TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE

Transcription

1 TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, M998 ( ) (EIC: BBD); M998A1 ( ) (EIC: BBN); TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, W/WINCH, M1038 ( ) (EIC: BBE); M1038A1 ( ) (EIC: BBP); TRUCK, UTILITY: HEAVY VARIANT, 4X4, M1097 ( ) (EIC: BBM); M1097A1 ( ) (EIC: BBU); M1097A2 ( ) (EIC: BB6); M1123 ( ) (EIC: B6G); TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, M966 ( ) (EIC: BBC); M966A1 ( ) (EIC: BBX); M1121 ( ) (EIC: B6H); TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1036 ( ) (EIC: BBH); TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1045 ( ); M1045A1 ( ) (EIC: BBR); M1045A2 ( ) (EIC: BB5); TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1046 ( ); M1046A1 ( ) (EIC: BBT); TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, M1025 ( ) (EIC: BBF); M1025A1 ( ) (EIC: BBV); M1025A2 ( ) (EIC: BB3); TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1026 ( ) (EIC: BBG); M1026A1 ( ) (EIC: BBQ); TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1043 ( ); M1043A1 ( ) (EIC: BBY); M1043A2 ( ) (EIC: BB4); TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1044 ( ); M1044A1 ( ) (EIC: BBS); TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1037 ( ) (EIC: BBK); TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, W/WINCH, M1042 ( ); TRUCK, AMBULANCE, 2-LITTER, ARMORED, 4X4, M996 ( ) (EIC: BBB); M996A1 ( ) (EIC: BB2); TRUCK, AMBULANCE, 4-LITTER, ARMORED, 4X4, M997 ( ) (EIC: BBA); M997A1 ( ) (EIC: BBZ) M997A2 ( ) (EIC: BB8); TRUCK, AMBULANCE, 2-LITTER, SOFT TOP, 4X4, M1035 ( ); M1035A1 ( ) (EIC: BBW); M1035A2 ( ) (EIC: BB9). Approved for public release; distribution is unlimited. ARMY TM AIR FORCE TO 36A12-1A MARINE CORPS TM /9B (SUPERSEDES TM , 20 AUGUST 1991) HOW TO USE THIS MANUAL INTRODUCTION 1-1 GENERAL MAINTENANCE 2-1 ENGINE MAINTENANCE 3-1 FUEL SYSTEM MAINTENANCE 4-1 COOLING SYSTEM MAINTENANCE 5-1 ELECTRICAL SYSTEM MAINTENANCE 6-1 TRANSMISSION MAINTENANCE 7-1 TRANSFER CASE MAINTENANCE 8-1 PROPELLER SHAFTS, AXLES, AND SUSPENSION MAINTENANCE HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND MARINE CORPS JANUARY 1996 iv 9-1 SERVICE BRAKE SYSTEM MAINTENANCE 10-1 STEERING SYSTEM MAINTENANCE 11-1 FRAME MAINTENANCE 12-1 BODY MAINTENANCE 13-1 SPECIAL PURPOSE BODIES MAINTENANCE 14-1 WINCH MAINTENANCE 15-1 SPECIAL PURPOSE KITS MAINTENANCE 16-1 TRANSMISSION REPAIR 17-1 TRANSFER CASE REPAIR 18-1 DIFFERENTIAL REPAIR 19-1 STEERING SYSTEM REPAIR 20-1 FRAME REPAIR 21-1 BODY REPAIR 22-1

2 *ARMY TM AIR FORCE TO 36A12-1A MARINE CORPS TM /9B TECHNICAL MANUAL HEADQUARTERS, NO DEPARTMENTS OF THE ARMY, NO /9B THE AIR FORCE, AND MARINE CORPS TECHNICAL ORDER NO. 36A12-1A Washington, D.C., 31 January 1996 TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, M998 ( ) (EIC: BBD); M998A1 ( ) (EIC: BBN); TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, W/WINCH, M1038 ( ) (EIC: BBE); M1038A1 ( ) (EIC: BBP); TRUCK, UTILITY: HEAVY VA R I A N T, 4X4, M1097 ( ) (EIC: BBM); M1097A1 ( ) (EIC: BBU); M1097A2 ( ) (EIC: BB6); M1123 ( ) (EIC: B6G); TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, M966 ( ) (EIC: BBC); M966A1 ( ) (EIC: BBX); M1121 ( ) (EIC: B6H); TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1036 ( ) (EIC: BBH); TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1045 ( ); M1045A1 ( ) (EIC: BBR); M1045A2 ( ) (EIC: BB5); TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1046 ( ); M1046A1 ( ) (EIC: BBT); TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, M1025 ( ) (EIC: BBF); M1025A1 ( ) (EIC: BBV); M1025A2 ( ) (EIC: BB3); TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1026 ( ) (EIC: BBG); M1026A1 ( ) (EIC: BBQ); TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1043 ( ); M1043A1 ( ) (EIC: BBY); M1043A2 ( ) (EIC: BB4); TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1044 ( ); M1044A1 ( ) (EIC: BBS); TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1037 ( ) (EIC: BBK); TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, W/WINCH, M1042 ( ); TRUCK, AMBULANCE, 2-LITTER, ARMORED, 4X4, M996 ( ) (EIC: BBB); M996A1 ( ) (EIC: BB2); TRUCK, AMBULANCE, 4-LITTER, ARMORED, 4X4, M997 ( ) (EIC: BBA); M997A1 ( ) (EIC: BBZ); M997A2 ( ) (EIC: BB8); TRUCK, AMBULANCE, 2-LITTER, SOFT TOP, 4X4, M1035 ( ); M1035A1 ( ) (EIC: BBW); M1035A2 ( ) (EIC: BB9). Approved for public release, distribution is unlimited. REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form (Recommended Changes to Equipment Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is h t t p : / / a e p s. r i a. a r m y. m i l. If you need a password, scroll down and click on ACCESS REQUEST FORM. The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or your letter, DA Form 2028, or DA Form direct to: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA - L C - C I P - W T, Rock Island, IL The address is a m s t a - a c - n m r i a. a r m y. m i l. The fax number is DSN or Commercial (309) (Marine Corps) Submit NAV M C to the Commanding General (826), MCLB, 814 Radford Blvd., Albany, GA HOW TO USE THIS MANUAL iv CHAPTER 1. INTRODUCTION Section I. General Information II. Equipment Description * This publication supersedes TM dated 20 AUGUST 1991 and all changes. Page Change 1 i

3 CHAPTER 2. GENERAL MAINTENANCE Section I. Repair Parts, Special Tools, Test, Measurement, and Diagnostic Equipment (TMDE), and Support Equipment II. Troubleshooting III. Air-Conditioning Troubleshooting IV. General Maintenance Instructions CHAPTER 3. ENGINE MAINTENANCE Section I. General Engine Maintenance II. Engine Replacement CHAPTER 4. FUEL SYSTEM MAINTENANCE CHAPTER 5. COOLING SYSTEM MAINTENANCE CHAPTER 6. ELECTRICAL SYSTEM MAINTENANCE CHAPTER 7. TRANSMISSION MAINTENANCE CHAPTER 8. TRANSFER CASE MAINTENANCE CHAPTER 9. PROPELLER SHAFTS, AXLES, AND SUSPENSION MAINTENANCE CHAPTER 10. SERVICE BRAKE SYSTEM MAINTENANCE CHAPTER 11. STEERING SYSTEM MAINTENANCE CHAPTER 12. FRAME MAINTENANCE CHAPTER 13. BODY MAINTENANCE CHAPTER 14. SPECIAL PURPOSE BODIES MAINTENANCE Section I. TOW and Armament Carrier Maintenance II. Ambulance Maintenance CHAPTER 15. WINCH MAINTENANCE Page ii

4 Page CHAPTER 16. SPECIAL PURPOSE KITS MAINTENANCE Section I. Arctic Winterization Kit II. Deleted CHAPTER 17. TRANSMISSION REPAIR Section I. Transmission Disassembly, Repair, and Assembly II. Transmission Testing CHAPTER 18. TRANSFER CASE REPAIR CHAPTER 19. DIFFERENTIAL REPAIR CHAPTER 20. STEERING SYSTEM REPAIR CHAPTER 21. FRAME REPAIR CHAPTER 22. BODY REPAIR Section I. Body Maintenance II. Body Repair APPENDIX A REFERENCES A-1 APPENDIX B EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST B-1 APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMS C-1 APPENDIX D TORQUE LIMITS D-1 APPENDIX E MANDATORY REPLACEMENT PARTS E-1 APPENDIX F BODY REPAIR MATERIALS F-1 APPENDIX G TOOL IDENTIFICATION LIST G-1 INDEX Index 1 Change 1 iii

5 CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMAT I O N 1-1. S C O P E a. This technical manual contains instructions for direct support and general support maintenance for 1-1/4 ton, 4X4, M998 series vehicles. b. Models included are: (1) M998 and M998A1, Cargo/Troop Carrier (2) M1038 and M1038A1, Cargo/Troop Carrier, W/W (3) M1097, M1097A1, M1097A2, and M1123, Heavy Variant (4) M966, M966A1, and M1121, TOW Carrier, Armored (5) M1036, TOW Carrier, Armored, W/W (6) M1045, M1045A1, and M1045A1 TOW Carrier, W/Supplemental Armor (7) M1046 and M1046A1, TOW Carrier, W/Supplemental Armor, W/W (8) M1025, M1025A1, and M1025A2, Armament Carrier, Armored (9) M1026 and M1026A1, Armament Carrier, Armored, W/W (10) M1043, and M1043A1, and M1043A2, Armament Carrier, W/Supplemental Armor (11) M1044 and M1044A1, Armament Carrier, W/Supplemental Armor, W/W (12) M1037, S250 Shelter Carrier (13) M1042, S250 Shelter Carrier, W/W (14) M996 and M996A1, 2-Litter, Armored Ambulance (15) M997, M997A1, and M997A2, 4-Litter, Armored Ambulance (16) M1035, M1035A1, and M1035A2, 2-Litter, Soft Top Ambulance 1-2. MAINTENANCE FORMS, RECORDS, AND REPORT S (Army) Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam , The Army Maintenance Management System (TAMMS). (Marine Corps) Refer to TM /1 series. Change 1 1-1

6 1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Refer to TM , Procedures for Destruction of Army Tank-Automotive Equipment to Prevent Enemy Use P R E PA R ATION FOR STORAGE AND SHIPMENT (Army) Refer to TM , Administrative Storage of Equipment and TM , Marking, Packaging and Shipment of Supplies and Equipment: General Packaging Instructions for Field Use. (Marine Corps) Refer to MCO R E P O RTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) (Army) If your M998 series vehicle needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at: Commander, U.S. Army Tank-Automotive and Armaments Command, ATTN: AMSTA-TR-Q, Warren, Michigan We'll send you a reply. (Marine Corps) Submit QDR's in accordance with MCO EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD) The quarterly Equipment Improvement Report and Maintenance Digest, TB series, contains valuable field information on the equipment covered in this manual. The information in the TB series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles covered in this manual. Many of these articles resulted from comments, suggestions, and improvement recommendations that you submitted to the EIR program. The TB series contains information on equipment improvements, minor alterations, proposed Modification Work Orders (MWOs), warranties (if applicable), actions taken on some of your DA Form 2028's (Recommended Changes to Publications), and advance information on proposed changes that may affect this manual. The information will help you in doing your job better and will help in keeping you advised of the latest changes to this manual. Also refer to DA Pam 25-30, Consolidated Index of Army Publications and Blank Forms, and Appendix A, References, of this manual. For those with access to the World Wide Web (www), the EIR MD can be viewed through the Army Electric Product Support. The site is METRIC SYSTEM The equipment described herein contains metric components and requires metric common and special tools; therefore, metric units in addition to standard units will be used throughout this publication. In addition, a metric conversion table is located on the inside back cover of this publication. 1-2 Change 1

7 1-8. MANDATORY REPLACEMENT PARTS The maintenance instructions contained herein make reference to removing and discarding piece parts such as: gaskets, lockwasher, cotter pins, O-ring seals, etc.; these items should be considered mandatory replacement items and replaced with new parts during assembly/installation EQUIPMENT DESCRIPTION Section II. EQUIPMENT DESCRIPTION AND DATA Detailed descriptions covering the 1-1/4 ton, 4X4, M998 series vehicles are in TM and TM TABULATED DATA Tabulated data is listed in table 1-1. This information includes only that data applicable to direct support and general support maintenance. Information not covered can be found in TM , TM , TM Table 1-1. Tabulated Data NOTE Standard and metric measurements will be used in this table and throughout the manual. A list of their abbreviations is provided below. TABULATED DATA ABBREVIATIONS MEASUREMENT ABBREVIATION MEASUREMENT ABBREVIATION Pint...pt Celsius...C Quart...qt Liter Gallon...gal. Centimeter...cm Inch......in. Kilometers Per Hour...kph Pound...lb KiloPascal... kpa Miles Per Hour...mph Maximum...max Pound Per Square Inch...psi Minimum...min Revolutions Per Minute...rpm Kilogram......kg Pound-Feet...lb-ft Newton Meter...N.m Gallons Per Minute...gpm Millimeter... mm Volt...V Ampere... A Horsepower......hp Liters Per Minute...Ipm Fahrenheit......F KiloWatt... kw 1-3

8 Table 1-1. Tabulated Data (Cont'd) 1. ENGINE Refer to TM for tabulated data on the engine. 2. ALTERNATOR STANDARD METRIC 60 Ampere: Manufacturer Prestolite Model......AMA-5104UT Output rpm (engine) Rated Voltage...28V 100 Ampere: Manufacturer......Leece-Neville Model......A AA Output rpm (engine) Rated Voltage...28V 100 Ampre: Manufacturer......Neihoff Model Output rpm (engine) Rated Voltage...28V 200 Ampere: Manufacturer......Leece-Neville Model......A AA Output rpm (engine) Rated Voltage V 200 Ampere: Manufacturer......Neihoff Model _ Output rpm (engine) Rated Voltage...28V 3. STARTER Manufacturer Prestolite Model......MFY Capacity hp 7.1 kw 4. TRANSMISSION Manufacturer Hydromatic Model......THM 400 (3L80) Torque Converter Ratio :1 Gear Ratios: Reverse :1 Drive... 1:1 Second :1 First :1 5. TRANSMISSION Manufacturer Hydromatic Model L80-E Torque Converter Stall Ratio and Direct Drive w/lock Up Clutch Gear Ratios: First :1 Second :1 Third :1 Fourth :1 Reverse :1 1-4

9 Table 1-1. Tabulated Data (Cont'd) STANDARD METRIC 6. TRANSFER CASE Manufacturer......New Process Gear Model w/intercooler Gear Ratios: High and High Lock :1 Low Lock :1 Model w/intercooler Gear Ratios: High and High Lock :1 Low Lock :1 7. DIFFERENTIAL Manufacturer AM General Type......Hypoid Gears Gear Ratio :1 (2.73:1) 8. GEARED HUB Manufacturer AM General Type Spur Gears Gear Ratio :1 9. SERVICE BRAKE CALIPER (FRONT) Manufacturer......Kelsey-Hayes Piston Diameter in. 10. SERVICE/PARKING BRAKE CALIPER (REAR) Manufacturer......Kelsey-Hayes Piston Diameter in. 11. SERVICE BRAKE ROTOR (FRONT) Manufacturer......Kelsey-Hayes Diameter in. Thickness in. 12. SERVICE/PARKING BRAKE ROTOR (REAR) Manufacturer......Kelsey-Hayes Diameter in. Thickness in. 66 mm 66 mm 267 mm 22 mm 267 mm 22 mm 13. STEERING GEAR Manufacturer......Saginaw Type......Variable Ratio Ratio... 13/16:1 14. POWER STEERING PUMP Manufacturer......Saginaw Model Capacity (engine 1500 rpm) gpm 9.8 lpm 15. FRAME Manufacturer AM General Type......Box No. of Crossmembers Five 1-5

10 Table 1-1. Tabulated Data (Cont'd) STANDARD 16. WINCH Manufacturer......Warn Capacity ,000 lb Drive... Electric 17. WINCH Model...MIL9000 Type Electric Drive, Thermal Cutoff Switch Capacity ,000 lb METRIC kg 4,086 kg 18. AIR-CONDITIONING COMPRESSOR Manufacturer Sanden Model Field coil...24v 1-6