items that you will need to operate and maintain the MTV vehicle. This
listing is for information only and is not authority to requisition the listed items. These items are authorized to you by
CTA 50-970, Expendable/Durable Items (except medical, class V repair parts, and heraldic items), or CTA 8-100, Army
Medical Department Expendable/Durable Items.

D-2. EXPLANATION OF COLUMNS

a. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative
instructions to identify the item, e.g., "Oil, Lubricating (Item 25, Appendix D).

b. Column (2) - Level. This column identifies the lowest level of maintenance that requires the item.

c. Column (3) - National Stock Number. This is the national stock number assigned to the item which you can
use to requisition it.

d. Column (4) - Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part
Number. This provides the other information you need to identify the item.

e. Column (5) - Unit of Measure. This code shows the physical measurement or count of an item, such as gallon,
dozen, gross, etc.

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M

1 O 4730-00-248-9340 Adapter, Pipe to Tube (81343) 4-4 010103B ea

1.1 O 4730-01-453-9651 Adapter, Straight, Pipe to Boss (19207) ea
12421890-001
1.2 O 4730-01-457-4025 Adapter, Straight, Pipe to Tube (96906) ea
MS51503B4-4
1.3 O 4730-00-760-3525 Adapter, Straight, Tube to Boss (81361) C116-3-71 ea
2 O 8040-00-273-8717 Adhesive (81348) MMM-A-121 pt
3 O 8040-00-152-0063 Adhesive (81348) MMM-A-1617 TY3 bt
4 O 8040-01-250-3969 Adhesive (05972) 242 ea
5 O 8040-00-117-8510 Adhesive (71984) 3145 RTV Clear tu
6 O 8040-00-776-9602 Adhesive (73168) 80055-31 kt
7 O 8040-00-522-3429 Adhesive (81349) (MIL-A-46106) oz

Change 1 D-1
TM 9-2320-366-20-3

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (CONT)

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M
8 O 8040-00-118-2695 Adhesive (72799) RTV162 kt
9 O 8040-01-331-7473 Adhesive (81349) (MIL-A-46106 GP3TY1) tu
10 O 8040-01-331-7470 Adhesive (81349) MIL-A-46106 oz
5 oz tube
10.1 O 8040-01-446-7842 Adhesive (01139) RTV123 ca
10.2 O 8040-00-728-3088 Adhesive (78500) 1199-T-3842 kt
6 oz
11 C 6850-00-174-1806 Antifreeze, Arctic Type (81349) (MIL-A-11755) dr
55 gl drum
12 C Antifreeze, Multi-Engine Type (58536) dr
(A-A-52624A)
6850-01-441-3218 Type I (Green) – 1 gal gal
6850-01-441-3221 Type I (Green) - 5 gal co
6850-01-441-3257 Type II (Purple) - 5 gal co
13 O 8030-00-597-5367 Antiseize Compound (81349) (MIL-A-907) lb
13.1 O 5340-01-454-4336 Bracket, Angle (0FW39) 12421859-001 ea
14 O 5340-00-450-5718 Cap and Plug Set (19207) 10935405 ea
14.1 O 5340-01-423-0972 Clamp, Loop (18076) S630H-20 ea
14.2 O 5340-01-377-6171 Clamp, Loop (18076) 5630H-24 ea
15 O 6850-00-926-2275 Cleaning Compound, Windshield (81349) O-C-1901 bt
16 oz bottle
16 O 7920-00-044-9281 Cloth, Cleaning (81349) (MIL-C-85043) bx
17 O Corrosion Preventive Compound (81349)
(MIL-C-16173)
8030-00-062-6950 Grade 1 - 1 qt can qt
8030-01-149-1731 Grade 2 - 1 qt can qt
8030-00-837-6557 Grade 3 - 1 pt can pt
8030-00-903-0931 Grade 4 - 1 pt can pt
18 O 8030-00-033-4291 Corrosion Preventive Compound (81349) bt
(MIL-C-82594)
8 oz can
18.1 O 2540-01-460-8048 Cover, Seat, Vehicular (27797) WM1058 ea
18.2 O 2540-01-463-8394 Cover, Seat, Vehicular (0FW39) WM1059 ea
19 C 9150-00-024-9621 Damping Fluid (81348) VV-D-1078 pt
20 O 7520-01-209-1152 Dispenser, Pressure Sensitive Adhesive Tape ea
(75037) STD-0-9
20.1 O 4730-01-454-1233 Elbow, Pipe to Boss (19207) 12421891-001 ea
20.2 O 4730-00-863-9098 Elbow, Pipe to Tube (30780) 4VBTXB ea
21 O 5330-01-325-6993 Gasket Forming Compound (05972) 515 ea
21.1 O Gasket Maker, RTV Silicone (05972) 5699 ea

D-2 Change 2
 TM 9-2320-366-20-3

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (CONT)

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M
22 O Grease, Automotive and Artillery (GAA)
(81349) (MIL-G-10924)
9150-01-197-7688 2-1/4 oz tube tu
9150-01-197-7690 1.75 lb can cn
9150-01-197-7689 6.5 lb can cn
9150-01-197-7692 35 lb can cn
23 O 9150-00-180-6382 Grease, General Purpose (81349) MIL-T-24139 lb
6.5 lb can
24 O 9150-00-935-4018 Grease, Molybenum Disulfide (81349) ca
(MIL-G-21164)
24.1 O 4720-01-469-9208 Hose Assembly, Nonmetallic (0FW39) ea
12418004-002
24.2 O Hose Assembly (0FW39) 12421278-003 ea
24.3 O Hose Assembly (0FW39) 12421858-002 ea
24.4 O Hose Assembly (0FW39) 12421858-003 ea
24.5 O Hose Assembly (0FW39) 12421858-004 ea
24.6 O Hose Assembly (0FW39) 12421858-005 ea
24.7 O 4720-01-384-0995 Hose Assembly, Nonmetallic (19207) ea
12421858-006
24.8 O Hose Assembly (0FW39) 12421927-001 ea
24.9 O Hose Assembly (0FW39) 12421927-002 ea
24.10 O Hose Assembly (0FW39) 12421927-003 ea
24.11 O 4720-01-469-9266 Hose Assembly, Nonmetallic (0FW39) ea
12421927-004
24.12 O Hose Assembly (0FW39) 12421991 ea
24.13 O 4720-00-988-3842 Hose Assembly, Nonmetallic (50599) R25679-1 ea
25 C Hydraulic Fluid A (81349) (MIL-H-5606)
9150-00-252-6383 1 qt can cn
9150-00-223-4134 1 gl can cn
26 O 7510-00-145-0559 Ink, Marking Stencil (81349) (MIL-I-43553) oz
27 O 7510-01-386-0787 Inking Pad, Rubber Stamp (88001) 0603A ea
28 O 5970-01-100-4464 Insulating Compound, Electrical (08800) tu
RTV-102WHITE
28.1 O 5970-01-378-3018 Insulation Sleeving, Electrical (06090) lg
ATUM-1/4-0-4FT
29 O 5970-00-838-5951 Insulation Sleeving, Electrical (06090) ft
CRN3-16BLACK
29.1 O 5970-01-161-6796 Insulation Sleeving, Electrical (06090) M23053/4-302-0 ft
29.2 O 5970-00-767-0524 Insulation Sleeving, Electrical (81349) (MIL-1-23053/5 4 ea
in.

Change 2 D-3
TM 9-2320-366-20-3

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (CONT)

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M

30 O 1650-00-166-4834 Lockwire (90166) 68A32 ea

31 O 9150-01-360-1905 Lubricant, Solid Film (81349) (MIL-L-46147) cn
16 oz can
31.1 O Modification Kit, Junction Box 6-576-100041 ea
(12361)
32 O 4730-00-019-0608 Nipple, Pipe (81996) A2303-12-52PC102 ea
33 O 4730-00-825-7304 Nipple, Tube (96906) MS51501B4 ea
34 O 5310-00-059-4265 Nut, Plain, Hex (89346) 98881R1 ea
34.1 C Oil, Commercial Burner Fuel, Grade FO-1
(ASTM D396)
34.2 C Oil, Commercial Burner Fuel, Grade FO-2
(ASTM D396)
35 C Oil, Fuel, Diesel, DF-A Arctic (81348) (VV-F-800)
9140-00-286-5282 5 gl can cn
9140-00-286-5283 Bulk gl
9140-00-286-5284 55 gl drum, 16 gauge dr
9140-00-286-5285 55 gl drum, 18 gauge dr
36 C Oil, Fuel, Diesel, DF-1, Winter (81348) (VV-F-800)
9140-00-286-5286 Bulk gl
9140-00-286-5287 5 gl can cn
9140-00-286-5288 55 gl drum, 16 gauge dr
9140-00-286-5289 55 gl drum, 18 gauge dr
37 C Oil, Fuel, Diesel, DF-2, Regular (81348) (VV-F-800)
9140-00-286-5294 Bulk gl
9140-00-286-5295 Can cn
9140-00-286-5296 55 gl drum, 16 gauge dr
9140-00-286-5297 55 gl drum, 18 gauge dr
38 C Oil, Lubricating, Arctic (81349) (MIL-L-46167)
9150-00-402-2372 5 gl can cn
9150-00-491-7197 55 gl drum dr
39 C Oil, Lubricating, Gear, GO 75W (81349)
(MIL-L-2105)
9150-01-035-5390 1 qt can cn
9150-01-035-5391 5 gl can cn
40 C Oil, Lubricating, Gear, 80W-90 (81349)
(MIL-L-2105)
9150-01-035-5392 1 qt can qt
9150-01-035-5393 5 gl can cn
9150-01-035-5394 55 gl drum, 16 gauge dr

D-4 Change 1
 TM 9-2320-366-20-3

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (CONT)

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M

41 O Oil, Lubricating, Gear, 85W-140 (81349)

(MIL-L-2105)
9150-01-048-4591 1 qt can qt
9150-01-035-5395 5 gl can cn
9150-01-035-5396 55 gl drum dr
42 C Oil, Lubricating, OE/HDO 10 (81349) (MIL-L-2104)
9150-00-183-7807 Bulk gl
9150-00-186-6668 5 gl can cn
9150-00-191-2772 55 gl drum dr
43 C 9150-00-189-6727 Oil, Lubricating, OE/HDO 10W (81349) cn
(MIL-L-2104)
1 qt can
44 C Oil, Lubricating, OE/HDO 15W-40 (81349)
(MIL-L-2104)
9150-01-152-4117 1 qt can cn
9150-01-152-4118 5 gl can cn
9150-01-152-4119 55 gl drum dr
45 C Oil, Lubricating, OE/HDO 30 (SAE 30) (81349)
(MIL-L-2104)
9150-00-183-7808 Bulk gl
9150-00-186-6681 1 qt can cn
9150-00-188-9858 5 gl can cn
9150-00-189-6729 55 gl drum, 18 gauge dr
46 C Oil, Lubricating, OE/HDO 40 (81349) (MIL-L-2104)
9150-00-405-2987 Bulk gl
9150-00-189-6730 1 qt can cn
9150-00-188-9862 5 gl can cn
47 O 5350-00-067-7639 Paper, Abrasive (28124) 02347 pg
pg contains 100 sheets
48 O 8010-01-146-2650 Polyurethane Coating (81349) (MIL-C-46168) kt
49 O 8030-00-181-8372 Primer, Sealing Compound (05972) 747-56 cn
50 C 7920-00-205-1711 Rag, Wiping (64067) 7920-00-205-1711 be
50 lb bale
51 DELETED
52 O 4020-00-106-9342 Rope, Nylon (81349) (MIL-R-24050) ro
53 O 7520-00-634-2442 Rubber Stamp Set, Fixed Type (02663) ea
W-5-3/8-AZ SET
53.1 O 5305-01-299-4602 Screw, Cap, Hex Hd (64678) 000933 006058 ea
53.2 O 5305-01-454-5938 Screw, Cap, Hex Hd (19207) 12419954-093 ea
53.3 O 5305-00-021-3740 Screw, Cap, Hex Hd (97942) 645A560H43 ea

Change 1 D-5
TM 9-2320-366-20-3

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (CONT)

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M

54 O 5305-01-296-0019 Screw, Cap, Socket Head (06888) SHCM75275

50 ct box bx
54.1 O 8030-01-157-0988 Sealing Compound (83574) PR-1422 A-1/2
6 oz ca
54.2 O 8030-01-371-8405 Sealing Compound (83574) PR-1422 B-1/2
6 oz ca
55 O 8030-00-111-2762 Sealing Compound (05972) 290-31 bt
55.1 O 8030-01-255-4144 Sealant (19207) 12297953 tb
55.2 O 8030-00-956-2397 Sealing Compound 104 ea
55.3 O 8030-00-728-9665 Sealant (62377) 80017 pt
56 O 8030-00-133-3164 Sealing Compound (05972) 571-31 bt
57 O 8030-00-148-9833 Sealing Compound (05972) 271-21 bx
58 O 8030-00-204-9149 Sealing Compound (05972) 592-41 tu
59 O 8030-00-656-1426 Sealing Compound (81349) (MIL-S-45180) pt
60 O 8030-01-025-1692 Sealing Compound (05972) 242-41 (MIL-S-46163) bt
61 O 8030-01-088-8140 Sealing Compound (52571) 9001512-0011 bt
62 O 8030-01-155-3238 Sealing Compound (11083) 6V6640 ml
63 C 7930-00-634-3935 Soap, Laundry (81348) P-S-1792 lb
64 O 3439-00-006-7764 Solder, Tin Alloy (81348) SN63WRAP3
1 lb spool sl
65 C Solvent, Dry Cleaning SD (P-D-680)
6850-00-281-1985 1 gl can cn
6850-00-664-5685 1 qt can cn
65.1 O Strap, Tiedown, Electrical Components (06383) ea
PLP2S
65.2 O 9320-01-244-0046 Tape, Adhesive, Rubber (18876) MIS-41157-08 ro
180 ft
66 O 8030-00-889-3534 Tape, Antiseizing (81349) (MIL-T-27730) ea
67 O 5640-00-103-2254 Tape, Duct (39428) 1791K70 ea
68 O 5970-00-644-3167 Tape, Insulation, Electrical (80063) TL83 ro
68.1 O 4730-00-138-8050 Tee, Pipe (81343) 8-8-8 140424C ea
69 O 5975-01-379-4997 Ties, Cable, Plastic (06383) PLT 35-C-O hd
69.1 C Turbine Fuel, Aviation, Kerosene Type
(MIL-T-83133), Grade JP-8
69.2 C Turbine Fuel, (MIL-F-16884), (NATO Code No. F75 or F-
72)
9140-00-255-7764 5 gl can cn
9140-00-273-2378 55 gl drum dr
9140-00-273-2377 1 gl can cn

D-6 Change 2
 TM 9-2320-366-20-3

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (CONT)

(1) (2) (3) (4) (5)
Item National Stock
Number Level Number Description U/M

69.3 C Turbine Fuel, (MIL-F-5624), Grade JP-4 (NATO Code

No. F40)
9130-00-273-2380 Drum, 16 gage dr
69.4 C Turbine Fuel, (MIL-T-5624), Grade JP-5
(NATO Code No. F-44)
9130-01-305-5596 Bulk gl
9130-01-250-6353 Drum, 16 gage dr
70 O 8010-00-180-6343 Varnish, Oil (23667) 515320 pt
71 O Wire, Electrical (80009) 175-0825-00
6145-01-148-2263 50 ft ft
72 O Wire, Nonelectrical (96906) MS20995C47
9505-00-555-8648 5 lb spool sl

Change 1 D-7/(D-8 Blank)

 TM 9-2320-366-20-3

APPENDIX E
ILLUSTRATED LIST OF MANUFACTURED ITEMS

Section I. INTRODUCTION

E-1. INTRODUCTION

This appendix includes complete instructions for manufacturing or fabricating authorized items locally. All bulk materials
needed to manufacture an item are listed by part number or specification number. Figures are provided as needed. See
standards and specifications DoD-Std-00100D(AR) and ANSI Y14.5M1982 for required details.

Section II. MANUFACTURED ITEMS INDEX

ITEM NAME/PART NUMBER ITEM DESCRIPTION PARA NO.

Brake Adjusting Tool Support E-2
Brake Plunger Seal Driver E-3
Cab Support Tool E-4
Dump Body Lifting Bracket E-5
Headlight Adjustment Screen E-6
M1089 30K Winch Test Adapter E-7
M1089 Solenoid Test Adapter E-8
Relay Test Wire E-9
Transmission Auxiliary Oil Cooler
Rubber Seal E-10
Wheel Bearing Shim Tool Rest E-11
12414690-001 Pneumatic Tube E-12
12414690-002 Pneumatic Tube E-12
12414690-003 Pneumatic Tube E-12
12414690-004 Pneumatic Tube E-12
12414690-005 Pneumatic Tube E-12
12414690-006 Pneumatic Tube E-12
12414690-007 Pneumatic Tube E-12
12414690-008 Pneumatic Tube E-12
12414690-009 Pneumatic Tube E-12
12414690-010 Pneumatic Tube E-12
12414690-101 Pneumatic Tube E-12
12414690-102 Pneumatic Tube E-12
12414690-103 Pneumatic Tube E-12
12414690-104 Pneumatic Tube E-12
12414690-105 Pneumatic Tube E-12
12414690-106 Pneumatic Tube E-12
12414690-107 Pneumatic Tube E-12
12414690-108 Pneumatic Tube E-12
12414690-109 Pneumatic Tube E-12
12414690-112 Pneumatic Tube E-12
12414690-113 Pneumatic Tube E-12
12414690-115 Pneumatic Tube E-12
12414690-118 Pneumatic Tube E-12
12414690-120 Pneumatic Tube E-12
12414690-125 Pneumatic Tube E-12
12414690-128 Pneumatic Tube E-12
12414690-129 Pneumatic Tube E-12
12414690-130 Pneumatic Tube E-12

Change 1 E-1
TM 9-2320-366-20-3

Section II. MANUFACTURED ITEMS INDEX (CONT)

ITEM NAME/PART NUMBER ITEM DESCRIPTION PARA NO.

12414690-131 Pneumatic Tube E-12
12414690-132 Pneumatic Tube E-12
12414690-133 Pneumatic Tube E-12
12414690-134 Pneumatic Tube E-12
12414690-135 Pneumatic Tube E-12
12414690-136 Pneumatic Tube E-12
12414690-137 Pneumatic Tube E-12
12414690-138 Pneumatic Tube E-12
12414690-139 Pneumatic Tube E-12
12414690-140 Pneumatic Tube E-12
12414690-141 Pneumatic Tube E-12
12414690-142 Pneumatic Tube E-12
12414690-143 Pneumatic Tube E-12
12414690-144 Pneumatic Tube E-12
12414690-145 Pneumatic Tube E-12
12414690-146 Pneumatic Tube E-12
12414690-147 Pneumatic Tube E-12
12414690-148 Pneumatic Tube E-12
12414690-149 Pneumatic Tube E-12
12414690-150 Pneumatic Tube E-12
12414690-151 Pneumatic Tube E-12
12414690-152 Pneumatic Tube E-12
12414690-153 Pneumatic Tube E-12
12414690-154 Pneumatic Tube E-12
12414690-155 Pneumatic Tube E-12
12414690-156 Pneumatic Tube E-12
12414690-157 Pneumatic Tube E-12
12414690-158 Pneumatic Tube E-12
12414690-159 Pneumatic Tube E-12
12414690-160 Pneumatic Tube E-12
12414690-161 Pneumatic Tube E-12
12414690-162 Pneumatic Tube E-12
12414690-163 Pneumatic Tube E-12
12414690-164 Pneumatic Tube E-12
12414690-165 Pneumatic Tube E-12
12414690-166 Pneumatic Tube E-12
12414690-167 Pneumatic Tube E-12
12414690-168 Pneumatic Tube E-12
12414690-169 Pneumatic Tube E-12
12414690-201 Pneumatic Tube E-12
12414690-202 Pneumatic Tube E-12
12414690-203 Pneumatic Tube E-12
12414690-205 Pneumatic Tube E-12
12414690-206 Pneumatic Tube E-12
12414690-207 Pneumatic Tube E-12
12414690-208 Pneumatic Tube E-12
12414690-209 Pneumatic Tube E-12
12414690-210 Pneumatic Tube E-12
12414690-211 Pneumatic Tube E-12
12414690-212 Pneumatic Tube E-12
12414690-215 Pneumatic Tube E-12

E-2
 TM 9-2320-366-20-3

ITEM NAME/PART NUMBER ITEM DESCRIPTION PARA NO.

12414690-216 Pneumatic Tube E-12
12414690-217 Pneumatic Tube E-12
12414690-218 Pneumatic Tube E-12
12414690-219 Pneumatic Tube E-12
12414690-220 Pneumatic Tube E-12
12414690-221 Pneumatic Tube E-12
12414690-222 Pneumatic Tube E-12
12414690-223 Pneumatic Tube E-12
12414690-224 Pneumatic Tube E-12
12414690-225 Pneumatic Tube E-12
12414690-228 Pneumatic Tube E-12
12414690-229 Pneumatic Tube E-12
12414690-230 Pneumatic Tube E-12
12414690-231 Pneumatic Tube E-12
12414690-232 Pneumatic Tube E-12
12414690-233 Pneumatic Tube E-12
12414690-234 Pneumatic Tube E-12
12414690-235 Pneumatic Tube E-12
12414690-236 Pneumatic Tube E-12
12414690-237 Pneumatic Tube E-12
12414690-238 Pneumatic Tube E-12
12414690-239 Pneumatic Tube E-12
12414690-240 Pneumatic Tube E-12
12414690-241 Pneumatic Tube E-12
12414690-242 Pneumatic Tube E-12
12414690-243 Pneumatic Tube E-12
12414690-244 Pneumatic Tube E-12
12414690-245 Pneumatic Tube E-12
12414690-246 Pneumatic Tube E-12
12414690-247 Pneumatic Tube E-12
12414690-248 Pneumatic Tube E-12
12414690-249 Pneumatic Tube E-12
12414690-301 Pneumatic Tube E-12
12414690-302 Pneumatic Tube E-12
12414690-303 Pneumatic Tube E-12
12416381P1 Non-Metallic Electrical Cable Conduit E-13
12416381P10 Non-Metallic Electrical Cable Conduit E-13
12416381P11 Non-Metallic Electrical Cable Conduit E-13
12416381P12 Non-Metallic Electrical Cable Conduit E-13
12416381P13 Non-Metallic Electrical Cable Conduit E-13
12416381P14 Non-Metallic Electrical Cable Conduit E-13
12416381P15 Non-Metallic Electrical Cable Conduit E-13
12416381P16 Non-Metallic Electrical Cable Conduit E-13
12416381P17 Non-Metallic Electrical Cable Conduit E-13
12416381P2 Non-Metallic Electrical Cable Conduit E-13
12416381P20 Non-Metallic Electrical Cable Conduit E-13
12416381P21 Non-Metallic Electrical Cable Conduit E-13
12416381P22 Non-Metallic Electrical Cable Conduit E-13
12416381P23 Non-Metallic Electrical Cable Conduit E-13
12416381P26 Non-Metallic Electrical Cable Conduit E-13
12416381P3 Non-Metallic Electrical Cable Conduit E-13
12416381P30 Non-Metallic Electrical Cable Conduit E-13
12416381P32 Non-Metallic Electrical Cable Conduit E-13

E-3
TM 9-2320-366-20-3

Section II. MANUFACTURED ITEMS INDEX (CONT)

ITEM NAME/PART NUMBER ITEM DESCRIPTION PARA NO.

12416381P34 Non-Metallic Electrical Cable Conduit E-13
12416381P35 Non-Metallic Electrical Cable Conduit E-13
12416381P36 Non-Metallic Electrical Cable Conduit E-13
12416381P37 Non-Metallic Electrical Cable Conduit E-13
12416381P38 Non-Metallic Electrical Cable Conduit E-13
12416381P4 Non-Metallic Electrical Cable Conduit E-13
12416381P5 Non-Metallic Electrical Cable Conduit E-13
12416381P6 Non-Metallic Electrical Cable Conduit E-13
12416381P7 Non-Metallic Electrical Cable Conduit E-13
12416381P8 Non-Metallic Electrical Cable Conduit E-13
12416381P9 Non-Metallic Electrical Cable Conduit E-13
12418037 Steering Gear Return Hose E-14
12418460-001 Transmission Oil Cooler Hose E-14
12418460-002 Transmission Oil Cooler Hose E-14
12418763 Lanyard Assembly E-15
12420196 Lanyard Assembly E-15
12420197-001 Non-Metallic Vent Air Hose E-16
12420197-002 Non-Metallic Vent Air Hose E-16
12420197-003 Non-Metallic Vent Air Hose E-16
12420197-004 Non-Metallic Vent Air Hose E-16
12420197-005 Non-Metallic Vent Air Hose E-16
12420197-006 Non-Metallic Vent Air Hose E-16
12420198-001 Non-Metallic Vent Air Hose E-16
12420198-002 Non-Metallic Vent Air Hose E-16
12420308-457 Personnel Heater Air Duct Hose E-17
12420308-760 Personnel Heater Air Duct Hose E-17
12420489 Block Seal E-18
3256-H-1048 CTIS Seal Driver E-19
3256-K-1051 Wheel Hub Grease Seal Driver E-20
Dimmer Switch Test Wire E-21
Purge Valve Tool E-22
M1089 30K Winch Air Hoses E-23
M1089 30K Winch Pneumatic Test Adapter E-24

E-4 Change 1
 TM 9-2320-366-20-3

Section III. MANUFACTURED ITEMS

E-2. BRAKE ADJUSTING TOOL SUPPORT

Make the brake adjusting tool support from 0.134 in. (3.4 mm) flat steel stock according to the following instructions.
Refer to the parts list and Figure E-1. Brake Adjusting Tool Support for details.

Item Part Number Material Description Size Qty

1 N/A Steel, ASTM A569 Sheet, 6.0 in. (152.4 mm) x 6.0 in. (152.4 mm) x 0.134 2
Hot Rolled in. (3.4 cm)

Figure E-1. Brake Adjusting Tool Support

a. All dimensions are in inches (millimeters).

b. Cut steel sheet as shown by dimensions on Figure E-1. Brake Adjusting Tool Support.
c. De-burr and remove sharp edges.

Change 1 E-5
TM 9-2320-366-20-3

E-3. BRAKE PLUNGER SEAL DRIVER

Figure E-2. Brake Plunger Seal Driver

a. All dimensions are in inches (millimeters).

b. Manufacture from round steel stock.
c. De-burr and remove sharp edges.

E-6
 TM 9-2320-366-20-3

E-4. CAB SUPPORT TOOL

Make the cab support tool from .38 inch (.96 cm) flat steel stock and angle iron stock according to the following
instructions. Refer to the parts list and Figure E-3. Cab Support Tool Strut and Cab Rest for details.

Item Part Number Material Description Size Qty

1 N/A Steel, Flat Bar 4.0 in. (10.2 cm) X 33.38 in. X (84.8 cm) X 0.38 1
in. (0.96 cm)
2 N/A Steel, Flat Bar 4.0 in. (10.2 cm) X 12.0 in. (30.5 cm) X 0.38 in. 1
(0.96 cm)
3 N/A Angle Iron 2.0 in. (5.1 cm) X 2.0 in. (5.1 cm) X 3.5 in. (8.9 2
cm)
4 H.S.105VW-1 Insulgrip, CSA 105 C

Figure E-3. Cab Support Tool Strut and Cab Rest

a. All dimensions are in inches (centimeters).

b. Cut cab support tool strut (1) from steel flat bar and bend to shape as shown in Figure E-3. Cab Support Tool
Strut and Cab Rest.
c. Cut cab support tool cab rest (2) from steel flat bar.
d. De-burr and remove sharp edges.

E-7
TM 9-2320-366-20-3

E-4. CAB SUPPORT TOOL (CONT)

Figure E-4. Cab Support Tool Seat

e. Remove flange side of cab support tool seats (3) as shown in Figure E-4. Cab Support Tool Seat.
f. Cut cab support tool seats (3) L and (3) R according to dimensions and left\right orientation shown on Figure E-4.
Cab Support Tool Seat.
g. De-burr and remove sharp edges.

E-8
 TM 9-2320-366-20-3

Figure E-5. Cab Support Tool Seat Layout

h. Position and clamp cab support tool seats (3) L and (3) R together as shown by dimensions on Figure E-5. Cab
Support Tool Seat Layout.
i. Weld cab support tool seat (3) L to cab support tool seat (3) R as identified on assembly table and Figure E-5.
Cab Support Tool Seat Layout.
j. Position and clamp cab support tool seats (3) L and (3) R to cab support tool strut (1) as shown by dimensions
on Figure E-5. Cab Support Tool Seat Layout.
k. Weld items clamped in step (f) as shown in Figure E-5. Cab Support Tool Seat Layout.
l. De-burr and remove sharp edges.

E-9
TM 9-2320-366-20-3

E-4. CAB SUPPORT TOOL (CONT)

Figure E-6. Cab Support Tool Assembly

m. Position and clamp cab support tool strut (1) to cab support tool cab rest (2) as shown by dimensions on Figure
E-6. Cab Support Tool Assembly, before insulgrip (4) is applied.
n. Weld cab support tool strut (1) to cab support tool cab rest (2).
o. Apply Insulgrip (4) to cab support tool cab rest (2) as described on material container.

E-10
 TM 9-2320-366-20-3

E-5. DUMP BODY LIFTING BRACKET

Make the dump body lifting bracket assembly from the front, rear, top, guide, and mount plates according to the
following instructions. Refer to the parts list tables and accompanying figures for details.

Item Part Number Name/Description Qty

1 N/A Rear Plate 1
2 N/A Top Plate 1
3 N/A Front Plate 1
4 N/A Guide Brace 1
5 N/A Plate, Mounting 1

Figure E-7. Dump Body Lifting Bracket

a. All dimensions are in inches (centimeters).

b. Position and clamp pieces (1 through 5) together as shown by dimensions on Figure E-7. Dump Body Lifting
Bracket.
c. Weld pieces together as shown in Figure E-7. Dump Body Lifting Bracket.
d. Coat all surfaces with Plastisol.

E-11
TM 9-2320-366-20-3

E-5. DUMP BODY LIFTING BRACKET (CONT)

Item Part Number Material Description Size Qty

1 N/A Plate, steel, ASTM A-36 6.0 in. (15.2 cm) X 4.0 in. (10.2 cm) X 0.375 in. 1
(0.95 cm)
2 N/A Plate, steel, ASTM A-36 3.25 in. (8.26 cm) X 4.0 in. (10.2 cm) X 0.375 1
in. (0.95 cm)
4 N/A Plate, steel, ASTM A-36 1.875 in. (10.2 cm) X 4.0 in. (10.2 cm) X 0.375 1
in. (0.95 cm)

Figure E-8. Rear, Top, and Guide Plate

a. All dimensions are in inches (centimeters).

b. Fabricate (1),(2), and (4) from ASTM A-36 steel plate as shown on Figure E-8. Rear, Top, and Guide Plate.
c. De-burr and remove sharp edges.

E-12
 TM 9-2320-366-20-3

Item Part Number Material Description Size Qty

3 N/A Plate steel, ASTM A36 10.5 in. (26.7 cm) X 4.0 in. (10.2 cm) X 0.375 1
in. (0.95 cm)
5 N/A Plate steel, ASTM A36 5.25 in. (13.3 cm) X 4.0 in. (10.2 cm) X 0.375 1
in. (0.95 cm)

Figure E-9. Front and Mounting Plate

a. All dimensions are in inches (centimeters).

b. Fabricate (3) and (5) from ASTM A-36 steel plate.
c. Drill 1-1/2 inch (3.84 cm) diameter hoe in (5) as shown on Figure E-9. Front and Mounting Plate.
d. Grind bevel edge of each plate for weld surface as shown on Figure E-9. Front and Mounting Plate.
e. De-burr and remove sharp edges.

E-13
TM 9-2320-366-20-3

E-6. HEADLIGHT ADJUSTMENT SCREEN

The headlight adjustment screen may be drawn on any vertical surface at least 50 in. (127 cm) high and 100 in. (254
cm) wide.

a. Draw two vertical lines (1) 50 in. (127 cm) high and 90.6 in. (230 cm) apart (centered on headlight adjustment
screen).

b. Locate two points 40 in. (101.6 cm) from floor and 13 in. (33 cm) toward the center from each vertical line (1).

c. Draw vertical line (2) about 3-5 in. (8-13 cm) centered on each of the two points.

d. Draw horizontal line (3) about 3-5 in. (8-13 cm) centered on each of the two points.

e. Measure out 4 in. (10 cm) along each vertical line (2) and horizontal line (3) from each of the two points to make
8 in. (20 cm) squares (4).

Figure E-10. Headlight Adjustment Screen

E-14
 TM 9-2320-366-20-3

E-7. M1089 30K WINCH TEST ADAPTER

Assemble the M1089 30K winch test adapter according to the following steps. Refer to the following parts list and
Figure E-11. M1089 30K Winch Test Adapter for details.

Part Number Material Description National Stock Qty

Number
4-4-4 100401BA Tee, Tube 4730-01-095-3430 1
4-6 100102BA Adapter, Straight, Pipe to Tube 4730-01-096-9398 1
207P-4 Coupling, Pipe 4730-00-881-1161 1
NB-4-035 Tubing, Nonmetallic 4720-01-071-4042 4 in.
MIL-T-27730 Tape, Antiseizing 8030-00-889-3534 1 roll

Figure E-11. M1089 30K Winch Test Adapter

a. All dimensions are in inches (millimeters).

b. Cut two pieces of nonmetallic tubing (1 and 2) to 2.0 in. (50.8 mm) long.
c. Remove three nuts (3), sleeves (4), and ferrules (5) from tube tee (6).
d. Install two nuts (3), sleeves (4), and ferrules (5) on nonmetallic tubing (1).
e. Install nonmetallic tubing (1) on tube tee (6).
f. Remove nut (7), sleeve (8), and ferrule (9) from straight adapter (10).
g. Install two nuts (3 and 7), sleeves (4 and 8), and ferrules (5 and 9) on nonmetallic tubing (2).
h. Install nonmetallic tubing (2) on tube tee (6).
i. Install nut (9) on straight adapter (10).
j. Apply one wrap of antiseizing tape to threads of straight adapter (10).
k. Install pipe coupling (11) on straight adapter (10).

Change 1 E-15
TM 9-2320-366-20-3

E-8. M1089 SOLENOID TEST ADAPTER

Assemble the M1089 solenoid test adapter according to the following steps. Refer to the following parts list and Figure
E-12. M1089 Solenoid Test Adapter for details.

Part Number Material Description National Stock Qty

Number
2-2-2 080401CA Tee, Tube 4730-01-214-6990 1
2-2 080202CA Elbow, Pipe to Tube 4730-00-845-5345 1
4-2 130140B Bushing, Pipe 4730-00-828-0171 1
NB-2-031 Tubing, Nonmetallic 4720-01-287-4499 24 in.

Figure E-12. M1089 Solenoid Test Adapter

a. All dimensions are in inches (millimeters).

b. Cut one piece of nonmetallic tubing (1) to 6.0 in. (152.4 mm) long.
c. Cut one piece of nonmetallic tubing (2) to 18.0 in. (457.2 mm) long.
c. Remove three nuts (3) and ferrule sleeves (4) from tube tee (5).
d. Install two nuts (3) and ferrule sleeves (4) on nonmetallic tubing (1).
e. Install nonmetallic tubing (1) on tube tee (5).
f. Remove nut (6) and ferrule sleeve (7) from pipe to tube elbow (8).
g. Install two nuts (3 and 6) and ferrule sleeves (4 and 7) on nonmetallic tubing (2).
h. Install nonmetallic tubing (2) on tube tee (5).
i. Install nut (6) on pipe to tube elbow (8).
j. Install pipe bushing (9) on pipe to tube elbow (8).

E-16
 TM 9-2320-366-20-3

E-9. RELAY TEST WIRE

Fabricate the relay test wire according to the following steps. Refer to the following parts list for materials.

Material Description National Stock Cut Length

Number
Wire, Electrical (MIL-W-16878) 6145-00-330-3318 6 in. (152 mm)

a. Dimensions are in inches (millimeters).

b. Cut a length of wire six inches (152 mm) long.
c. Remove approximately 3/4 in. (19 mm) of electrical insulation from each end of wire.

E-10. TRANSMISSION AUXILIARY OIL COOLER RUBBER SEAL

Fabricate the transmission auxiliary oil cooler rubber seals in accordance with the following parts list.

Part Number Description National Stock Cut Length

Number inches mm
MIL-R-6130 Tape, Adhesive, Rubber 9320-00-501-7537 24.7 627

E-11. WHEEL BEARING SHIM TOOL REST

Fabricate the wheel bearing shim tool rest according to the following steps. Refer to the following parts list for
materials.

Part Number National Stock Number Description

QQ-T-570 9510-00-866-1037 Bar, Metal

a. Dimensions are in inches (millimeters)

b. Cut metal bar to 9.0 inches (228.6 mm) long.
c. De-burr and remove sharp edges from ends of metal bar.

E-12. PNEUMATIC TUBES FABRICATION

Cut pneumatic tubes from bulk tubing stock listed in Table E-1. Pneumatic Tube Lengths. Use a fine-toothed
hacksaw or suitable cutting device and cut tubing to required length.

Table E-1. Pneumatic Tube Lengths

Bulk Tubing Cut Length
Tube Part Part Number
Number inches cm

12414690-001 NT-100-4 (79470) 18.1 46.0

12414690-002 NT-100-4 (79470) 16.0 40.6
12414690-003 NT-100-4 (79470) 15.0 38.1
12414690-004 NT-100-4 (79470) 74.8 190.0
12414690-005 NT-100-4 (79470) 69.7 177.0

E-17
TM 9-2320-366-20-3

E-12. PNEUMATIC TUBES FABRICATION (CONT)

Table E-1. Pneumatic Tube Lengths (Cont)

Bulk Tubing Cut Length
Tube Part Part Number
Number inches cm

12414690-006 NT-100-4 (79470) 239.0 607.0

12414690-007 NT-100-4 (79470) 254.8 647.0
12414690-008 NT-100-4 (79470) 286.3 727.0
12414690-009 NT-100-4 (79470) 294.1 747.0
12414690-010 NT-100-4 (79470) 180.0 457.2
12414690-101 J844TYBSIZE 3/8 (81343) 18.0 45.7
12414690-102 J844TYBSIZE 3/8 (81343) 35.4 90.0
12414690-103 J844TYBSIZE 3/8 (81343) 20.9 53.0
12414690-104 J844TYBSIZE 3/8 (81343) 13.8 35.0
12414690-105 J844TYBSIZE 3/8 (81343) 11.8 30.0
12414690-106 J844TYBSIZE 3/8 (81343) 20.5 52.0
12414690-107 J844TYBSIZE 3/8 (81343) 39.0 99.0
12414690-108 J844TYBSIZE 3/8 (81343) 15.4 39.0
12414690-109 J844TYBSIZE 3/8 (81343) 23.0 58.4
12414690-112 J844TYBSIZE 3/8 (81343) 80.0 198.0
12414690-113 J844TYBSIZE 3/8 (81343) 11.4 29.0
12414690-115 J844TYBSIZE 3/8 (81343) 82.8 210.2
12414690-118 J844TYBSIZE 3/8 (81343) 11.8 30.0
12414690-120 J844TYBSIZE 3/8 (81343) 11.9 30.2
12414690-125 J844TYBSIZE 3/8 (81343) 10.8 27.3
12414690-128 J844TYBSIZE 3/8 (81343) 180.1 457.5
12414690-129 J844TYBSIZE 3/8 (81343) 39.3 99.7
12414690-130 J844TYBSIZE 3/8 (81343) 164.4 417.5
12414690-131 J844TYBSIZE 3/8 (81343) 180.1 457.5
12414690-132 J844TYBSIZE 3/8 (81343) 219.5 557.5
12414690-133 J844TYBSIZE 3/8 (81343)
12414690-134 J844TYBSIZE 3/8 (81343) 277.4 704.5
12414690-135 J844TYBSIZE 3/8 (81343) 325.0 825.5
12414690-136 J844TYBSIZE 3/8 (81343) 332.5 844.6
12414690-137 J844TYBSIZE 3/8 (81343) 51.0 129.5
12414690-138 J844TYBSIZE 3/8 (81343) 67.0 170.2
12414690-139 J844TYBSIZE 3/8 (81343) 98.5 250.2
12414690-140 J844TYBSIZE 3/8 (81343) 106.0 269.2
12414690-141 J844TYBSIZE 3/8 (81343) 52.5 133.4
12414690-142 J844TYBSIZE 3/8 (81343) 68.5 174.0
12414690-143 J844TYBSIZE 3/8 (81343) 100.0 254.0
12414690-144 J844TYBSIZE 3/8 (81343) 107.5 273.0

E-18
 TM 9-2320-366-20-3

Table E-1. Pneumatic Tube Lengths (Cont)

Bulk Tubing Cut Length
Tube Part Part Number
Number inches cm
12414690-145 J844TYBSIZE 3/8 (81343)
12414690-146 J844TYBSIZE 3/8 (81343) 267.3 679.0
12414690-147 J844TYBSIZE 3/8 (81343) 283.1 719.0
12414690-148 J844TYBSIZE 3/8 (81343) 314.6 799.0
12414690-149 J844TYBSIZE 3/8 (81343) 322.4 819.0
12414690-150 J844TYBSIZE 3/8 (81343) 296.1 752.0
12414690-151 J844TYBSIZE 3/8 (81343) 343.5 872.5
12414690-152 J844TYBSIZE 3/8 (81343) 36.0 91.5
12414690-153 J844TYBSIZE 3/8 (81343) 32.0 81.3
12414690-154 J844TYBSIZE 3/8 (81343) 48.0 122.0
12414690-155 J844TYBSIZE 3/8 (81343) 79.5 202.0
12414690-156 J844TYBSIZE 3/8 (81343) 87.0 221.0
12414690-157 J844TYBSIZE 3/8 (81343) 59.5 151.1
12414690-158 J844TYBSIZE 3/8 (81343) 66.5 169.0
12414690-159 J844TYBSIZE 3/8 (81343) 98.0 249.0
12414690-160 J844TYBSIZE 3/8 (81343) 105.5 268.0
12414690-161 J844TYBSIZE 3/8 (81343) 48.0 122.0
12414690-162 J844TYBSIZE 3/8 (81343) 36.0 91.5
12414690-163 J844TYBSIZE 3/8 (81343) 161.5 410.2
12414690-164 J844TYBSIZE 3/8 (81343) 120.0 304.8
12414690-165 J844TYBSIZE 3/8 (81343) 78.0 198.1
12414690-166 J844TYBSIZE 3/8 (81343) 108.0 274.3
12414690-167 J844TYBSIZE 3/8 (81343) 168.0 426.7
12414690-168 J844TYBSIZE 3/8 (81343) 108.0 274.3
12414690-169 J844TYBSIZE 3/8 (81343) 72.0 182.9
12414690-201 C608-100BLK (13174) 14.8 37.5
12414690-202 C608-100BLK (13174) 14.1 35.7
12414690-203 C608-100BLK (13174) 6.5 16.5
12414690-205 C608-100BLK (13174) 14.5 36.8
12414690-206 C608-100BLK (13174) 14.8 37.7
12414690-207 C608-100BLK (13174) 15.6 39.5
12414690-208 C608-100BLK (13174) 6.7 17.0
12414690-209 C608-100BLK (13174) 19.5 49.5
12414690-210 C608-100BLK (13174) 15.5 39.3
12414690-211 C608-100BLK (13174) 8.0 20.3
12414690-212 C608-100BLK (13174) 17.0 43.0
12414690-215 C608-100BLK (13174) 163.0 414.0
12414690-216 C608-100BLK (13174) 160.0 406.4
12414690-217 C608-100BLK (13174) 62.6 159.0

E-19
TM 9-2320-366-20-3

E-12. PNEUMATIC TUBES FABRICATION (CONT)

Table E-1. Pneumatic Tube Lengths (Cont)

Bulk Tubing Cut Length
Tube Part Part Number
Number inches cm
12414690-218 C608-100BLK (13174) 119.8 304.2
12414690-219 C608-100BLK (13174) 69.0 175.3
12414690-220 C608-100BLK (13174) 45.5 115.6
12414690-221 C608-100BLK (13174) 12.6 32.0
12414690-222 C608-100BLK (13174) 5.5 14.0
12414690-223 C608-100BLK (13174) 14.6 37.1
12414690-224 C608-100BLK (13174) 170.0 431.8
12414690-225 C608-100BLK (13174) 174.0 442.0
12414690-228 C608-100BLK (13174) 3.5 8.9
12414690-229 C608-100BLK (13174) 62.2 158.1
12414690-230 C608-100BLK (13174) 14.6 37.0
12414690-231 C608-100BLK (13174) 60.5 153.7
12414690-232 C608-100BLK (13174) 126.4 321.0
12414690-233 C608-100BLK (13174) 142.1 361.0
12414690-234 C608-100BLK (13174)
12414690-235 C608-100BLK (13174)
12414690-236 C608-100BLK (13174) 131.9 335.0
12414690-237 C608-100BLK (13174) 147.6 375.0
12414690-238 C608-100BLK (13174) 179.5 456.0
12414690-239 C608-100BLK (13174) 187.0 475.0
12414690-240 C608-100BLK (13174) 111.5 283.2
12414690-241 C608-100BLK (13174) 127.5 324.0
12414690-242 C608-100BLK (13174) 159.0 404.0
12414690-243 C608-100BLK (13174) 166.5 423.0
12414690-244 C608-100BLK (13174) 41.0 104.2
12414690-245 C608-100BLK (13174) 57.0 144.8
12414690-246 C608-100BLK (13174) 88.6 225.0
12414690-247 C608-100BLK (13174) 96.0 244.0
12414690-248 C608-100BLK (13174) 48.0 122.0
12414690-249 C608-100BLK (13174) 54.0 137.2
12414690-301 PFT-10B-BLK-100 (61424) 19.0 48.3
12414690-302 PFT-10B-BLK-100 (61424) 56.0 142.2
12414690-303 PFT-10B-BLK-100 (61424) 118.1 300.0

E-20
 TM 9-2320-366-20-3

E-13. NON-METALLIC ELECTRICAL CABLE CONDUIT FABRICATION

Make conduit to cover electrical cables described on 1241638 from bulk tube stock listed in Table E-2. Non-Metallic
Electrical Cable Conduit Lengths. Use a fine-toothed hacksaw or suitable cutting device and cut hose/tube to required
length.

Table E-2. Non-Metallic Electrical Cable Conduit Lengths

Cut Length
Tube Part Number Bulk Tube Part Number
inch cm
12416381P1 49008 8.9 22.6
12416381P10 49008 17.8 45.2
12416381P11 49008 29.9 75.9
12416381P12 49008 33.0 83.8
12416381P13 49008 13.9 35.3
12416381P14 49008 4.0 10.2
12416381P15 49008 17.4 44.2
12416381P16 49008 3.2 8.1
12416381P17 49008 4.5 11.4
12416381P2 49008 16.2 41.1
12416381P20 27413 32.8 83.3
12416381P21 27413 9.2 23.4
12416381P22 27413 8.0 20.3
12416381P23 27413 23.3 59.2
12416381P26 49008 2.5 6.4
12416381P3 27413 7.3 18.5
12416381P30 49007 17.0 43.2
12416381P32 49005 1.7 4.3
12416381P34 49005 20.7 52.6
12416381P35 49005 21.8 55.4
12416381P36 49005 5.5 14.0
12416381P37 49005 8.0 20.3
12416381P38 49008 3.7 9.4
12416381P4 49008 12.0 30.5
12416381P5 49008 26.0 66.0
12416381P6 49008 7.7 19.6
12416381P7 49008 26.7 67.8
12416381P8 49008 5.2 13.2
12416381P9 49008 16.8 42.7

E-21
TM 9-2320-366-20-3

E-14. STEERING GEAR RETURN HOSE AND TRANSMISSION OIL COOLER HOSES
FABRICATION

Cut the following hoses from bulk hose using a fine-toothed hacksaw or suitable cutting device.

Cut Length
Hose Part Number Bulk Hose Part Number inches cm
12418037 A110 (30327) 75.5 191.7
12418460-001 MS521302B110360 (96906) 17.5 44.4
12418460-002 MS521301A206R (96906) 16.0 40.6

E-15. LANYARD ASSEMBLIES P/N 12418763 AND 12420196 FABRICATION

Make the following lanyard assemblies from bulk cable material, sleeves, and tab material and assemble according to
Figure E-14. Lanyard Assembly. The following parts list identifies part numbers and lengths of cut pieces.

Item Part Number Material Description Size Qty

1 MIL-W-83420 Type 1, 1/16 in. stranded wire 4 in. (102 mm) 1
Comp B cable
2 MS51844-22 Sleeve 2
3 N/A Tab, Stainless Steel ASTM .06 in. (16 cm) X .37 in. (9.5 mm) X 1.25 1
A617 in. (32 mm)

E-22
 TM 9-2320-366-20-3

Figure E-14. Lanyard Assembly

a. All dimensions are in inches (millimeters).

b. Make from bulk cable and flat steel material as identified in parts list.
c. Drill two 0.19 in. (4.8 mm) diameter holes through tab material as shown on Figure E-14. Lanyard Assembly.
d. De-burr and remove sharp edges.
e. Bend tab as shown on Figure E-14. Lanyard Assembly.
f. Form loops on cable ends and insert sleeve material over cable on one end of cable and over cable and through
sleeve at other end of cable as shown in Figure E-14. Lanyard Assembly.
g. Crimp two sleeves over cable ends.

E-23
TM 9-2320-366-20-3

E-16. NON-METALLIC VENT AIR HOSES FABRICATION

Cut the following vent air hoses from bulk hose using a fine-toothed hacksaw or suitable cutting device.

Cut Length
Hose Part Number Bulk Hose Part Number inches cm
12420197-001 483666 (02280) 180.0 457.2
12420197-002 483666 (02280) 120.0 304.8
12420197-003 483666 (02280) 96.0 243.8
12420197-004 483666 (02280) 36.0 91.4
12420197-005 483666 (02280) 156.0 396.2
12420197-006 483666 (02280) 72.0 182.9
12420198-001 881-16 (98441) 120.0 304.8
12420198-002 11657469 36.0 91.4

E-17. PERSONNEL HEATER AIR DUCT HOSE FABRICATION

Cut the following hoses from bulk hose using a fine-toothed hacksaw or suitable cutting device.

Cut Length
Hose Part Number Bulk Hose Part Number inches cm
12420308-457 8711054 (19207) 18.3 46.4
12420308-760 8711054 (19207) 30.4 77.2

E-18. BLOCK SEAL 12420489 FABRICATION

Make block seal from P/N (0VXY8) STN2.38X.5. Use a suitable cutting tool to cut seal to 0.52 inch (1.3 cm) long.

E-24
 TM 9-2320-366-20-3

E-19. CTIS SEAL DRIVER 3256-H-1048

Used on Front, Intermediate, and Rear Axle CTIS Seals.

Figure E-15. CTIS Seal Driver

a. All dimensions are in inches (millimeters).

b. Manufacture from round steel stock.
c. De-burr and remove sharp edges.

E-25
TM 9-2320-366-20-3

E-20. WHEEL HUB GREASE SEAL DRIVER 3256-K-1051

Figure E-16. Wheel Hub Grease Seal Driver

a. All dimensions are in inches (millimeters).

b. Manufacture from round steel stock.
c. De-burr and remove sharp edges.

E-26
 TM 9-2320-366-20-3

E-21. DIMMER SWITCH TEST WIRE

Fabricate the dimmer switch test wire according to the following steps. Refer to the following parts list for materials.

Material Description National Stock Number Quantity Cut Length

Wire, Electrical 6145-01-229-4134 1 12 in (305 mm)

(M168678/14BKE9)

Pin, Grooved, Headless 5315-01-156-6314 1

(12258939-1)

Contact, Electrical 5999-01-150-8808 1

(12258939-2)

a. Dimensions are in inches (millimeters).

b. Cut a length of electrical wire approximately 12 in. (305 mm) long.
c. Remove approximately 1/4 in. (6 mm) of insulation from each end of electrical wire.
d. Crimp headless grooved pin on one end of electrical wire.
e. Crimp electrical contact on opposite end of electrical wire.

Change 1 E-27
TM 9-2320-366-20-3

E-22. PURGE VALVE TOOL

Fabricate Purge Valve Tool according to the following instructions. Refer to Figure E-17. Purge Valve Tool for details.

Item Part Number Material Description Size Qty

1 N/A Steel, ASTM A 108 or A576 Grade 1015-1025, BAR 14.0 in. (356 mm) 1
(Ref UNS G10150-G10250).
Finish Black Oxide Coat, Class I, IAW MIL-C-13924.

Figure E-17. Purge Valve Tool

a. All dimensions are in inches (cm).

b. Cut steel bar (1) and bend to shape as shown in Figure E-17.
c. Dimensional limits apply after coating.
d. All edges shall be broken and free from burrs.
e. Metal Stamp, electro etch, or engrave with the following marking IAW MIL-STD-130: 19207-12379968 MFR-19207.

E-28 Change 1
 TM 9-2320-366-20-3

E-23. M1089 30K WINCH AIR HOSES

Cut air hoses and convoluted tubing from bulk hose stock listed in Table E-3. M1089 30K Winch Air Hose Lengths and
Fittings. Use a fine-toothed hacksaw or suitable cutting device and cut air hoses and convoluted tubing to required
length.

Table E-3. M1089 30K Air Hose Lengths and Fittings

Convoluted
Hose Cut Tubing Cut
Length Bulk Length
Bulk Convoluted Fittings
Hose Name Fittings
Hose P/N in. mm Tubing P/N in. mm P/N
Qty.

Air Supply NB-4-035 96.0 2438 12420924-001 94.0 2388 4-100110B 2

4-100115B 2
63NTA-4 2

Manifold Supply NB-4-035 40.0 1016 12420924-001 38.0 965 4-100110B 2

4-100115B 2
63NTA-4 2

LH freespool NB-4-035 66.0 1676 12420924-001 64.0 1626 4-100110B 2

4-100115B 2
63NTA-4 2

RH freespool NB-4-035 48.0 1219 12420924-001 46.0 1168 4-100110B 2

4-100115B 2
63NTA-4 2

LH regulator NB-4-035 12.0 305 N/A N/A N/A 4-100110B 2

input 4-100115B 2
63NTA-4 2

RH regulator NB-4-035 12.0 305 N/A N/A N/A 4-100110B 2

input 4-100115B 2
63NTA-4 2

LH check valve NB-4-035 3.0 76 N/A N/A N/A 4-100110B 2

return 4-100115B 2
63NTA-4 2

RH check valve NB-4-035 3.0 76 N/A N/A N/A 4-100110B 2

return 4-100115B 2
63NTA-4 2

Front LH tension NB-4-035 48.0 1219 12420924-001 46.0 1168 4-100110B 2

supply 4-100115B 2
63NTA-4 2

Front RH tension NB-4-035 66.0 1676 12420924-001 64.0 1626 4-100110B 2

supply 4-100115B 2
63NTA-4 2

Change 1 E-29
TM 9-2320-366-20-3

Table E-3. M1089 30K Air Hose Lengths and Fittings (Cont)

Convoluted
Hose Cut Tubing Cut
Length Bulk Length
Bulk Convoluted Fittings
Hose Name Fittings
Hose P/N in. mm Tubing P/N in. mm P/N
Qty.

RH 30K winch NB-2-016 40.0 1016 N/A N/A N/A 2-2 1

supply 100102BA 1
2-2
100202BA

NB-2-016 40.0 1016 N/A N/A N/A 2-2 2

RH 30K winch 100102BA
return

Underlift fold NB-2-016 40.0 1016 N/A N/A N/A 2-2 1

supply 100102BA

Underlift fold NB-2-016 40.0 1016 N/A N/A N/A 2-2 1

return 100102BA 1
2-2
100202BA

Underlift supply NB-2-016 40.0 1016 N/A N/A N/A 2-2 2

100102BA

Underlift return NB-2-016 40.0 1016 N/A N/A N/A 2-2 1

100102BA 1
2-2
100202BA

Stinger supply NB-2-016 40.0 1016 N/A N/A N/A 2-2 2

100102BA

Stinger Return NB-2-016 40.0 1016 N/A N/A N/A 2-2 1

100102BA 1
2-2
100202BA

LH 30K Winch NB-2-016 40.0 1016 N/A N/A N/A 2-2 1

supply 100102BA 1
2-2
100202BA

LH 30K winch NB-2-016 40.0 1016 N/A N/A N/A 2-2 2

return 100102BA

E-30 Change 1
 TM 9-2320-366-20-3

E-24. M1089 30K WINCH PNEUMATIC TEST ADAPTER

Assembly the M1089 30K winch pneumatic test adapter to the following steps. Refer to the following parts list and
Figure E-18. M1089 30K Winch Pneumatic Test Adapter for details.

Part Number Material Description National Stock Number Qty.

NB-4-035 Tubing, Nonmetallic 4720-01-071-4042 14 in. (355.6 mm)

MIL-T-27730 Tape, antiseizing 8030-00-889-3534 1 roll

207P-4 Coupling, Pipe 4730-00-881-1161 1

4-6 100102 BA Adapter, Straight, Pipe to 4730-01-096-9398 1

Tube

4-4 100101 BA Nipple, Tube 4730-01-091-4012 1

Figure E-18. M1089 30K Winch Pneumatic Test Adapter

a. All dimensions are in inches (millimeter).

b. Cut piece of nonmetallic tubing (1) to 14.0 in. (355.6 mm).
c. Remove two nuts (2), ferrules (3), and sleeves (4) from tube nipple (5).
d. Install nut (2), ferrule (3), and sleeve (4) on nonmetallic tubing (1).
e. Install nonmetallic tubing (1) on tube nipple (5).
f. Remove nut (6), ferrule (7), and sleeve (8) from straight adapter (9).
g. Install nut (6), ferrule (7), and sleeve (8) on nonmetallic tubing (1).
h. Install nonmetallic tubing (1) on straight adapter (9).
i. Apply on wrap of antiseizing tape to threads of straight adapter (9).
j. Install pipe coupling (10) on straight adapter (9).
k. Retain nut (2), ferrule (3), and sleeve (4) for future use.

Change 1 E-31/(E-32 Blank)

 TM 9-2320-366-20-3

APPENDIX F
TORQUE LIMITS

F-1. GENERAL

This appendix provides general torque limits for screws and nuts used on the vehicle. Special torque limits are shown
in the maintenance procedures for applicable components. Use the general torque limit given in this appendix when
specific torque limits are not given in the maintenance procedure. These general torque limits can not be applied to
screws that retain rubber components. The rubber components will be damaged before the torque limit is reached.
If a special torque limit is not given in the maintenance instructions for a fastener which retains a rubber component,
tighten the screw or nut until it touches metal, then tighten one more turn. Whenever possible, the tightening force
(torque) should be applied to the nut side of the fastener group.

F-2. TORQUE LIMITS

Refer to Table F-1. Torque Limits for SAE and ANSI Fasteners for torque limits on standard (SAE and ANSI) screws
and free spinning nuts. Refer to Table F-2. Torque Limits for SAE and ANSI Prevailing Torque Nuts for torque
limits on standard (SAE and ANSI) self-locking nuts. Refer to Table F-3. Torque Limits for Metric Screws and Free
Spinning Nuts for torque limits on metric screws and free spinning nuts. Refer to Table F-4. Torque Limits for
Metric Prevailing Torque Nuts for torque limits on metric self-locking nuts.

F-3. USE OF TORQUE TABLES

(1) Measure the diameter of the screw to be installed.

(2) Count the number of threads per inch.

(3) Under the heading DIAMETER look down the column

until the diameter of the screw is found. (There are
usually two lines beginning with the same diameter.)

(4) Under the heading THREADS PER INCH (SAE and

ANSI) or THREAD PITCH (metric), find the number of
threads per inch that matches the number counted in
step (2).

(5) To find the grade of the screw, match the markings on

the head to the correct picture under CAPSCREW HEAD
MARKINGS on the torque table.

(6) Look down the column under the picture found in step
(5) until the torque limit (lb-ft or N·m) for the diameter
and threads per inch (or thread pitch, in the case of
metric fasteners) of the screw are located.

F-1
TM 9-2320-366-20-3

APPENDIX F
TORQUE LIMITS
Table F-1. Dry Torque Limits for SAE and ANSI Screws and Free Spinning Nuts

Material Grade Markings

NOTE
Manufacturer’s marks
may vary. These are all
SAE Grade 5.
SAE Grade 2 SAE Grade 5 SAE Grade 8

Diameter Threads Torque

per inch

inch lb-ft N·m lb-ft N·m lb-ft N·m

1/4 20 3-5 5-7 5-7 8-10 8-10 10-14

1/4 28 4-6 5-7 6-8 9-11 8-12 12-16

1/4 32 4-6 5-7 7-9 9-11 9-13 12-16

5/16 18 7-9 9-13 11-15 15-21 15-21 21-29

5/16 24 8-10 11-15 12-16 17-23 17-23 24-32

5/16 32 9-11 12-16 14-18 18-24 19-25 27-34

3/8 16 13-17 17-23 20-26 27-35 28-38 38-50

3/8 24 15-19 20-26 22-30 31-41 32-42 43-57

3/8 32 15-21 21-27 24-32 33-43 33-45 55-61

7/16 14 20-28 28-38 32-42 43-57 44-60 61-81

7/16 20 23-31 31-41 35-47 48-64 49-67 68-90

7/16 28 25-33 33-45 37-51 51-69 54-72 73-97

1/2 13 32-42 43-57 49-65 66-88 68-92 93-123

1/2 20 35-47 48-64 55-73 74-98 77-103 105-139

1/2 28 38-50 51-67 58-78 79-105 82-110 111-149

9/16 12 55-61 62-82 70-94 95-127 98-132 134-178

9/16 18 50-68 69-91 78-104 105-141 109-147 149-199

9/16 24 53-71 72-96 82-110 111-149 115-155 158-210

5/8 11 62-84 85-113 95-129 131-175 136-182 184-246

5/8 18 70-94 96-128 108-146 148-198 154-206 209-279

5/8 24 73-99 100-134 114-154 155-207 161-217 219-293

F-2
 TM 9-2320-366-20-3

Table F-1. Dry Torque Limits for SAE and ANSI Screws and Free Spinning Nuts (Cont)

Material Grade Markings

Manufacturer’s marks
may vary. These are all
SAE Grade 5
SAE Grade 2 SAE Grade 5 SAE Grade 8

Diameter Threads Torque

per inch

inch lb-ft N·m lb-ft N·m lb-ft N·m

11/16 24 99-133 135-181 153-207 209-279 217-291 296-394

3/4 10 110-148 150-200 171-229 232-310 240-324 328-438

3/4 16 123-165 168-224 190-256 259-345 269-361 366-488

3/4 20 127-171 174-232 197-265 268-358 278-374 379-505

13/16 20 252-340 345-459 357-481 487-649

7/8 9 275-369 374-498 387-521 528-704

7/8 14 303-407 413-551 427-575 583-777

7/8 20 319-429 435-579 450-606 614-818

15/16 20 395-531 538-718 558-750 760-1014

1 8 411-553 560-748 581-781 792-1056

1 12 450-606 614-818 636-856 867-1155

1 20 483-649 658-878 681-917 929-1239

1-1/16 18 576-776 782-1044 813-1095 1109-1479

1-1/8 7 507-683 693-923 824-1108 1123-1497

1-1/8 12 570-766 776-1034 923-1241 1258-1678

1-1/8 18 600-806 817-1089 971-1307 1324-1766

1-3/16 18 709-953 966-1288 1149-1545 1566-2088

1-1/4 7 716-964 976-1302 1161-1563 1584-2112

1-1/4 12 793-1067 1081-1441 1286-1730 1754-2338

1-1/4 18 831-1117 1132-1510 1346-1812 1835-2447

1-5/16 18 965-1299 1316-1754 1565-2105 2134-2846

1-3/8 6 939-1263 1281-1707 1523-2049 2076-2768

F-3
TM 9-2320-366-20-3

APPENDIX F
TORQUE LIMITS
Table F-2. Dry Torque Limits for SAE and ANSI Prevailing Torque Nuts
Material Grade Markings

SAE Grade 5 SAE Grade 8

Hole Threads Torque

Diameter per inch

inch lb-ft N·m lb-ft N·m

1/4 20 10-12 14-16 15-17 20-24

1/4 28 12-14 16-18 14-18 21-25

5/16 18 20-24 27-33 26-32 36-44

5/16 24 22-26 30-36 29-35 40-48

3/8 16 35-41 47-55 48-58 65-77

3/8 24 38-46 53-63 53-63 72-86

7/16 14 55-65 74-88 75-91 103-123

7/16 20 60-70 81-97 80-98 110-132

1/2 13 86-102 116-138 113-137 154-184

1/2 20 92-110 125-149 127-153 177-207

9/16 12 120-144 162-194 168-202 229-273

9/16 18 135-161 183-219 179-217 244-294

5/8 11 165-199 226-270 226-272 306-368

5/8 18 181-219 246-296 244-296 331-401

3/4 10 296-354 402-480 395-479 538-648

3/4 16 310-376 422-508 424-516 576-698

7/8 9 460-554 625-749 612-746 833-1009

7/8 14 503-607 684-822 652-800 888-1082

1 8 686-828 933-1121 941-1141 1280-1544

F-4
 TM 9-2320-366-20-3

Table F-3. Dry Torque Limits for Metric Screws and Free Spinning Nuts
Material Grade Markings

Metric Grade 4.8 Metric Grade 8.8 Metric Grade 10.9 Metric Grade 12.9

Diameter Thread Torque

Pitch
mm lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m

6 1 3 4-5 5-7 7-9 7-9 10-13 8-11 11-15

8 1.25 7-9 9-11 13-17 17-23 17-23 23-31 21-27 27-37

8 1 7-9 9-13 14-18 18-24 19-25 25-33 21-29 29-39

10 1.5 13-17 17-23 25-33 33-45 34-46 46-62 40-54 54-72

10 1.25 14-18 18-24 26-34 35-47 36-48 49-65 42-56 57-77

10 0.75 15-19 21-27 29-39 39-53 40-54 54-72 47-63 63-85

12 1.75 22-30 30-40 43-57 58-78 60-80 81-107 69-93 94-126

12 1.5 23-31 32-42 46-60 61-81 63-83 85-113 73-97 99-131

12 1.25 24-32 33-45 47-63 65-85 65-87 88-118 76-102 104-138

12 1 26-34 34-46 49-65 67-89 68-90 93-123 80-106 108-144

14 2 36-48 48-74 69-91 93-125 95-127 129-173 112-148 151-201

14 1.5 39-51 52-70 75-99 99-135 103-137 140-186 120-160 163-217

15 1 51-69 69-93 100-132 135-179 137-183 187-249 160-214 218-290

16 2 55-73 75-99 107-143 145-193 148-198 201-267 173-231 235-313

16 1.5 59-79 80-106 114-152 155-207 158-210 214-286 184-246 250-334

18 1.5 166-222 225-301 230-306 311-415 268-358 364-486

20 2.5 209-279 283-377 289-385 392-522 338-450 458-610

20 1.5 232-308 315-419 321-427 435-579 375-499 508-678

20 1 244-324 330-440 337-449 457-609 394-524 534-712

22 2.5 285-379 387-515 394-524 534-712 461-613 624-832

22 1.5 313-417 424-566 432-576 586-782 664-884 900-1200

24 3 361-481 489-653 499-665 677-903 584-778 791-1055

24 2 394-524 534-712 545-725 738-984 725-965 982-1310

25 1.5 467-621 633-843 645-859 875-1167 754-1004 1023-1363

F-5
TM 9-2320-366-20-3

APPENDIX F
TORQUE LIMITS
Table F-4. Dry Torque Limits for Metric Prevailing Torque Nuts
Material Grade Markings

Metric Grade 4.8 Metric Grade 8.8 Metric Grade 10.9 Metric Grade 12.9

Diameter Thread Torque

Pitch
mm lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m

6 1 5-6 7-8 7-9 10-12 10-12 14-17 11-14 15-19

8 1.25 12-14 16-18 18-22 24-30 24-30 32-40 27-33 36-46

8 1 12-14 16-20 19-23 25-31 25-31 34-42 28-36 38-48

10 1.5 21-25 28-34 33-41 44-56 44-56 60-76 50-64 68-86

10 1.25 21-25 29-35 34-42 46-58 46-58 63-79 53-67 71-91

10 0.75 23-27 31-37 37-47 49-63 50-64 68-86 57-73 77-99

12 1.75 33-41 46-56 55-69 74-94 75-95 102-128 85-109 115-147

12 1.5 35-43 47-57 56-72 77-97 78-98 106-134 89-113 120-152

12 1.25 36-44 48-60 58-74 79-101 81-103 109-139 91-117 125-159

12 1 37-45 50-62 61-77 82-104 84-106 114-144 95-121 129-165

14 2 53-65 72-88 87-109 117-149 118-150 160-204 134-172 182-232

14 1.5 57-69 76-94 92-116 125-159 126-160 171-217 143-183 194-248

16 2 79-97 107-131 130-166 177-225 178-228 243-309 204-262 277-355

16 1.5 82-102 112-138 138-176 187-239 189-241 256-328 215-277 292-376

18 1.5 197-253 267-343 271-347 367-471 309-399 420-542

20 2.5 248-318 337-431 342-438 464-594 391-503 530-682

20 1.5 271-349 369-473 374-480 507-651 428-552 580-750

20 1 283-365 384-494 390-502 529-681 447-577 606-784

22 2.5 335-429 455-583 460-592 624-802 526-680 714-922

22 1.5 363-467 492-634 499-643 676-872 730-950 990-1290

24 3 420-540 569-733 577-743 783-1009 662-856 897-1161

24 2 453-583 614-792 622-804 844-1090 803-1043 1088-1416

F-6
 TM 9-2320-366-20-3

Table F-5. Wet Torque Limits for SAE and ANSI Screws and Free Spinning Nuts

Material Grade Markings

NOTE
Manufacturer’s marks
may vary. These are all
SAE Grade 5.
SAE Grade 2 SAE Grade 5 SAE Grade 8

Diameter Threads Torque

per inch

inch lb-ft N·m lb-ft N·m lb-ft N·m

1/4 20 4 6 6 8 9 12

1/4 28 5 7 7 9 10 14

5/16 18 8 11 13 18 18 24

5/16 24 9 12 14 19 20 27

3/8 16 15 20 23 31 35 47

3/8 24 17 23 25 34 35 47

7/16 14 24 33 35 47 55 75

7/16 20 25 34 40 54 60 81

1/2 13 35 47 55 75 80 108

1/2 20 40 54 65 88 90 122

9/16 12 50 68 80 108 110 149

9/16 18 55 75 90 122 130 176

5/8 11 70 95 110 149 170 231

5/8 18 80 108 130 176 180 244

3/4 10 120 163 200 271 280 380

3/4 16 140 190 220 298 320 434

7/8 9 110 149 300 407 460 624

7/8 14 120 163 320 434 500 678

1 8 160 217 440 597 680 922

1 12 170 231 480 651 740 1003

1-1/8 7 220 298 600 814 960 1302

1-1/8 12 260 353 660 895 1080 1464

F-7
TM 9-2320-366-20-3

APPENDIX F
TORQUE LIMITS
Table F-5. Wet Torque Limits for SAE and ANSI Screws and Free Spinning Nuts (Cont)

Material Grade Markings

Manufacturer’s marks
may vary. These are all
SAE Grade 5
SAE Grade 2 SAE Grade 5 SAE Grade 8

Diameter Threads Torque

per inch

inch lb-ft N·m lb-ft N·m lb-ft N·m

1-1/4 7 320 434 840 1139 1360 1844

1-1/4 12 360 488 920 1248 1500 2034

1-3/8 6 420 570 1100 1492 1780 2414

1-3/8 12 460 624 1260 1709 2040 2766

F-8
 TM 9-2320-366-20-3

APPENDIX G
MANDATORY REPLACEMENT PARTS

Section I. INTRODUCTION

G-1. SCOPE

This appendix lists mandatory replacement parts you will need to maintain the MTV vehicle.

G-2. EXPLANATION OF COLUMNS

a. Column (1) - Item Number. This number is assigned to each entry in the listing and is
referenced in the Initial Setup of the applicable task under
Materials/Parts.

b. Column (2) - Nomenclature. Name or identification of the part.

c. Column (3) - Part Number. The manufacturer's part number.

d. Column (4) - National Stock Number. The National stock number of the part.

Section II. MANDATORY REPLACEMENT PARTS LIST

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

1 BLADE, WINDSHIELD WIPER 105.384 2540-01-364-1621

2 BOLT, MACHINE 12414307-065 5306-01-382-5054
3 BOOT KIT, EXHAUST DQ6025 4730-01-417-3197
4 BUMPER, NONMETALLIC 1011-05 5340-01-342-1110
5 BUMPER, RUBBER 12419182 5340-01-410-8397
6 BUSHING, SLEEVE 7-199-002668 3120-01-367-6894
7 CHANNEL, RUBBER ZZR765/2-001A7 9390-01-420-4560
8 CLAMP 12421183-005 4730-01-447-4312
9 CLAMP 12411183-006 4730-01-447-4313
9.1 CLAMP, WIRE ROPE, SADDLED MS51868-56 4030-00-042-7882
10 COVER, FLUID FILTER 12412628 2590-01-414-1243
11 DECAL 12340917 7690-01-256-4909
12 FASTENER TAPE MIL-F-21840 8315-00-006-9855
13 FASTENER TAPE 50-534718-19 8315-00-935-6762
14 FILTER ASSEMBLY 75223-11 2940-01-417-9333

Change 2 G-1
 TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

15 FILTER ELEMENT 1048011 2940-01-385-8931

16 FILTER ELEMENT, FLUID K05-0104 2910-01-377-3128
17 FILTER ELEMENT, FLUID R22146 2910-01-360-6366
17.1 FILTER ELEMENT, FLUID ST117073098-000 2910-01-467-4594
18 FILTER ELEMENT, FLUID 29507750 2940-01-361-2405
19 FILTER ELEMENT, FLUID 599791 4460-01-284-2344
20 FILTER ELEMENT, FLUID 931558 2940-01-363-4377
21 FILTER ELEMENT, INTAKE AIR CLEANER P52-7750 2940-01-361-2407
22 FILTER, FUEL 7E9763 2910-01-363-3089
23 FILTER, OIL 1R0739 2940-00-029-0388
24 GASKET F337576M6
25 GASKET M28840/24HA 5935-01-421-9754
26 GASKET QS-1181 5330-01-058-3788
27 GASKET 10-36675-18 5330-00-298-0190
27.1 GASKET 11446 5330-00-247-4174
28 GASKET 119-2940 5330-01-424-7905
29 GASKET 12412394 5330-01-371-6199
29.1 GASKET 12421155 5330-01-295-0115
29.2 GASKET 12421469 5330-01-453-2980
29.3 GASKET 3N4087 5330-01-061-8003
30 GASKET 350700 5330-01-295-3053
31 GASKET 350903 5330-00-576-4626
32 GASKET 352200 5330-01-421-6105
33 GASKET 352302 5330-01-421-6107
34 GASKET 353400 5330-01-421-6102
35 GASKET 353806 5330-01-421-6103
36 GASKET 353810 5330-01-450-6666
37 GASKET 355148 5330-01-423-0596
38 GASKET 355175 5330-01-423-0623
39 GASKET 3K3257 5330-01-305-6550
40 GASKET 4P1624 5330-01-360-5934

G-2 Change 1
 TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

41 GASKET 4W0549 5330-01-347-3207

42 GASKET 9Y8103 5330-01-360-5931
43 GASKET and PREFORMED PACKING KIT P4-4 5330-00-122-0624
43.1 GASKET and PREFORMED PACKING SET 9X8318 5330-01-360-9098
44 GASKET, FUEL FILTER 7C1159 5330-01-360-5941
45 NOT USED
46 GASKET, THERMOSTAT 2W7212 5330-01-347-3206
47 GROMMET, NONMETALLIC MS21266-3N 5325-00-926-1394
48 GROMMET, NONMETALLIC MS35489-109 5325-00-290-0074
49 GROMMET, NONMETALLIC MS35489-6 5325-00-263-6632
50 GROMMET, NONMETALLIC 12412334-2 9320-01-456-1672
51 GROMMET, NONMETALLIC 12417598 5325-01-375-1299
52 GROMMET, NONMETALLIC 12421402 5325-01-440-2178
53 GROMMET, NONMETALLIC 4082-37634-01 5325-01-194-3076
54 GROMMET, NONMETALLIC 50S12-1-1AA 5325-01-145-0105
55 GROMMET, NONMETALLIC 8741442 5325-00-088-6147
55.1 HEAD, FLUID FILTER 7632-002-144 2940-01-387-4397
56 INDICATOR, SIGHT, LIQUID SLT-1214 6680-01-356-8162
57 INSERT, NYLON 12SWS2520 5310-01-439-8881
58 INSERT, NYLON 12SWS2542 5310-01-439-8883
59 INSERT, NYLON 12421463-003 5310-01-453-2087
60 INSULATOR, TANK A1394J 5970-01-385-7317
61 INSULATOR, TANK A1394K 5970-01-385-7262
62 NOT USED
63 KIT, FILTER 29526899 5330-01-453-0770
64 KIT, FILTER 29503829
65 LAMP, INCANDESCENT CM7-7373 6240-00-270-6824
66 LAMP, INCANDESCENT CM7376 6240-00-499-6278
67 LATCH, BAIL HEAD 68-20-101-10 2540-01-232-2470
68 LOCKNUT 0770-023-003 5310-01-423-3725
69 LOCKWASHER ABCH207-LW-1/2
70 LOCKWASHER ABCH207-LW-3/8

Change 2 G-3
TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

71 LOCKWASHER D70336/1-20 5310-01-110-7933

72 LOCKWASHER D70336/3-50 5310-01-439-2542
73 LOCKWASHER D70336/3-52 5310-01-439-2543
73.1 LOCKWASHER ERNA245 5310-00-584-5272
74 LOCKWASHER MS35333-136 5310-01-078-9699
75 LOCKWASHER MS35333-78 5310-00-261-7156
76 LOCKWASHER MS35335-30 5310-00-209-0788
77 LOCKWASHER MS35335-31 5310-00-596-7693
78 LOCKWASHER MS35335-33 5310-00-209-0786
79 LOCKWASHER MS35335-36 5310-00-550-3503
80 LOCKWASHER MS35335-37 5310-00-209-5116
81 LOCKWASHER MS35335-38 5310-00-616-6354
82 LOCKWASHER MS35335-58 5310-00-209-1366
83 LOCKWASHER MS35335-61 5310-00-527-3634
84 LOCKWASHER MS35335-62 5310-00-184-9562
85 LOCKWASHER MS35337-25 5310-00-012-1637
86 LOCKWASHER MS35338-100 5310-00-261-8278
87 LOCKWASHER MS35338-103 5310-00-184-8971
88 LOCKWASHER MS35338-137 5310-00-933-8119
89 LOCKWASHER MS35338-138 5310-00-933-8120
90 LOCKWASHER MS35338-141 5310-00-984-7042
90.1 LOCKWASHER MS35338-147 5310-00-926-5871
91 LOCKWASHER MS35338-41 5310-00-045-4007
92 LOCKWASHER MS35338-42 5310-00-045-3299
93 LOCKWASHER MS35338-43 5310-00-045-3296
94 LOCKWASHER MS35338-44 5310-00-582-5965
95 LOCKWASHER MS35338-45 5310-00-407-9566
96 LOCKWASHER MS35338-46 5310-01-334-4710
97 LOCKWASHER MS35338-47 5310-00-209-0965
98 LOCKWASHER MS35338-51 5310-00-584-7888
99 LOCKWASHER MS35338-58 5310-00-702-6286
100 LOCKWASHER MS51414-1 5310-01-235-2057

G-4 Change 2
 TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

101 LOCKWASHER MS51414-2 5310-01-310-1098

102 LOCKWASHER MS51414-4 5310-01-251-9276
103 LOCKWASHER N9015 5310-01-046-0186
104 LOCKWASHER N9459 5310-01-348-8393
105 LOCKWASHER N9461 5310-01-348-8392
105.1 LOCKWASHER XP1113 5310-01-460-5991
105.2 LOCKWASHER 10241 5310-01-416-3010
105.3 LOCKWASHER 10030
106 LOCKWASHER 114021 5310-01-081-0798
107 LOCKWASHER 1229-S-513-C 5310-01-062-3384
108 LOCKWASHER 12412477-14
109 LOCKWASHER 12412601-02 5310-01-387-1152
110 LOCKWASHER 12414570-005 5310-01-452-9420
111 LOCKWASHER 12414570-011 5310-01-374-3292
112 LOCKWASHER 12414570-013 5310-01-374-4515
113 LOCKWASHER 12414570-015 5310-01-388-2043
113.1 LOCKWASHER 12414570-019 5310-01-470-2362
114 LOCKWASHER 12414570-021 5310-01-374-4516
115 NOT USED
116 NOT USED
117 NOT USED
118 LOCKWASHER 1729B262 5310-00-964-7811
119 NOT USED
120 MOUNT, RESILIENT 12413126 5340-01-439-3765
121 MOUNT, RESILIENT 12418476 5340-01-377-0693
122 NUT, CLIP MS90724-24 5310-01-074-5041
123 NUT, CONDUIT BL75 5975-00-642-7261
124 NUT, CONDUIT 141 5975-00-152-1075
125 NUT, CONDUIT 143 5975-00-714-8031
126 NUT, PLAIN, BLIND RIVET ALS7-632-80 5325-01-465-0001
127 NUT, PLAIN, HEX MS35649-282 5310-00-934-9757
127.1 NUT, PLAIN, ROUND 1727N40 5310-00-123-2572
128 NUT, SELF-LOCKING DIN-934STM6 5310-01-342-2739

Change 2 G-5
TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

129 NUT, SELF-LOCKING MS20500-524 5310-00-208-4023

130 NUT, SELF-LOCKING MS21042-04 5310-00-811-6419
130.1 NUT, SELF-LOCKING MS21045L5 5310-00-857-5559
131 NUT, SELF-LOCKING MS21083N08 5310-00-941-6019
132 NUT, SELF-LOCKING MS21083N6 5310-00-926-1852
133 NUT, SELF-LOCKING MS51922-1 5310-00-088-1251
134 NUT, SELF-LOCKING MS51922-17 5310-00-087-4652
135 NUT, SELF-LOCKING MS51922-2 5310-00-929-1807
136 NUT, SELF-LOCKING MS51922-33 5310-00-225-6993
137 NUT, SELF-LOCKING MS51922-49 5310-00-269-4040
138 NUT, SELF-LOCKING MS51922-5 5310-00-959-7600
139 NUT, SELF-LOCKING MS51922-57 5310-00-067-6356
140 NUT, SELF-LOCKING MS51922-65 5310-00-225-6992
141 NUT, SELF-LOCKING MS51922-9 5310-00-984-3806
142 NUT, SELF-LOCKING N9406 5310-01-362-6171
143 NUT, SELF-LOCKING N9410 5310-01-348-8398
143.1 NUT, SELF-LOCKING N9453 5310-01-348-8314
144 NUT, SELF-LOCKING N9467 5310-01-350-4257
144.1 NUT, SELF-LOCKING N9556 5310-01-423-0880
145 NUT, SELF-LOCKING 12301125 5310-01-210-0199
146 NUT, SELF-LOCKING 12412476-09 5310-01-445-6346
146.1 NUT, SELF-LOCKING 12411174-008
147 NUT, SELF-LOCKING 12412476-11 5310-01-407-7178
148 NUT, SELF-LOCKING 12412476-12
149 NUT, SELF-LOCKING 12412478-04 5310-01-381-9901
150 NUT, SELF-LOCKING 12414308-002 5310-01-381-9819
151 NUT, SELF-LOCKING 12414308-003 5310-01-377-1549
152 NUT, SELF-LOCKING 12414308-004 5310-01-369-5703
153 NUT, SELF-LOCKING 12414308-007 5310-01-369-6073
154 NUT, SELF-LOCKING 12414308-017 5310-01-381-9830
155 NUT, SELF-LOCKING 12414308-018 5310-01-369-3337
156 NUT, SELF-LOCKING 12414308-019 5310-01-369-9522

G-6 Change 2
 TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

157 NUT, SELF-LOCKING 12414308-020 5310-01-381-9849

158 NUT, SELF-LOCKING 12414308-021 5310-01-369-3338
159 NUT, SELF-LOCKING 12414308-022 5310-01-417-1262
160 NUT, SELF-LOCKING 12414308-023 5310-01-369-6705
161 NUT, SELF-LOCKING 12414308-025 5310-01-369-6706
162 NUT, SELF-LOCKING 12414308-027 5310-01-369-3339
163 NUT, SELF-LOCKING 12414308-078
164 NUT, SELF-LOCKING 12414315-002 5310-01-374-1381
165 NUT, SELF-LOCKING 12414315-003 5310-01-374-1382
166 NUT, SELF-LOCKING 12414315-005 5310-01-372-3023
167 NUT, SELF-LOCKING 12414315-006 5310-01-369-3332
168 NUT, SELF-LOCKING 12414315-009 5310-01-365-7236
169 NUT, SELF-LOCKING 12414315-015 5310-01-462-0580
170 NUT, SELF-LOCKING 12414315-017 5310-01-368-8065
171 NUT, SELF-LOCKING 12414420-004 5310-01-370-0010
172 NUT, SELF-LOCKING 12419003 5310-01-376-0773
173 NUT, SELF-LOCKING 29514660
174 NUT, SELF-LOCKING 7-660-081600 5310-01-390-8487
175 NUT, SELF-LOCKING 7-660-082504 5310-01-354-8734
176 NUT, SELF-LOCKING 7794625 5310-00-579-1031
177 NUT, SELF-LOCKING 7951286 5310-00-789-0398
178 PACKING, PREFORMED A82777 5330-00-579-6495
178.1 PACKING, PREFORMED F4001-16 5331-01-466-0354
179 PACKING, PREFORMED J515-16-3 5331-01-465-3634
180 PACKING, PREFORMED 5999807 5331-01-456-9156
181 PACKING, PREFORMED MS28775-011 5330-00-582-2133
181.1 PACKING, PREFORMED MS28775-910 5331-00-448-6753
182 PACKING, PREFORMED MS28778-10 5330-00-285-9842
183 PACKING, PREFORMED MS28778-12 5330-00-251-8839
184 PACKING, PREFORMED MS28778-16 5330-00-804-5694
185 PACKING, PREFORMED MS28778-20 5330-00-816-3546

Change 1 G-7
TM 9-2320-366-20-2

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

186 PACKING, PREFORMED MS28778-4 5330-00-805-2966

187 PACKING, PREFORMED MS28778-6 5330-00-804-5695
188 PACKING, PREFORMED MS9955-113 5330-01-374-2325
189 PACKING, PREFORMED M25988/1-246 5330-01-189-6351
189.1 PACKING, PREFORMED M83461/1-442 5330-01-183-0987
190 PACKING, PREFORMED OR420A 5330-01-389-6028
191 PACKING, PREFORMED 11639519-1 5330-00-463-0200
191.1 PACKING, PREFORMED 12422548-004 5331-01-059-1141
192 PACKING, PREFORMED 1509 5330-00-172-1919
192.1 PACKING, PREFORMED 195045 5331-00-618-5361
192.2 PACKING, PREFORMED 19755 5331-01-415-9632
192.3 PACKING, PREFORMED 198336 5331-00-584-1840
193 PACKING, PREFORMED 2-012N507-90 5330-01-092-5502
194 PACKING, PREFORMED 2-018N507-90 5330-01-092-5503
195 PACKING, PREFORMED 2M4453 5330-00-074-3768
196 PACKING, PREFORMED 22617-16 5330-01-168-0885
197 PACKING, PREFORMED 23043446 5330-01-424-6629
197.1 PACKING, PREFORMED 250192 5331-01-417-5105
197.2 PACKING, PREFORMED 251216 5330-01-417-5107
198 PACKING, PREFORMED 29500969 5330-01-360-7852
199 PACKING, PREFORMED 29503383 5330-01-360-6017
200 PACKING, PREFORMED 3-906N552-90 5330-01-104-1093
201 PACKING, PREFORMED 3-908N552-90 5330-00-929-8171
202 PACKING, PREFORMED 3D2824 5330-00-944-8281
203 PACKING, PREFORMED 3J1907 5330-01-333-6444
204 PACKING, PREFORMED 3J7354 5330-00-952-8008
205 PACKING, PREFORMED 3K0360 5330-00-948-6482
206 PACKING, PREFORMED 4J5477 5330-00-855-8059
207 PACKING, PREFORMED 4L9564 5330-00-828-8639
207.1 PACKING, PREFORMED 420828 5340-01-417-3788
208 PACKING, PREFORMED 5-X-1155 5330-01-392-1637
209 PACKING, PREFORMED 5F7054 5330-00-339-6224

G-8 Change 2
 TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

210 PACKING, PREFORMED 5P7813 5330-01-335-0042

211 PACKING, PREFORMED 6V8397 5330-00-579-6495
212 PACKING, PREFORMED 673268
213 PACKING, PREFORMED 673269 5330-01-395-1252
214 PACKING, PREFORMED 7F8267 5330-00-291-7353
215 PACKING, PREFORMED 7320658 5330-00-297-7106
216 PACKING, PREFORMED 9604792-001 5330-01-429-3089
217 PAD, CUSHIONING 12413120 2590-01-474-8307
218 PARTS KIT, DEHYDRATOR RN-60-A 4440-01-337-7324
219 PARTS KIT, HYDRAULIC PUMP P1-12RP 4320-00-125-3208
220 PARTS KIT, SEAL REPLACEMENT SK10-2 5330-01-350-4474
221 PARTS KIT, SEAL REPLACEMENT SK10-3 5330-01-350-4472
222 PARTS KIT, SEAL REPLACEMENT SK10-4 5330-01-343-2745
222.1 PARTS KIT, SEAL REPLACEMENT, SKD1VW 5330-01-309-2603
MECHANICAL
223 PIN, COTTER K-2412-Z 5315-01-179-9882
224 PIN, COTTER MS24665-151 5315-00-815-1405
225 PIN, COTTER MS24665-298 5315-00-234-1861
226 PIN, COTTER MS24665-385 5315-00-187-9382
227 PIN, COTTER MS24665-394 5315-00-234-1628
228 PIN, COTTER MS24665-423 5315-00-013-7228
229 PIN, COTTER MS24665-455 5315-00-187-9392
230 PIN, COTTER MS24665-457 5315-00-187-9393
231 PIN, COTTER MS24665-459 5315-00-187-9394
232 PIN, COTTER MS24665-494
233 PIN, COTTER MS24665-498 5315-00-849-9854
234 PIN, COTTER MS24665-628 5315-00-846-0126
235 PIN, COTTER MS24665-654 5315-00-187-9413
236 PIN, COTTER MS24665-69 5315-00-828-8190
236.1 PIN, COTTER XB-781-1 5315-01-369-1346
237 NOT USED
238 PIN, SPRING MS16562-142 5315-00-058-6115

Change 1 G-9
TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

239 PIN, SPRING MS16562-146 5315-00-853-3814

240 PLASTIC STRIP 352700 5330-01-396-2109
241 RECEPTACLE 50R4-1-1AA 5325-01-049-2049
241.1 REPAIR KIT, GOVERNOR RN32W
241.2 RETAINER, PACKING 11863-012 5330-01-417-7795
241.3 RETAINER, PACKING 202624 5330-01-417-7794
242 RETAINER A-1205-D-2344 5330-01-360-5253
243 RIVET, BLIND AD66H 5320-01-008-8204
243.1 RIVET, BLIND MS20601AD5W3 5320-00-582-3299
243.2 RIVET, BLIND MS20601B4W2 5320-00-616-5274
244 RIVET, BLIND MS20604B3W2 5320-00-721-9075
245 RIVET, BLIND M24243/1-B302 5320-00-999-0397
246 RIVET, BLIND M24243/1-B610 5320-00-454-5156
247 RIVET, BLIND M24243/1-D404 5320-00-865-8994
248 RIVET, BLIND M24243/1-D502 5320-00-850-3248
249 RIVET, BLIND M24243/1-D504 5320-01-020-9756
250 RIVET, BLIND M24243/1-D506 5320-00-850-3225
251 RIVET, BLIND M24243/1-D604 5320-00-850-3233
252 RIVET, BLIND M24243/1-D608 5320-00-850-3246
253 RIVET, BLIND M24243/1-D610 5320-01-030-3218
254 RIVET, BLIND M24243/1-F402 5320-00-129-9706
254.1 RIVET, BLIND M24243/1F608 5320-01-392-0699
254.2 RIVET, BLIND M24243/1F610
255 RIVET, BLIND M24243/6-A503H 5320-00-490-2238
256 RIVET, BLIND NAS1398C5A4 5320-00-321-2521
257 RIVET, BLIND SD64BSLF 5320-01-397-3347
258 RIVET, BLIND 206057 5320-01-411-0081
259 RIVET, COMPRESSION 12418469 5320-01-376-0699
260 RUBBER STRIP 12412581 9320-01-399-4888
260.1 SCREW, CAP CSH5-24-39 5305-01-479-7857
261 SCREW, CAP 12414475-131 5303-01-363-0703

G-10 Change 2
 TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER

262 SCREW, CAP 6V-2315 5306-01-433-4753

263 SCREW, SELF-LOCKING MS16998-61L 5305-01-211-3097
264 SEAL VC08G1R0B 5330-01-389-6109
265 SEAL 355150 5330-01-423-0689
266 SEAL ASSEMBLY, CTIS A1205-Q-2435 5330-01-360-7753
267 SEAL ASSEMBLY, HUB A1205-R-2254 5330-01-360-5252
268 SEAL RING, METAL 29505809 5330-01-360-5329
269 SEAL, NONMETALLIC CC3350 5330-01-431-7575
270 SEAL, NONMETALLIC 12417725 5330-01-375-2908
270.1 SEAL, NONMETALLIC 077032935 5330-01-387-2167
271 SEAL, NONMETALLIC 673999 5310-01-454-5553
271.1 SEAL, PLAIN N72143 5330-01-453-4462
271.2 SEAL, SHAFT SE-RUR25-2 5330-01-135-3376
272 SEAL, URETHANE FOAM 12420420-001 5680-01-453-8912
273 SEAL, URETHANE FOAM 12420420-002 5680-01-453-8485
274 SEAL, URETHANE FOAM 12420420-003 5680-01-453-8486
274.1 SEMICONDUCTOR DEVICE, DIODE JANTX1N3957 5961-00-181-0661
274.2 SPIDER, UNIVERSAL JOINT, VEHICULAR R279X
274.3 SPLICE, CONDUCTOR M7928/5-4 5940-01-079-1375
274.4 SPLICE, CONDUCTOR M83519/1-2 5940-01-136-2540
274.5 SPLICE, CONDUCTOR M83519/1-3 5940-01-135-7077
274.6 SPLICE, CONDUCTOR M83519/1-5 5940-01-135-7079
274.7 SPLICE, CONDUCTOR 12420927-001 5940-01-456-1319
275 SPLICE, CONDUCTOR 23035 5940-01-210-9261
276 SPLICE, CONDUCTOR 23075 3830-01-210-9260
276.1 SPACER 12422545 5365-01-490-6790
277 TERMINAL, LUG MS20659-163 5940-00-113-3145
278 TERMINAL, LUG MS20659-164 5940-00-113-3148
278.1 TERMINAL, LUG 12420344 5940-01-082-3321
279 TERMINAL, LUG MS25036-122 5940-00-113-8190
279.1 WASHER, FLAT 12414473-010 5310-01-374-6990
280 WASHER, FLAT 12417948-004 5365-01-436-8308

Change 2 G-11
TM 9-2320-366-20-3

Section II. MANDATORY REPLACEMENT PARTS LIST (CONT)

(1) (2) (3) (4)
ITEM NO. NOMENCLATURE PART NUMBER NATIONAL STOCK
NUMBER
280.1 WASHER, FLAT 251391 5310-01-417-1041
280.2 WASHER, FLAT 990 3861 5310-01-155-1911
281 WASHER, FLAT RUBBER 900.032 5330-01-378-7541
282 WASHER, KEY TW107 5310-01-014-5136
283 WASHER, NYLON MS51859-16 5310-01-381-9990
284 WASHER, NYLON 12421464-001
285 WASHER, NYLON 12421464-002 5310-01-445-6828
286 WASHER, SPRING D63474/1-30 5310-01-413-8475
287 WASHER, SPRING 110 7289 5310-01-246-1387
288 WASHER, SPRING 12414559-021 5310-01-374-4517
289 WASHER, SPRING 12414560-009 5310-01-333-5517
290 WASHER, SPRING 12414560-011 5310-01-421-9556
291 WASHER, SPRING 12414560-017 5310-01-395-0820
292 WASHER, SPRING 12414560-018 5310-01-381-3281
293 WASHER, SPRING 12414560-019 5310-01-369-6074
294 WASHER, SPRING 12417503 5310-01-406-6326
295 WASHER, SPRING 12418220 5310-01-372-3495
296 WASHER, SPRING 128BSTM4 5310-01-333-5517
297 WASHER, SPRING 12414560-009 5310-01-333-5517

G-12 Change 2
 TM 9-2320-366-20-3

APPENDIX H
LUBRICATION ORDER AND SERVICES

SECTION I. INTRODUCTION

H-1. GENERAL

The information contained in this appendix provides the lubrication/services requirements for the MTV vehicle.

a. Adherence. Intervals (on-condition or hardtime) and the related man-hour times are based on normal operation.
The man-hour time specified is the time needed to do all the services prescribed for a particular interval. On-
condition (OC) oil sample intervals will be applied unless changed by the Army Oil Analysis Program (AOAP)
laboratory. Change the hardtime interval if the lubricants are contaminated or if operating the equipment under
adverse operating conditions, including longer-than-usual operating hours. The calendar interval may be extended
during periods of low activity. If extended, adequate preservation precautions must be taken. Hardtime intervals
will be applied in the event AOAP laboratory support is not available. Hardtime intervals must be applied during
the warranty period.

Intervals shown in this lubrication order and services are based on mileage/calendar, and in some cases mileage alone.
An example of a mileage/calendar interval is: Q, which means every 3,000 miles (4,827 km) or quarterly (every three
months). The lubrication is to be performed at whichever interval occurs first for the vehicle. An example of a mileage
alone interval is: 6K, which stands for every 6,000 miles (9,654 km). The lubrication/services is to be performed at the
mileage indicated regardless of the calendar interval.

WARNING

• Dry Cleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in well-ventilated area; avoid contact with skin, eyes, and clothes, and do not breath
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for
Type I Dry Cleaning Solvent is 100 F (38 C) and for Type II is 138 F (50 C). Failure to comply
may result in serious injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and
medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts
eyes, immediately flush eyes with water and get medical attention. Failure to comply may
result in injury to personnel.

b. Cleaning fittings before lubricating. Clean parts with dry cleaning solvent (SD P-D-680) (Item 65, Appendix
D) or equivalent. Dry before lubricating. Dashed arrows indicate lubrication on both sides of the equipment.

c. Lubricating after fording. If fording occurs, lubricate all fittings below fording depth and check submerged
gearboxes for presence of water.

d. Lubricating after high-pressure washing. After a thorough washing, lubricate all grease fittings and oil can
points outside and underneath vehicle.

e. Level of Maintenance. The lowest level of maintenance authorized to lubricate a point is Operator/Unit
Maintenance (O). Operator/crew (C) may lubricate points authorized for Unit Maintenance (O) when authorized
by Unit Maintenance (O).

f. Localized views. A reference to the appropriate localized view is given after most lubrication entries. Localized
views begin on page H-13.

Change 2 H-1
TM 9-2320-366-20-3

H-1. GENERAL (CONT)

g. Interval Symbols. The lubrications/services interval symbols will be used as applicable:

Q-quarterly/3,000 mi (4,827 km) (whichever occurs first)

S-semiannually/6,000 mi (9,654 km) (whichever occurs first)
A-annually/12,000 mi (19,308 km) (whichever occurs first)
B-biennially/24,000 mi (38,616 km) (whichever occurs first)
3K-every 3,000 mi (4,827 km) (no calendar interval)
6K-every 6,000 mi (9,654 km) (no calendar interval)
12K-every 12,000 mi (19,308 km) (no calendar interval)
24K-every 24,000 mi (38,616 km) (no calendar interval)

H-2. OIL FILTERS

Oil filters shall be serviced/changed as applicable, when:

a. They are known to be contaminated, or clogged;

b. Service is recommended by AOAP laboratory analysis; or

c. At prescribed hardtime intervals while vehicle is under warranty, or if AOAP is not available/used as
required.

H-3. AOAP SAMPLING INTERVAL

WARNING

• Engine oil is hot and under pressure. The oil sampling valve releases oil proportionally to the
amount of pressure applied to valve. Activate oil sampling valve by pressing in slowly to
prevent injury to personnel. Failure to comply may result in injury to personnel.

• Wear safety goggles when taking oil sample. Oil is under pressure and could cause injury to
personnel. Failure to comply may result in injury to personnel.

Units participating in AOAP will sample engine oil every 3,000 miles (4,827 km) or 6 months, whichever occurs
first and change engine oil as directed by AOAP. Units participating in AOAP will sample transmission oil every
6,000 miles (9,654 km) or 12 months, whichever occurs first and change transmission oil as directed by AOAP.
Units participating in AOAP will sample hydraulic system oil initially after 6 weeks or 10 hours of operation,
whichever occurs first. After initial oil change samples should be taken every 12 months or 50 hours of operation,
whichever occurs first and change hydraulic oil as directed by AOAP.

H-4. WARRANTY HARDTIME STATEMENT

"For equipment under manufacturer's warranty, hardtime oil service intervals shall be followed. Intervals shall
be shortened if lubricants are known to be contaminated or if operation is under adverse conditions (such as
longer than usual operating hours, extended idling periods, extreme dust)."

H-2 Change 2
 TM 9-2320-366-20-3

SECTION II. LUBRICATION/SERVICES CHART

H-5. LUBRICATION/SERVICES KEY

LUBRICANTS
Specification Type
MIL-L-2104 Lubricating Oil, Internal Combustion Engine, Combat/Tactical
(OE/HDO) Service
MIL-L-46167 Lubricating Oil, Internal Combustion Engine, Arctic
(OEA)
MIL-L-2105 Lubricating Oil, Gear, Multipurpose
(GO)
MIL-G-10924 Grease, Automotive and Artillery
(GAA)
MIL-G-18458 Grease, Wire-Rope and Exposed Gear
(GW)
MIL-H-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance
(OHA)

DESCRIPTION CAPACITY EXPECTED TEMPERATURES

Above +40 F +40 F to -15 F -15 F to -50 F
(Above +4 C) (+4 C to -26 C) (-26 C to -46 C)
Engine crankcase 25 qt OE/HDO-15/40 OE/HDO-15/40 OEA
(24 L)
Transmission (total system) (all 49.3 qt OE/HDO-15/40 OE/HDO-10 OEA
models except M1088 and M1089) (46.7 L)
Transmission (at oil change) (all 36.8 qt OE/HDO-15/40 OE/HDO-10 OEA
models except M1088 and M1089) (34.7 L)
Transmission (total system) 58.6 qt OE/HDO-15/40 OE/HDO-10 OEA
(M1088 and M1089) (55.4 L)
Transmission (at oil change) 31.8 qt OE/HDO-15/40 OE/HDO-10 OEA
(M1088 and M1089) (30.0 L)
Transmission (after overhaul) 39.0 qt OE/HDO-15/40 OE/HDO-10 OEA
(37.0 L)
Steering system 5 qt OE/HDO-10 OE/HDO-10 OEA
(4.8 L)
Hydraulic reservoir 27 gal OE/HDO-10 OE/HDO-10 OEA
(except M1089) (102.2 L)
Hydraulic tank 74 gal OE/HDO-10 OE/HDO-10 OEA
(M1089) (280 L)
Front axle differential 9.5 qt GO-80/90 GO-80/90 SAE 75W90 OR
(maximum capacity) (9 L) GO-75
Intermediate axle 14.7 qt GO-80/90 GO-80/90 SAE 75W90 OR
differential (13.9 L) GO-75
(maximum capacity)
Rear axle differential 12.15 qt GO-80/90 GO-80/90 SAE 75W90 OR
(maximum capacity) (11.5 L) GO-75
Front axle planetary hubs 11-13 oz GO-80/90 GO-80/90 SAE 75W90 OR
(0.33-0.38 L) GO-75

Change 2 H-3
TM 9-2320-366-20-3

H-5. LUBRICATION/SERVICES KEY (CONT)

DESCRIPTION CAPACITY EXPECTED TEMPERATURES

Above +40 F +40 F to -15 F -15 F to -50 F
(Above +4 C) (+4 C to -26 C) (-26 C to -46 C)
Rear axle bogie 0.5 qt GO-85/140 GO-85/140 GO-85/140
(0.5 L)
15K Self-Recovery Winch (SRW) As Required GO-85/140 GO-80/90 GO-75
30K winches As Required GO-85/140 GO-80/90 GO-75
Propeller shaft universal and slip As Required GAA GAA GAA
joints
Tie rod ends As Required GAA GAA GAA
Towing pintle assembly As Required GAA GAA GAA
Fifth wheel As Required GAA GAA GAA
Spring bolts and spring shackles As Required GAA GAA GAA
Front axle shaft U-joints and As Required GAA GAA GAA
steering knuckles
Front axle inner wheel bearing As Required GAA GAA GAA
Intermediate axle inner wheel As Required GAA GAA GAA
bearing
Rear axle inner wheel bearing As Required GAA GAA GAA
Front lifting beam As Required GAA GAA GAA
15K Self-Recovery Winch (SRW) As Required GW GW GW
cable
30K winch cables As Required GW GW GW
Air/hydraulic power unit 3 pt OHA OHA OHA
(1.4 L)
Backup hydraulic pump 19 oz OHA OHA OHA
(562 ml)

COOLANT
Specification Type
A-A-52624A Antifreeze, Multi-Engine Type
MIL-A-11755 Antifreeze, Arctic-Type

DESCRIPTION CAPACITY EXPECTED TEMPERATURES

Above +40 F +40 F to -15 F -15 F to -50 F
(Above +4 C) (+4 C to -26 C) (-26 C to -46 C)
Cooling system 14 qt A-A-52624A A-A-52624A
(engine only) (13 L)
Cooling system 50.3 qt A-A-52624A A-A-52624A N/A
(total system) (47.6 L)
Cooling system 52.8 qt A-A-52624A A-A-52624A N/A
(total system) (49.9 L)
(M1088, M1089)
Cooling system, Arctic 64.8 qt N/A N/A MIL-A-11755
(total system) (61.3 L)
Cooling system, Arctic 76.5 qt N/A N/A MIL-A-11755
(total system) (72.4 L)
(M1088, M1089)

H-4 Change 2
 TM 9-2320-366-20-3

CLEANING AGENT
Specification Type
P-D-680 Dry Cleaning Solvent, SD-II
O-C-1901 Cleaning Compound, Windshield

EXPECTED TEMPERATURES
DESCRIPTION CAPACITY
Above +15 F +15 F to -15 F -15 F to -50 F
(Above -9 C) (-9 C to -26 C) (-26 C to -46 C)
All metal parts as required N/A SD-II (all temperatures)

Windshield washer 7.5 qt 2/3 water to 1/2 water to 1/3 water to

reservoir (7.1 L) 1/3 O-C-1901 1/2 O-C-1901 2/3 O-C-1901

For arctic operation refer to FM 9-207.

H-6. LUBRICATION/SERVICES INTERVALS

Intervals Total Man-Hours

Quarterly (Q) Lubrication performed once every three months or 3,000 mi. 2.0
(4,827 km).*
Semi-annually (S) Lubrication performed once every six months or 6,000 mi. 6.0
(9,654 km).*
Annually (A) Lubrication performed once every year or every 12,000 mi. 1.5
(19,308 km).*
Biennially (B) Lubrication performed once every two years or every 24,000 3.5
mi. (38,616 km).*
3K Lubrication performed once every 3,000 mi. (4,827 km).** 1.0
6K Lubrication performed once every 6,000 mi. (9,654 km).** 1.0
12K Lubrication performed once every 12,000 mi. (19,308 km).** 6.5
24K Lubrication performed once every 24,000 mi. (38,616 km).** 0.5

* Whichever occurs first.

** No calendar interval.

Change 2 H-5
TM 9-2320-366-20-3

H-7. LOCATOR VIEWS

LUBRICANT INTERVAL INTERVAL LUBRICANT

Engine Oil Filter (O)

Engine Crankcase
(See note 2 and view C)
Breather (O)
(See note 17 and view A)

Fuel Filter (O) Crankcase

(See note 6 and view A) Drain and Fill (O)
(See note 1 and views C
and D)

Fuel/Water Separator (O)

(See note 5 and view B) Front Axle Inner Wheel
Bearing
Repack (O)
(See note 27)

Cooling System (O) Power Steering Reservoir

(See note 7) Drain and Fill (O)
(See note 4 and view G)

Transmission Filter (O)

(See note 3 and view F) Power Steering Filter (O)
(See note 4 and view G)

Transmission
Drain and Fill (O)
(See note 3 and views D, Rear Axle Bogie
E, and F) Drain and Fill (O)
(See note 28 and view AG)

Intermediate Axle and

Rear Axle Inner Wheel
Bearing Repack (O)
(See note 27) 15K Self-Recovery Winch
(SRW) Cable Rear Roller
Fairlead
Towing Pintle Fill (O)
Fill (O) (See note 29 and views AE
(See note 16 and views J and AF)
and K)

CHASSIS

NOTE: Dashed arrows indicate lubrication on both sides of vehicle.

H-6 Change 2
 TM 9-2320-366-20-3

LUBRICANT INTERVAL INTERVAL LUBRICANT

Spring Bolt
Fill (O)
Spring Shackle
(See note 18 and view H)
Fill (O)
(See note 18 and view I)
Brake Wedge and Air
Tie Rod Ends Chamber (O)
Fill (O) (See note 21 and view L)
(See note 13 and view N)
Backup Hydraulic Pump
Drain and Fill (O)
Universal and Slip Joints (See note 10 and view R)
Fill (O)
(See note 9 and view P) Air/Hydraulic Power Unit
Drain and Fill (O)
(See note 10 and view S)
Battery Posts (O)
(See note 19 and view Q)

Air Dryer (O)

(See note 37 and view BB)

Universal and Slip Joints

Brake Wedge and Air
Fill (O)
Chamber (O)
(See note 9 and view P)
(See note 21 and view M)

Universal Joint and Slip

Joints
Fill (O)
(See note 9 and view P)

Brake Wedge and Air

Chamber (O)
(See note 21 and view M)

CHASSIS

NOTE: Dashed arrows indicate lubrication on both sides of vehicle.

H-7
TM 9-2320-366-20-3

H-7. LOCATOR VIEWS (CONT)

LUBRICANT INTERVAL INTERVAL LUBRICANT

Front Axle Front Axle

Check and Fill (O) Drain and Fill (O)
(See note 11 and view T) (See note 11 and view T)

Axle Shaft U-Joints Wheel End Planetary

Fill (O) Hubs
(See note 20 and view U) Drain and Fill (O)
(See note 12 and view V)
Steering Knuckles
Fill (O) Wheel End Planetary
(See note 20 and view U) Hubs
Check and Fill (O)
(See note 12 and view V)

Front Lifting Beam

Clean and Grease (O) 15K Self-Recovery Winch
(See note 36 and view AI) (SRW) Cable
Fill (O)
(See note 14 and view W)

Hydraulic Reservoir and 15K Self-Recovery Winch

Filter (SRW)
Drain and Fill (O) Check and Fill (O)
(See note 8 and view X) (See note 15 and view Y)

Intermediate Axle Screen 15K Self-Recovery Winch

and Plug Oil Filter (SRW)
Assembly Drain and Fill (O)
Clean (O) (See note 15 and view Y)
(See note 31 and view AH)

Intermediate Axle
Check and Fill (O) Intermediate Axle
(See note 11 and view T) Drain and Fill (O)
(See note 11 and view T)

Rear Axle
Check and Fill (O) Rear Axle
(See note 11 and view T) Drain and Fill (O)
(See note 11 and view T)

CHASSIS

NOTE: Dashed arrows indicate lubrication on both sides of vehicle.

H-8 Change 2
 TM 9-2320-366-20-3

LUBRICANT INTERVAL INTERVAL LUBRICANT

15K Self-Recovery Winch

(SRW) Cable Front Roller
Fairlead
Fill (O)
(See note 29 and views Z
and AA)

Hydraulic Tank and Filter

Drain and Fill (O)
(See note 22 and view AD)

30K Winch Cable

Fill (O)
(See note 14 and view AB)

30K Winch Cable Guide

Rollers
Fill (O)
(See note 30 and view AB)

Pay-Out Assembly Lower

Tension Sheave
Fill (O)
(See note 30 and view BA) 30K Winch Cable Guide
Rollers
Fill (O)
(See note 30 and view AC)

M1089

NOTE: Dashed arrows indicate lubrication on both sides of vehicle.

H-9
TM 9-2320-366-20-1

H-7. LOCATOR VIEWS (CONT)

Erection Cylinder and

Tension Link Pivots
Fill (O) Turntable Bearing and
(See note 34 and view AL) Pinion Gear Teeth
Fill (O)
Lift Cylinder Pivots (See note 26 and view AM)
Fill (O)
(See note 34 and view AJ) Hoist
Check and Fill (O)
(See note 24 and view AN)
Erection Cylinder Pivots
Fill (O) Hook Block Sheave
(See note 34 and view AK) Fill (O)
(See note 34 and view AO)

Tension Link Pivots Boom Wear Pads

Fill Fill (O)
(See note 34 and view AL) (See note 23)

Tension Links
Grease (O)
(See note 38 and view BC)

Turntable Bearing
Fill (O)
(See note 32 and view AP)
Boom Sheave
Turntable Gearbox Fill (O)
Check and Fill (O) (See note 34 and view AR)
(See note 25 and view AQ)

Hoist Cable Top and Bottom Plate

Fill (O) Fill (O)
(See note 14) (See note 33)

M1089 MATERIAL HANDLING CRANE (MHC)

NOTE: Dashed arrows indicate lubrication on both sides of vehicle.

H-10 Change 2
 TM 9-2320-366-20-3

LUBRICANT INTERVAL INTERVAL LUBRICANT

Hoist
Check and Fill (O) Lift Cylinder Pivots
(See note 24 and view AS) Fill (O)
(See note 34 and view AV)

Erection Cylinder and

Boom Wear Pads Tension Link Pivots
Fill (O) Fill (O)
(See note 23) (See note 34 and view AW)

Boom Sheave Erection Cylinder and

Fill (O) Tension Link Pivots
(See note 34 and view AT) Fill (O)
(See note 34 and view AX)

Tension Link
Grease (O)
(See note 38 and view BC)

Hoist Cable Turntable Bearing and

Fill (O) Pinion Gear Teeth
(See note 14) Fill (O)
(See note 26 and view AY)
Turntable Gearbox
Check and Fill (O) Turntable Bearing
(See note 25 and view AU) Fill (O)
(See note 32 and view AZ)

M1084/M1086 MATERIAL HANDLING CRANE (MHC)

NOTE: Dashed arrows indicate lubrication on both sides of vehicle.

Change 1 H-11
TM 9-2320-366-20-1

H-7. LOCATOR VIEWS (CONT)

LUBRICANT INTERVAL INTERVAL LUBRICANT

Camlock Assembly
Fill (O)
(See note 35)

Left and Right Lift

Cylinder Pivots
Fill (O)
(See note 35)

Crossbar Bushing
Fill (O)
(See note 35)
Left and Right Lower Arm
Pivots
Fill (O)
(See note 35)

M1089 UNDERLIFT ASSEMBLY

NOTE: Dashed arrows indicate lubrication on both sides of vehicle

H-12 Change 2
 TM 9-2320-366-20-1

H-8. LOCAL VIEWS

Change 2 H-13
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-14 Change 2
TM 9-2320-366-20-3

H-15
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-16 Change 2
TM 9-2320-366-20-3

H-17
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-18 Change 2
TM 9-2320-366-20-1

Change 2 H-19
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-20 Change 2
 TM 9-2320-366-20-3

Change 1 H-21
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-22 Change 2
TM 9-2320-366-20-3

H-23
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-24 Change 2
TM 9-2320-366-20-3

H-25
TM 9-2320-366-20-1

H-8. LOCAL VIEWS (CONT)

H-9. LUBRICATION/SERVICES NOTES

1. ENGINE CRANKCASE. Check engine oil level daily. Change engine oil at initial 5,000 miles (8,045 km).
During the remainder of the 12,000 mile (19,308 km)/18 month warranty period. Units participating in AOAP will
sample engine oil every 3,000 miles (4,827 km) or 6 months, whichever occurs first and change oil as directed by
AOAP. Units not participating in AOAP, will change engine oil every 6,000 miles (9,654 km) or every six months,
whichever occurs first. After expiration of engine warranty period, Units participating in AOAP will perform engine oil
change as directed by AOAP. Units not participating in AOAP will change engine oil every 6,000 miles (9,654 km) or
every six months, whichever occurs first, or when operating in dusty areas or under severe operating conditions,
change the oil every 3,000 miles (4,827 km) or every three months, whichever occurs first. Drain engine oil when
engine is warm. Refill engine crankcase with OE/HDO specified for the ambient temperature. Engine oil is full when
level is within crosshatch marks on the dipstick. Do not overfill.

2. ENGINE OIL FILTER. Filter is replaced each time the crankcase is drained. If water or metal particles are
detected during oil filter replacement, notify Direct Support Maintenance personnel before refilling crankcase (para 3-
4).

3. TRANSMISSION. Check transmission oil level daily. Change transmission oil at initial 5,000 miles (8,045 km).
During the remainder of the 24 month/unlimited mileage warranty. Units participating in AOAP will sample
transmission oil every 6,000 miles (9,654 km) or 12 months, whichever occurs first and change oil as directed by
AOAP. Units not participating in AOAP will perform transmission oil change every 24,000 miles (38,616 km) or once
every two years, whichever occurs first. Drain transmission oil when engine is warm. Refill with OE/HDO specified
for ambient temperature. Add oil until the proper level is reached (TM 9-2320-366-10-1). Do not overfill. Replace
oil filters each time transmission oil is changed (para 8-9).

4. POWER STEERING. Check power steering oil level weekly. Change the oil every 24,000 miles (38,616 km).
Disconnect upper and lower hoses from steering gear and drain oil. Refill power steering pump reservoir with
OE/HDO specified for the ambient temperature. Reservoir is full when oil is between the two marks on the dipstick.
Do not overfill. Remove dipstick, wipe clean and install dipstick fully into reservoir. Remove dipstick and read oil
level. Replace oil filter each time power steering oil is changed (para 13-8).

H-26 Change 2
 TM 9-2320-366-20-3

5. FUEL/WATER SEPARATOR. Replace filter element every 6,000 miles (9,654 km) or once every six months,
whichever occurs first (para 4-13).

6. FUEL FILTER. The fuel particle filter is replaced when a new fuel/water separator filter element is installed. The
normal replacement interval is every 6,000 miles (9,654 km) or once every six months, whichever occurs first (para 4-14).

7. ENGINE COOLANT. Check engine coolant level daily. Change the coolant and flush the cooling system every
24,000 miles (38,616 km) or once every two years, whichever occurs first. Fill radiator overflow tank with an Ethylene
Glycol/water mixture as specified in 0-A-548D. Service the cooling system before the specified interval if:

• Coolant is heavily contaminated.

• Engine overheats.
• Oil cooler has failed allowing oil and coolant to mix.

8. HYDRAULIC RESERVOIR AND FILTER (All Models Except M1089). Check oil level weekly and make sure oil
level gage reads F (full). Units participating in AOAP will sample oil annually and change oil and filter as directed by
AOAP. Units not participating in AOAP will change oil and filter every two years. Drain oil and refill hydraulic reservoir
with OE/HDO specified for ambient operating temperature. Fill hydraulic reservoir until oil level gage reads F (full). Do
not overfill. Replace oil filter each time oil is changed (para 19-13).

9. DRIVE SHAFT UNIVERSAL and SLIP YOKE.

Lubricate drive shafts with GAA every 3,000 miles (4,827 km) or once every three months, whichever occurs first, using a
low pressure lubrication gun. If operating conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once
every month, whichever occurs first. Perform drive shaft hinging inspection every time drive shafts are serviced (para 9-
3).

• UNIVERSAL JOINT:
A. Apply grease to both grease fittings until new grease purges from all four bearing caps.
B. If grease does not purge from all four bearing caps, perform the following steps:
(1) Loosen two screws on bearing cap that does not purge, approximately 1/4 in.
(2) Apply grease to grease fitting for bearing cap that does not purge until bearing cap purges.
(3) Remove and discard the two screws loosened in step (1).
(4) Position two replacement screws in bearing cap and tighten down evenly.
(5) Tighten two screws to 26-35 lb-ft (35-47 N m).

• SLIP JOINT:
A. Apply grease until grease appears at the vent in the welch plug.
B. Place your finger over the welch plug vent and add grease until grease purges from the dust seal.
C. If grease does not purge from the dust seal, inspect drive shaft slip yoke (para 9-2).

10. AIR/HYDRAULIC POWER UNIT and BACKUP HYDRAULIC PUMP. Change OHA oil every 24,000 miles (38,616
km) or once every two years, whichever occurs first. To service air/hydraulic power unit and backup hydraulic pump refer
to vehicle para 19-8, Air Transportability Hydraulic System Service.

11. ALL AXLE DIFFERENTIALS. Check oil level in differentials every 3,000 miles (4,827 km). Check oil level with
vehicle parked on level surface and axle differential at ambient temperature, allowing at least one hour to cool down after
vehicle operation. If oil is checked when axle differential is hot, it is normal for oil to spill out of the port due to expansion
from the heat. Oil level is considered full if it is within one inch of the bottom of the fill port. If oil spills from the fill port
when the axle differential is cool, it is overfull. Allow oil to drain until no more drains out. If the oil level is more than one
inch below the bottom of the fill port, refill axle differential with GO specified for the ambient temperature until level with
bottom of fill port. Change the oil every 24,000 miles (38,616 km) or once every two years, whichever occurs first. Drain
oil when hot after operation.

Change 2 H-27
TM 9-2320-366-20-3

H-9. LUBRICATION/SERVICES NOTES (CONT)

12. FRONT AXLE WHEEL END PLANETARY HUBS. There are two lube intervals for the front axle wheel end planetary
hubs.

a. Check and fill front axle wheel end planetary hubs every 3,000 miles (4,827 km) or once every three months,
whichever occurs first, as follows:

(1) Position vehicle on a level surface. Allow 15 minutes for vehicle to cool before checking oil levels.
(2) Position fill port at 4 o'clock position. If oil flows from fill port when plug is loosened, let oil drain to correct
level. If oil level is below fill port, fill hub with GO specified for the ambient temperature until oil is level with fill
port.

b. Drain and fill front axle wheel end planetary hubs every 24,000 miles (38,616 km) or once every two years,
whichever occurs first, following the repacking of the inner wheel bearings, or whenever wheel end assemblies are
taken apart for other maintenance as follows:

(1) Position vehicle on a level surface.

(2) Position fill port at the 6 o'clock (down) position.
(3) Drain hub oil (allow a minimum of 15 minutes for oil to drain down from vent tubes).
(4) Refill hubs with 11-13 ounces of GO specified for the ambient temperature.

13. TIE ROD ENDS. Lubricate tie rod ends with GAA every 6,000 miles (9,654 km) or once every six months, whichever
occurs first, using a low pressure lubrication gun, until new grease is seen purging from the boot area. If operating
conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

14. WINCH CABLES:

CAUTION

Do not use dry cleaning solvent to clean winch cables. Use of dry cleaning solvent will remove lubricant
from inner strands of winch cables. Failure to comply may result in damage to equipment.

a. After winch operation:

Refer to FM 5-125.

b. Care of wire rope:

Refer to FM 5-125.

c. Inspection of wire rope:

Refer to FM 5-125.

d. Every six months:

(1) Unwind entire length of winch cable (TM 9-2320-366-10-1).

(2) Soak and clean winch cable with new OE/HDO 30.
(3) Wipe off excess OE/HDO 30.
(4) Coat winch cable with GW.
(5) Rewind winch cable (TM 9-2320-366-10-1).

H-28 Change 2
 TM 9-2320-366-20-3

15. 15K SRW. Check 15K SRW gear oil level every 6,000 miles (9,654 km) or once every six months, whichever
occurs first. Refill 15K SRW with GO specified for ambient temperature. Change oil every 12,000 miles (19,308 km)
or once every year, whichever occurs first. Use procedure (a) to check and fill oil level; use procedure (b) to change
oil.

a. Check and fill oil level as follows:

(1) Shift the freespool mechanism to the disengage position so the drum can be freely rotated.
(2) Rotate the drum to where either plug is near the top of the 15K SRW. Remove the plug.
(3) Rotate the drum 90 degrees in the direction that allows the other plug to be near the top of the 15K SRW.
Remove the plug.

NOTE

Oil level is full if a small amount of oil runs out of lower plug.

(4) Add oil until a small amount of oil runs out of lower plug hole.
(5) Apply adhesive (Item 3, Appendix D) to plug and position plug in top hole.
(6) Rotate drum until open hole is at top.
(7) Apply adhesive (Item 3, Appendix D) to plug and position plug in top hole.
(8) Tighten plugs to 13-15 lb-ft (18-20 N·m).

b. Change oil as follows:

(1) Shift the freespool mechanism to the disengage position so the drum can be freely rotated.
(2) Rotate the drum to where either plug is near the top of the 15K SRW. Remove the plug.
(3) Rotate the drum 90 degrees in the direction that allows the other plug to be near the top of the 15K SRW.
Remove the plug.
(4) Position drain pan (Item 39, Appendix C) under 15K SRW.
(5) Rotate the drum until either hole is straight down to the bottom of the 15K SRW. Allow the oil to drain
completely.
(6) Rotate the drum until either hole is at top.

NOTE

Oil level is full if a small amount of oil runs out of lower plug.

(7) Add oil until a small amount of oil runs out of lower plug hole.
(8) Apply adhesive (Item 3, Appendix D) to plug and position plug in top hole.
(9) Rotate drum until open hole is at top.
(10) Apply adhesive (Item 3, Appendix D) to plug and position plug in top hole.
(11) Tighten plugs to 13-15 lb-ft (18-20 N·m).

16. TOWING PINTLE. Lubricate towing pintle with GAA every 6,000 miles (9,654 km) or once every six months,
whichever occurs first, using a low pressure lubrication gun until new grease is seen purging.

H-29
TM 9-2320-366-20-3

H-9. LUBRICATION/SERVICES NOTES (CONT)

WARNING

• Dry Cleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in well-ventilated area; avoid contact with skin, eyes, and clothes, and do not breath
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for
Type I Dry Cleaning Solvent is 100 F (38 C) and for Type II is 138 F (50 C). Failure to comply
may result in serious injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get medical attention. Failure to comply may result in
injury to personnel.

17. ENGINE CRANKCASE BREATHER. Remove crankcase breather and clean with Dry Cleaning Solvent (SD P-D-680)
(Item 65, Appendix D) or equivalent, and replace o-ring seal every 6,000 miles (9,654 km) or once every six months,
whichever occurs first (para 3-5).

18. FRONT AXLE SPRING BOLT and SPRING SHACKLE. Lubricate front axle spring bolt and spring shackle with
GAA every 3,000 miles (4,827 km) or once every three months, whichever occurs first, using a low pressure lubrication
gun until grease appears between pins and bushings at both ends of spring bolt and spring shackle. If pins do not
accept grease, notify Direct Support to remove pins. Clean and inspect pins and bushings, replace if necessary. If
operating conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs
first.

19. BATTERY POSTS. Service batteries in accordance with TM 9-6140-200-14, every 6,000 miles (9,654 km) or once
every six months, whichever occurs first.

20. FRONT AXLE SHAFT UNIVERSAL JOINTS and STEERING KNUCKLES. Lubricate universal joints every 3,000
miles (4,827 km) or once every three months, whichever occurs first. Lubricate steering knuckles with GAA every 6,000
miles (9,654 km) or once every six months, whichever occurs first, using a low pressure lubrication gun. If operating
conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

21. BRAKE WEDGE and AIR CHAMBER: BRAKE SPIDER, SELF-ADJUSTER MECHANISM, AND WEDGE
ASSEMBLY. Clean and lubricate (with GAA) areas of spider and hardware that contact the brake shoes. Disassemble,
clean and lubricate the self-adjuster mechanism. Clean and lubricate the wedge head, rollers and ramps in the plungers.
Clean and lubricate every 6,000 miles (9,654 km). If operating conditions are severe or abnormal, service at 3,000 miles
(4,827 km) or once every three months, whichever occurs first, or when any of the following occur: Refer to para 11-4
and 11-5

• Seals are replaced

• Plungers are removed
• Brakes are relined
• Grease becomes contaminated or hardened

22. HYDRAULIC TANK (M1089). Check oil level weekly and make sure oil level indicates FULL. Units participating in
AOAP will sample oil annually and change oil and filter as directed by AOAP. Units not participating in AOAP will
change oil and filter every two years. Drain oil and refill hydraulic tank with OE/HDO specified for ambient operating
temperature. Fill hydraulic tank until oil level is at the FULL mark on the sight glass. Do not overfill. Replace hydraulic
oil filter (para 19-20) when oil is changed. Check oil level with Material Handling Crane (MHC) in the stowed position.

H-30 Change 2
 TM 9-2320-366-20-3

23. BOOM WEAR PADS (M1084/M1086/M1089). Lubricate every 6,000 miles (9,654 km) or once every six months,
whichever occurs first. Coat boom wear pads with GAA while boom is extended, for the lower wear pads, boom must be
retracted and access cover removed at rear of base boom to grease the upper wear pads. Extend boom in and out while
applying grease. This method assures full lubrication for entire length of boom. If operating conditions are severe or
abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

24. HOIST ASSEMBLY DRUM (M1084/M1086/M1089). Check hoist assembly drum oil level every 6,000 miles (9,654
km) or every six months, whichever occurs first. Check oil level in hoist assembly drum using two pipe plugs (90
degrees apart) on the drum housing. Operate hoist assembly drum so that one pipe plug is positioned at top of drum (fill
point) and the other is accessible and level with ground (check level point). Oil level is full if a small quantity of oil runs
from check level opening. If oil level is low, add oil at fill opening. to drain, operate drum so that one pipe plug is bottom
of drum. Remove plug to drain. Drain and refill with GO specified for the ambient temperature, if oil becomes
contaminated.

25. SWING DRIVE GEARBOX (M1084/M1086/M1089). Check swing drive gearbox oil level every 6,000 miles (9,654
km) or once every six months, whichever occurs first. Oil level is checked by removing pipe plug located on side of gear
reducer. Oil level is full if a small quantity of oil runs out of opening. Add oil at fill point if necessary. Notify Direct
Support to drain and refill with GO specified for the ambient temperature, if oil becomes contaminated.

26. RING GEAR TEETH and PINION GEAR TEETH (M1084/M1086/M1089). Lubricate every 6,000 miles (9,654 km),
after washing, or once every six months, whichever occurs first. Apply a light coat of GAA to ring gear teeth and pinion
gear teeth. Operate MHC (TM 9-2320-366-10) to rotate turntable. This will allow grease to be applied to all gear teeth. If
operating conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs
first.

27. FRONT, INTERMEDIATE, and REAR AXLE INNER WHEEL BEARINGS. Repack inner wheel bearings with GAA
every 12,000 miles (19,308 km), when semiannual PMCS inspection of service brakes reveals oil leak from inner
hub, or whenever wheel end assemblies are taken apart for other maintenance (para 10-2).

28. REAR AXLE BOGIE. Change oil every 6,000 miles (9,654 km) or once every six months, whichever occurs first.
Remove six screws and rear axle bogie cover from one side at a time. Raise axle on opposite side of vehicle to allow oil
to drain out. Lower axle and repeat on other side of vehicle. Apply thin bead of silicone adhesive sealant 593 to seating
surface of housing. Position cover (with fill plug at the 1 o'clock position) and six screws on housing. Tighten six
screws to 24 lb-ft (32 N m). Remove plug from cover and plug from top of rear axle bogie housing. Refill rear axle bogie
with GO specified for the ambient temperature, until level with port on housing cover. Install plugs in cover and housing.

29. 15K SELF-RECOVERY WINCH (SRW) CABLE ROLLER FAIRLEADS. Lubricate with GAA every 6,000 miles
(9,654 km) or once every six months, whichever occurs first, using a low pressure lubrication gun. If operating
conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

30. 30K WINCH CABLE GUIDE ROLLERS and PAY-OUT LOWER TENSION SHEAVE. Lubricate with GAA every
6,000 miles (9,654 km) or once every six months, whichever occurs first, using a low pressure lubrication gun. If
operating conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs
first.

Change 2 H-31
TM 9-2320-366-20-3

H-9. LUBRICATION/SERVICES NOTES (CONT)

WARNING

• Dry Cleaning Solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in well-ventilated area; avoid contact with skin, eyes, and clothes, and do not breath
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for
Type I Dry Cleaning Solvent is 100 F (38 C) and for Type II is 138 F (50 C). Failure to comply
may result in serious injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get medical attention. Failure to comply may result in
injury to personnel.

31. SCREEN and PLUG OIL FILTER ASSEMBLY (intermediate axle only). Clean the area around the screen and
plug oil filter assembly. Remove the screen and plug oil filter assembly. Clean with Dry Cleaning Solvent (Item 65,
Appendix D) or equivalent, every 12,000 miles (19,308 km) or once every year, whichever occurs first. Clean filter each
time the differential is drained. If screen is crushed or bent, replace with a new one. Clean the screen cavity in the
carrier of all debris and particles. If excessive amount of metal particles are detected during oil filter servicing, notify
Direct Support Maintenance personnel before refilling differential.

32. TURNTABLE BEARING (M1084/M1086/M1089). Lubricate with GAA every 6,000 miles (9,654 km), after washing,
or once every six months, whichever occurs first. Use a low pressure lubrication gun. Apply lubrication to grease fitting
inside turntable bearing. Operate MHC (TM 9-2320-366-10) to rotate turntable bearing through full range of travel
between applications of grease. This method assures full lubrication of the turntable bearing. If operating conditions are
severe or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

33. TOP and BOTTOM PLATES (M1089). Lubricate every 6,000 miles (9,654 km) or once every six months, whichever
occurs first. Coat top and bottom plates with GAA. Extending outriggers in and out while applying grease assures full
lubrication for the entire length of top and bottom plates. If operating conditions are severe or abnormal, service at 1,000
miles (1,609 km) or once every month, whichever occurs first.

34. CRANE GREASE FITTINGS (M1084/M1086/M1089). Lubricate with GAA every 6,000 miles (9,654), after washing,
or once every six months, whichever occurs first. Use a low pressure lubrication gun. If operating conditions are severe
or abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

35. UNDERLIFT ASSEMBLY GREASE FITTINGS. Lubricate with GAA every 6,000 miles (9,654), after washing, or
once every six months, whichever occurs first. Use a low pressure lubrication gun. If operating conditions are severe or
abnormal, service at 1,000 miles (1,609 km) or once every month, whichever occurs first.

36. FRONT LIFTING BEAM. Remove left and right lifting beams and clean with Dry Cleaning Solvent (Item 65,
Appendix D) or equivalent, every 6,000 miles (9,654 km) or once every six months, whichever occurs first. Apply a light
coat of GAA to lifting beams. If operating conditions are severe or abnormal, service at 1,000 miles (1,609 km) or once
every month, whichever occurs first.

37. AIR DRYER. Service air dryer (para 23-11) every 12,000 miles (19,308 km) or annually, whichever occurs first.

38. TENSION LINKS. Lubricate tension link(s) every three months with GAA.

39. FRONT LEAF SPRING AND REAR BOGIE AXLE. At initial 1000 miles (1609 km) of vehicle operation, tighten U-
bolts to 390-510 lb-ft (529-692 N•m).

H-32 Change 2
 TM 9-2320-366-20-3

APPENDIX J
ADDITIONAL AUTHORIZATION LIST (AAL)

Section I. INTRODUCTION

J-1. SCOPE

This appendix lists additional items you are authorized for the support of the MTV.

J-2. GENERAL

This list identifies items that do not have to accompany the MTV and that do not have to be turned in with it. These
items are all authorized to you by Common Tables of Allowance (CTA), Modification Table of Organization and
Equipment (MTOE), Tables of Distribution and Allowances (TDA), or Joint Table of Allowance (JTA).

J-3. EXPLANATION OF LISTING

National Stock Numbers, description, and quantities are provided to help you identify and request the additional items
you require to support this equipment.

Section II. ADDITIONAL AUTHORIZATION LIST

(1) (2) (3) (4)

National Stock Description Qty
Number (CAGE) Part Number U/M Auth

6685-01-193-1733 10,000 PSI Transducer: EA 1

(19207) 12258956

J-1/(J-2 Blank)
 TM 9-2320-366-20-3

APPENDIX K
TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART
Section I. INTRODUCTION

K-1. INTRODUCTION

This appendix lists the various transmission controls and configuration modifications that may be required to permit
the transmission to function correctly. This appendix will guide the mechanic through the hardware selection process
by identifying compatibility issues between the transmission controls (WTEC II/WTEC III) and the numerous revisions
of the Allison MD3070PT transmission (PRE-ID w/ 24-pin connector, PRE-ID w/ 31-pin connector, TID 1, TID 2, and
TID 3). Refer to Figure 1. After replacing any component of the transmission controls or the transmission assembly,
perform calibration procedures in TM 9-2320-366-20-4 paragraph 8-2 or 8-3.

K-2. EXPLANATION OF COLUMNS

a. Column (1) - Installed Controls or Controls Being Installed. This column lists all of the variables concerning
which version of transmission controls are installed in the vehicle, or may need to be installed, to communicate
correctly with the transmission.

b. Column (2) - Installed Transmission or Transmission Being Installed. This column lists all of the various
revisions of the Allison MD3070PT transmissions that may be installed in the vehicle.

c. Column (3) - Required Modification. This column lists the various electrical interface (hardware) modifications
that may be required to allow the transmission controls to communicate with the transmission.

K-3. HOW TO USE THIS CHART

a. Determine which controls and transmission are installed in the vehicle.

b. Determine which component requires replacement.

c. Read across the row to column (3) to determine the required modification.

Section II.

TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART

(1) (2) (3)
Installed Controls or Installed Transmission or Required Modification
Controls Being Installed Transmission Being Installed (Refer to Section III)
WTEC II PRE-ID w/ 24-pin connector No modification required.
(with 24-pin connector) (transmission serial number prior to
6510032369)
WTEC II PRE-ID w/ 31-pin connector Install 31-pin connector.
(with 24-pin connector) (transmission serial number
6510032369 to 6510090785)
WTEC II TID 1 Install 31-pin connector.
(with 24-pin connector) (transmission serial number
6510090786 to 6510142171)
WTEC II TID 2 Install 31-pin connector and replace
(with 24-pin connector) (transmission serial number transmission internal wiring harness.
6510142172 to 6510262116)

Change 1 K-1
TM 9-2320-366-20-3

TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART (CONT)

(1) (2) (3)
Installed Controls or Installed Transmission or Required Modification
Controls Being Installed Transmission Being Installed (Refer to Section III)
WTEC II TID 3 Install 31-pin connector, replace
(with 24-pin connector) (transmission serial number transmission internal wiring harness,
1
6510262117 and subsequent) and reprogram WTEC II TEPSS.
WTEC II PRE-ID w/ 24-pin connector Install adapter cable assembly.
(with 31-pin connector) (transmission serial number prior to
6510032369)
WTEC II PRE-ID w/ 31-pin connector No modification required.
(with 31-pin connector) (transmission serial number
6510032369 to 6510090785)
WTEC II TID 1 No modification required.
(with 31-pin connector) (transmission serial number
6510090786 to 6510142171)
WTEC II TID 2 Replace transmission internal wiring
(with 31-pin connector) (transmission serial number harness.
6510142172 to 6510262116)
WTEC II TID 3 Replace transmission internal wiring
(with 31-pin connector) (transmission serial number harness and reprogram WTEC II
1
6510262117 and subsequent) TEPSS.
WTEC III PRE-ID w/ 24-pin connector Install adapter cable assembly and ID
(with ECU manufactured prior to (transmission serial number prior to harness.
2
October 1999) 6510032369)
WTEC III PRE-ID w/ 31-pin connector Install ID harness.
(with ECU manufactured prior to (transmission serial number
2
October 1999) 6510032369 to 6510090785)
WTEC III TID 1 No modification required.
(with ECU manufactured prior to (transmission serial number
2
October 1999) 6510090786 to 6510142171)
WTEC III TID 2 No modification required.
(with ECU manufactured prior to (transmission serial number
2
October 1999) 6510142172 to 6510262116)
1
WTEC III TID 3 Reprogram WTEC III ECU or install
(with ECU manufactured prior to (transmission serial number new WTEC III ECU (P/N 12421787-
2
October 1999) 6510262117 and subsequent) 002).
WTEC III PRE-ID w/ 24-pin connector Install adapter cable assembly and ID
(with ECU manufactured after (transmission serial number prior to harness.
3
October 1999) 6510032369)
WTEC III PRE-ID w/ 31-pin connector Install ID harness.
(with ECU manufactured after (transmission serial number
3
October 1999) 6510032369 to 6510090785)
WTEC III TID 1 No modification required.
(with ECU manufactured after (transmission serial number
3
October 1999) 6510090786 to 6510142171)

1
Reprogramming can only be accomplished by an authorized Allison Transmission distributor. You must provide the
transmission serial number of the transmission being installed to ensure correct reprogramming. If at a later time, an
earlier version transmission is installed in a WTEC II equipped vehicle, WTEC II TEPSS will require reprogramming
again.
2
Vehicle serial number 012477 and lower. Refer to Figure 1.
3
Vehicle serial number 012478 and higher. Refer to Figure 1.

K-2 Change 2
 TM 9-2320-366-20-3

(1) (2) (3)

Installed Controls or Installed Transmission or Required Modification
Controls Being Installed Transmission Being Installed (Refer to Section III)
WTEC III TID 2 No modification required.
(with ECU manufactured after (transmission serial number
3
October 1999) 6510142172 to 6510262116)
WTEC III TID 3 No modification required.
(with ECU manufactured after (transmission serial number
3
October 1999) 6510262117 and subsequent)

Section III.

MODIFICATION PARTS IDENTIFICATION

Identification Part Number/NSN Description

31-pin connector 300130 Converts a transmission external wiring harness from a

5935-21-921-1813 24-pin ("D" type) connector to a 31-pin (round type)
connector.
Transmission internal wiring 29529474 Converts a TID 2 transmission to a TID 1 configuration to
harness 6150-01-481-8088 allow WTEC II controls to communicate with the
transmission.
Gasket 29503283 Required when replacing transmission internal wiring
5330-01-360-9035 harness.
ID harness 200100 Allows WTEC III controls to communicate with a PRE-ID
6150-21-921-1191 transmission.
Adapter cable assembly 29519210 Adapts a PRE-ID transmission with 24-pin ("D" type)
6150-01-420-5987 connector to a transmission external wiring harness with a
31-pin (round) connector.

Change 2 K-3
TM 9-2320-366-20-3

MODIFICATION PARTS IDENTIFICATION (CONT)

K-4 Change 1
 TM 9-2320-366-20-3

SUBJECT INDEX
Subject Para Subject Para

A A (Cont)

Accelerator Pedal Replacement . . . . . . . . . . . . 4-21 Auxiliary

Air Panel Cable Assembly Replacement . . . . . . . 7-58
Cab Leveling Air Springs Do Not Panel Replacement . . . . . . . . . . . . . . . . . . . . 7-8
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Starter Solenoid Replacement . . . . . . . . . . . . 7-6
Compressor Inlet and Outlet Coolant Axle Troubleshooting . . . . . . . . . . . . . . . . . . . . 2-25
Tubes Replacement . . . . . . . . . . . . . . . . . . 6-11
Charge Air Cooler to Air Inlet Elbow B
Tubes and Hoses Replacement . . . . . . . . . . 4-5
Intake Air Cleaner Filter Element, Air Backup Light Assembly Replacement/
Cleaner Assembly, and Particle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Extraction Tube Replacement . . . . . . . . . . . . 4-2 Batteries
Pressure Transmitter Replacement . . . . . . . . 7-44 Disconnecting/Connecting Batteries . . . . . . . 7-57
Radiator/Charge Air Cooler Replacement . . . . 6-2 Battery
Transport Troubleshooting . . . . . . . . . . . . . . 2-31 /Battery Cables Replacement . . . . . . . . . . . . 7-55
Air Cleaner Box Replacement . . . . . . . . . . . . . . . . . . . . 7-56
Intake Air Cleaner Filter Element, Tester Replacement . . . . . . . . . . . . . . . . . . . 7-54
Air Cleaner Assembly, and Particle to 100 Amp Reverse Polarity Relay
Extraction Tube Replacement . . . . . . . . . . . . 4-2 12 VDC Cable Assembly
Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-74
Audible Alarm Replacement . . . . . . . . . . . . . 7-43 to 100 Amp Reverse Polarity Relay
Chemical Alarm Kit Cable Assembly 24 VDC Cable Assembly
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-59 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-75
Troop Transport Alarm Does Not to Shunt Cable Assembly Replacement . . . . . 7-76
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 to Starter Cable Assembly
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-77
Belts Replacement . . . . . . . . . . . . . . . . . . . . . 7-3 Belt
Brackets Replacement . . . . . . . . . . . . . . . . . . 7-4 Drive Belt and Tension Pulley
Ground Strap Replacement . . . . . . . . . . . . . 7-71 Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-13
100 Amp Alternator Replacement . . . . . . . . . . 7-2 Belts
100 Amp Alternator to Reverse Polarity Alternator Belts Replacement . . . . . . . . . . . . . 7-3
Relay 12 VDC Cable Replacement . . . . . . . 7-72 Blackout Drive Light Replacement/
100 Amp Alternator to Reverse Polarity Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Relay 24 VDC Cable Replacement . . . . . . . 7-73 Body
Amp Dump Body Hydraulic System
100 Amp Alternator Replacement . . . . . . . . . . 7-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-32
100 Amp Alternator to Reverse Polarity M1090/M1094 Dump Body Switch
Relay 12 VDC Cable Replacement . . . . . . . 7-72 Replacement/Adjustment . . . . . . . . . . . . . . 7-23
100 Amp Alternator to Reverse Polarity Box
Relay 24 VDC Cable Replacement . . . . . . . 7-73 Battery Box Replacement . . . . . . . . . . . . . . . 7-56
100 Amp Reverse Polarity Relay Crane Remote Control Box Repair . . . . . . . . 7-32
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-30 M1084/M1086 Junction Box Assembly
100 Amp Voltage Regulator Replacement . . . . 7-5 Replacement/Repair . . . . . . . . . . . . . . . . . 7-27
Assembly M1089 Junction Box Assembly
General Assembly Instructions . . . . . . . . . . . 2-45 Replacement/Repair . . . . . . . . . . . . . . . . . 7-32
Audible Alarm Replacement . . . . . . . . . . . . . . . 7-43 M1089 Wrecker Remote Control Box
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Brackets
Alternator Brackets Replacement . . . . . . . . . . 7-4

Change 1 INDEX-1
TM 9-2320-366-20-3

SUBJECT INDEX (CONT)

Subject Para Subject Para

B (Cont) C (Cont)

Breather Cable (Cont)

Crankcase Breather Replacement . . . . . . . . . . 3-5 M1089 LH or RH 30K Winch Cable Drum
Tensioner Does Not Operate . . . . . . . . . . . 2-37
C M1093/M1094 Cab Clearance
and Marker Lights Lower Cable
Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-62
Clearance Marker Lights Cable Assembly M1093/M1094 Cab Clearance
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-66 and Marker Lights Upper Cable
Does Not Lower . . . . . . . . . . . . . . . . . . . . . . 2-36 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-63
Does Not Raise . . . . . . . . . . . . . . . . . . . . . . 2-36 NATO Power Cable Replacement . . . . . . . . . 7-70
Left-Hand Door and Cab Marker Lights Right-Hand Door and Cab Marker
Cable Assembly Replacement . . . . . . . . . . 7-61 Lights Cable Assembly Replacement . . . . . 7-64
Leveling Air Springs Do Not Operate . . . . . . . 2-31 STE/ICE-R Cable Assembly
M1093/M1094 Cab Clearance and Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-65
Marker Lights Lower Cable Throttle Control Cable
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-62 Replacement/Adjustment . . . . . . . . . . . . . . 4-18
M1093/M1094 Cab Clearance and Throttle Position Sensor (TPS) Cable
Marker Lights Upper Cable Assembly Replacement . . . . . . . . . . . . . . . 4-16
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-63 Windshield Washer Pump Electromagnetic
Right-Hand Door and Cab Marker Interference (EMI) Cable Assembly
Lights Cable Assembly Replacement . . . . . 7-64 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-67
Tilt and Spare Tire Retainer Windshield Wiper Electromagnetic
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-36 Interference (EMI) Cable
Tilt, Spare Tire Retainer, and Suspension Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-68
Compression Will Not Work . . . . . . . . . . . . 2-31 WTEC II Dashboard Cable Assembly
to Chassis Ground Strap Replacement . . . . . 7-78 Replacement/Repair . . . . . . . . . . . . . . . . . 7-10
Cable WTEC III Dashboard Cable Assembly
Auxiliary Panel Cable Assembly Replacement/Repair . . . . . . . . . . . . . . . . . 7-11
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-58 100 Amp Alternator to Reverse Polarity
Battery/Battery Cables Replacement . . . . . . . 7-55 Relay 12 VDC Cable Replacement . . . . . . . 7-72
Battery to Shunt Cable Assembly 100 Amp Alternator to Reverse Polarity
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-76 Relay 24 VDC Cable Replacement . . . . . . . 7-73
Battery to Starter Cable Assembly Central
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-77 Five Central Tire Inflation System
Battery to 100 Amp Reverse Polarity (CTIS) Indicator Lights Flashing . . . . . . . . . 2-24
Relay 12 VDC Cable Assembly Tire Inflation System (CTIS) Cable
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-74 Assembly Replacement . . . . . . . . . . . . . . . 7-60
Battery to 100 Amp Reverse Polarity Tire Inflation System (CTIS) ECU Indicates
Relay 24 VDC Cable Assembly No Fault Code But System Fails to Inflate
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-75 or Deflate . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Central Tire Inflation System (CTIS) Cable Tire Inflation System (CTIS)
Assembly Replacement . . . . . . . . . . . . . . . 7-60 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-24
Chemical Alarm Kit Cable Assembly Two Steady Mode Lights Illuminate on
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-59 Central Tire Inflation System (CTIS)
Left-Hand Door and Cab Marker Lights ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Cable Assembly Replacement . . . . . . . . . . 7-61

INDEX-2 Change 1
 TM 9-2320-366-20-3

Subject Para Subject Para

C (Cont) C (Cont)

Charge Cooling System Maintenance

Air Cooler to Air Inlet Elbow Tubes and Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Hoses Replacement . . . . . . . . . . . . . . . . . . . 4-5 Cover
Turbocharger to Charge Air Cooler Tube Valve Cover Replacement . . . . . . . . . . . . . . . 3-3
and Hoses Replacement . . . . . . . . . . . . . . . 4-4 Crane
Radiator/Charge Air Cooler Replacement . . . . 6-2 Light Material Handling Crane (LMHC)
Checking and Stenciling High/Low Hand Does Not Operate . . . . . . . . . . . . . . . . . . . 2-31
Throttle Positions . . . . . . . . . . . . . . . . . . . . . 4-22 Light Material Handling Crane (LMHC)
Chemical Hoist IN Does Not Operate . . . . . . . . . . . . . 2-31
Alarm Kit Cable Assembly Light Material Handling Crane (LMHC)
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-59 Hoist OUT Does Not Operate . . . . . . . . . . . 2-31
Circuit Breaker, Diode, and Relay M1084/M1086 Crane Power Cable
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Assembly Replacement . . . . . . . . . . . . . . . 7-79
Cleaning Crane Remote Control Box Repair . . . . . . . . . . 7-32
General Cleaning Instructions . . . . . . . . . . . . 2-42 Crankcase Breather Replacement . . . . . . . . . . . 3-5
Clearance CTIS
And Marker Light Assemblies Central Tire Inflation System (CTIS) Cable
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-38 Assembly Replacement . . . . . . . . . . . . . . . 7-60
Cab Clearance and Marker Lights Cable Central Tire Inflation System (CTIS)
Assembly Replacement . . . . . . . . . . . . . . . 7-66 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-24
M1093/M1094 Cab Clearance and Central Tire Inflation System (CTIS)
Marker Lights Lower Cable Assembly ECU Indicates No Fault Code But System
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-62 Fails to Inflate or Deflate . . . . . . . . . . . . . 2-24
M1093/M1094 Cab Clearance and CTIS Repeatedly Resumes Cycling
Marker Lights Upper Cable Assembly 30 Seconds After Indicator Lights
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-63 Stop Flashing . . . . . . . . . . . . . . . . . . . . . 2-24
Composite Five Central Tire Inflation System
Front Light Assembly Replacement/ (CTIS) ECU Indicator Lights Flashing . . . . . 2-24
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Four CTIS ECU Indicator Lights
Taillight Assembly Replacement/Repair . . . . . 7-39 Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Compressor Two Steady Mode Lights Illuminate
Air Compressor Inlet and Outlet Coolant on Central Tire Inflation System
Tubes Replacement . . . . . . . . . . . . . . . . . . 6-11 (CTIS) ECU . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Control Cylinder
M1089 Wrecker Remote Control Box M1084/M1086 Jack Cylinder Proximity
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Sensor Replacement . . . . . . . . . . . . . . . . . 7-51
One Wrecker Function Does Not Operate M1089 Fold Cylinder Does Not
From Wrecker Remote Control . . . . . . . . . . 2-37 Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Coolant M1089 Stinger/Telescopic Lift
Bypass Tube Replacement . . . . . . . . . . . . . . . 6-7 Cylinders/Fold Cylinder/Right
Lower Coolant Hose Replacement . . . . . . . . 6-10 30K Winch Do Not Operate . . . . . . . . . . . . 2-33
Temperature Gage Sensor M1089 Underlift Telescopic Lift
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-45 Cylinder(s) Does Not Operate . . . . . . . . . . . 2-33
Temperature Light Switch Cylinders
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-22 M1089 Stinger/Telescopic Lift
Upper Coolant Tube and Hoses Cylinders/Fold Cylinder/Right
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 6-9 30K Winch Do Not Operate . . . . . . . . . . . . 2-33
Cooler
Charge Air Cooler to Air Inlet Elbow
Tubes and Hoses Replacement . . . . . . . . . . 4-5

Change 1 INDEX-3
TM 9-2320-366-20-3

SUBJECT INDEX (CONT)

Subject Para Subject Para

D E
Dashboard ECU
WTEC II Cable Assembly Replacement/ Central Tire Inflation System (CTIS)
Repair ........................................................... 7-10 ECU Indicates No Fault Code But System
WTEC III Cable Assembly Replacement/ Fails to Inflate or Deflate ............................... 2-24
Repair ........................................................... 7-11 Five Central Tire Inflation System
Differential (CTIS) ECU Indicator Lights Flashing ............... 2-24
Axle Differential(s) Noisy ................................... 2-25 Four CTIS ECU Indicator Lights
Fan and Differential Lock Solenoids Flashing ........................................................ 2-24
Replacement ................................................. 7-24 Frequency ECU Replacement ........................... 7-31
Digitization Kit Two Steady Modes Lights Illuminate
No Power to Digitization Rack ........................... 2-34 on Central Tire Inflation System
No Power to Driver Visual Enhancement (CTIS) ECU ................................................... 2-24
(DVE) ........................................................... 2-34 Windshield Wiper ECU Replacement ................. 7-69
No Power to Enhanced Position Location WTEC II Transmission ECU Pushbutton
Reporting System (EPLRS) ............................ 2-34 Shift Selector (TEPSS) Dimmer
No Power to Mobile Tracking system (MTS)........ 2-34 Module Replacement ...................................... 7-13
No Power to Mobile Tracking System (MTS) Electrical Gages Replacement .............................. 7-14
Sense........................................................... 2-34 EMI
No Power to Precision Lightweight Global Windshield Washer Pump Electromagnetic
Positioning System Receiver (PLGR) ............... 2-34 Interference (EMI) Cable Assembly
No Power to SINCGAR/Force XXI Battle Replacement ................................................. 7-67
Command Brigade and Below (FBCB).............. 2-34 Windshield Wiper Electromagnetic
Dimmer Interference (EMI) Cable
Switch Replacement ......................................... 7-12 Replacement ................................................. 7-68
WTEC II Transmission ECU Pushbutton Engine
Shift Selector (TEPSS) Dimmer Module and Transmission Oil Sampling Valves
Replacement ................................................. 7-13 Replacement ................................................... 3-6
Diode Fan and Fan Clutch Assembly
Circuit Breaker, Diode, and Relay Replacement ................................................. 6-14
Replacement ................................................... 7-9 Maintenance Introduction .................................... 3-1
Disassembly Speed Sensor Replacement/
General Disassembly Instructions ...................... 2-41 Adjustment .................................................... 7-46
Disconnecting/Connecting Batteries ...................... 7-57 Ether
Display Sensor Replacement ........................................ 7-47
Lighted Indicator Display Replacement/ Starting Aid Replacement ................................. 4-15
Repair ........................................................... 7-16 Exhaust
Door Muffler and Exhaust Heat Shields
Left-Hand Door and Cab Marker Replacement ................................................... 5-2
lights Cable Assembly Replacement ................ 7-61 Pipe Replacement .............................................. 5-3
Right-Hand Door and Cab Marker System Maintenance Introduction ........................ 5-1
lights Cable Assembly Replacement ................ 7-64 External
Drive Belt and Tension Pulley No Service or External Hydraulic Power
Replacement ................................................... 6-13 From M1089 .................................................. 2-33
Drum
M1089 LH or RH 30K Winch Cable Drum F
Tensioner Does Not Operate ........................... 2-37
Dump Fan
Body Does Not Lower ....................................... 2-32 and Differential Lock Solenoids
Body Does Not Raise ....................................... 2-32 Replacement ................................................. 7-24
Body Drifts Down From Raised Position ............. 2-32 Engine Fan and Fan Clutch Assembly
Body Hydraulic System Troubleshooting ............ 2-32 Replacement ................................................. 6-14
M1090/M1094 Dump Body Switch Radiator Fan Shrouds Replacement ..................... 6-4
Replacement/Adjustment ................................ 7-23

INDEX-4 Change 2
 TM 9-2320-366-20-3

Subject Para Subject Para

F (Cont) G (Cont)
Filter General
Fuel Filter and Filter Base Replacement ............. 4-12 Assembly Instructions ...................................... 2-45
Fuel Filter Tubes Replacement .......................... 4-10 Cleaning Instructions ........................................ 2-42
Fuel/Water Separator and Filter Disassembly Instructions .................................. 2-41
Replacement ................................................. 4-13 Inspection Instructions ...................................... 2-43
Oil Filter Replacement ........................................ 3-4 Installation Instructions ..................................... 2-46
Five Central Tire Inflation System (CTIS) Removal Instructions ........................................ 2-40
ECU Indicator Lights Flashing ........................... 2-24 Repair Instructions ........................................... 2-44
Flasher Unit Replacement .................................... 7-25 Governor
Fold Linkage Replacement ....................................... 4-12
M1089 Fold Cylinder Does Not Ground Handling.................................................. 2-39
Operate......................................................... 2-33 Ground Strap
M1089 Stinger/Telescopic Lift Alternator Ground Strap Replacement ................ 7-71
Cylinders/Fold Cylinder/Right Cab to Chassis Ground Strap
30K Winch Do Not Operate............................. 2-33 Replacement ................................................. 7-78
Four CTIS ECU Indicator Lights
Flashing .......................................................... 2-24 H
Freespool
Main Winch LH Freespool Does Not Hand
Operate......................................................... 2-37 Throttle Lever Replacement/
Main Winch RH Freespool Does Not Adjustment .................................................... 4-17
Operate......................................................... 2-37 Throttle Checking and Stenciling
Main Winch LH or RH Freespool(s) High/Low Hand Throttle Positions .................... 4-22
Does Not Operate .......................................... 2-37 Headlight and Housing Replacement/
Frequency ECU Replacement ............................... 7-31 Repair/ Adjustment ........................................... 7-41
Front Heater
Composite Front Light Assembly Personnel Heater Hoses Replacement ................. 6-8
Replacement/Repair ....................................... 7-40 Hoist
Fuel Light Material Handling Crane (LMHC)
Filter and Filter Base Replacement .................... 4-12 Hoist IN Does Not Operate.............................. 2-31
Filter Tubes Replacement ................................. 4-10 Light Material Handling Crane (LMHC)
Hoses Replacement ........................................... 4-9 Hoist OUT Does Not Operate .......................... 2-31
Pressure Regulating Valve Replacement .............. 4-3 Horn and Bracket Replacement ............................ 7-53
Ratio Control Tube Replacement .......................... 4-6 Hose
System Bleeding.............................................. 4-11 Lower Coolant Hose Replacement ..................... 6-10
System Maintenance Introduction ........................ 4-1 Hoses
Tank Replacement ............................................. 4-8 Charge Air Cooler to Air Inlet Elbow
/Water Separator and Filter Replacement ........... 4-13 Tubes and Hoses Replacement ......................... 4-5
Fuel Hoses Replacement .................................... 4-9
G Personnel Heater Hoses Replacement ................. 6-8
Turbocharger to Charge Air Cooler
Gages Tube and Hoses Replacement ........................... 4-4
Electrical Gages Replacement .......................... 7-14 Upper Coolant Tube and Hoses
(Non-Electrical) Maintenance Replacement ................................................... 6-9
Housing
Headlight and Housing Replacement/
Repair/Adjustment ......................................... 7-41
Hydraulic
Dump Body Hydraulic System
Troubleshooting ............................................. 2-32

Change 2 INDEX-5
TM 9-2320-366-20-3

SUBJECT INDEX (CONT)

Subject Para Subject Para

H (Cont) I (Cont)

Hydraulic (Cont) Introduction (Cont)

M1084/M1086 Material Handling Crane Electrical System Maintenance
(MHC) Hydraulic Troubleshooting . . . . . . . . 2-35 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
No Service or External Hydraulic Power Engine Maintenance Introduction . . . . . . . . . . 3-1
From M1089 . . . . . . . . . . . . . . . . . . . . . . . 2-33 Exhaust System Maintenance
Steering Hydraulic System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-30 Fuel System Maintenance Introduction . . . . . . 4-1
Wrecker Hydraulic System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-33 J

I Jack
M1084/M1086 Jack Cylinder Proximity
Indicator Sensor Replacement . . . . . . . . . . . . . . . . . 7-51
CTIS Repeatedly Resumes Cycling Junction
30 Seconds After Indicator Lights M1084/M1086 Junction Box Assembly
Stop Flashing . . . . . . . . . . . . . . . . . . . . . 2-24 Replacement/Repair . . . . . . . . . . . . . . . . . 7-27
Five Central Tire Inflation System (CTIS) M1089 Junction Box Assembly
ECU Indicator Lights Flashing . . . . . . . . . . 2-24 Replacement/Repair . . . . . . . . . . . . . . . . . 7-32
Four CTIS ECU Indicator Lights
Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 K
Lighted Indicator Display
Replacement/Repair . . . . . . . . . . . . . . . . . 7-16 Kit
Inlet Chemical Alarm Kit Cable Assembly
Charge Air Cooler to Air Inlet Elbow Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-59
Tubes and Hoses Replacement . . . . . . . . . . 4-5
Inspection L
General Inspection Instructions . . . . . . . . . . . 2-43
Installation Leans to One Side or Rear Of Vehicle
General Installation Instructions . . . . . . . . . . 2-46 Sags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Instructions Left
General Assembly Instructions . . . . . . . . . . . 2-45 Hand Door and Cab Marker Lights Cable
General Cleaning Instructions . . . . . . . . . . . . 2-42 Assembly Replacement . . . . . . . . . . . . . . . 7-61
General Disassembly Instructions . . . . . . . . . 2-41 M1089 Stifflegs/Left 30K Winch/15K
General Inspection Instructions . . . . . . . . . . . 2-43 Self-Recovery Winch (SRW) Do Not
General Installation Instructions . . . . . . . . . . 2-46 Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
General Removal Instructions . . . . . . . . . . . . 2-40 Lever
General Repair Instructions . . . . . . . . . . . . . 2-44 Hand Throttle Lever Replacement/
Instrument Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Panel Assembly Replacement/Repair . . . . . . 7-15 Throttle Control Lever Replacement . . . . . . . 4-20
Intake Air Cleaner Filter Element, Air Cleaner Lifting Plate Replacement . . . . . . . . . . . . . . . . . 3-2
Assembly, and Particle Extraction Tube Light
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Backup Light Assembly Replacement/
Introduction Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Cooling System Maintenance Blackout Drive Light Replacement/
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

INDEX-6 Change 1
 TM 9-2320-366-20-3

Subject Para Subject Para

L (Cont) M

Light (Cont) Main

Clearance and Marker Light Assemblies Light Switch Replacement . . . . . . . . . . . . . . 7-17
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-38 Winch LH Freespool Does Not
Coolant Temperature Light Switch Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-22 Main Winch RH Freespool Does Not
Composite Front Light Assembly Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Replacement/Repair . . . . . . . . . . . . . . . . . 7-40 Main Winch LH or RH Freespool(s)
No Overspeed Warning Light and/or Does Not Operate . . . . . . . . . . . . . . . . . . . 2-37
Overspeed Pressure Change . . . . . . . . . . . 2-24 Maintenance Introduction . . . . . . . . . . . . . . . . . 2-38
Lighted Indicator Display Replacement/ Marker
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Cab Clearance Marker Lights Cable
Lights Assembly Replacement . . . . . . . . . . . . . . . 7-66
Cab Clearance Marker Lights Cable Clearance and Marker Light Assemblies
Assembly Replacement . . . . . . . . . . . . . . . 7-66 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-38
Five Central Tire Inflation System (CTIS) Left Hand Door and Cab Marker Lights
ECU Indicator Lights Flashing . . . . . . . . . . 2-24 Cable Assembly Replacement . . . . . . . . . . 7-61
Four CTIS ECU Indicator Lights M1093/M1094 Cab Clearance and
Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Marker Lights Lower Cable
Left Hand Door and Cab Marker Lights Assembly Replacement . . . . . . . . . . . . . . . 7-62
Cable Assembly Replacement . . . . . . . . . . 7-61 M1093/M1094 Cab Clearance and
M1093/M1094 Cab Clearance and Marker Lights Upper Cable
Marker Lights Lower Cable Assembly Replacement . . . . . . . . . . . . . . . 7-63
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-62 Right Hand Door and Cab Marker Lights
M1093/M1094 Cab Clearance and Cable Assembly Replacement . . . . . . . . . . 7-64
Marker Lights Upper Cable Material Handling Crane
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-63 M1084/M1086 Material Handling Crane
Right Hand Door and Cab Marker Lights (MHC) Hand Pump Will Not Work . . . . . . . . 2-35
Cable Assembly Replacement . . . . . . . . . . 7-64 M1084/M1086 Material Handling Crane
Two Steady Mode Lights Illuminate on (MHC) Hydraulic Troubleshooting . . . . . . . . 2-35
Central Tire Inflation System (CTIS) M1089 Material Handling Crane (MHC)
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Does Not Operate . . . . . . . . . . . . . . . . . . . 2-33
Linkage M1089 Material Handling Crane (MHC)
Governor Linkage Replacement . . . . . . . . . . 4-12 Hand Pump Does Not Work . . . . . . . . . . . . 2-33
LMHC MHC
Light Material Handling Crane (LMHC) M1084/M1086 Material Handling Crane
Does Not Operate . . . . . . . . . . . . . . . . . . . 2-31 (MHC) Hand Pump Will Not Work . . . . . . . . 2-35
Light Material Handling Crane (LMHC) M1084/M1086 Material Handling Crane
Hoist IN Does Not Operate . . . . . . . . . . . . . 2-31 (MHC) Hydraulic Troubleshooting . . . . . . . . 2-35
Light Material Handling Crane (LMHC) M1089 Material Handling Crane (MHC)
Hoist OUT Does Not Operate . . . . . . . . . . . 2-31 Does Not Operate . . . . . . . . . . . . . . . . . . . 2-33
Lower Coolant Hose Replacement . . . . . . . . . . 6-10 M1089 Material Handling Crane (MHC)
Lubrication Hand Pump Does Not Work . . . . . . . . . . . . 2-33
AOAP Sampling Intervals . . . . . . . . . . . . . . . H-3 Module
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 WTEC II Transmission ECU Pushbutton
Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6 Shift Selector (TEPSS) Dimmer Module
Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-13
Local Views . . . . . . . . . . . . . . . . . . . . . . . . . H-8 Motor
Locator Views . . . . . . . . . . . . . . . . . . . . . . . H-7 Starting Motor Replacement . . . . . . . . . . . . . . 7-7
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-9 Muffler and Exhaust Heat Shields
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . H-2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warranty Hardtime Statement . . . . . . . . . . . . H-4

Change 1 INDEX-7
TM 9-2320-366-20-3

SUBJECT INDEX (CONT)

Subject Para Subject Para

M (Cont) N
M1084/M1086 NATO Power Cable Replacement .......................... 7-70
Jack Cylinder Proximity Sensor No
Replacement ................................................. 7-51 Overspeed Warning Light and/or
Junction Box Assembly Overspeed Pressure Change ............................. 2-24
Replacement/Repair ....................................... 7-27 Power to Digitization Rack ................................ 2-34
Material Handling Crane (MHC) Hand Power to Driver Visual Enhancement (DVE) ........ 2-34
Pump Will Not Work ...................................... 2-35 Power to Enhanced Position Location
Material Handling Crane (MHC) Hydraulic Reporting System (EPLRS) ............................ 2-34
Troubleshooting ............................................. 2-35 Power to Mobile Tracking system (MTS)............. 2-34
M1088/M1089 Power to Mobile Tracking System (MTS)
Stationary Worklight Assembly Sense........................................................... 2-34
Replacement/Repair ....................................... 7-42 Power to Precision Lightweight Global
M1089 Positioning System Receiver (PLGR) ............... 2-34
Fold Cylinder Does Not Operate ........................ 2-33 Power to SINCGAR/Force XXI Battle
Junction Box Assembly Command Brigade and Below (FBCB).............. 2-34
Replacement/Repair ....................................... 7-32 Response When Turning Steering Wheel............ 2-26
LH 30K Winch Does Not Operate ...................... 2-33 Service or External Hydraulic Power
LH or RH 30K Winch Cable Drum From M1089 .................................................. 2-33
Tensioner Does Not Operate ........................... 2-37
LH or RH 30K Winch Does Not O
Pay-In ........................................................... 2-37
Material Handling Crane (MHC) Does Oil
Not Operate................................................... 2-33 Filter Replacement ............................................. 3-4
Material Handling Crane (MHC) Hand Pressure Switch Replacement ........................... 7-48
Pump Does Not Work .................................... 2-33 Pressure Transmitter Replacement .................... 7-49
No Service or External Hydraulic Power One Wrecker Function Does Not Operate
From M1089 .................................................. 2-33 From Wrecker Remote Control .......................... 2-37
RH 30K Winch Does Not Operate...................... 2-33 Orifice Tube Assembly Replacement ....................... 4-5
Stiffleg(s) Does Not Operate or Operates Overflow
Slowly........................................................... 2-33 Radiator Overflow Tank and Bracket
Stifflegs/Left 30K Winch/15K Replacement/Repair ......................................... 6-3
Self-Recovery Winch (SRW) Do Not Overspeed
Operate......................................................... 2-33 No Overspeed Warning Light and/or
Stinger Does Not Operate ................................. 2-33 Overspeed Pressure Change ........................... 2-24
Stinger/Telescopic Lift Cylinders/Fold
Cylinder/Right 30K Winch Do Not P
Operate......................................................... 2-33
Terminal Board Replacement ............................. 7-33 Panel
Underlift Telescopic Lift Cylinder(s) Does Auxiliary Panel Cable Assembly
Not Operate................................................... 2-33 Replacement ................................................. 7-58
Wrecker Control Panel Toggle Switch Auxiliary Panel Replacement ............................... 7-8
Replacement ................................................. 7-34 Instrument Panel Assembly Replacement/
Wrecker Remote Control Box Repair.................. 7-35 Repair ........................................................... 7-15
M1090/M1094 M1089 Wrecker Control Panel Toggle
Dump Body Switch Replacement/ Switch Replacement ...................................... 7-34
Adjustment .................................................... 7-23 Pay-In
M1093/M1094 M1089 LH or RH 30K Winch Does
Cab Clearance and Marker Lights Lower Not Pay-In ..................................................... 2-37
Cable Replacement ........................................ 7-62
Cab Clearance and Marker Lights Upper
Cable Replacement ........................................ 7-63

INDEX-8 Change 2
 TM 9-2320-366-20-3

Subject Para Subject Para

P (Cont) R
Pedal Radiator
Accelerator Pedal Replacement ......................... 4-21 /Charge Air Cooler Replacement .......................... 6-2
Personnel Fan Shrouds Replacement .................................. 6-4
Heater Hoses Replacement ................................. 6-8 Overflow Tank and Bracket Replacement/
Pipe Repair ............................................................. 6-3
Exhaust Pipe Replacement ................................. 5-3 Rear
Pneumatic Leans to One Side or Rear Of
Wrecker Pneumatic Troubleshooting .................. 2-37 Vehicle Sags ................................................. 2-28
Power Regulator
No Power to Digitization Rack ........................... 2-34 100 Amp Voltage Regulator
No Power to Driver Visual Enhancement Replacement ................................................... 7-5
(DVE) ........................................................... 2-34 Relay
No Power to Enhanced Position Location Battery to 100 Amp Reverse Polarity
Reporting System (EPLRS) ............................ 2-34 Relay 12 VDC Cable Replacement .................. 7-74
No Power to Mobile Tracking system (MTS)........ 2-34 Battery to 100 Amp Reverse Polarity
No Power to Mobile Tracking System (MTS) Relay 24 VDC Cable Replacement .................. 7-75
Sense........................................................... 2-34 Circuit Breaker, Diode, and Relay
No Power to Precision Lightweight Global Replacement ................................................... 7-9
Positioning System Receiver (PLGR) ............... 2-34 100 Amp Alternator to Reverse Polarity
No Power to SINCGAR/Force XXI Battle Relay 12 VDC Cable Replacement .................. 7-72
Command Brigade and Below (FBCB).............. 2-34 100 Amp Alternator to Reverse Polarity
Preparation Relay 24 VDC Cable Replacement .................. 7-73
for Storage or Shipment .................................... 2-48 100 Amp Reverse Polarity Relay
for Storage or Shipment Introduction .................. 2-47 Replacement ................................................. 7-30
Pressure Remote
Air Pressure Transmitter Replacement ............... 7-44 Crane Remote Control Box Repair ..................... 7-32
No Overspeed Warning Light and/or M1089 Wrecker Remote Control Box
Overspeed Pressure Change ........................... 2-24 Repair ........................................................... 7-35
Oil Pressure Switch Replacement ...................... 7-48 One Wrecker Function Does Not Operate
Oil Pressure Transmitter Replacement ............... 7-49 From Wrecker Remote Control ........................ 2-37
Pulls Removal
Wanders, Pulls to One Side, or General Removal Instructions ............................ 2-40
Shimmies ...................................................... 2-26 Repair
Wanders, Pulls to One Side, or General Repair Instructions ............................... 2-44
Shimmies ...................................................... 2-28 Reverse Polarity
Pump Battery to 100 Amp Reverse Polarity
M1084/M1086 Material Handling Crane Relay 12 VDC Cable Replacement .................. 7-74
(MHC) Hand Pump Will Not Work .................... 2-35 Battery to 100 Amp Reverse Polarity
M1089 Material Handling Crane (MHC) Relay 24 VDC Cable Replacement .................. 7-75
Hand Pump Does Not Work ............................ 2-33 100 Amp Reverse Polarity Relay
Water Pump and Fittings Replacement .............. 6-12 Replacement ................................................. 7-30
Windshield Washer Pump Electromagnetic 100 Amp Alternator to Reverse Polarity
Interference (EMI) Cable Assembly Relay 12 VDC Cable Replacement .................. 7-72
Replacement ................................................. 7-67 100 Amp Alternator to Reverse Polarity
Pushbutton Relay 24 VDC Cable Replacement .................. 7-73
Start Inhibit Pushbutton Switch Right
Replacement ................................................. 7-19 Hand Door and Cab Marker Lights Cable
Starter Pushbutton Switch Assembly Replacement .................................. 7-64
Replacement ................................................. 7-20 M1089 Stinger/Telescopic Lift Cylinders/
WTEC II Transmission ECU Pushbutton Fold Cylinder/Right 30K Winch Do
Shift Selector (TEPSS) Dimmer Module Not Operate................................................... 2-33
Replacement ................................................. 7-13 Rocker Switches Replacement ............................. 7-18
Rod
Throttle Control Threaded Rod
Replacement .................................................... 4-19

Change 2 INDEX-9
TM 9-2320-366-20-3

SUBJECT INDEX (CONT)

Subject Para Subject Para

S S (Cont)

Self-Recovery Speed
M1089 Stifflegs/Left 30K Winch/15K Engine Speed Sensor Replacement/
Self-Recovery Winch (SRW) Do Not Operate 2-33 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-46
15K Self-Recovery Winch (SRW) System SRW
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-29 15K Self-Recovery Winch (SRW) System
15K Self-Recovery Winch (SRW) Will Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-29
Not Work . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 15K Self-Recovery Winch (SRW) Will
Sensor Not Work . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Coolant Temperature Gage Sensor Start
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-45 Inhibit Pushbutton Switch
Engine Speed Sensor Replacement/ Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-19
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Starter
Ether Sensor Replacement . . . . . . . . . . . . . . 7-47 Auxiliary Starter Solenoid Replacement . . . . . . 7-6
M1084/M1086 Jack Cylinder Proximity Battery to Starter Cable Assembly
Sensor Replacement . . . . . . . . . . . . . . . . . 7-51 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-77
Throttle Position Sensor (TPS) Cable Pushbutton Switch Replacement . . . . . . . . . . 7-20
Assembly Replacement . . . . . . . . . . . . . . . 4-16 Starting
Transmission Engine Speed Sensor Ether Starting Aid Replacement . . . . . . . . . . 4-15
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-52 Motor Replacement . . . . . . . . . . . . . . . . . . . . 7-7
Shift Stationary
WTEC II Transmission ECU Pushbutton M1088/M1089 Stationary Worklight
Shift Selector (TEPSS) Dimmer Module Assembly Replacement/Repair . . . . . . . . . . 7-42
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-13 STE/ICE-R Cable Assembly Replacement . . . . 7-65
Shimmies Steering
Wanders, Pulls to One Side, or Excessive Play When Turning Steering
Shimmies . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Wanders, Pulls to One Side, or Hard or Will Not Work . . . . . . . . . . . . . . . . . 2-30
Shimmies . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Hydraulic System Troubleshooting . . . . . . . . 2-30
Shipment No Response When Turning Steering
Preparation for Storage or Shipment . . . . . . . 2-48 Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Preparation for Storage or Shipment System Maintenance Introduction . . . . . . . . . 13-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2-26
Shrouds Stiffleg
Radiator Fan Shrouds Replacement . . . . . . . . 6-4 M1089 Stiffleg(s) Does Not Operate or
Shunt Operates Slowly . . . . . . . . . . . . . . . . . . . . 2-33
Battery to Shunt Cable Assembly Stifflegs
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-76 M1089 Stifflegs/Left 30K Winch/15K
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Self-Recovery Winch (SRW) Do Not
Solenoid Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Auxiliary Starter Solenoid Replacement . . . . . . 7-6 Stinger
Fan and Differential Lock Solenoids M1089 Stinger Does Not Operate . . . . . . . . . 2-33
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-24 M1089 Stinger/Telescopic Lift Cylinders/
Spare Fold Cylinder/Right 30K Winch Do
Tire Retainer Does Not Lower . . . . . . . . . . . 2-36 Not Operate . . . . . . . . . . . . . . . . . . . . . . . 2-33
Tire Retainer Does Not Raise . . . . . . . . . . . . 2-36 Storage
Special Purpose Kit Troubleshooting . . . . . . . . 2-34 Preparation for Storage or Shipment . . . . . . . 2-48
Preparation for Storage or Shipment
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 2-47

INDEX-10 Change 1
 TM 9-2320-366-20-3

Subject Para Subject Para

S (Cont) T (Cont)

Storage Maintenance Procedures . . . . . . . . . . . 2-49 Tank

Suspension Fuel Tank Replacement . . . . . . . . . . . . . . . . . 4-8
System Troubleshooting . . . . . . . . . . . . . . . . 2-28 Radiator Overflow Tank and Bracket
Will Not Compress or Return to Normal . . . . . 2-31 Replacement/Repair . . . . . . . . . . . . . . . . . . 6-3
Switch Telescopic
Dimmer Switch Replacement . . . . . . . . . . . . 7-12 M1089 Stinger/Telescopic Lift Cylinders/
M1089 Wrecker Control Panel Toggle Fold Cylinder/Right 30K Winch Do
Switch Replacement . . . . . . . . . . . . . . . . . 7-34 Not Operate . . . . . . . . . . . . . . . . . . . . . . . 2-33
M1090/M1094 Dump Body Switch Temperature
Replacement/Adjustment . . . . . . . . . . . . . . 7-23 Coolant Temperature Gage Sensor
Main Light Switch Replacement . . . . . . . . . . 7-17 Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-45
Oil Pressure Switch Replacement . . . . . . . . . 7-48 Coolant Temperature Light Switch
Start Inhibit Pushbutton Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-22
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-19 Water Temperature Switch
Starter Pushbutton Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-50
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-20 Tensioner
Turn Signal Switch Replacement . . . . . . . . . 7-26 M1089 LH or RH 30K Winch Cable
Water Temperature Switch Drum Tensioner Does Not Operate . . . . . . . 2-37
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-50 Terminal
Switches M1089 Terminal Board Replacement . . . . . . 7-33
Rocker Switches Replacement . . . . . . . . . . . 7-18 Tester
System Battery Tester Replacement . . . . . . . . . . . . . 7-54
Dump Body Hydraulic System Thermostat
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-32 Housing Replacement . . . . . . . . . . . . . . . . . . 6-6
Fuel System Bleeding . . . . . . . . . . . . . . . . . 4-11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cooling System Maintenance Throttle
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Control Cable Replacement/Adjustment . . . . . 4-18
Electrical System Maintenance Control Lever Replacement . . . . . . . . . . . . . 4-20
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Control Threaded Rod Replacement . . . . . . . 4-19
Exhaust System Maintenance Hand Throttle Lever Replacement/
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Fuel System Maintenance Introduction . . . . . . 4-1 Position Sensor (TPS) Cable Assembly
Steering Hydraulic System Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-30 Tilt
Suspension System Troubleshooting . . . . . . . 2-28 Cab Tilt and Spare Tire Retainer
Wrecker Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-33 Cab Tilt, Spare Tire Retainer, and
15K Self-Recovery Winch (SRW) System Suspension Compression Will
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-29 Not Work . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Tire
T Central Tire Inflation System (CTIS)
Cable Assembly Replacement . . . . . . . . . . 7-60
Tachometer Replacement . . . . . . . . . . . . . . . . 7-21 Central Tire Inflation System (CTIS)
Taillight ECU Indicates No Fault But System
Composite Taillight Assembly Fails to Inflate or Deflate . . . . . . . . . . . . . 2-24
Replacement/Repair . . . . . . . . . . . . . . . . . 7-39 Central Tire Inflation System (CTIS)
Tailpipe Replacement . . . . . . . . . . . . . . . . . . . . 5-4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-24
CTIS Repeatedly Resumes Cycling
30 Seconds After Indicator Lights
Stop Flashing . . . . . . . . . . . . . . . . . . . . . 2-24

Change 1 INDEX-11
TM 9-2320-366-20-3

SUBJECT INDEX (CONT)

Subject Para Subject Para

T (Cont) T (Cont)
Tire (Cont) Troubleshooting (Cont)
Five Central Tire Inflation System (CTIS) Suspension System Troubleshooting ................. 2-28
Indicator Lights Flashing ................................. 2-24 Wrecker Hydraulic System
Four CTIS Indicator Lights Troubleshooting ............................................. 2-33
Flashing ........................................................ 2-24 Wrecker Pneumatic Troubleshooting .................. 2-37
Spare Tire Retainer Does Not Lower................... 2-36 Tube
Spare Tire Retainer Does Not Raise................... 2-36 Turbocharger to Charge Air Cooler Tube
Two Steady Mode Lights Illuminate on and Hoses Replacement ................................... 4-4
Central Tire Inflation System (CTIS) Coolant Bypass Tube Replacement ..................... 6-7
ECU ............................................................. 2-24 Fuel Ratio Control Tube Replacement .................. 4-6
TPS Intake Air Cleaner Filter Element, Air
Throttle Position Sensor (TPS) Cable Cleaner Assembly, and Particle Extraction
Assembly Replacement .................................. 4-16 Tube Replacement ........................................... 4-2
Trailer Orifice Tube Assembly Replacement .................... 4-5
Excessive Movement of Trailer King Pin Upper Coolant Tube and Hoses
In Fifth Wheel ................................................ 2-27 Replacement ................................................... 6-9
Transmission Tubes
Engine and Transmission Oil Sampling Charge Air Cooler to Air Inlet Elbow
Valves Replacement ......................................... 3-6 Tubes and Hoses Replacement ......................... 4-5
Engine Speed Sensor Replacement ................... 7-52 Turbocharger to Charge Air Cooler Tube
WTEC II Transmission ECU Pushbutton and Hoses Replacement ..................................... 4-4
Shift Selector (TEPSS) Dimmer Module Turn Signal Switch Replacement ........................... 7-26
Replacement ................................................. 7-13 Two
Transmitter Steady Mode Lights Illuminate on
Air Pressure Transmitter Replacement ............... 7-44 Central Tire Inflation System (CTIS)
Oil Pressure Transmitter Replacement ............... 7-49 ECU ............................................................. 2-24
Transport/Transportability
Air Transport Troubleshooting ............................ 2-31 U
Troop Transport Alarm Does Not
Operate......................................................... 2-31 Underlift
Troop M1089 Underlift Telescopic Lift
Transport Alarm Does Not Operate .................... 2-31 Cylinder(s) Does Not Operate.......................... 2-33
Troubleshooting Upper Coolant Tube and Hoses
15K Self-Recovery Winch (SRW) System Replacement ..................................................... 6-9
Troubleshooting ............................................. 2-29
Axle Troubleshooting ........................................ 2-25 V
Dump Body Hydraulic System
Troubleshooting ............................................. 2-32 Valve
Fifth Wheel Troubleshooting .............................. 2-27 Cover Replacement ............................................ 3-3
M1084/M1086 Material Handling Crane Fuel Pressure Regulating Valve
(MHC) Hydraulic Troubleshooting..................... 2-35 Replacement ................................................... 4-3
Special Purpose Kit Troubleshooting .................. 2-34 Voltage
Steering Hydraulic System 100 Amp Voltage Regulator
Troubleshooting ............................................. 2-30 Replacement ................................................... 7-5
Steering Troubleshooting................................... 2-26

INDEX-12 Change 2
 TM 9-2320-366-20-3

Subject Para Subject Para

W W (Cont)

Wanders, Windshield
Pulls to One Side, or Washer Pump Electromagnetic Interference
Shimmies . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 (EMI) Cable Assembly Replacement . . . . . . 7-67
Pulls to One Side, or Wiper ECU Replacement . . . . . . . . . . . . . . . 7-69
Shimmies . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Wiper Electromagnetic Interference
Warning (EMI) Cable Replacement . . . . . . . . . . . . . 7-68
No Overspeed Warning Light and/or Wiper
Overspeed Pressure Change . . . . . . . . . . . 2-24 Windshield Wiper ECU Replacement . . . . . . 7-69
Washer Windshield Wiper Electromagnetic
Windshield Washer Pump Electromagnetic Interference (EMI) Cable
Interference (EMI) Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-68
Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-67 Worklight
Water M1088/M1089 Stationary Worklight
Fuel/Water Separator and Filter Assembly Replacement/Repair . . . . . . . . . . 7-42
Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-13 Wrecker
Pump and Fittings Replacement . . . . . . . . . . 6-12 Hydraulic System Troubleshooting . . . . . . . . 2-33
Temperature Switch Replacement . . . . . . . . . 7-50 M1089 Wrecker Control Panel Toggle
Wheel Switch Replacement . . . . . . . . . . . . . . . . . 7-34
Fifth Wheel Troubleshooting . . . . . . . . . . . . . 2-27 M1089 Wrecker Remote Control Box
Fifth Wheel Will Not Lock When Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Trailer to Tractor . . . . . . . . . . . . . . . . . . . . 2-27 One Wrecker Function Does Not Operate
Fifth Wheel Will Not Unlock When From Wrecker Remote Control . . . . . . . . . . 2-37
Disconnecting Trailer From Tractor . . . . . . . 2-27 Pneumatic Troubleshooting . . . . . . . . . . . . . 2-37
No Response When Turning Steering
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Winch
M1089 LH or RH 30K Winch Cable
Drum Tensioner Does Not Operate . . . . . . . 2-37
M1089 LH or RH 30K Winch Does
Not Pay-In . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
M1089 RH 30K Winch Does Not Operate . . . 2-33
M1089 Stifflegs/Left 30K Winch/15K
Self-Recovery Winch (SRW) Do Not
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
M1089 Stinger/Telescopic Lift Cylinders/
Fold Cylinder/Right 30K Winch Do
Not Operate . . . . . . . . . . . . . . . . . . . . . . . 2-33
15K Self-Recovery Winch (SRW) System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2-29
15K Self-Recovery Winch (SRW) Will
Not Work . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Main Winch LH Freespool Does Not
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Main Winch RH Freespool Does Not
Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Main Winch LH or RH Freespool(s)
Does Not Operate . . . . . . . . . . . . . . . . . . . 2-37

Change 1 INDEX-13/(INDEX-14 Blank)

 TM 9-2320-366-20-3

GLOSSARY
ABBREVIATIONS
ANSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . American National Standards Institute

CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise

CTIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central Tire Inflation System

CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise

ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Unit

EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Interference

LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Emitting Diode

LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Hand

LMHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Material Handling Crane

MAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Allocation Chart

MHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling Crane

NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization

NBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, or Chemical

NO/NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normally Open/Normally Closed

O/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outrigger

PDP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Distribution Panel

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

PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Takeoff

RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Hand

SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Society of Automotive Engineers

SRW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Recovery Winch

STE/ICE-R . . . . . . . . . . . . . . . . . . . . . . . Simplified Test Equipment/Internal Combustion Engine-Reprogrammable

TEPSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECU Pushbutton Shift Selector

TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Manual

TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thottle Position Sensor

Glossary-1
TM 9-2320-366-20-3

GLOSSARY
ABBREVIATIONS (CONT)

TPSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Pushbutton Shift Selector

VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts Direct Current

VIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Interface Module

WTEC II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . World Transmission Electronic Controls (version 2)

WTEC III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . World Transmission Electronic Controls (version 3)

Glossary-2
 By Order of the Secretary of the Army:

DENNIS J. REIMER
General, United States Army
Chief of Staff

Administrative Assistant to the

Secretary of the Army
05127

DISTRIBUTION: To be distributed in accordance with the initial distribution

number (IDN) 380940, requirements for TM 9-2320-366-20-3.

U.S. GOVERNMENT PRNITING OFFICE:1998-746-025/80065

 Use Part II (reverse) for Repair Parts and DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists (RPSTL) and Supply
BLANK FORMS Catalogs/Supply Manuals (SC/SM).
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) FROM: (Activity and location) (Include ZIP Code)

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE

PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

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

USAPA V3.01
 Use Part II (reverse) for Repair Parts and DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists (RPSTL) and Supply
BLANK FORMS Catalogs/Supply Manuals (SC/SM).
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) FROM: (Activity and location) (Include ZIP Code)

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE

PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

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

USAPA V3.01
 Use Part II (reverse) for Repair Parts and DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists (RPSTL) and Supply
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PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
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PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
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PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
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 THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE SQUARE MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 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 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Lb 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

LIQUID MEASURE TEMPERATURE

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 5/9 (°F - 32) = °C
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 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°

APPROXIMATE CONVERSION FACTORS

TO CHANGE TO MULTIPLY BY TO CHANGE TO MULTIPLY BY

Inches . . . . . . . . . . . . . . . . Centimeters . . . . . . . . 2.540 Centimeters . . . . . . . Inches . . . . . . . . . . . . . 0.394

Inches . . . . . . . . . . . . . . . . Millimeters . . . . . . . . . . 25.4 Millimeters . . . . . . . . Inches . . . . . . . . . . . . 0.0394
Feet . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . 0.305 Meters . . . . . . . . . . . Feet . . . . . . . . . . . . . . . 3.280
Yards . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . 0.914 Meters . . . . . . . . . . . Yards . . . . . . . . . . . . . . 1.094
Miles . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . 1.609 Kilometers . . . . . . . . Miles . . . . . . . . . . . . . . 0.621
Square Inches . . . . . . . . . . Square Centimeters . . 6.451 Sq Centimeters . . . . . Square Inches . . . . . . . 0.155
Square Feet . . . . . . . . . . . . Square Meters . . . . . . 0.093 Square Meters . . . . . Square Feet . . . . . . . . 10.764
Square Yards . . . . . . . . . . . Square Meters . . . . . . 0.836 Square Meters . . . . . Square Yards . . . . . . . . 1.196
Square Miles . . . . . . . . . . . Square Kilometers . . . 2.590 Square Kilometers . . Square Miles . . . . . . . . 0.386
Acres . . . . . . . . . . . . . . . . . Square Hectometers . 0.405 Sq Hectometers . . . . Acres . . . . . . . . . . . . . . 2.471
Cubic Feet . . . . . . . . . . . . . Cubic Meters . . . . . . . 0.028 Cubic Meters . . . . . . Cubic Feet . . . . . . . . . 35.315
Cubic Yards . . . . . . . . . . . . Cubic Meters . . . . . . . 0.765 Cubic Meters . . . . . . Cubic Yards . . . . . . . . . 1.308
Fluid Ounces . . . . . . . . . . . Milliliters . . . . . . . . . . 29.57 Milliliters . . . . . . . . . . Fluid Ounces . . . . . . . . 0.034
Pints . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . 0.473 Liters . . . . . . . . . . . . Pints . . . . . . . . . . . . . . 2.113
Quarts . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . 0.946 Liters . . . . . . . . . . . . Quarts . . . . . . . . . . . . . 1.057
Gallons . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . 3.785 Liters . . . . . . . . . . . . Gallons . . . . . . . . . . . . . 0.264
Ounces . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . 28.35 Grams . . . . . . . . . . . Ounces . . . . . . . . . . . . 0.035
Pounds . . . . . . . . . . . . . . . Kilograms . . . . . . . . . 0.454 Kilograms . . . . . . . . . Pounds . . . . . . . . . . . . . 2.205
Pounds (force) . . . . . . . . . . Newtons . . . . . . . . . . 4.448 Newtons . . . . . . . . . . Pounds (force) . . . . . . 0.2248
Short Tons . . . . . . . . . . . . . Metric Tons . . . . . . . . 0.907 Metric Tons . . . . . . . Short Tons . . . . . . . . . . 1.102
Pound-Feet . . . . . . . . . . . . Newton-Meters . . . . . 1.356 Newton-Meters . . . . . Pound-Feet . . . . . . . . . 0.738
Pounds/Sq Inch . . . . . . . . . Kilopascals . . . . . . . . 6.895 Kilopascals . . . . . . . . Pounds per Sq Inch . . . 0.145
Miles per Gallon . . . . . . . . . Kilometers per Liter . . 0.425 Km per Liter . . . . . . . Miles per Gallon . . . . . . 2.354
Miles per Hour . . . . . . . . . . Kilometers per Hour . . 1.609 Km per Hour . . . . . . Miles per Hour . . . . . . . 0.621

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