Volume No. 1
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, M998 (2320-01-107-7155) (EIC: BBD); M998A1 (2320-01-371-9577) (EIC: BBN); TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, W/WINCH, M1038 (2320-01-107-7156) (EIC: BBE); M1038A1 (2320-01-371-9578) (EIC: BBP); TRUCK, UTILITY: HEAVY VA R I A N T, 4X4, M1097 (2320-01-346-9317) (EIC:BBM); M1097A1 (2320-01-371-9583) (EIC: BBU); M1097A2 (2320-01-380-8604) (EIC: BB6); M1123 (2320-01-455-9593) (EIC: B6G); TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, M966 (2320-01-107-7153) (EIC: BBC); M966A1 (2320-01-372-3932) (EIC: BBX); M1121 (2320-01-456-1282) (EIC: B 6 H ) ; TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1036 (2320-01-107-7154) (EIC: BBH); TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1045 (2320-01-146-7191); M1045A1 (2320-01-371-9580) (EIC: BBR); M1045A2 (2320-01-380-8229) (EIC: BB5); TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1046 (2320-01-146-7188); M1046A1 (2320-01-371-9582) (EIC: BBT); TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, M1025 (2320-01-128-9551) (EIC: BBF); M1025A1 (2320-01-371-9584) (EIC: BBV); M1025A2 (2320-01-380-8233) (EIC: BB3); TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1026 (2320-01-128-9552) (EIC: BBG); M1026A1 (2320-01-371-9579) (EIC: BBQ); TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1043 (2320-01-146-7190); M1043A1 (2320-01-372-3933) (EIC: BBY); M1043A2 (2320-01-380-8213) (EIC: BB4); TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1044 (2320-01-146-7189); M1044A1 (2320-01-371-9581) (EIC: BBS); TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1037 (2320-01-146-7193) (EIC: BBK); TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, W/WINCH, M1042 (2320-01-146-7187); TRUCK, AMBULANCE, 2-LITTER, ARMORED, 4X4, M996 (2310-01-111-2275) (EIC: BBB); M996A1 (2310-01-372-3935) (EIC: BB2); TRUCK, AMBULANCE, 4-LITTER, ARMORED, 4X4, M997 (2310-01-111-2274) (EIC: BBA); M997A1 (2310-01-372-3934) (EIC: BBZ); M997A2 (2310-01-380-8225) (EIC: BB8); TRUCK, AMBULANCE, 2-LITTER, SOFT TOP, 4X4, M1035 (2310-01-146-7194); M1035A1 (2310-01-371-9585) (EIC: BBW); M1035A2 (2310-01-380-8290) (EIC: BB9).
| Chapter Description | Number |
|---|---|
| HOW TO USE THIS MANUAL | 0 |
| INTRODUCTION | 1-1 |
| SERVICE AND TROUBLESHOOTING INSTRUCTIONS | 2-1 |
| ENGINE SYSTEMS MAINTENANCE | 3-1 |
| ELECTRICAL SYSTEMS MAINTENANCE | 4-1 |
| TRANSMISSION AND TRANSFER CASE MAINTENANCE | 5-1 |
| PROPELLER SHAFTS AXLES AND SUSPENSION MAINTENANCE | 6-1 |
| BRAKE SYSTEM MAINTENANCE | 7-1 |
| WHEELS AND STEERING MAINTENANCE | 8-1 |
| FRAME MAINTENANCE MAINTENANCE | 9-1 |
| BODY AND ACCESSORIES MAINTENANCE | 10-1 |
| SPECIAL PURPOSE BODIES MAINTENANCE | 11-1 |
| SPECIAL PURPOSE KITS | 12-1 |
| PREPARATION FOR STORAGE OR SHIPMENT | 13-1 |
| for public release; distribution is unlimited. |
| VOLUME 1 OF 3 | |
|---|---|
| v HOW TO USE THIS MANUAL | |
| CHAPTER 1 | INTRODUCTION |
| Section I. | General Information |
| II. | Equipment Description and Data |
| III. | Principles of Operation |
| CHAPTER 2 | SERVICE AND TROUBLESHOOTING INSTRUCTIONS |
| Section I. | Repair Parts, Special Tools, Test, Measurement, and Diagnostic |
| Equipment (TMDE), and Support Equipment | |
| II. | Service Upon Receipt |
| III. | Preventive Maintenance Checks and Services |
| IV. | Electrical/Mechanical Systems Troubleshooting |
| VOLUME 2 OF 3 | |
| CHAPTER 3 | ENGINE SYSTEMS MAINTENANCE |
| Section I. | Lubrication System Maintenance |
| II. | Fuel System Maintenance |
| III. | Accelerator System Maintenance |
| IV. | Exhaust System Maintenance |
| V. | Cooling System Maintenance |
| CHAPTER 4 | ELECTRICAL SYSTEM MAINTENANCE |
| Section I. | Generating and Protective Control Box/Distribution Box System Maintenance |
| I.1. | Dual Voltage Alternator and Regulator System Maintenance |
| II. | Starter and Starting Control System Maintenance |
| III. | Instruments, Sending Units, Switches, and Horn Maintenance |
| IV. | Transfer Case and Transmission Electrical Maintenance |
| V. | Lighting System Maintenance |
| VI. | Battery System Maintenance |
| VII. | Ambulance Electrical System Maintenance |
| CHAPTER 5 | TRANSMISSION AND TRANSFER CASE MAINTENANCE |
| Section I. | Transmission Maintenance |
| II. | Transfer Case Maintenance |
| CHAPTER 6 | PROPELLER SHAFTS, AXLES, AND SUSPENSION MAINTENANCE |
| Section I. | Propeller Shafts Maintenance |
| II. | Front and Rear Axles Maintenance |
| III. | Suspension Maintenance |
| CHAPTER 7 | BRAKE SYSTEM MAINTENANCE |
| Section I. | Parking Brake System Maintenance |
| II. | Service Brake System Maintenance |
| III. | Rear Dual Service/Parking Brake System Maintenance |
| CHAPTER 8 | WHEELS AND STEERING MAINTENANCE |
| Section I. | Wheel and Runflat System Maintenance |
| II. | Steering Components Maintenance |
| CHAPTER 9 | FRAME MAINTENANCE |
| VOLUME 3 OF 3 | |
| CHAPTER 10 | BODY AND ACCESSORIES MAINTENANCE |
| Section I. | Body Maintenance |
| II. | Body Accessories Maintenance |
| III. | Winch Maintenance |
| CHAPTER 11 | SPECIAL PURPOSE BODIES MAINTENANCE |
| CHAPTER 12 | SPECIAL PURPOSE KITS MAINTENANCE |
| Section I. | Deep Water Fording Kit Maintenance |
| Section II. | Troop Seat Kit Maintenance |
| Section III. | 100 Ampere Alternator Kit Maintenance |
| Section IV. | Arctic Winterization Kits Maintenance |
| Section V. | Arctic Winterization Crew Top Kits Maintenance |
| Section VI. | Troop/Cargo Winterization Kit Maintenance |
| Section VII. | Communications Kits Maintenance |
| Section VIII. | 81 MM Mortar Kit Maintenance |
| Section IX. | Traversing Bar Kit Maintenance |
| Section X. | M1097, M1097A1, and M1097A2 Special Purpose Kits Maintenance |
| Section XI. | Accessory Kits Installation |
| Section XII. | Cargo Barrier and Net Kit Maintenance |
| CHAPTER 13 | PREPARATION FOR STORAGE OR SHIPMENT |
| Section I. | General Instructions |
| II. | Preparation for Storage and Shipment |
| APPENDIX A | REFERENCES |
| APPENDIX B | MAINTENANCE ALLOCATION CHART |
| APPENDIX C | EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST |
| APPENDIX D | ILLUSTRATED LIST OF MANUFACTURED ITEMS |
| APPENDIX E | TORQUE LIMITS |
| APPENDIX F | WIRING DIAGRAMS AND SCHEMATIC |
| APPENDIX G INDEX | MANDATORY REPLACEMENT PARTS |
HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND MARINE CORPS JANUARY 1996
Brain damage or death can result from heavy exposure. Precautions must be followed to ensure crew safety when the personnel heater, main, or auxiliary engine of any vehicle is operated for any purpose.
Drycleaning solvent is flammable and will not be used near an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment.
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
Diesel fuel is highly flammable. Do not perform any procedure near fire, flames, or sparks. Severe injury or death will result.
Do not touch hot exhaust system components with bare hands. Severe injury will result. - Do not remove surge tank filler cap before releasing internal pressure when engine temperature is above 190°F (88°C). Steam or hot coolant under pressure will cause injury.
Do not drain oil when engine is hot. Severe injury to personnel will result. - Always wear eye protection when bleeding brakes. Failure to do this may cause injury if brake fluid comes in contact with eyes.
Do not perform battery system checks or inspections while smoking or near fire, flames, or sparks.
Batteries may explode causing damage to vehicle, injury, or death to personnel.
Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or disconnected battery ground cable contacts battery terminal, a direct short will result, causing injury to personnel, or damage to equipment.
Use caution when testing thermostat. Hot water will cause burns. - Negative battery cable must be disconnected before disconnecting any harness from protective control box, or serious injury to personnel or damage to equipment will result.
Keep hands and arms away from fan blade and drivebelts while engine is running, or serious injury may result.
Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and do not smoke when performing maintenance on batteries. Injury will result if acid contacts eyes or skin.
When removing battery cable clamps, disconnect ground cable first. Ensure all switches are in OFF position before disconnecting ground cable. Do not allow tools to come in contact with vehicle when disconnecting cable clamps. A direct short can result, causing instant heating of tools, tool damage, battery damage, or battery explosion.
Allow transmission/transfer case to cool before performing maintenance. Failure to do this may cause injury.
Always apply parking brake and chock opposite wheel before removing wheel. Avoid removing wheel when vehicle is on sloping terrain. Injury to personnel or damage to equipment may result.
Gloves must be worn whenever handling winch cable. Severe injury may result. - Opening one end of cargo door without ensuring opposite end is securely closed will cause both ends to open simultaneously, resulting in injury to personnel or damage to equipment.
Direct all personnel to stand clear during engine hoisting operations. Failure to do this may cause injury to personnel.
Hydraulic jacks are used for raising and lowering, and are not used to support vehicle. Never work under vehicle unless wheels are blocked and it is properly supported. Injury or damage to equipment may result if vehicle suddenly shifts or moves.
Remove only the inner group of nuts when removing a wheel from the vehicle. Removing the outer nuts which hold the rim together while the assembly is inflated could result in serious injury or death.
In all disassembly of the wheel assembly operations, ensure the tire is totally deflated before removing wheel nuts. Failure to follow proper safety precautions could cause serious injury or death.
Never inflate a wheel assembly with the wheel locknuts removed in an attempt to separate inner and outer rim halves. The assembly will separate under pressure resulting in serious injury or death.
Never use wheel assemblies with studs which are damaged, loose, or have damaged threads. Damaged studs can cause improper assembly, which could cause individual fasteners to fail. Any of these situations could cause serious injury or death.
Never use tubes in wheel assemblies. Use of a tube defeats built-in safety features, and could allow the wheel to come apart under pressure, resulting in serious injury or death.
Use only replacement parts specified in TM 9-2320-280-24P. Wheels assembled with components which do not meet specifications could cause the assembly to separate under pressure, resulting in serious injury or death.
Never inflate a wheel assembly without having checked wheel locknut torques to ensure to wheel locknuts are tightened to specifications. An assembly with improperly tightened locknuts could separate under pressure resulting in serious injury or death.
Always use a tire inflation cage for inflation purposes. Stand on one side of cage, during inflation, never directly in front. Keep hands out of the cage during inflation. Inflate assembly to recommended pressure, using a clip-on air chuck. Do not exceed 30 psi (207 kPa) cold bias tire inflation pressure or 50 psi (344 kPa) cold radial tire inflation pressure. Failure to follow these instructions may result in serious injury or death.
Never mix radial tires and bias ply tires on the same vehicle. Injury to personnel or damage to equipment may result.
Rear steps must be raised before disconnecting retractor lever from rear steps. Failure to do this may cause injury to personnel and damage to equipment.
NBC contaminated filters must be handled and disposed of only by authorized and trained personnel.
The unit commander or senior officer in charge of maintenance personnel must ensure that prescribed protective clothing (FM 3-4) is used, and prescribed safety measures and decontamination procedures (FM 3-5) are followed. The local unit SOP is responsible for final disposal of contaminated air filters. Failure to do this may cause severe injury to personnel.
Seatbelts are to be replaced as a set. Failure to do this may cause injury to personnel or damage to equipment.
The Department of Transportation requires 105 mm cannon ammunition to be in wooden boxes when transporting ammunition on public highways, by fixed wing aircraft, rail, or ship. Movement of cannon ammunition in fiber containers (inner pack) in the HMMWV ammunition rack is restricted to other than public highways.
MARINE CORPS TM 2320-20/7B CHANGE HEADQUARTERS NO. 2 DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND MARINE CORPS Washington, D.C., 15 July 2004