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TM 9-2320-279-34-1

Transmission Maintenance Instructions (Cont)

7-10. TRANSMISSION HOUSING REPAIR (CONT).

(9)

Remove

(10)

Remove

fourth clutch pressure tap plug (10).
reverse signal switch plug (11).

(11) Remove five studs (12).

b . C l e a n i n g / I n s p e c t i o n .

WARNlNG

Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. ‘lb avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash

immediately with soap and water.

(1) Clean transmission housing and all metal parts with dry cleaning solvent.
(2) Inspect parts for damage. Replace damaged parts.
(3) If signs of damage to transmission housing are noted, replace transmission housing.

c. Assembly.

(1) Install five studs (1).

7 - 7 0

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Summary of Contents for 2320-01-097-0248

Page 1: ...8216 TRUCK TANK FUEL WITH WINCH M978A2R1 2320 01 492 8226 TRUCK TANK FUEL WITHOUT WINCH M978 2320 01 100 7672 TRUCK TANK FUEL WITHOUT WINCH M978A2 2320 01 492 8215 TRUCK TANK FUEL WITHOUT WINCH M978A...

Page 2: ......

Page 3: ...immediate medical attention For artificial respiration refer to FM 21 11 BE AWARE that the gas particulate filter unit or the field protection mask for nuclear biological chemical protection WILL NOT...

Page 4: ...om vehicles involved in winching operations A snapped cable or shifting load can cause serious injury or death W A R N I N G Always wear heavy gloves when handling winch cables Never let cable run thr...

Page 5: ...ted 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 NB...

Page 6: ...ry or death to personnel S When grinding avoid creating excess heat on CARC painted surfaces near grinding area CARC paint can ignite if heated Failure to comply may result in serious injury or death...

Page 7: ...1 492 8215 TRUCK TANK FUEL WITHOUT WINCH M978A2R1 2320 01 492 8225 TRUCK TRACTOR WITH WINCH WITHOUT CRANE M983 2320 01 097 0247 TRUCK TRACTOR WITH WINCH WITHOUT CRANE M983A2 2320 01 492 8223 TRUCK TRA...

Page 8: ...ing hand 4 Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the illustration identification number Remove Pages Insert Pages A thru C D blank A thru...

Page 9: ...0 01 492 8215 TRUCK TANK FUEL WITHOUT WINCH M978A2R1 2320 01 492 8225 TRUCK TRACTOR WITH WINCH WITHOUT CRANE M983 2320 01 097 0247 TRUCK TRACTOR WITH WINCH WITHOUT CRANE M983A2 2320 01 492 8223 TRUCK...

Page 10: ...by a miniature pointing hand 4 Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the illustration identification number Remove Pages Insert Pages A th...

Page 11: ...UCK WRECKER RECOVERY M984E1 2320 01 195 7641 TRUCK CARGO WITH WINCH M985 2320 01 097 0261 TRUCK CARGO WITHOUT WINCH M985 2320 01 100 7673 TRUCK CARGO WITH WINCH M985E1 2320 01 194 7032 TRUCK CARGO WIT...

Page 12: ...6 105 6 106 6 111 6 114 6 111 6 114 6 119 6 120 6 119 6 120 6 122 13 6 122 14 blank 6 122 13 6 122 14 blank 6 123 6 124 6 123 6 124 6 131 6 132 6 131 6 132 6 133 6 134 blank 6 133 6 134 blank 7 67 7...

Page 13: ...ECKER RECOVERY M984E1 2320 01 195 7641 TRUCK CARGO WITH WINCH M985 2320 01 097 0261 TRUCK CARGO WITHOUT WINCH M985 2320 01 100 7673 TRUCK CARGO WITH WINCH M985E1 2320 01 194 7032 TRUCK CARGO WITHOUT W...

Page 14: ...inistrative Assistant to the Secretary of the Army ERIC K SHINSEKI General United States Army Chief of Staff Official 0026313 DISTRIBUTION To be distributed in accordance with the Initial Distribution...

Page 15: ...TH WINCH M985 2320 01 097 0261 TRUCK CARGO WITHOUT WINCH M985 2320 01 100 7673 TRUCK CARGO WITH WINCH M985E1 2320 01 194 7032 TRUCK CARGO WITHOUT WINCH M985E1 2320 01 194 7031 Approved for public rele...

Page 16: ...7 thru 2 122 2 127 and 2 128 2 129 through 2 136 deleted none 2 137 and 2 138 2 138 1 2 138 2 blank 2 139 and 2 140 3 7 and 3 8 3 13 thru 3 16 3 19 and 3 20 3 25 and 3 26 6 1 and 6 2 6 7 and 6 8 6 13...

Page 17: ...28 F B DA 2028 F B DA 2028 F B Cover Insert Pages 8 37 thru 8 44 8 47 thru 8 54 9 3 thru 9 6 9 11 and 9 12 9 15 and 9 16 9 19 and 9 20 9 20 1 9 20 2 blank 9 21 and 9 22 9 25 and 9 26 9 35 and 9 36 9 3...

Page 18: ...IS J REIMER General United States Army Chief of Staff Administrative Assistant to the Secretary of the Army 05642 DISTRIBUTION To be distributed in accordance with the Initial Distribution Number IDN...

Page 19: ...TH WINCH M985E1 TRUCK CARGO WITHOUT WINCH M985E1 TM 9 2320 279 34 1 3 June 1987 is changed as follows 1 Remove old pages and insert new pages as indicated below 2 New or changed material is indicated...

Page 20: ...The Adjutant General C A R L E V U O N O General United States Army Chief of Staff Distribution To be distributed in accordance with DA Form 12 38 Direct Support and General Support maintenance requir...

Page 21: ......

Page 22: ......

Page 23: ...ES IN THIS PUBLICATION IS 780 CONSISTING OF THE FOLLOWING Page WP Change Page WP Change Page WP Change No No No No No No Cover 7 Blank 7 a b 0 c d 7 i ii 6 ii 1 6 ii 2 blank 6 iii 0 iv v 3 vi viii 1 1...

Page 24: ...6 122 14 Blank 5 6 123 0 6 124 5 6 125 6 130 0 6 131 6 132 5 6 133 5 6 134 Blank 5 7 1 7 7 0 7 8 3 7 9 7 10 0 7 10 1 3 7 10 2 Blank 3 7 11 7 19 0 7 20 3 7 21 7 22 0 7 23 3 7 24 7 26 0 7 27 3 7 28 7 30...

Page 25: ...0 8 2 3 8 2 1 0 8 2 2 Blank 0 8 3 0 8 4 3 8 5 8 6 0 8 7 3 8 8 3 8 9 8 11 0 8 12 3 8 13 8 17 0 8 18 3 8 19 8 20 0 8 21 8 22 3 8 23 8 24 0 8 25 8 29 3 8 30 8 32 0 8 33 8 34 3 8 35 8 37 0 8 38 3 8 39 8 4...

Page 26: ......

Page 27: ...20 01 492 8215 TRUCK TANK FUEL WITHOUT WINCH M978A2R1 2320 01 492 8225 TRUCK TRACTOR WITH WINCH WITHOUT CRANE M983 2320 01 097 0247 TRUCK TRACTOR WITH WINCH WITHOUT CRANE M983A2 2320 01 492 8223 TRUCK...

Page 28: ...793 0726 or Commercial 309 782 0726 M983 with crane and M985E1 without winch are no longer in the fleet Ignore all references to these vehicles The M984E1 and M984A1 are the same vehicle All reference...

Page 29: ...ter 7 72 Section VI Gear Unit and Main Shaft 7 77 Section VII Clutch Assemblies 7 91 Section VIII Valve Bodies and Governor 7 135 CHAPTER 8 TRANSFER CASE MAINTENANCE 8 1 Section I Introduction 8 1 Sec...

Page 30: ......

Page 31: ...tion V Steering System Adjustments CHAPTER 14 SUSPENSION MAINTENANCE 14 1 Section I Introduction Section II Spring Assembly 14 1 14 1 Section III Lateral Torque Rod and Equalizer Beams 14 11 CHAPTER 1...

Page 32: ...ection V Section VI Section VII CHAPTER 23 Section I Section II Section III Section IV Section V APPENDIXES Introduction Service and Inspection Pump Pump Motor and Auxiliary Pump Flow Meter Air Elimin...

Page 33: ...Valve 17 15 Overload Solenoid M977 Only 17 16 Hoist Hoses and Tubes Left Side 17 16 4 Hoist Hoses and Tubes Right Side 17 16 5 Lift Cylinder Swing Drive 17 16 6 17 16 7 Main Lines 17 16 8 Shutdown Va...

Page 34: ...7 21 17 22 17 23 17 24 17 25 Title Page Nomenclature Cross Reference 1 6 Significant Hazards and Safety Recommendations l 7 Troubleshooting Fault Symptom Index 2 2 Troubleshooting Subject Index 2 5 Tr...

Page 35: ...ne Listed below are some of the special features which have been put into help locate and use needed information The front cover index provides a quick reference to chapters and sections that will be...

Page 36: ...edures have columns with the headings MALFUNCTION TEST OR INSPECTION and CORRECTIVE ACTION Starting at step 1 read the procedure Each step describes what to do and what to look for Follow the steps in...

Page 37: ...ls are listed below M977 Cargo vehicle with self recovery winch fig 1 1 Cargo vehicle without self recovery winch M978 Fuel tanker vehicle with self recovery winch fig 1 2 Fuel tanker vehicle without...

Page 38: ...1 1 Figure 1 1 Figure 1 2 TM 9 2320 279 34 1 1 2...

Page 39: ...Figure 1 3 Figure 1 4 TM 9 2320 279 34 1 1 3...

Page 40: ...1 1 Figure 1 5 Figure 1 6 TM 9 2320 279 34 1 1 4...

Page 41: ...nagement System TAMMS 1 3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Command decision according to the tactical situation will determine when the destruction of the M977 series vehicles will be...

Page 42: ...to the EIR program The TB 43 0001 39 series contains information on equipment improvements minor alterations proposed Modification Work Orders MWO s warranties if applicable actions taken on some of...

Page 43: ...on Vehicle instability with Ensure that outriggers are down on firm ground side Abnormal crane use slope does not exceed five degrees and crane is not overloaded Fire with M978 tanker No smoking flame...

Page 44: ...uction plates are located on the heater compartment cover in the cab and at each of the fixed operating stations 2 The outrigger leg signs are located on each of the outrigger cylinders 3 The load cap...

Page 45: ...nspection are also covered Section Il REPAIR PARTS SPECIAL TOOLS AND TEST EQUIPMENT Parts Tools and Test Equipment 2 2 COMMON TOOLS AND EQUIPMENT There are common tools and general mechanics tool sets...

Page 46: ...ections in the order listed and try to return the vehicle or component to operation after each test inspection and corrective action has been performed c Refer to the figures and foldouts listed below...

Page 47: ...oes not operate not registering 2 25 2 No flow through meter or meter runs too slowly 2 25 SELF RECOVERY WINCH 1 Self recovery winch does not work 2 26 HEAVY DUTY WINCH M984 1 Winch cable will not pay...

Page 48: ...respond to controller 2 64 Crane operation is not smooth in remote control mode 2 67 Control rods do not move completely in or out 2 70 Crane will not raise or extend in remote operation but will low...

Page 49: ...will not retract 2 126 5 ARCTIC HEATER 1 Coolant pump fails to operate indicator light comes on Model A 2 128 2 Arctic heater diagnostic troubleshooting Direct Level Model B 2 129 Table 2 2 Troublesho...

Page 50: ...rane M977 M985 2 106 Boom will not lower or will not lower completely Material Handling Crane M983 2 42 Boom will not raise Material Handling Crane M977 M985 2 100 Boom will not raise load Material Ha...

Page 51: ...ot operate Material Handling Crane M977 M985 2 83 Crane will not operate in one or more remote control functions Material Handling Crane M983 2 61 Crane will not unfold or will not unfold completely M...

Page 52: ...or retract Material Handling Crane M977 M985 2 86 Outrigger leg will not support load Material Handling Crane M977 M985 2 86 Outrigger operation slow or erratic Material Handling Crane M977 M985 2 85...

Page 53: ...n Neutral Vehicle pulls to one side Vehicle steers hard in one or both directions Wheel turns restricted Winch cable will not payout Winch does not work Winch jerks Winch makes excessive or unusual no...

Page 54: ...NE HIGH IDLE DOES NOT OPERATE NOTE On M984 winch remote controller switch must be operated instead of LATCH switch Step 1 Check that throttle control solenoid operates when ENGINE PTO ENGAGE and LATCH...

Page 55: ...ove forward or backward and may cause personal injury or death Chock wheels to prevent forward or reverse movement Set parking brake TM 9 2320 279 10 Start engine and set service brakes Put transfer c...

Page 56: ...k for 25 to 30 psi 172 to 207 kPa lube system pressure If pressure is 25 to 30 psi 172 to 207 kPa disassemble transmission and check for damaged torque converter para 7 7 7 8 Step 2 Check for low main...

Page 57: ...missing replace preformed packing para 7 12 If preformed packing is not damaged or missing disassemble transmission and inspect oil pump main pressure regulator valve and control valve body for loose...

Page 58: ...725 to 965 kPa disassemble transmission and inspect lubrication pressure regulator and converter bypass valve for damage paras 7 9 7 20 Inspect all other moving parts for damage from lack of oil Step...

Page 59: ...speed With parking brake applied shift transmission into DRIVE Check for 105 to 140 psi 725 to 965 kPa main system pressure If pressure is 105 to 140 psi 725 to 965 kPa go to step 4 Step 2 Check for c...

Page 60: ...E R R A T I C A L L Y C O N T Step 4 Remove oil pan para 7 11 Manually shift transmission and see if manual shaft and detent lever engage selector valve and that actuator pin is attached to detent le...

Page 61: ...ent screws pump hub seal rings and converter pump hub para 7 9 EXCESSIVE CREEP IN FIRST AND REVERSE Step 1 Check for too high engine idle speed If idle speed is more than 750 rpm adjust engine idle sp...

Page 62: ...to 1 380 kPa gage at rear governor test port Start engine and shift transmission into DRIVE Release parking brake and drive vehicle until engine tachometer reads approximately 1650 rpm Check for 83 t...

Page 63: ...para 7 21 Step 2 Check for defective control valve Remove modulator valve para 7 21 Check valve stop in transmission for free movement in Check that spring pushes valve stop out when released and is n...

Page 64: ...ts para 7 20 If selector valve engages disassemble transmission and valve body to check for applied clutch packs or leaking or sticking valves in valve body paras 7 15 7 16 7 17 7 18 7 19 7 20 9 T R A...

Page 65: ...ately 1200 rpm Check for 140 to 175 psi 965 to 1 206 kPa main system pressure If pressure is 140 to 175 psi 965 to 1 206 kPa disassemble transmission and inspect forward and first clutches for damage...

Page 66: ...I N C H E S T A N K E R P U M P 2 W I N C H O R C R A N E J E R K S W H E N O P E R A T E D O R W I L L N O T P U L L L O A D 3 R E T R I E V E R O R C R A N E C Y L I N D E R S D O N O T O P E R A T...

Page 67: ...2 3 para 19 4 19 4 2 3 T M 9 2 3 2 0 2 7 9 3 4 1 Troubleshooting Malfunctions Cont T a b l e 2 3 T r o u b l e s h o o t i n g C o n t 2 2 2 1...

Page 68: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 2 2...

Page 69: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 2 3...

Page 70: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 4...

Page 71: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 24 1 2 24 2blank...

Page 72: ......

Page 73: ...and blocking rotor gears Replace defective displacement and blocking rotor gears para 22 8 Step 4 Remove flowmeter para 22 7 Remove rear cover and bearing plate from meter housing para 22 8 Check for...

Page 74: ...leshooting Malfunction 3 Step 2 Check for defective winch counterbalance valve Disconnect and plug brake release line at fitting Install a 0 to 3000 psi 0 to 20 700 kPa gage on fitting Start engine an...

Page 75: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 27...

Page 76: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 8...

Page 77: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 28 1...

Page 78: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 8 2...

Page 79: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 28 3...

Page 80: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 8 4...

Page 81: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 2 8 5...

Page 82: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 8 6...

Page 83: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 28 7...

Page 84: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 2 8 8...

Page 85: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont Figure 2 2 Main Control Valve M983 2 2 9...

Page 86: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont Figure 2 3 Outrigger Control Valve M983 2 3 0...

Page 87: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont Figure 2 4 System Back Pressure No Load M983 2 31...

Page 88: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 3 2...

Page 89: ...d TM 9 2320 279 20 a I n s t a l l a t i o n 1 Remove plug 1 from outrigger 2 Install adapter 3 in port 2 3 Install nipple 4 in adapter 3 4 Connect gage 5 to adapter 6 control valve port 2 5 Connect q...

Page 90: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 3 4...

Page 91: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 3 5...

Page 92: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 36...

Page 93: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 3 7...

Page 94: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 3 8...

Page 95: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 3 9...

Page 96: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 4 0...

Page 97: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 41...

Page 98: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 4 2...

Page 99: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 4 3...

Page 100: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 4 4...

Page 101: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 4 5...

Page 102: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 4 6...

Page 103: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 4 7...

Page 104: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 4 8...

Page 105: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 4 9...

Page 106: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 5 0...

Page 107: ...T M 9 2 3 2 0 2 7 9 3 4 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 51...

Page 108: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 5 2...

Page 109: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 5 3...

Page 110: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 5 4...

Page 111: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 5 5...

Page 112: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 5 6...

Page 113: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 5 7...

Page 114: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 5 8...

Page 115: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 5 9...

Page 116: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 6 0 Figure 2 6 Power Distribution Board Wiring Diagram M983...

Page 117: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 61...

Page 118: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont Figure 2 7 12V Electric Motor Tester Circuit Schematic M983 2 6 2...

Page 119: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 6 3 Figure 2 8 12V Electric Motor Tester Circuit Wiring Diagram M983...

Page 120: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 6 4...

Page 121: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 65...

Page 122: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 6 6...

Page 123: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 6 7...

Page 124: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 68...

Page 125: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 6 9...

Page 126: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 7 0...

Page 127: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 71...

Page 128: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 7 2...

Page 129: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 7 3...

Page 130: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 7 4...

Page 131: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 7 5...

Page 132: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 7 6...

Page 133: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 77...

Page 134: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 78...

Page 135: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 7 9...

Page 136: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 8 0...

Page 137: ...s into control valves slowing or completely blocking oil flow When troubleshooting the M977 M985 and M984E1 material handling cranes refer to foldout sheets 3 4 and 5 of Hydraulic Schematics Wiring Di...

Page 138: ...rates Set ENGINE and PTO ENGAGE switches to ON Move crane POWER switch ON and OFF several times Listen for clicking sound of solenoid to tell if solenoid operates If solenoid clicks but crane will not...

Page 139: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 8 3...

Page 140: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 8 4...

Page 141: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 8 5...

Page 142: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 8 6...

Page 143: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 8 7...

Page 144: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 8 8...

Page 145: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 89...

Page 146: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 9 0...

Page 147: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 91...

Page 148: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 9 2...

Page 149: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 9 3...

Page 150: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 9 4...

Page 151: ...T M 9 2 3 2 2 7 9 3 4 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 9 5...

Page 152: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 9 6...

Page 153: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 9 7...

Page 154: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 9 8...

Page 155: ...warning TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 9 9...

Page 156: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 0 0...

Page 157: ...2 for M984E1 Do not remove extension cylinder Step 3 Check for overload sensor switch adjustment para 17 33 for M977 and M985 para 17 33 1 for M984E1 If switch es cannot be adjusted replace para 6 12...

Page 158: ...heck for damaged lift cylinder lines and damaged lift cylinder Replace damaged lift cylinder lines para 17 2 for M977 and M985 para 17 2 1 for M984E1 Refer to step 6 if lift cylinder appears damaged W...

Page 159: ...ep 4 Check main hydraulic pressure adjustment para 17 31 for M977 and M985 para 17 31 1 for M984E1 If main hydraulic pressure cannot be adjusted repair crane control valve para 17 28 for M977 and M985...

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Page 161: ...T M 9 2 3 2 0 2 7 9 3 4 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 0 3...

Page 162: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 0 4...

Page 163: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 0 5...

Page 164: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 0 6...

Page 165: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 0 7...

Page 166: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 0 8...

Page 167: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 109...

Page 168: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 1 0...

Page 169: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 111...

Page 170: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 30 Troubleshooting Cont 2 112...

Page 171: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 1 3...

Page 172: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 114...

Page 173: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 115...

Page 174: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 1 6...

Page 175: ...a 1800 psi 12 411 kPa M985 1800 psi 12 411 kPa 2000 psi 13 790 kPa M984E1 1400 psi 9 653 kPa 1600 psi 11032 kPa If pressure is outside of the range shown while at full swing replace CW or CCW swing dr...

Page 176: ...g drive valve body swing drive valve hoses and tubes or swing drive motor hydraulic hoses and tubes Operate crane TM 9 2320 279 10 Operate SWING control CW or CCW If motor binds or there are grinding...

Page 177: ...1 SWING OPERATION ERRATIC OR SLOW IN ONE DIRECT ION ONLY Step 1 Check for defective turntable Operate crane TM 9 2320 279 10 Operate SWING control CW or CCW Watch for any binding and listen for grindi...

Page 178: ...320 279 10 Operate SWING control in both directions Hydraulic pressure should be within the range shown when operated from turntable stop to turntable stop M977 1600 psi 11032 kPa 1800 psi 12 411 kPa...

Page 179: ...k for defective swing drive motor Remove swing drive motor para 17 7 for M977 and M985 para 17 7 1 for M984E1 Do not remove swing drive valve body swing drive valve hoses and tubes or swing drive moto...

Page 180: ...tational stop Step 2 Check for contamination or damaged swing drive valves Set up hydraulic pressure tester Operate crane TM 9 2320 279 10 Operate SWING control in both directions Hydraulic pressure s...

Page 181: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 2 3...

Page 182: ...9 2320 279 34 1 T r o u b l e s h o o t i n g M a l f u n c t i o n s C o n t 2 7 T R O U B L E S H O O T I N G I N S T R U C T I O N S C O N T T a b l e 2 3 T r o u b l e s h o o t i n g C o n t 2 1...

Page 183: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 2 5...

Page 184: ...I L L N O T M O V E Step 1 Check for excessively high pressure in system Set up hydraulic pressure tester on crane control valve Operate crane TM 9 2320 279 10 If pressure is more than 3000 psi 20 685...

Page 185: ...WARNING TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 126 1...

Page 186: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 2 6 2...

Page 187: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 2 6 3...

Page 188: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 2 6 4...

Page 189: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont Table 2 3 Troubleshooting Cont 2 1 2 6 5...

Page 190: ...TM 9 2320 279 34 1 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont 2 1 2 6 6...

Page 191: ...until relief valve engages TM 9 2320 279 10 If pressure is correct remove holding valves from cylinder and check for damage or clogging Lift cylinder Extend 400 psi 2 758 kPa para 13 30 2 Retract 2500...

Page 192: ...vere burns or electrical shock 1 COOLANT PUMP FAILS TO OPERATE INDICATOR LIGHT COMES ON MODEL A Check for defective coolant pump Figure 2 9 Arctic Coolant Pump Test Remove coolant pump assembly TM 9 2...

Page 193: ...t occur The latest fault is displayed with either AF or F1 If more than one fault code is displayed troubleshoot the latest fault code first S All organizational level troubleshooting must be complete...

Page 194: ...34 1 2 130 Change 6 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont ARCTIC HEATER KIT CONT 2 ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING DIRECT LEV...

Page 195: ...ctic heater temperature sensor at room temperature 13_ to 77_F 25_ to 25_C Connect probes across arctic heater internal harness connector terminals No 14 and 18 If resistance reading is not between 65...

Page 196: ...1 2 132 Change 6 Troubleshooting Malfunctions Cont 2 7 TROUBLESHOOTING INSTRUCTIONS CONT Table 2 3 Troubleshooting Cont ARCTIC HEATER KIT CONT 2 ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING DIRECT LEVEL...

Page 197: ...operates go to Step 50 Step 7 If Fault Code Retrieval Device FCRD is available clear fault code 015 and go to Step 50 Step 8 If Fault Code Retrieval Device FCRD is not available replace arctic heater...

Page 198: ...tic heater glow pin harness para 21 3 and go to Step 50 Step 13 Perform continuity check on arctic heater glow pin harness wires Connect probes to arctic heater internal harness connector terminals No...

Page 199: ...L MODEL B CONT NOTE Steps 16 through 21 are for fault code 033 Step 16 Remove arctic heater control unit para 21 3 Step 17 Check operation of arctic heater blower by connecting an external 24 vdc powe...

Page 200: ...HOOTING DIRECT LEVEL MODEL B CONT Step 18 Connect arctic heater harness connector to arctic heater control unit para 21 3 Step 19 Check voltage at arctic heater control unit internal connector Place p...

Page 201: ...blower is turned on Connect arctic heater internal harness connector to arctic heater control unit Back probe arctic heater internal harness connector Place positive probe at terminal No 13 Place neg...

Page 202: ...for fault codes 037 042 or 059 Step 22 Remove arctic heater control unit para 21 3 Step 23 Perform resistance check across arctic heater temperature sensor at room temperature 13_ to 77_F 25_ to 25_C...

Page 203: ...l line from arctic heater and place in graduated 1 quart 950 ml measuring container b Turn arctic heater switch on c Observe fuel delivery Fuel metering pump will start approximately 63 seconds after...

Page 204: ...Audible clicking and no or low fuel flow may indicate the arctic heater fuel system is not primed S Arctic heater may go into lockout code 050 due to too many start attempts If arctic heater goes into...

Page 205: ...de Retrieval Device FCRD is not available replace arctic heater control unit para 21 3 and go to Step 50 NOTE Steps 39 through 41 are for fault codes 051 064 or 065 Step 39 Remove arctic heater contro...

Page 206: ...44 are for fault codes 053 054 055 or 056 Step 42 Remove arctic heater control unit para 21 3 Step 43 Perform resistance check across arctic heater flame sensor at room temperature 13_ to 77_F 25_ to...

Page 207: ...3_ to 77_F 25_ to 25_C Connect probes across arctic heater internal harness connector terminals No 14 and 18 If resistance reading is not between 650 and 1000 ohms replace arctic heater temperature se...

Page 208: ...R KIT CONT 2 ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING DIRECT LEVEL MODEL B CONT NOTE Step 49 is for fault codes 001 002 010 011 043 047 048 090 093 094 or 097 Step 49 Replace arctic heater control uni...

Page 209: ...functions 5 As soon as parts are removed cap or cover open tubes hoses fittings and openings in equipment to keep dust dirt and other objects out of internal parts Use suitable containers to catch coo...

Page 210: ...parts such as brackets panels and light framework Because of time required and chance of later failure weld only when replacement parts are not available Grounding To ensure good ground connections cl...

Page 211: ...degreasing 5 Remove parts from degreaser Check that all oil passages and cavities are clean and clear Before coating with rust preventive Item 53 Appendix C run thin flexible wire through oil passage...

Page 212: ......

Page 213: ...general direction indicates improper cooling c Grinding cracks fine sharp lines tightly packed On some surfaces cracks may be shallow and hard to see Grinding cracks are usually caused by a glazed gri...

Page 214: ...9 2320 279 20 to prepare vehicle for storage or shipment b Refer to TB 9 2300 281 35 for overseas shipment instructions c Refer to TB 9 2300 281 35 for Basic Issue Items BII packing instructions 2 11...

Page 215: ...s of the engine C A U T I O N Do not use tape to close off fuel or oil openings Sticky surface of tape will mix with fuel or oil and will get in the engine lines Cap or tape over open tubes hoses fitt...

Page 216: ...cks Section III ENGINE ASSEMBLY Supplies Compound sealing pipe thread Item 29 Appendix C Tags identification Item 60 Appendix C Sealant RTV200 Electrical Item 55 2 Appendix C Connector electrical butt...

Page 217: ...ers 2 Remove clamp 3 from muffler 4 Remove nut 5 and clamp 6 from turbocharger 7 Pull exhaust pipe 8 from turbocharger 7 Remove exhaust pipe 8 from muffler 4 N O T E Tag and mark hoses before removal...

Page 218: ...S T A L L A T I O N C O N T 8 Remove four nuts 15 and screws 16 9 Soldier A and Soldier B remove muffler assembly 17 10 Remove two nuts 18 lockwashers 19 and screws 20 from cross brace 21 11 Remove nu...

Page 219: ...rates lifting device 14 15 16 17 Remove plug 26 from access hole 27 N O T E There are 12 torque converter screws Each must be centered in access hole for removal Soldier A looks in access hole 27 whil...

Page 220: ...s 30 lockwashers 31 and three clamps 32 from top of transmission torque converter housing 33 Remove 11 screws lockwashers and one clamp from bottom of housing Loosen clamps 34 35 and 36 and remove thr...

Page 221: ...sher 44 NOTE Tag and mark wires before disconnecting 23 Disconnect five wires 45 from solenoid 46 24 Remove nut 47 and lockwasher 48 25 Disconnect seven starter wires 49 from starter 50 26 27 Remove t...

Page 222: ...279 34 1 Engine Maintenance Instructions Cont 3 3 ENGINE REMOVAL lNSTALLATION CONT 28 Remove ether starting aid tube 56 from air inlet housing 57 29 Disconnect plug 58 from wires 59 at ether starting...

Page 223: ...oses 61 62 and 63 from steering pump 64 31 Disconnect two hoses 65 and 66 from air compressor 67 32 Disconnect two hoses 68 and 69 from governor 70 33 Disconnect STE ICE connector 71 34 Remove nut 72...

Page 224: ...Cont 36 Remove nut 76 lockwasher 77 washer 78 and screw 79 37 Move clamp 80 and transmission dipstick tube 81 aside 38 39 40 3 1 0 Disconnect plug 82 Disconnect plug 83 from PTO pressure switch 84 Cut...

Page 225: ...TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 41 Disconnect hose 87 42 Disconnect connector 88 43 Disconnect two connectors 89 3 11...

Page 226: ...Maintenance Instructions Cont 44 Remove nut 90 washer 91 spacer 92 and screw 93 from each of two engine supports 94 45 3 1 2 Soldier A and Soldier B remove three nuts 95 and screws 96 from each side o...

Page 227: ...fting slightly to see if balanced If engine starts to tilt lower and adjust chain lengths Unbalanced engine may swing causing damage Soldier A and Soldier B slide engine frame support 97 forward on ve...

Page 228: ...est by lifting slightly to see if balanced If engine starts to tilt lower and adjust chain lengths Unbalanced engine can swing causing damage Make sure hoses and wires are secured and moved out of the...

Page 229: ...screws 7 in top of transmission torque converter housing 8 while Soldier B installs one clamp 11 lockwashers and screws in bottom of housing 7 Soldier A and Soldier B position engine frame support 9...

Page 230: ...n biscuit mounts 13 on front engine support 14 11 Soldier A lubricates and installs two screws 15 while Solider B installs two bottom spacers 16 two washers 17 and nuts 18 12 Solider A holds two screw...

Page 231: ...TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 3 1 7...

Page 232: ...3 3 TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 3 1 8...

Page 233: ...r A looks in access hole 22 and tells Soldier B to stop turning torque converter 25 when screw hole 27 is centered in access hole 19 Install but do not fully tighten one torque converter screw 28 20 I...

Page 234: ...er B to stop turning pulley nut 23 when torque converter screw 28 is centered in access hole 22 Soldier A tightens torque converter screw 28 to 105 to 115 lb ft 142 to 156 N m NOTE Repeat steps 23 24...

Page 235: ...TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 3 21...

Page 236: ...3 3 TM 9 2320 279 34 1 Engine Maintaince Instructions Cont 3 22...

Page 237: ...TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 3 2 3...

Page 238: ...3 3 TM 9 2320 279 34 1 E n g i n e M a i n t e n a n c e I n s t r u c t i o n s C o n t 3 2 4...

Page 239: ...1 42 Install two wires 66 with two nuts 67 Install two cables 68 with two nuts 69 43 44 Install seven starter wires 70 on stud 71 with washer 71 1 lockwasher 72 and nut 73 Install five solenoid wires...

Page 240: ...CONT 45 Connect airhose 78 46 Connect two fuel hoses 79 and 80 47 Install three hoses 81 82 and 83 and tighten clamps 84 85 and 86 48 Install one end of cross brace 87 with two lockwashers 88 and nut...

Page 241: ...TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 3 2 7...

Page 242: ...3 3 TM 9 2320 279 34 1 Engine Maintenance Instructions Cont 3 2 8...

Page 243: ...onnecting 2 Disconnect hose 2 and remove reducer bushing 3 adapter 4 and elbow 5 Move oil return hose 6 out of way 3 Remove reducer bushing 7 and elbow 8 4 Remove two screws 9 lockwasher 10 washers 11...

Page 244: ...3 4 TM 9 2320 279 34 1 E n g i n e M a i n t e n a n c e I n s t r u c t i o n s C o n t 3 3 0...

Page 245: ...T M 9 2 3 2 0 2 7 9 3 4 1 Engine Maintenance Instructions Cont 3 31...

Page 246: ...mounting bracket 8 with two screws 9 lockwasher 10 and washers 11 6 Install reducer bushing 12 and elbow 13 7 Install reducer bushing 14 adapter 15 and elbow 16 NOTE Install cushion clips and plastic...

Page 247: ...I I N T R O D U C T I O N 4 1 GENERAL This chapter contains maintenance instructions for repair of fuel system components at the direct support maintenance level The subassemblies and parts which mus...

Page 248: ...4 2 TM 9 2320 279 34 1 Fuel Sustem Maintenance Instructions Cont 4 2...

Page 249: ...T M 9 2 3 2 0 2 7 9 3 4 1 Fuel System Maintenance Instructions Cont 4 3 4 4 blank...

Page 250: ......

Page 251: ...hapter contains maintenance instructions for repair of the cooling system at the direct support maintenance level Subassemblies and parts which must be removed before cooling components can be repaire...

Page 252: ...5 2 T M 9 2 3 2 0 2 7 9 3 4 1 Cooling System Maintenance Instructions Cont 5 2...

Page 253: ...WARNING TM 9 2320 279 34 1 Cooling System Maintenance Instructions Cont 5 3...

Page 254: ...5 2 TM 9 2320 279 34 1 Cooling System Maintenance Instructions Cont 5 4...

Page 255: ...1 1 6 64 Crane Overload Sensor Switches Removal Installation M977 M985 6 12 6 64 6 Crane Overload Sensor Switches and Plate and Terminal Box Removal Installation M984E1 6 12 1 6 70 Cab Wiring Harness...

Page 256: ...ix C Compound sealing lubricating Item 25 Appendix C Tags identification Item 60 Appendix C Grease automotive and artillery Item 34 Appendix C removed TM 9 2320 279 20 Voltage regulator removed Specia...

Page 257: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 3...

Page 258: ...6 2 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 4...

Page 259: ...TM 9 2320 279 34 1 Electrical System Maintemance Instructions Cont 6 5...

Page 260: ...6 2 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 6...

Page 261: ...tifier is defective 5 Connect negative test lead to negative rectifier 3 6 Touch positive test lead to each of three eyelet terminals 2 in turn If resistance is high negative rectifier 3 is defective...

Page 262: ...and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water CA...

Page 263: ...CAUTION TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 9...

Page 264: ...6 2 TM 9 2320 279 34 1 E l e c t r i c a l S y s t e m M a i n t e n a n c e I n s t r u c t r i o n s C o n t 6 10...

Page 265: ...TM 9 2320 279 34 1 E l e c t r i c a l S y s t e m M a i n t e n a n c e I n s t r u c t i o n s C o n t 6 11...

Page 266: ...6 2 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 12...

Page 267: ...s and install drive end housing 40 on stator 36 25 Install three washers 45 screws 46 and locknuts 47 26 27 Install two wires 15 and 16 into brush holder adapter 48 Install brush holder adapter 48 and...

Page 268: ...kwashers 57 and screws 58 CAUTION Wires can be shorted out if rubbing on shaft 31 Install preformed packing 59 and cover 60 with four screws 61 NOTE Spacer is installed with notch facing away from hou...

Page 269: ...ERNATOR REPAIR Models All Test Equipment None Special Environmental Conditions None General Safety Instructions None Level of Maintenance Direct Support a Disassembly 1 Remove nut 1 from ignition IGN...

Page 270: ...ove locknut 16 from shaft 17 10 Remove alternator 14 from vise 11 Remove pulley 18 from shaft 17 12 Remove cooling plate 19 key 20 and spacer 21 from shaft 17 13 Remove screw 22 lockwasher 23 and clip...

Page 271: ...ng housing Failure to comply may result in damage to stator wires NOTE Rotor will remain attached to drive end housing during removal 17 Remove drive end housing 38 and rotor assembly 39 from slip rin...

Page 272: ...omply may damage bushing 23 Remove lower mounting screw 51 lockwasher 52 washer 53 plastic washer 54 positive rectifier 44 with bushing 55 and bushing 56 from slip ring end housing 25 24 Remove screw...

Page 273: ...ing 69 and two washers 70 from slip ring end housing 25 28 Position slip ring end housing 25 in press and remove bearing 71 29 Remove bushing 72 from slip ring end housing 25 30 Position drive end hou...

Page 274: ...egative test lead of multimeter to bare metal surface on positive rectifier 1 NOTE If multimeter does not indicate low resistance in step 2 positive rectifier is defective Replace rectifier 2 Touch po...

Page 275: ...multimeter does not indicate low resistance in step 8 positive rectifier is defective Replace rectifier 8 Touch negative test lead separately to each of three eyelet terminals 2 NOTE If resistance re...

Page 276: ...ment is less replace rotor 14 Measure diameter of shaft 8 c Cleaning Inspection WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well vent...

Page 277: ...nt appearance cracks broken edges 9 Check brush wear and replace if length measures less than 0 19 in 4 8 mm 10 Check drive end housing bearing for smooth rotation If bearing binds replace bearing 11...

Page 278: ...bushing 8 in slip ring end housing 6 9 Remove slip ring end housing 6 from press 10 Coat bearing 7 rollers with grease 11 Install negative rectifier 9 in slip ring end housing 6 with bushing 10 two w...

Page 279: ...Failure to comply may result in damaged wiring 16 Install positive terminal screw 30 negative terminal screw 31 two insulation bushings 32 regulator holder 28 new gasket 33 and two nuts 34 in slip rin...

Page 280: ...end housing 6 and regulator studs 36 with three nuts 40 20 Aline screw holes on slip ring end housing 6 stator 41 and drive end housing 1 21 Install slip ring end housing 6 on drive end housing 1 wit...

Page 281: ...on regulator studs 36 with nuts 52 24 Secure three wires 51 to slip ring end housing 6 with screw 53 lockwasher 54 and clip 55 25 Position spacer 56 key 57 cooling plate 58 pulley 59 and locknut 60 on...

Page 282: ...result in damage to equipment NOTE Regulator must be positioned close to housing to allow installation of wires 31 Install red wire 25 on positive terminal of voltage regulator 66 with lockwasher 67 a...

Page 283: ...s repairer Equipment Condition TM or Para Condition Description TM 9 2320 279 20 Starter removed References None Special Tools None 6 3 STARTER SOLENOID REMOVAL INSTALLATION Models All Test Equipment...

Page 284: ...6 3 TM 9 2320 279 34 1 Electrical Sustem Maintenance Instructions Cont 6 16...

Page 285: ...d injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water NOTE Apply electrical s...

Page 286: ...6 3 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 18...

Page 287: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 19...

Page 288: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 20...

Page 289: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 21...

Page 290: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 22...

Page 291: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 23...

Page 292: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 24...

Page 293: ...WARNING TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 25...

Page 294: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 26...

Page 295: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 27...

Page 296: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 28...

Page 297: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 29...

Page 298: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 30...

Page 299: ...Electrical System Maintenance Instructions Cent TM 9 2320 279 34 1 6 31...

Page 300: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 3 2...

Page 301: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 3 3...

Page 302: ...6 4 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 34...

Page 303: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cent 6 3 5...

Page 304: ...6 5 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cent S e c t i o n I l l C R A N E S Y S T E M E L E C T R I C A L 6 3 6...

Page 305: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 6 3 7...

Page 306: ...6 5 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 38...

Page 307: ...6 6 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 39...

Page 308: ...6 6 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 40...

Page 309: ...6 7 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 41...

Page 310: ...6 7 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 4 2...

Page 311: ...WARNING TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 43...

Page 312: ...6 8 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 44...

Page 313: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 4 5...

Page 314: ...6 8 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 46...

Page 315: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 47...

Page 316: ...6 9 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 48...

Page 317: ...WARNING TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 49...

Page 318: ...6 9 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 50...

Page 319: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 51...

Page 320: ...6 9 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 52...

Page 321: ...TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 53...

Page 322: ...6 10 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 54...

Page 323: ...6 11 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 55...

Page 324: ...6 11 TM 9 2320 279 34 1 Electrical System Maintenance Instructions Cont 6 56...

Page 325: ...s Cont 7 Disconnect cable 11 from junction box 12 8 Remove two nuts 13 lockwashers 14 and guard 15 9 Remove four nuts 16 lockwashers 17 and junction box 12 N O T E Tag and mark electrical connectors b...

Page 326: ...D i s a s s e m b l y 1 Remove cap 1 2 Remove four screws 2 lockwashers 3 washers 4 and cover 5 from box 6 N O T E Tag and mark wires before removing or disconnecting 3 Remove two screws 7 and three w...

Page 327: ...ve two screws 19 lockwasher 20 washers 21 and relay module 22 Remove two screws 23 lockwashers 24 and washers 25 N O T E Connector must be removed with cable module 10 Remove cable module 26 connector...

Page 328: ...O N B O X C O N N E C T O R R E M O V A L R E P A I R I N S T A L L A T I O N M 9 7 7 M 9 8 5 CONT 13 Remove pin 33 from connector 17 14 Remove pin 33 from wire 34 c A s s e m b l y 1 Install pin 1 o...

Page 329: ...cables 10 connector 3 and cable module 11 6 Install two washers 12 lockwashers 13 and screws 14 7 Install relay module 15 with two screws 16 lockwasher 17 ant washer 18 8 Connect eight wires 19 9 Ins...

Page 330: ...O V A L R E P A I R I N S T A L L A T I O N M 9 7 7 M 9 8 5 CONT 11 12 Install nut 24 switch 25 lockwasher 26 and sealnut 27 Install three wires 28 with two screws 29 13 Install cover 30 on box 6 with...

Page 331: ...tall guard 5 two lockwashers 6 and nuts 7 Connect cable 8 to junction box 2 T M 9 2 3 2 0 2 7 9 3 4 1 Install seal 9 and two wires 10 in connector 11 Connect two wires 10 to socket 12 with two screws...

Page 332: ...R E M O V A L R E P A I R I N S T A L L A T I O N M 9 8 4 E 1 This task covers a Removal d Installation b Disassembly e Follow on Maintenance c Assembly INITIAL SETUP Models Equipment Condition M984E...

Page 333: ...from high idle box 2 N O T E Remove all wire ties as necessary 2 3 4 Remove two nuts 3 lockwashers 4 flatwashers 5 and screws 6 Remove two nuts 7 lockwashers 8 flatwashers 9 screws 10 and front brace...

Page 334: ...l three pins must be removed at the same time Remove three pins 14 from connector 13 Remove three pins 14 from wires 15 N O T E Tag and mark all wires 9 Remove four screws 16 lockwashers 17 washers 18...

Page 335: ...lockwashers 39 and washers 40 from relay module 41 Remove cable module 37 relay module 41 and connector 28 from box 20 Disconnect seven connectors 42 Remove relay module 41 disconnect two connectors...

Page 336: ...ires 4 3 Install 11 pins 3 in connector 5 and three plugs 6 4 Connect seven wires 7 from relay module 8 to seven wires 9 from cable module 10 and two 5 6 7 6 64 4 w i r e s 1 1 w i t h n i n e c o n n...

Page 337: ...d lockwasher 29 on switch 27 Install switch 27 in box 13 with seal nut 30 Install cover 31 with four washers 32 lockwashers 33 and screws 34 15 Install three pins 35 on wires 36 16 Install three pins...

Page 338: ...N E O V E R L O A D S E N S O R S W I T C H E S R E M O V A l I N S T A L L A T I O N M 9 7 7 M 9 8 5 This task covers a Main Overload Switch Removal e Mast Overload Switch Removal M977 only b Main Ov...

Page 339: ...lag and mark wires before removal 1 Disconnect three wires 1 at connectors 2 2 Remove nut 3 and main overload switch 4 from mounting bracket 5 b M a i n O v e r l o a d S w i t c h I n s t a l l a t...

Page 340: ...ten nut 6 and jamnut 7 until one screw thread is below surface of nut 6 Adjust nut 8 and jamnut 9 until main overload switch 1 is 1 4 in 6 mm from switch sensing plate 10 c R e d u c e d O v e r l o a...

Page 341: ...ont d R e d u c e d O v e r l o a d S w i t c h I n s t a l l a t i o n M 9 7 7 o n l y 1 Install reduced overload switch 1 on mounting bracket 2 with nut 3 2 Connect three wires 4 to connectors 5 fig...

Page 342: ...is below surface of nut 6 Adjust nut 8 and jamnut 9 until reduced overload switch 1 is 1 4 in 6 mm from switch sensing plate 10 N O T E Remove clips and plastic cable ties 2 Remove four screws 3 and...

Page 343: ...w on Maintenance Adjust overload sensor switches para 17 33 END OF TASK Electrical System Maintenance Instructions Cont f M a s t O v e r l o a d S w i t c h I n s t a l l a t i o n M 9 7 7 o n l y 1...

Page 344: ...pment Condition M984E1 TM or Para Condition Description Test Equipment TM 9 2320 279 10 Crane in operating condition N o n e TM 9 2320 279 10 Position crane for access Special Too1s Special Environmen...

Page 345: ...itches before removing 3 Remove nut 8 and overload switch 9 from mounting bracket 10 N O T E The three overload switches are removed the same way Remove clamp wire ties and clips as necessary Iag and...

Page 346: ...e same way Remove wire clips and ties as necessary 8 Remove connector 23 spacer 24 and grommet 25 from fitting 26 N O T E Tag and mark wires before removing 9 Loosen three screws 27 on terminal board...

Page 347: ...res 35 Remove eight nuts 36 and fittings 26 Remove four screws 37 nuts 38 and lockwashers 39 Remove two strips 40 from box 22 b I n s t a l l a t i o n 1 Install two strips 1 in box 2 2 Install four s...

Page 348: ...R E M O V A L I N S T A L L A T I O N M 9 8 4 E 1 C O N T 7 8 9 l0 11 12 6 70 4 Install box 2 with four lockwashers 12 clamp 13 and nuts 14 to boom 15 Install eight connectors 16 spacers 17 and gromm...

Page 349: ...30 15 Install mounting flange 30 on mast 31 with four screws 32 N O T E The four overload switches are installed the same way 16 Install overload switch 33 on mounting bracket 34 with nut 35 N O T E...

Page 350: ...R E M O V A L I N S T A L L A T I O N M 9 8 4 E 1 C O N T 1 9 I n s t a l l b r a c k e t 4 0 w i t h t w o s c r e w s 4 1 l o c k w a s h e r s 4 2 a n d n u t s 4 3 N O T E Settings are made the sa...

Page 351: ...M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 21 Connect three connectors 44 c Follow on Maintenance Adjust hoist overload protection switches para 17 25 1 END OF TASK 6 70...

Page 352: ...0 279 20 Starter switch removed Supplies TM 9 2320 279 20 TRACTION CONTROL Connector electrical butt Item 31 indicator light removed Appendix C TM 9 2320 279 20 ENGINE STOP switch Tags identification...

Page 353: ...er 7 clip 8 five ground wires 9 lockwasher 10 washer 11 and screw 12 from panel 13 Remove two screws 14 and wires 15 from switch 16 Remove four screws 17 and headlight guard 18 Remove two screws 19 an...

Page 354: ...Disconnect two turn signal light connectors 24 and 25 Disconnect three plugs 26 from left headlight 27 Remove four nuts 28 washers 29 and 10 wires 30 from each of two brake stoplight switches 31 11 D...

Page 355: ...e 38 5 from left step clearance light base 38 6 14 Using insert removal tool disconnect right step clearance light wire 39 from plug 40 14 1 Remove two screws 40 1 and right step clearance light housi...

Page 356: ...A T I O N C O N T 19 20 21 6 7 4 18 Remove electrical tape from three neutral start switch wires 48 and disconnect wires at connectors 49 Remove screw 50 clamp 51 and heater control cable 52 Disconne...

Page 357: ...3 24 25 26 27 Remove 11 screws 59 and two heater compartment covers 60 Remove eight screws 61 and heater compartment cover 62 Disconnect plug 63 from power takeoff PTO harness 64 Disconnect connector...

Page 358: ...ght screws 69 and console side panel 70 Disconnect three wires 71 from ON OFF switch 72 and HIGH LOW switch 73 N O T E WORK LIGHT switch is on M983 M984 and M984E1 only 30 31 6 7 6 Disconnect two wire...

Page 359: ...re will have to be pulled Disconnect domelight wire 84 at connector 85 Remove four screws 86 and headlight guard 87 up through console Disconnect three plugs 88 from right headlight 89 Remove screw 90...

Page 360: ...ing harness 95 from circuit breaker rack 98 inside console 54 39 Disconnect one harness wire 99 from starter relay 100 and two harness wires 101 from horn relay 102 40 Pull neutral start switch wires...

Page 361: ...and three receptacles 112 from console 54 47 Remove cab wiring harness 95 b I n s t a l l a t i o n 1 2 3 N O T E All cab wiring harness connections need to be secure Tie all excess wiring together w...

Page 362: ...nnect one harness wire 15 to horn relay 16 Connect cab wiring harness 1 to circuit breaker rack 17 Pull right composite light wires 18 through hole in heater compartment 19 N O T E Tie right composite...

Page 363: ...wire 31 to connector 32 Install domelight 33 with two screws 34 Connect wire 35 to center terminal on heater fan switch 36 N O T E WORK LIGHT switch is on M983 M984 and M984E1 only 18 Connect two wire...

Page 364: ...stall both switches so that up position is ON HIGH and down position is OFF LOW 19 Connect three wires 42 to ON OFF switch 43 20 Connect three wires 44 to HIGH LOW switch 45 21 Install console side pa...

Page 365: ...gs 55 to cab wiring harness connectors 56 under cab console floor 57 Install heater control cable 58 with clamp 59 and screw 60 Connect two wires 61 to stoplight switch 62 with two lockwashers 63 and...

Page 366: ...m Maintenance Instructions Cont 6 13 CAB WIRING HARNESS REMOVAL INSTALLATION CONT 32 Connect plug 66 to blackout light 67 33 Connect two wires 68 to connectors 69 at electric horns 70 34 Connect conne...

Page 367: ...se 75 2 with mounting screw 75 4 35 3 Install left step clearance light housing 75 5 on left step clearance light base 75 2 with two screws 75 6 36 Using insert removal tool connect wire 76 at plug 77...

Page 368: ......

Page 369: ...light connectors 80 38 Connect three plugs 81 to left headlight 82 39 Connect two side turn signal wires 83 to connectors 84 40 Install 10 wires 85 to each of two brake stoplight switches 86 with four...

Page 370: ...crews 95 and lockwashers 96 44 Install headlight guard 97 with four screws 98 45 Install clip 99 and five ground wires 100 behind panel 101 with screw 102 washer 103 lockwasher 104 lockwasher 105 and...

Page 371: ...279 20 7 Connect batteries TM 9 2320 279 20 END OF TASK Supplies Connector electrical butt Item 31 Appendix C Sealant RTV200 Electrical Item 55 2 Appendix C Tags identification Item 60 Appendix C Tap...

Page 372: ...R e m o v a l N O T E Tag and mark all connections and wires before disconnecting Cut plastic cable ties as necessary 1 Disconnect two connectors 1 from two receptacles 2 2 Disconnect two pin connect...

Page 373: ...harness 9 from engine harness 7 at connector 10 5 Remove nut 11 and disconnect wire 12 from transmission temperaturre sending unit 13 6 Cut wire 14 to transmission lockup solenoid 15 6 8 9 N O T E On...

Page 374: ...A L L A T I O N C O N T N O T E All cushion clips are removed the same way M984E1 does not have cushion clip 8 Remove screw 18 washer 19 and cushion clip 20 to free engine harness 7 from upper flange...

Page 375: ...13 Disconnect wire from tachometer sending unit 25 at harness connector 26 Cut wire to disconnect high idle solenoid wire at connector 27 Cut left engine brake wire 28 at electrical butt connector 29...

Page 376: ...emove two nuts 34 and disconnect two wires 35 from engine shutdown solenoid 36 Return nuts to shutdown solenoid terminals 37 17 Remove nut 38 and washer 39 Disconnect wires 40 and 41 from starter sole...

Page 377: ...6 from oil pressure sending unit 57 21 Pull two wires 58 from low oil pressure switch 59 22 Remove screw 60 Disconnect wire 61 from low engine oil switch 62 23 Remove screw 63 and disconnect wire 64 2...

Page 378: ...14 ENGINE WIRING HARNESS REMOVAL lNSTALLATION CONT 26 Remove nut 69 and disconnect wire 70 from starter solenoid 71 27 Remove three nuts 72 and washers 73 Disconnect two wires 74 and 75 from terminal...

Page 379: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 6 9 5...

Page 380: ...asily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on...

Page 381: ...ess all the way to the left and connect lead 5 to water temperature sending unit 6 with washer 7 lockwasher 8 and nut 9 Connect lead 10 to high water temperature switch 11 with washer 12 lockwasher 13...

Page 382: ...Cont 6 14 ENGINE WIRING HARNESS REMOVAL INSTALLATION CONT 8 Connect wire 22 to starter solenoid 23 with nut 24 9 Connect ether start ground wire 25 to bracket 26 with screw 27 10 Connect wire 28 with...

Page 383: ...ure switch 36 Connect wire 37 to oil pressure sending unit 38 with lockwasher 39 and nut 40 15 Connect wire 41 and harness wires 42 and 44 to starter terminal 45 with lockwasher 46 and nut 47 16 Conne...

Page 384: ...ne shutdown solenoid 58 and push slip on terminals onto terminals of buffer switch 62 20 Pull together right engine brake wire 63 and its companion wire 64 from harness Insert stripped ends of each wi...

Page 385: ...t Connect high idle solenoid wire 69 to connector 70 Push connector 71 of tachometer sending unit 72 firmly into harness connector 73 24 Connect push on terminals 74 of two wires 75 to water temperatu...

Page 386: ...nstall cushion clip 79 around engine harness 1 and secure cushion clip to flange of transmission 80 with washer 81 and screw 82 N O T E On M984E1 power takeoff is turned around 27 Connect two wires 83...

Page 387: ...ine harness 93 at connector 94 N O T E M984E1 uses two cushion clips 31 Anchor engine harness 1 to lower right flange of transmission 80 with cushion clip 95 washer 96 and screw 97 c F o l l o w o n M...

Page 388: ...0 Appendix C Tape insulation electrical Item 62 Appendix C Ties cable plastic Item 65 Appendix C Personnel Required MOS 63W Wheel vehicle repairer TM or Para Condition Description TM 9 2320 279 10 Shu...

Page 389: ...moved 3 Remove nut 7 lockwasher 8 washer 9 screw 10 and cushion clip 11 from chassis wiring harness 12 NOTE Do step 4 for wiring each rear composite light 4 Disconnect four connectors 13 NOTE Do step...

Page 390: ...7 and M985 only 6 Disconnect 4 pin crane power connector 16 N O T E Left and right clearance light wiring harnesses are removed the same 7 8 9 10 11 6 1 0 6 Pull clearance light wiring harness 17 from...

Page 391: ...Disconnect crane power connector 25 Push back sleeving 26 and loom 27 Remove connector 28 from harness work light branch 29 and work light wires 30 N O T E Ground wire will come free when right rear s...

Page 392: ...Remove three nuts 38 lockwashers 39 screws 40 washers 41 three cushion clips 42 and chassis wiring harness 12 Remove two screws 43 cushion clips 44 and chassis wiring harness 12 N O T E Chassis wirin...

Page 393: ...l connector on chassis wiring harness must be turned sideways to fit through transfer case mount 21 Pull chassis wiring harness 12 through transfer case mount 51 22 Remove tape from speedometer cable...

Page 394: ...l connector at end of cable will not fit through clearance 24 Pull chassis wiring harness 12 up to crossmember 58 in front of transfer case 59 N O T E All cushion clips plastic cable ties and hardware...

Page 395: ...ke pressure switch 64 28 Pull back rubber boot 65 on air dryer 66 NOTE M983 with crane has three wires Do step 29 1 for M978 only if equipped with high mount stop light 29 Remove nut 67 two lockwasher...

Page 396: ...A L I N S T A L L A T I O N C O N T 31 Remove nut 73 lockwasher 74 screw 75 and two cushion clips 76 32 Pull chassis wiring harness 12 out from cab 77 33 Loosen lockring 78 and back shell 79 from cha...

Page 397: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 1 1 3...

Page 398: ...NG HARNESS REMOVAL INSTALLATION CONT 3 Route chassis wiring harness 1 up under cab beside chassis engine harness 7 NOTE Do step 4 1 for M978 only if equipped with high mount stop light 4 Connect chass...

Page 399: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 1 1 5...

Page 400: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 1 1 6...

Page 401: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 117...

Page 402: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 1 1 8...

Page 403: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 119...

Page 404: ...Connect clearance light wiring harness 65 with electrical butt connector 66 25 Close loom 67 over clearance light wiring harness 65 26 Connect 4 pin crane power connector 68 NOTE Do step 27 for M978...

Page 405: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical Systems Maintenance Instructions Cont 6 1 2 1...

Page 406: ...6 15 1 TM 9 2320 279 20 TM 9 2320 279 20 Appendix C TM 9 2320 279 34 1 Electrical System Maintenance Cont 6 122...

Page 407: ...sconnect clearance light wire 12 Remove wire from cover 11 4 Disconnect four taillight wires 13 5 Remove clearance light wire 12 taillight wires 12 and grommet 14 from fender 15 6 Remove grommets 14 f...

Page 408: ...11 Remove nut 22 two lockwashers 23 and three wires 24 Remove nut 24 1 lockwasher 24 21 wires 24 3 and 24 4 and screw 24 5 from right side axle stop 24 6 Disconnect connector 25 from clearance light...

Page 409: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 122 3...

Page 410: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 122 4...

Page 411: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 122 5...

Page 412: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 122 6...

Page 413: ...TM 9 2320 279 34 1 Electrical System Maintenance Cont 6 1 2 2 7...

Page 414: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 122 8...

Page 415: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 1 2 2 9...

Page 416: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 122 10...

Page 417: ...connector 61 to high idle control box 58 22 Install grommets 62 on taillight and clearance light wires 56 and 57 23 Push taillight and clearance light wires 56 and 57 through holes in rear fenders 59...

Page 418: ...ce light connectors 65 through grommet 66 Connect connector 65 to wire 56 Connect four taillight wires 57 Install cover 67 screws 68 lockwashers 69 and nuts 70 28 Install trailer electrical connector...

Page 419: ...erences None Special Tools None 6 16 CHASSIS ENGINE WIRING HARNESS REMOVAL INSTALLATION Models All except M984E1 Test Equipment None Special Environmental Conditions None General Safety Instructions N...

Page 420: ......

Page 421: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 6 1 2 3...

Page 422: ...up under cab floor 14 Bundle harness 15 to chassis engine harness with plastic cable ties along length of harness NOTE Connectors are keyed to fit proper receptacles only 5 Connect two plug connectors...

Page 423: ...6 17 TM 9 2320 279 20 TM 9 2320 279 20 Appendix C Appendix C T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 6 1 2 5...

Page 424: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 1 2 6...

Page 425: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 6 1 2 7...

Page 426: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Instructions Cont 6 1 2 8...

Page 427: ...Electrical System Maintenance Cont T M 9 2 3 2 0 2 7 9 3 4 1 6 1 2 9...

Page 428: ...T M 9 2 3 2 0 2 7 9 3 4 1 Electrical System Maintenance Cont 6 1 3 0...

Page 429: ...Description Para 7 91 Batteries disconnected TM 9 2320 279 10 Pump module rear doors opened References None Special Tools None 6 18 HIGH MOUNT STOP LAMP HARNESS REMOVAL INSTALLATION M978 Models M978...

Page 430: ...itions after section of high mount stop lamp harness is removed Note routing of high mount stop lamp harness to ensure proper installation 5 Remove high mount stop lamp harness 8 from vehicle b Instal...

Page 431: ...high mount stop lamp 5 on right hand door 6 4 Install guard 7 on door 6 with four screws 8 5 Repeat steps 3 and 4 for left hand door c Follow on Maintenance 1 Connect batteries para 7 91 2 Close pump...

Page 432: ......

Page 433: ...nor Removal Installation 7 23 Section 1 I N T R O D U C T I O N P a g e 7 1 7 1 7 3 7 8 7 3 3 7 3 6 7 4 7 7 5 0 7 5 5 7 6 8 7 7 2 7 7 6 7 7 7 7 8 9 7 9 1 7 1 0 6 7 1 1 6 7 1 2 2 7 1 3 0 7 1 3 5 7 1 5...

Page 434: ...pect surfaces in contact with gaskets packings or seals for nicks burrs or scratches Remove any defect before assembly Before inspection oil bearings lightly with same type of oil used in transmission...

Page 435: ...Section III 7 3 TM 9 2320 279 10 TM 9 2320 279 20 TM 9 2320 279 20 T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3...

Page 436: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 4...

Page 437: ...Transmission Maintenance Instructions Cont T M 9 2 3 2 0 2 7 9 3 4 1 7 5...

Page 438: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 6...

Page 439: ...rews 16 and nuts 17 9 Install switch 18 with screw 19 washer 20 spacer 21 washer 22 and nut 23 10 Install washer 24 and cotter pin 25 d Follow on Maintenance 1 Install shift control TM 9 2320 279 20 2...

Page 440: ...oved Compound sealing pipe thread Item 29 M984 Appendix C TM 9 2320 279 20 Right and left rear splash Oil lubricating Item 47 Appendix C guards removed Tags identification Item 60 Appendix C TM 9 2320...

Page 441: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 9...

Page 442: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 10...

Page 443: ...screws 36 lockwashers 37 and two clamp halves 38 and move fitting 39 with preformed packing 39 1 aside NOTE Trucks with guard perform step 19 1 Trucks without guard proceed to step 21 19 1 Loosen two...

Page 444: ......

Page 445: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 1 1...

Page 446: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions C o n t 7 1 2...

Page 447: ...Transmission Maintenance Instructions T M 9 2 3 2 0 2 7 9 3 4 1 C o n t 7 1 3...

Page 448: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 1 4...

Page 449: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 1 5...

Page 450: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 1 6...

Page 451: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 1 7...

Page 452: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 18...

Page 453: ...e nuts 124 and washers 125 from base of FY10 126 61 Remove screw 127 62 Remove PTO 126 and hydraulic pump 128 from transmission 120 CAUTlON Access hole must be covered to prevent dust and dirt from en...

Page 454: ...Adhesives solvents and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated a...

Page 455: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 2 1...

Page 456: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 2 2...

Page 457: ...Soldier A looks in access hole 20 while Soldier B turns pulley nut 22 clockwise 14 When screw hole is centered Soldier A tells Soldier B to stop turning pulley nut 22 and Soldier A instaIls remaining...

Page 458: ...ATION CONT 17 Connect hose 24 to elbow 25 18 Remove chains from transmission 5 and attach to engine lifting eyes 26 19 Soldier A installs three mounting biscuits 27 between transmission mount 9 and br...

Page 459: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 2 5...

Page 460: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 2 6...

Page 461: ...tion shift cable 40 on transmission oil pan 41 Install shift lever 42 with nut 43 Install clamp 44 with two screws 45 and nuts 46 Install dipstick tube 47 with fitting 48 Tighten fitting to 90 to 100...

Page 462: ...REMOVAL INSTALLATION CONT M984E1 has one hose on bracket 34 Connect bracket 53 with screw 54 and locknut 55 35 Connect hose 56 to modulator valve 57 36 Install insulating washer 58 washer 59 wire 60...

Page 463: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 2 9...

Page 464: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3 0...

Page 465: ...ard 89 1 under two flat washers 89 2 with two lockwashers 89 3 and screws 89 4 49 Deleted NOTE DO steps 50 through 59 for M984E1 50 51 52 53 54 55 56 Connect hose 92 to fitting 93 on heavy duty winch...

Page 466: ...N CONT 57 Connect hose 104 to fitting 105 58 Connect hose 106 to fitting 107 on pump 108 59 Connect hose 109 to fitting 110 60 Install lockwasher 111 on cross brace 112 61 Install one end of cross bra...

Page 467: ...Transmission Maintenance Instructions Cont T M 9 2 3 2 0 2 7 9 3 4 1 7 32 1 7 32 2 blank...

Page 468: ......

Page 469: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3 3...

Page 470: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3 4...

Page 471: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3 5...

Page 472: ...7 6 Para 7 4 Appendix C Appendix C T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3 6...

Page 473: ...from access cover 7 Remove access cover 7 and gasket 8 7 Install lifting device to lifting bracket 8 Raise lifting device until it supports weight of flywheel 3 NOTE Use flywheel lifting bracket to tu...

Page 474: ...with converter housing or be in a position to fall Take care to prevent torque converter turbine from falling and becoming damaged 10 Soldier A removes flywheel 3 with torque converter turbine 11 fro...

Page 475: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 3 9...

Page 476: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 4 0...

Page 477: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 4 1...

Page 478: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 4 2...

Page 479: ...ating oil to seal ring 6 and install 8 Apply lubricating oil to inner hub 7 of piston 5 and to piston seal surface 8 of flywheel 9 9 Aline six holes 10 with six pins 11 10 Install piston 5 on hub 3 Ma...

Page 480: ...83229 the old style flywheel and backplate were used If either flywheel or backplate are to be replaced they must be replaced with the new two keyed flywheel and backplate 13 Aline notch 15 with key 1...

Page 481: ...ring 3 and converter seal ring 4 with lubricating oil Install turbine shaft seal ring 3 in groove and snap ends together Install converter seal ring 4 on torque converter pump 5 Coat torque converter...

Page 482: ...wheel for access to screw holes inside converter housing 9 Install 29 screws 8 and washers 9 through holes 10 in flywheel 7 Tighten screws until snug 10 Tighten 30 screws 8 to 41 to 49 lb ft 56 to 66...

Page 483: ...ara 7 5 Transmission installed on transmission stand Para 7 6 Flywheel assembly removed Special Environmental Conditions None General Safety Instructions None Level of Maintenance General Support NOTE...

Page 484: ...goggles shield and gloves 2 Use clean lint free cloth or compressed air to dry parts cleaned with drycleaning solvent 3 Inspect parts for damage Replace damaged parts 4 Coat all parts with lubricatin...

Page 485: ...roller bearing 6 seats Position stator 1 with roller race 7 up Turn roller race 7 counterclockwise to lock in place e Installation CAUTION Keep outer face of stator down so bearings and springs will...

Page 486: ...ing Item 46 Appendix C Solvent drycleaning Item 57 Appendix C General Safety Instructions None Personnel Required MOS 63W Wheel vehicle repairer References None Equipment Condition TM or Para Conditio...

Page 487: ...TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 5 1...

Page 488: ...TM 9 2320 279 34 1 7 5 2 C h a n g e 2...

Page 489: ...ot tighten bolt 8 Install three more screws 9 and lockstrips 8 at 3 6 and 9 o clock positions 9 Snug screws in sequence 12 6 3 and 9 o clock CAUTION Failure to tighten screws using sequential tighteni...

Page 490: ...MOVAL REPAIR INSTALLATION CONT 3 4 Install pump 3 in torque converter housing 4 Install bearing installer tool around ground sleeve 5 and on bearing 6 5 6 7 Place bearing installer tool handle over be...

Page 491: ...w on Maintenance INITIAL SETUP Models All Personnel Required MOS 63W Wheel vehicle repairer 2 Test Equipment References None None Special Tools Equipment Condition Pitot tube guide screws 2 J6889 1 Fr...

Page 492: ...e converter housing during installation of holding fixtures Seven screws and lockwashers remain to hold torque converter housing on transmission housing 3 Remove seven screws 6 and lockwashers 7 holdi...

Page 493: ...CAUTION TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 57...

Page 494: ...7 9 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 58...

Page 495: ...4 15 16 17 18 19 Soldier A removes retaining ring 18 while Soldier B pushes retainer washer 19 NOTE Tag and mark all parts Remove retainer washer 19 valve stop 20 valve spring 21 and lockup shift valv...

Page 496: ...entilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 1 Clean all metallic parts with drycleaning solvent and inspect for damage If there...

Page 497: ...1 12 Install three screws 6 across front support assembly 5 Install 15 screws 7 around outer edge of front support assembly 5 Install screw 8 Tighten three screws 6 15 screws 7 and screw 8 to 36 to 43...

Page 498: ...stop 16 Install retainer washer 17 on valve spring 15 Soldier A installs retaining ring 18 while Soldier pushes retainer washer 17 Install spring 19 converter bypass valve 20 valve seat 21 and suppor...

Page 499: ...l screw 30 Tighten screw to 9 to 11 lb ft 12 to 15 N m 24 Check clearance between backplate 29 drive gear 27 and driven gear 25 Maximum clearance is 0 006 in 0 15 mm 25 Turn oil pump 28 over 26 Apply...

Page 500: ...ng in groove 33 on oil pump 28 28 Turn torque converter housing 3 on side 29 Aline screw holes in oil pump 28 with holes in torque converter housing 3 30 Soldier A installs oil pump 28 while Soldier B...

Page 501: ...CAUTION Transmission Maintenance Instructions Cont TM 9 2320 279 34 1 7 65...

Page 502: ...7 9 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 6 6...

Page 503: ...l seven screws 13 and lockwashers 14 Tighten screws to 67 to 80 lb ft 90 to 108 N m WARNING Adhesives solvents and sealing compounds can burn easily can give off harmful vapors and are harmful to skin...

Page 504: ...pplies Solvent drycleaning Item 57 Appendix C Compound sealing lubricating Item 25 Appendix C This task covers a Disassembly c Assembly b Cleaning Inspection d Follow on Maintenance INITIAL SETUP Pers...

Page 505: ...emove selector lever 3 from manual shaft 2 3 Remove cotter pin 4 4 Remove locknut 5 5 Hold detent lever 6 with one hand and remove manual shaft 2 by pulling shaft through oil seal 7 6 Remove detent le...

Page 506: ...can give off harmful vapors and are harmful to skin and clothing lb avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin...

Page 507: ...ntilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 5 Coat outside of oil seal 5 with sealing and lubricating compound and install oil s...

Page 508: ...FILTER 7 11 OIL PAN REMOVAL INSTALLATION This task covers a Disassembly b Installation c Follow on Maintenance INITIAL SETUP Models All Test Equipment None Special Tools None Supplies Compound sealing...

Page 509: ...oval 1 Remove two screws 1 lockwashers 1 1 bracket 2 and two spacers 3 NOTE Support oil pan while removing screws 2 Remove remaining 21 screws 4 holding oil pan 5 to transmission 6 3 Remove oil pan 5...

Page 510: ...vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash imme...

Page 511: ...ten screws NOTE Oil pan has to be drawn evenly to transmission 8 9 Alternately tighten each screw 8 and 11 180 apart in a crisscross pattern to 10 lb ft 14 N m Tighten each screw 8 and 11 again using...

Page 512: ...ies Oil lubricating Item 46 Appendix C Personnel Required MOS 63W Wheel vehicle repairer References None Equipment Condition TM or Para Condition Description Para 7 11 Oil pan removed Special Environm...

Page 513: ...e Installation c Cleaning Inspection f Follow on Maintenance INITIAL SETUP Models All Test Equipment None Personnel Required MOS 63W Wheel vehicle repairer 2 References None Special Tools Sun gear bu...

Page 514: ...ket to main shaft 1 of gear unit assembly 2 and secure lifting device to bracket 2 Soldier A removes gear unit assembly 2 from transmission housing 3 while Soldier B operates lifting device 3 Remove l...

Page 515: ...TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 7 9...

Page 516: ...7 13 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cent 7 8 0...

Page 517: ...4 and 25 and carriers 1 5 and 20 End play must be between 0 008 and 0 031 in 0 203 and 0 787 mm CAUTION Do not drill into the carrier assemblies NOTE If end play between piston gears and carriers is o...

Page 518: ...ent or sealing compound gets on skin or clothing wash immediately with soap and water 1 Clean all metal parts with drycleaning solvent NOTE All planetary gears in a carrier assembly are replaced as a...

Page 519: ...positioned with front end up 2 3 4 5 6 7 8 Position center carrier assembly 4 in press with front end up Position roller bearings 1 in pinion 5 Position steel thrust washer 3 at each end of pinion 5...

Page 520: ...r 11 Position bushing 7 at bore of small end of sun gear shaft 9 Aline bushing so interlock split is more than 45 degrees from swaging hole in sun gear shaft NOTE When installing Teflon impregnated bu...

Page 521: ...Clamp holding fixture in vise Set sun gear shaft 9 in holding fixture with small end up Position sun gear bushing reamer and pilot tool J28489 1 CAUTION Keep reamer rotating at full drill speed when p...

Page 522: ......

Page 523: ...in 13 mm electric drill machine bushing at approximately 75 to 150 rpm while adding lubricating oil in bore at sides of sun gear shaft 9 Check inner diameter of bushings for runout Runout must not exc...

Page 524: ...6 27 Install lube orifice plug 17 on large end of main shaft 18 28 Position main shaft 18 through internal gear 14 and spur gear shaft 15 29 Install spiral locking ring 19 29 1 Apply lubrication to ra...

Page 525: ...2 Install thrust washer 23 on base of main shaft 18 33 install center carrier assembly 4 in transmission drum 12 34 Install spur gear 24 in transmission drum 12 35 Install retaining ring 25 in transmi...

Page 526: ...carrier assembly 4 Install thrust washer 28 on front carrier assembly 27 40 Install driven gear 29 in front carrier assembly 27 e Installation NOTE External tanged clutch plates 2 have two thicknesse...

Page 527: ...7 14 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 8 9...

Page 528: ...7 14 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 9 0...

Page 529: ...isassembly e Installation c Cleaning Inspection f Follow on Maintenance INITIAL SETUP Models All Test Equipment None Personnel Required MOS 63W Wheel vehicle repairer 2 References None Special Tools C...

Page 530: ...m transmission housing 6 while Soldier B operates lifting device 3 Hold turbine shaft 1 and remove forward clutch assembly 2 outer race 3 roller bearing 4 and inner race 5 4 Place forward clutch assem...

Page 531: ...TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 9 3...

Page 532: ...7 15 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 9 4...

Page 533: ...utch assemblies will have a seal ring If seal ring is removed discard and do not replace during installation 12 Remove forward clutch piston 15 from forward clutch assembly 4 13 Remove inner seal ring...

Page 534: ...TION CONT CAUTION Do not damage pitot collector ring during removal 16 Pry pitot collector ring 20 loose from forward clutch assembly 4 17 Place PTO gear removal fixture in press 18 Install forward cl...

Page 535: ...lothing wash immediately with soap and water 1 Clean all metal parts with drycleaning solvent and inspect for damage Replace damaged parts 2 Turbine shaft is pressed in forward clutch housing and shou...

Page 536: ...l retaining ring 2 in groove 3 on outside of forward clutch assembly 1 Wear heat resistant gloves to prevent burning hands when handling hot PTO gear 4 Heat PTO gear 4 in oven or oil bath to 350 to 37...

Page 537: ...ctor ring installer on oil collector ring 6 and install oil collector ring 11 Remove collector ring installer 12 13 Using staking tool Soldier A bends edge of oil collector ring 6 in groove in forward...

Page 538: ...h driving hub 10 with 980 to 1020 lb load Measure distance from base of clutch pack 11 to machined surface 12 of hub 10 to get clutch pack thickness If forward clutch piston 7 is an A piston clutch pa...

Page 539: ...CAUTION TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 101...

Page 540: ...7 15 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 102...

Page 541: ...bricate and install thrust bearing 20 on thrust bearing race 19 32 Coat bearing race 21 with lubricating oil and install 33 Install forward clutch drive hub 22 on forward clutch assembly 1 34 35 Soak...

Page 542: ...10 38 Lubricate and install two seal rings 24 on turbine shaft 13 e Installation WARNING Be sure forward clutch hub and fourth clutch driving hub are installed in the forward clutch assembly If these...

Page 543: ...port 6 to lock up fourth clutch plates 4 Soldier A holds air pressure in fourth clutch assembly 4 while Soldier B removes fourth clutch alinement fixture 5 Soldier A continues to apply air pressure in...

Page 544: ...Appendix C Compound retaining Item 24 Appendix C Compound sealing pipe thread Item 29 Appendix C Grease general purpose lithium base Item 36 Appendix C Personnel Required MOS 63W Wheel vehicle repair...

Page 545: ...semblies contain paper friction plates Discard all paper friction plates They are replaced by graphite friction plates 8 Remove two steel plates 11 one friction plate 12 and rear planetary ring gear 1...

Page 546: ...ATION CONT 4 5 Position rear cover 1 on side Use wooden block for support Remove output shaft 7 from rear cover 1 6 Press output shaft 7 from bearing 8 spacer 9 and speedometer drive gear 10 7 Screw l...

Page 547: ...1 11 Compress clutch spring compressor and remove large external retaining ring 14 12 Remove clutch spring compressor 13 14 15 16 Remove piston spring retainer 15 from first clutch piston 16 Remove 30...

Page 548: ...an give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin o...

Page 549: ...79 24P for identification of parts 1 2 3 4 5 6 7 8 Stack 13 clutch plates 1 and 2 on flat surface of press starting with steel plate 1 and alternating with friction plate 2 Place first clutch piston 3...

Page 550: ...nstall governor support pin 7 in rear cover 8 to a depth of 5 886 to 5 896 in 149 50 to 149 76 mm Coat inner seal ring 9 and outer seal ring 10 with lubricating oil Install inner seal ring 9 and outer...

Page 551: ...aining ring 15 Remove clutch spring compressor NOTE The orifice plug must clear the chamfer at the front of the plug bore in the output shaft 18 19 20 21 22 Install small orifice plug 16 in output sha...

Page 552: ...ipe thread sealing compound and install in rear cover 8 25 Install bushing 25 2 and plug 26 in rear cover 8 26 Torque plug 25 plug 25 11 and plug 26 to 4 to 5 lb ft 5 to 7 N m e Installation 1 Soak si...

Page 553: ...ange face of rear cover to help aline cover with transmission 9 Soldier A alines screw holes and installs rear cover 6 on transmission 3 while Soldier B operates lifting device Soldier B removes lifti...

Page 554: ...plastic Item 65 Appendix C Solvent dry cleaning Item 57 Appendix C Grease general purpose lithium base Item 36 Appendix C Personnel Required MOS 63W Wheel vehicle repairer References None Equipment Co...

Page 555: ...n plates 6 from fourth clutch housing 1 3 4 5 6 Install fourth clutch housing 1 in hydraulic press Compress spring retainer 7 with clutch spring compressor Remove retaining ring 8 Release pressure fro...

Page 556: ...seal rings must be replaced 11 Remove inner seal ring 12 from fourth clutch housing 1 or fourth clutch piston 9 c Cleaning Inspection WARNING Adhesives solvents and sealing compounds can burn easily...

Page 557: ...air used for cleaning purposes will not exceed 30 psi 207 kPa Use only with effective chip guarding and personal protective equipment goggles shield and gloves 4 Dry ball pockets 1 with compressed ai...

Page 558: ......

Page 559: ...e of press starting with steel plate 2 and alternating with friction plate 3 3 Place backplate 4 on clutch plates 2 and 3 4 5 6 7 Press evenly on backplate 4 with 980 to 1020 lb load 4359 to 4536 9 N...

Page 560: ...eal ring 9 and hub 10 of fourth clutch housing 11 with lubricating oil NOTE For Model A do step 11 for Model B do step 11 1 11 Install seal ring 9 on hub 10 with seal ring lip 12 pointing down 11 1 In...

Page 561: ...CAUTION T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 121...

Page 562: ...7 17 7 18 TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 122...

Page 563: ...e support housing anchor screw 5 and washer 6 5 Remove retaining ring 7 holding center support housing 8 NOTE Center support housing is fitted to transmission housing with very little clearance and ma...

Page 564: ...AlR lNSTALLATlON CONT b Disassembly 1 Remove third clutch piston 1 from center support housing 2 2 Remove outer seal ring 3 and inner seal ring 4 from third clutch piston 1 3 Cut and remove four retai...

Page 565: ...e solvent or sealing compound gets on skin or clothing wash immediately with soap and water 1 Clean all metallic parts with drycleaning solvent and inspect for damage Replace damaged parts 2 Replace p...

Page 566: ...n 4 in front cavity of center support housing 1 5 Install 20 piston release springs 5 in pockets on third clutch piston 4 6 Install clutch ring 6 on third clutch piston 4 Clutch ring must be pushed co...

Page 567: ...clutch plates 9 and 10 Press evenly on third clutch piston 4 with 980 to 1020 lb load 4359 to 4536 9 N Measure distance from base of clutch pack 11 to thrust pad 12 Clutch pack thickness must be 3 01...

Page 568: ...r support housing is fitted to transmission housing with very little clearance and may bind if transmission housing is cold Heat transmission housing with heat lamp or warm current of air 3 Lower cent...

Page 569: ...rmine lug with tightest fit a Blue color coded retaining ring is 0 148 to 0 150 in 3 76 to 3 81 mm thick b Yellow color coded retaining ring is 0 152 to 0 154 in 3 86 to 3 91 mm thick c White color co...

Page 570: ...sion housing 4 f Follow on Maintenance Install fourth clutch assembly para 7 17 END OF TASK 7 19 SECOND CLUTCH AND CENTER SUPPORT HOUSING REMOVAL REPAIR INSTALLATION This task covers a Removal b Disas...

Page 571: ...es 3 from transmission housing 4 NOTE Some clutch assemblies contain paper friction plates Discard all paper friction plates They are replaced by graphite friction plates b Disassembly 1 Remove second...

Page 572: ...er 1 Clean all metallic parts with drycleaning solvent and inspect for damage Replace damaged parts 2 Replace piston release springs if any three in each set of 20 do not meet the following load heigh...

Page 573: ...s evenly on second clutch piston 1 with 980 to 1020 lb load 4359 to 4536 9 N Measure distance from base of clutch pack 8 to top of thrust pad 9 Clutch pack thickness must be 3 136 to 3 168 in 79 66 to...

Page 574: ...be installed on top of stack 2 3 4 install steel plates 2 with gap 3 facing as shown lnstall 12 clutch plates 1 and 2 starting with friction plate 1 and alternating with steel Plate 2 install retainin...

Page 575: ...7 20 CONTROL VALVE BODY REMOVAL REPAIR INSTALLATION TM 9 2320 279 34 1 Transmission Maintenance Instructions Cont 7 135...

Page 576: ...7 20 T M 9 2 3 2 0 2 7 9 3 4 1 Transmission Maintenance Instructions Cont 7 136...

Page 577: ...valve pin 12 from oil transfer plate 3 W A R N I N G All valves are under spring tension Release springs slowly to avoid personal injury CAUTION Do not use magnets to remove valve bodies Magnetized va...

Page 578: ...25 Remove last two screws 25 evenly while holding down trimmer valve cover 26 Remove trimmer valve cover Remove plug 27 and governor screen assembly 28 from control valve body 5 14 Remove two springs...

Page 579: ...immer valve 43 from control valve body 5 17 Remove accumulator valve 44 spring 45 and valve stop 46 18 Remove two springs 47 and 48 valve stop 49 plug 50 and fourth clutch trimmer valve 51 from contro...

Page 580: ...6 spring spacer 57 spring 58 and one two relay valve 59 Remove retaining pin 60 spring 61 valve stop 62 and accumulator valve 63 NOTE Record each notch on adjusting rings that touch retaining pins 22...

Page 581: ...4 Remove retaining pin 72 adjusting ring 73 valve spring 74 valve stop 75 one two modulator valve 76 and one two shift valve 77 from control valve body 5 25 Remove retaining pin 78 adjusting ring 79 v...

Page 582: ...TALLATION CONT 26 Remove retaining pin 84 adjusting ring 85 valve spring 86 valve stop 87 three four modulator valve 88 and three four shift valve 89 from control valve body 5 27 Remove retaining pin...

Page 583: ...Replace springs which do not meet load length specifications listed in Table 7 2 Table 7 2 Spring Load Length Specifications Spring Lubrication Length Length Text Reference Without Load Under Load Lo...

Page 584: ...ve 3 4 Shift valve 3 4 Relay valve Trimmer 65 0 2 77 70 4 1 45 36 8 2 27 57 7 2 18 55 4 1 52 38 6 1 84 46 7 1 68 42 7 2 65 67 3 2 51 63 8 2 69 68 3 2 18 55 4 1 33 49 3 1 49 37 9 1 10 27 9 1 94 49 3 1...

Page 585: ...in 5 in control valve body 1 4 Install two three relay valve 6 spring 7 and valve stop 8 in control valve body 1 5 Press valve stop 8 and install retainer pin 9 in control valve body 1 Install valves...

Page 586: ...stall third clutch trimmer valve 20 plug 21 spring 22 spring 23 and valve stop 24 in control valve body 1 9 Install first clutch trimmer valve 25 plug 26 secondary spring 27 primary spring 28 and valv...

Page 587: ...8 to 12 lb ft 11 to 16 N m 12 Install trimmer regulator valve 35 valve spring 36 and valve stop 37 in control valve body 1 13 Press valve stop 37 and install retaining pin 38 in control valve body 1 1...

Page 588: ...ing 47 Aline pinhole in valve stop 46 with pinholes in control valve body 1 Press adjusting ring 47 and install retaining pin 48 in control valve body 1 19 Install two three shift valve 49 two three m...

Page 589: ...spring 57 valve stop 58 and adjusting ring 59 Aline pinhole in valve stop 58 with pinholes in control valve body 1 Press adjusting ring 59 and install retaining pin 60 in control valve body 1 Install...

Page 590: ...stop 73 with pinholes in control valve body 1 Press valve stop 73 and install retaining pin 74 in control valve body 1 Install valve stop 75 spring 76 and priority valve 77 in control valve body 1 36...

Page 591: ...sher 88 on oil transfer plate 89 bottom side Soldier A installs retaining pin 90 while Soldier B presses down on spring cup washer 88 Install four 0 25 in 6 4 mm check balls 91 93 94 and 95 and 0 3125...

Page 592: ...from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water CAUTION Care must be exercised when grinding the lo...

Page 593: ...ck surface to the top of the locator boss prior to grinding 1 1 Removing material from the housing locator boss to a dimension of 1 500 inches 38 mm as measured from the transmission housing oil track...

Page 594: ...ctor valve 4 2 Install three screws 5 3 Install seven screws 6 4 Install two screws 7 and washers 8 5 Install 15 screws 9 in control valve body 1 6 Install manual detent lever 10 and screw 11 in contr...

Page 595: ...Para Condition Description TM 9 2320 279 10 Shut off engine Special Environmental Conditions None General Safety Instructions None Level of Maintenance Direct Support a Removal NOTE Tag and mark hose...

Page 596: ...ent Condition None TM or Para Special Tools Condition Description Para 7 12 Internal filter element None removed Supplies Special Environmental Conditions Solvent dry cleaning Item 57 Appendix C None...

Page 597: ...ful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap a...

Page 598: ...lement para 7 12 END OF TASK 7 23 GOVERNOR REMOVAL INSTALLATION This task covers a Removal b Installation c Follow on Maintenance INITIAL SETUP Models All References None Test Equipment None Special T...

Page 599: ...d remove from transmission 4 b Installation 1 Turn governor 5 counterclockwise in port 6 to install 2 Aline holes in gasket 3 and cover 2 with holes in port 6 3 Install four screws 1 cover 2 and gaske...

Page 600: ......

Page 601: ...28 8 29 8 34 8 36 8 38 8 41 8 42 8 44 8 45 8 47 8 52 8 54 8 1 GENERAL This chapter contains maintenance instructions for removal installation and repair of the transfer case and components at the dir...

Page 602: ...10 Transfer case in neutral LO 9 2320 279 12 Transfer case drained TM 9 2320 279 10 Air system drained TM 9 2320 279 20 Propeller shafts removed TM 9 2320 279 20 Speedometer sending unit removed Suppl...

Page 603: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 2 1 8 2 2 blank...

Page 604: ......

Page 605: ...ase Maintenance Instructions Cont 8 2 TRANSFER CASE REMOVAL lNSTALLATION CONT N O T E 8 Cut plastic cable ties as needed airhoses 12 and 13 Disconnect 9 Loosen two nuts 14 and slide shift cable 7 out...

Page 606: ...Remove two screws 16 lockwashers 17 and shift cable bracket 15 11 Remove two screws 18 and retainer washer 19 NOTE Some models of vehicles have a washer under head of screw 12 Remove nut 20 lockwashe...

Page 607: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 5...

Page 608: ...8 2 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 6...

Page 609: ...7 Install three screws 10 and lockwashers 11 in left front of mounting bracket 2 8 Lower lifting device and move lifting device aside NOTE Some models of vehicles have a washer under head of screw 9 I...

Page 610: ...rea If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 11 Apply silicone adhesive sealant to end and splined surface of output shaft 20 Apply sealing...

Page 611: ...TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 9...

Page 612: ...8 2 T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 1 0...

Page 613: ...r case support assembly removed Special Environmental Conditions None General Safety Instructions None Level of Maintenance Direct Support a Removal NOTE Left and right brackets are removed and instal...

Page 614: ...8 Appendix C Grease automotive and artillery Item 34 Appendix C Compound sealing Item 26 Appendix C Compound sealing pipe thread Item 28 1 Appendix C Tags identification Item 60 Appendix C Personnel R...

Page 615: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 1 3...

Page 616: ...8 4 T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 14...

Page 617: ...TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 1 5...

Page 618: ...8 4 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 1 6...

Page 619: ...easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets o...

Page 620: ...clothing wash immediately with soap and water 1 Apply light bead of adhesive to inside flange of end cap 1 Apply sealing compound to threads of six screws 2 Install six screws 2 lockwashers 3 and end...

Page 621: ...TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 1 9...

Page 622: ...8 4 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 2 0...

Page 623: ...mbly 17 as shown Install lower shift rod assembly 17 in front case half 4 with spring disk end down and spacer 16 against front case half Install spacers 18 and 19 on lower rear output shaft assembly...

Page 624: ...solvent or sealing compound gets on skin or clothing wash immediately with soap and water 19 20 21 22 22 1 Coat threads of six screws 26 with sealing compound and install screws and lockwashers 27 Tig...

Page 625: ...WARNING Transfer Case Maintenance Instructions Cont TM 9 2320 279 34 1 8 23...

Page 626: ...8 4 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 2 4...

Page 627: ...to threads of six screws Repeat step 38 then go to step 44 38 Install end cap 45 with six 39 lockwashers 44 and screws 43 Tighten screws to 60 lb ft 81 N m Remove plug 47 from end cap 45 Clean off old...

Page 628: ...apter and strainer 52 with pipe thread sealing compound and install adapter and strainer 48 Coat threads of elbow 53 with pipe thread sealing compound and install elbow and hose 54 49 Turn workstand t...

Page 629: ...m open tire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 58 Coat end of lower front output shaft assembly 65 wi...

Page 630: ...320 279 10 Shut off engine LO 9 2320 279 12 Transfer case oil drained TM 9 2320 279 20 Propeller shafts removed Special Tools None Special Environmental Conditions None Supplies Grease automotive and...

Page 631: ...er grade 5 or grade 8 Torque screws accordingly 4 1 Apply sealing compound to threads of two screws 1 5 Install retaining washer 2 and two screws 1 Tighten grade 8 screws to 88 lb ft 119 N m Tighten g...

Page 632: ...mbly 1 2 3 4 5 Remove two screws 1 and pump drive plate 2 Remove spacer 3 and piston ring 4 Place top input shaft assembly 5 in suitable press with large gear 6 up Press top input shaft 5 out of beari...

Page 633: ...Transfer Case Maintenance Instructions Cont TM 9 2320 279 34 1 8 31...

Page 634: ...8 6 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 32...

Page 635: ...stall large gear 12 over top input shaft 1 11 Install spacer 13 12 Press bearing 14 to seat against spacer 13 13 Install spacer 15 and piston ring 16 14 Install pump drive plate 17 NOTE Retaining scre...

Page 636: ...endix C Personnel Required MOS 63W Wheel vehicle repairer Equipment Condition TM or Para Condition Description Center shaft on clean work surface Special Environmental Conditions None General Safety I...

Page 637: ...TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 3 5...

Page 638: ...8 7 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 3 6...

Page 639: ...s and are harmful to skin and clothing lb avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediate...

Page 640: ...NT OUTPUT SHAFT REPAIR This task covers a Disassembly c Assembly b Cleaning Inspection d Follow on Maintenance INITIAL SETUP Models All Test Equipment None References None Equipment Condition TM or Pa...

Page 641: ...TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 39...

Page 642: ...8 9 TM 9 2320 279 34 1 Transfer Case Maintenance Instructions Cont 8 4 0...

Page 643: ...l Conditions None General Safety Instructions None Level of Maintenance General Support Adhesives solvents and sealing compounds can burn easily can give off harmful vapors and are harmful to skin and...

Page 644: ...wo screws 3 together with lockwire 4 5 Install two spacers 5 and 6 on shift rod 1 d Follow on Maintenance None END OF TASK 8 11 LOWER SHIFT ROD ASSEMBLY REPAIR This task covers a Disassembly c Assembl...

Page 645: ...d area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 1 Clean all metal parts in drycleaning solvent 2 Inspect all parts for wear or damage 3 Rep...

Page 646: ...Conditions None Oil lubricating Item 48 Appendix C Solvent dry cleaning Item 57 Appendix C General Safety Instructions None Personnel Required MOS 63W Wheel vehicle repairer References None Equipment...

Page 647: ...8 13 Appendix C Appendix C Transfer Case Maintenance Instructions Cont T M 9 2 3 2 0 2 7 9 3 4 1 8 4 5...

Page 648: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 4 6...

Page 649: ...sealing pipe thread Item 28 1 Appendix C Tags identification Item 60 Appendix C Solvent drycleaning Item 57 Appendix C Oil lubricating Item 46 Appendix C Compound sealing Item 26 Appendix C Adhesive...

Page 650: ...Instructions Cont 8 14 LOCKOUT SHIFT CHAMBER REMOVAL REPAlR lNSTALLATlON CONT 3 Remove plug 6 and preformed packing 7 4 Remove locknut 8 and copper washer 9 5 Remove two screws 10 lockwashers 11 locko...

Page 651: ...injury NOTE A vise may be used to relieve spring pressure when disassembling chamber 1 Remove two nuts 1 and screws 2 2 Remove ring clamp 3 and open vise 3 Remove front cover 4 4 Remove diaphragm 5 a...

Page 652: ...y with soap and water 1 Clean all metal parts in drycleaning solvent 2 Inspect all metal parts for damage 3 Replace damaged parts d Assembly 1 Install diaphragm 1 guide 2 and nut 3 on air pressure pla...

Page 653: ...vent or sealing compound gets on skin or clothing wash immediately with soap and water 5 Coat threads of two screws 10 with sealing compound and install screws lockwashers 11 and rear part of chamber...

Page 654: ...7 5 Install connector 8 6 Connect two airhoses 9 and 10 f Follow on Maintenance Start engine build END OF TASK up air pressure check for leaks TM 9 2320 279 10 8 15 LUBRICATION PUMP REMOVAL INSTALLAT...

Page 655: ...ire and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 1 Coat pipe threads of fitting 2 with pipe thread sealing comp...

Page 656: ...aning Item 57 Appendix C Paper abrasive garnet emery cloth Item 51 Appendix C Personnel Required MOS 63W Wheel vehicle repairer References None Equipment Condition TM or Para Condition Description Lub...

Page 657: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 5 5...

Page 658: ...T M 9 2 3 2 0 2 7 9 3 4 1 Transfer Case Maintenance Instructions Cont 8 5 6...

Page 659: ...rential Carrier Axle No 2 Removal Installation 9 10 Differential Carrier Axle No l Repair 9 11 Differential Carrier Axle No 2 Repair 9 12 Ball Socket Removal Installation 9 13 Axles No land No 2 Ball...

Page 660: ...9 2 AXLE SHAFT ASSEMBLY REMOVAL REPAIR INSTALLATION T M 9 2 3 2 0 2 7 9 3 4 1 Section Il AXLE ASSEMBLIES 9 2...

Page 661: ...ake spider 3 from axle skein 2 5 Remove axle shaft assembly 5 from ball socket 4 b Dissssembly CAUTION Before splitting cage ring axle shafts and cage ring halves must be marked to insure correct asse...

Page 662: ...ion 6 1 2 3 W A R N I N G Adhesives solvents and sealing compounds can bum easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and...

Page 663: ...can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open tire and use in well ventilated area If adhesive solvent or sealing compou...

Page 664: ...MOVAL INSTALLATION This task covers a Removal b Installation c Follow on Maintenance INITIAL SETUP Models All Test Equipment None Special Tools None Supplies Preventive rust Item 53 Appendix C oil lub...

Page 665: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 7...

Page 666: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 8...

Page 667: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 9...

Page 668: ...9 4 AXLE NO 2 REMOVAL INSTALLATION T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 10...

Page 669: ...xle 13 NOTE Do not disconnect frame end of torque rod Some models of vehicles contain washers between torque rod and axle Perform step 5 1 for these models Remove two locknuts 14 screws 15 and four wa...

Page 670: ...n only be installed with inner beam end adapter 4 Install two screws 4 four washers 5 four beam end adapters 6 and two nuts 7 loosely NOTE Some models of vehicles require washers between torque rod an...

Page 671: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 1 3...

Page 672: ...Disassembly e Installation c Cleaning Inspection f Follow on Maintenance INITIAL SETUP Personnel Required MOS 63W Wheel vehicle repairer Equipment Condition TM or Para Condition Description LO 9 2320...

Page 673: ...Cont a Removal 1 Remove screw 1 and lockwasher 2 NOTE Perform step 2 for Non A2 and A2R1 model vehicles Perform step 2 1 for A2 and A2R1 model vehicles 2 Remove 11 nuts 3 lockwashers 4 and four taper...

Page 674: ......

Page 675: ...n all metal parts with dry cleaning solvent W A R N I N G Compressed air used for cleaning purposes will not exceed 30 psi 207 kPa Use only with effective chip guarding and personal protective equipme...

Page 676: ...t or sealing compound gets on skin or clothing wash immediately with soap and water NOTE Perform step 2 for Non A2 and A2R1 model vehicles Perform step 2 1 for A2 and A2R1 model vehicles 2 Apply silic...

Page 677: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 1 7...

Page 678: ...9 6 T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 1 8...

Page 679: ...III DIFFERENTIAL CARRIERS 9 7 DIFFERENTIAL CARRIER AXLE NO 1 REMOVAL INSTALLATION This task covers a Removal c Installation b Cleaning Inspection d Follow on Maintenance INITIAL SETUP Models All Test...

Page 680: ...l carrier 2 2 Remove 12 nuts 3 lockwashers 4 and three air line brackets 1 from differential carrier 2 2 1 Remove four nuts 3 and lockwashers 4 from differential carrier 2 2 2 Tag and mark placement o...

Page 681: ...soap and water 2 Use drycleaning solvent to clean axle housing 2 3 Use clean cloth to wipe dry 4 Inspect mounting studs 3 for cracks breaks and damaged threads Replace if damaged 5 Inspect axle housin...

Page 682: ......

Page 683: ...all three air line brackets 4 12 lockwashers 5 and nuts 6 Tighten nuts to 180 lb ft 244 N m NOTE Ensure 2 1 4 inch and 1 3 4 inch screws are positioned as tagged and marked during removal 5 1 5 2 Inst...

Page 684: ...ription LO 9 2320 279 12 Axle drained Special Tools Socket 2 7 8 in IM 923 Supplies TM 9 2320 279 20 Propeller shafts removed Special Environmental Conditions None Solvent drycleaning Item 57 Appendix...

Page 685: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 2 3...

Page 686: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 2 4...

Page 687: ...rmed only if end play adjustment is required If measured end play is more than allowable amount shims must be removed If measured end play is less than allowable amount shims must be added To correct...

Page 688: ...ers a Disassembly c Assembly b Cleaning Inspection d Follow on Maintenance INITIAL SETUP ModeIs References All None Equipment Condition Test Equipment TM or Para Condition Description None Differentia...

Page 689: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 2 7...

Page 690: ...9 9 T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 28...

Page 691: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 2 9...

Page 692: ...9 9 T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 3 0...

Page 693: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 3 1...

Page 694: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 3 2...

Page 695: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 33...

Page 696: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 3 4...

Page 697: ...RIER AXLE NO 2 REMOVAL lNSTALLATlON This task covers a Removal b Cleaning Inspection c Installation d Follow on Maintenance INITIAL SETUP Models All Test Equipment None Special Tools None Supplies Sol...

Page 698: ...s 2 and bracket 3 from differential carrier 4 Remove 10 nuts 5 lockwashers 6 and two brackets 7 Mark location and remove four tapered dowels 8 3 1 Remove four nuts 5 lockwashers 6 and tapered dowels 8...

Page 699: ...cks breaks and damaged threads Replace if damaged 5 Inspect axle housing 2 for cracks or damage Replace if damaged c Installation WARNING Keep out from under differential carrier Serious injury may re...

Page 700: ......

Page 701: ...al carrier 1 in axle 2 while Soldier B operates lifting device 5 Install bracket 3 two lockwashers 4 and screws 5 6 Install four tapered dowels 6 7 Install two brackets 7 10 lockwashers 8 and nuts 9 7...

Page 702: ...ar Item 44 Appendix C Solvent drycleaning Item 57 Appendix C Dye prussian blue Item 32 Appendix C Lockwire Item 39 Appendix C Adhesive sealant silicone Item 6 Appendix C Compound sealing and thread lo...

Page 703: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No land No 2 Maintenance lnstructions Cont 9 3 9...

Page 704: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 0...

Page 705: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 1...

Page 706: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 2...

Page 707: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 3...

Page 708: ...9 11 TM 9 2320 279 34 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 44...

Page 709: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 4 5...

Page 710: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 6...

Page 711: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 7...

Page 712: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 4 8...

Page 713: ...TM 9 2320 279 34 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 49...

Page 714: ...9 11 T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 0...

Page 715: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 1...

Page 716: ...TM 9 2320 279 34 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 2...

Page 717: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 3...

Page 718: ...9 11 T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 5 4...

Page 719: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance lnstructions Cont 9 5 5...

Page 720: ...9 12 DIFFERENTIAL CARRIER AXLE NO 2 REPAIR T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 6...

Page 721: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 57...

Page 722: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 8...

Page 723: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 5 9...

Page 724: ...9 12 DIFFERENTIAL CARRIER AXLE NO 2REPAIR Cont T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 6 0...

Page 725: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cent 9 6 1...

Page 726: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 6 2...

Page 727: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 6 3...

Page 728: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 6 4...

Page 729: ...of a kit This kit will contain parts not required in this application Refer to TM 9 2320 279 24P for proper identification of parts WARNING Compressed air used for cleaning purposes will not exceed 3...

Page 730: ...PAIR CONT c Assembly 1 Install bearing cone 1 on differential case flanged half 2 2 Install bearing cone 3 on differential case plain half 4 3 Install thrust washer 5 and side gear 6 in differential c...

Page 731: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 6 7...

Page 732: ...9 12 T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 6 8...

Page 733: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 69...

Page 734: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No 1 and No 2 Maintenance Instructions Cont 9 7 0...

Page 735: ...T M 9 2 3 2 0 2 7 9 3 4 1 Axles No land No 2 Maintenance lnstructions Cont 9 71...

Page 736: ...TM 9 2320 279 34 1 9 72...

Page 737: ...and use in well ventilated area If adhesive solvent or sealing compound gets on skin or clothing wash immediately with soap and water 51 52 53 54 55 Apply sealing compound to flange of bearing cage 23...

Page 738: ...casting inside carrier 59 Soldier A installs assembled ring gear and differential 38 into differential carrier 17 while Soldier B operates lifting device CAUTION Threads on bearing adjusters can be da...

Page 739: ...wo bearing adjusters and there is no backlash Rotate ring gear 13 and check for bind If ring gear binds loosen bearing adjuster 36 then tighten until ring gear does not bind Tighten bearing adjuster 4...

Page 740: ...bearing adjuster resists movement then tighten two or three more notches Repeat step 72 To remove backlash loosen bearing adjuster 46 five or six notches Tighten bearing adjuster 36 one notch Tighten...

Page 741: ...tern that was recorded at disassembly is reached If pattern was incorrect pattern runs off gear tooth at disassembly then after assembly review steps 84 through 87 and adjust backlash as required unti...

Page 742: ...rn C remove backlash steps 77 through 80 Repeat steps 81 through 83 NOTE To add or remove shims in steps 86 and 87 remove ring gear and differential assembly steps 15 through 23 in Disassembly and pin...

Page 743: ...Repeat steps 72 through 83 88 Tighten four screws 41 and 44 to 370 to 430 lb ft 502 to 583 NOTE Bearing adjuster may be turned slightly to aline adjuster locks 89 Install adjuster lock 49 and cotter p...

Page 744: ...ocknut 48 and pinion 30 Install bearing cup 54 in differential carrier 17 Install bearing 55 on side gear 56 Install bushing 57 in end of output shaft 58 Apply lubricating oil to two preformed packing...

Page 745: ...four bushings 62 and side pinions 63 and install bushings side pinions and thrust washers 64 on spider 102 Aline matchmarks and install inter axle differential case halves 65 and 66 on spider 61 with...

Page 746: ...l Tools None Supplies Grease automotive and artillery Item 34 Appendix C Adhesive Item 2 1 Appendix C c Installation d Follow on Maintenance Equipment Condition TM or Para Condition Description TM 9 2...

Page 747: ...Steps 2 and 3 are for both left and right sides 2 Remove pipe plug 4 3 Remove four screws 5 lockwashers 6 bottom cover 7 and shims 8 from ball socket 3 Record number and thickness of shims TA191143 NO...

Page 748: ...Remove four screws 15 and lockwashers 16 9 Remove brake chamber mounting bracket 17 10 Measure and record length from top of stop bolt 18 to top of nut 19 11 Remove nut 19 and stop bolt 18 from ball...

Page 749: ...25 NOTE 15 through 21 are for both left and right sides Remove lower axle ball trunnion 26 by driving lower axle ball trunnion upward into ball and bushing assembly 27 Remove two screws 28 and end pla...

Page 750: ...arings if they are not seated while hammering 18 Hammer around top of ball socket 3 until upper and lower bearing cups 31 and 32 are 1 8 in 3 18 mm above and below ball socket surface 19 Tip ball sock...

Page 751: ...ngs for loose rollers and cracked or broken races Replace if damaged Inspect seals for tears Replace torn seals Inspect bushings for gouges and out of round condition If bushing is gouged or more than...

Page 752: ...r bearing 8 in bearing cup 1 TA191158 6 With brake air chamber mounting surface 9 facing to the rear and mounting holes 10 facing outward install ball socket 3 over ball and bushing assembly 11 7 8 ba...

Page 753: ...Tighten screws to 40 lb ft 54 N m NOTE Install same number and thickness of shims as removed 11 Install shims 16 bottom cover 17 four lockwashers 18 and screws 19 12 Tighten screws 19 to 185 lb ft 251...

Page 754: ...s 19 through 25 are for left ball socket only Install same number and thickness of shims as removed 19 Install shims 24 on four studs 6 NOTE Install steering arm with flange side down 20 Install steer...

Page 755: ...nion through lubrication fitting 34 29 Hook spring scale on end of ball socket 3 30 Pull spring scale and check that ball socket 3 will move with pull of 35 to 45 lb 16 to 20 kg If it does go to step...

Page 756: ...to each seal joint Excess adhesive can cause seal to become brittle and damaged NOTE Cut seal ends square before installation Be certain grooved side of seal faces upward Seals may be one piece on Mo...

Page 757: ...perform step 35 If assembling Model B perform step 35 1 35 Install seal retainer halves 35 and other half of seal 34 1 so it overlaps second joint and butts up against other half of seal on both ends...

Page 758: ......

Page 759: ...seal retainer halves 35 and six screws 36 Apply silicone adhesive sealant between seal retainer halves 35 Aline seal retainer halves 35 and install six lockwashers 37 and screws 36 Tighten six screws...

Page 760: ...ecial Tools Para 9 13 Ball socket removed None Special Environmental Conditions Supplies None Adhesive sealant silicone Item 6 Appendix C Solvent dry cleaning Item 57 Appendix C General Safety Instruc...

Page 761: ...ushing 9 If difference in measurement is less than 0 008 in 0 203 mm or more than 0 020 in 0 508 mm remove bushing from axle ball 10 WARNING Adhesives solvents and sealing compounds can burn easily ca...

Page 762: ...mpounds can burn easily can give off harmful vapors and are harmful to skin and clothing To avoid injury or death keep away from open fire and use in well ventilated area If adhesive solvent or sealin...

Page 763: ...Repair 9 9 Axle shaft assembly removal repair installation 9 2 Axles No 1 and No 2 axle shaft assembly removal repair installation 9 2 Axles No 1 and No 2 ball bushing and oil seal removal installati...

Page 764: ...cription Compressed air warning Connector and junction box M977 M985 removal repair installation Connector and junction box M984E1 removal repair installation Control distribution board crane M983 rem...

Page 765: ...arness removal installation 6 16 Engine general maintenance instructions 3 2 Engine maintenance 3 1 Engine to engine stand removal installation 3 4 Engine troubleshooting 2 7 Engine wiring harness rem...

Page 766: ...torque converter removal repair installation Housing transmission repair How to use this manual Hydraulic system troubleshooting I ICE STE wiring harness removal installation Identification tanker com...

Page 767: ...removal installation Motor starter repair and testing Mounting brackets transfer case removal installation N Names equipment and model numbers No 1 axle removal installation No 1 axle differential car...

Page 768: ...instruction Power distribution board wiring diagram M983 Power interconnecting cables M983 removal installation Pre embarkation inspection Preparation for storage or shipment Pressure tester setup M9...

Page 769: ...r solenoid removal installation Starting fluid warning Stator torque converter removal repair installation Steering system troubleshooting STE ICE wiring harness removal installation Storage or shipme...

Page 770: ...on Control valve body removal repair installation Forward clutch assembly removal repair installation Fourth clutch assembly removal repair installation General maintenance instructions Housing repair...

Page 771: ...udible level warning indicators M983 removal installation w Warning alarm switch tilt removal installation Warning indicators visual and audible level M983 removal installation Warnings Adhesives and...

Page 772: ...mber Wiring harness removal installation Cont Chassis 6 15 Chassis M984E1 6 15 1 Chassis Engine 6 16 Engine 6 14 STE ICE 6 17 Y Yoke and oil seal axles No 1 and No 2 removal installation 9 6 Yoke outp...

Page 773: ...igadier General United States Army The Adjutant General Distribution To be distributed in accordance with DA Form 12 38 Direct and General Support Maintenance requirements for Truck Cargo 10 Ton 8x8 H...

Page 774: ......

Page 775: ...T M 9 2 3 2 0 2 7 9 3 4 1...

Page 776: ......

Page 777: ...TM 9 2320 279 34 1...

Page 778: ......

Page 779: ...TM 9 2320 279 34 1...

Page 780: ...PIN 062143 000...

Page 781: ...id not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the...

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