TM T.O. 36A12-1C

Transcription

1 T.O. 36A12-1C TECHNICAL MANUAL VOLUME 1 OF 2 TROUBLE SHOOTING DIRECT SUPPORT AND GENERAL SUPPORT LEVEL 5-TON, 6X6, M39 SERIES TRUCKS (MULTIFUEL) TRUCK, CHASSIS: M40A2C, M61A2, M6A2; TRUCK, CARGO: M54A2, M54A2C, M55A2; TRUCK, DUMP: M51A2; TRUCK, TRACTOR: M52A2; TRUCK, WRECKER, MEDIUM: 543a2 THE STYLE OF THIS TM IS EXPERIMENTAL. IT IS BEING TRIED BY THE ARMY ONLY ON A LIMITED BASIS DEPARTMENTS OF THE ARMY AND THE AIR FORCE FEBRUARY 1981

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3 T.O. 36A12-1C TECHNICAL MANUAL NO TECHNICAL ORDER NO. 36A12-lC DEPARTMENTS OF THE ARMY AND THE AIR FORCE WASHINGTON, DC, 25 February 1981 TECHNICAL MANUAL VOLUME 1 OF 2 TROUBLESHOOTING DIRECT SUPPORT AND GENERAL SUPPORT LEVEL 5-TON, 6X6, M39 SERIES TRUCKS (MULTIFUEL) Model NSN without Winch NSN with Winch Truck, Chassis M40A2C M61A2 M63A Truck, Cargo M54A2 M54A2C M55A Truck, Dump M51A Truck, Tractor M52A Truck, Wrecker, Medium M543A Current as of 25 Jul 80. *This manual together with TM , 25 February 1981; TM , 25 February 1981; TM , 25 February 1981 and TM , 25 February 1981 supersedes so much of TM , 13 September 1964 as pertains to multifuel vehicles including all changes.

4 I REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedure, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in the back of this manual direct to: commander, US Army Tank-Automotive Command. TTN: DRSTA-MB. Warren. Michigan A reply will be furnished to you. TABLE OF CONTENTS VOLUME 1 OF 2 Paragraph Page CHAPTER 1. CHAPTER 2. CHAPTER 3. CHAPTER 4. CHAPTER 5. CHAPTER 6. CHAPTER 7. CHAPTER 8. CHAPTER 9. CHAPTER 10. GENERAL INFORMATION Scope Organization Troubleshooting Approach TROUBLESHOOTING APPROACH General Approach Troubleshooting Index Test Equipment Procedures Index Troubleshooting Roadmaps Fault Symptom Index Sample Troubleshooting Procedure TROUBLESHOOTING INDEX General Index TEST EQUIPMENT PROCEDURES INDEX General Index TROUBLESHOOTING ROADMAPS General Roadmaps FAULT SYMPTOM INDEXES General Indexes SAMPLE TROUBLESHOOTING PROCEDURES General Sample Detailed Procedures ENGINE SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered ENGINE SYSTEM TEST PROCEDURES General Test Set-up Test Procedure FUEL SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered ii

5 TABLE OF CONTENTS-CONT CHAPTER 11. CHAPTER 12. CHAPTER 13. CHAPTER 14. CHAPTER 15. CHAPTER 16. CHAPTER 17. CHAPTER 18. CHAPTER 19. CHAPTER 20. CHAPTER 21. CHAPTER 22. CHAPTER 23. CHAPTER 24. FUEL SYSTEM SUPPORT DIAGRAMS General FUEL SYSTEM TEST PROCEDURES General Test Set-Up Test Procedure COOLING SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered ELECTRICAL SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered ELECTRICAL SYSTEM TEST PROCEDURES Test Procedures FRONT AXLE SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered FRONT AXLE SYSTEM TEST PROCEDURES General Test Set-Up Test Procedure REAR AXLE SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered STEERING SYSTEM TROUBLESHOOTING Equipment Items Covered , Equipment Items Not Covered FRONT WINCH SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered REAR WINCH SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered M543A2 WRECKER SYSTEM TROUBLESHOOTING Equipment Items Covered Equipment Items Not Covered M543A2 WRECKER SYSTEM TEST PROCEDURES General Test Set-Up Test Procedure DEEP WATER FORDING SYSTEM TROUBLE- SHOOTING Equipment Items Covered , Equipment Items Not Covered VOLUME 2 OF 2 Part 1 of 4 CHAPTER 1. GENERAL MAINTENANCE INFORMATION CHAPTER 2. ENGINE SYSTEM GROUP MAINTENANCE Paragraph Page iii

6 TM Section I. Section II. Section III. Section IV. Section V. Section VI. Section VII. Section VIII. CHAPTER 3. Section I. Section II. CHAPTER 4. Section I. Section II. Section III. Section IV. Section V. CHAPTER 5. Section I. Section II. Section III. Section IV. CHAPTER 6. Section I. Section II. Section III. Section IV. Section V. Section VI. Section VII. Section VIII. CHAPTER 7. Section I. Section II. CHAPTER 8. Section I. Section II. Section III. CHAPTER 9. Section I. Section II. Section III. Section IV. CHAPTER 10. Section I. Section II. TABLE OF CONTENTS-CONT Scope Engine Assembly Crankcase, Block, and Cylinder Head Crankshaft Flywheel Valves, Camshaft, and Timing System Engine Lubricating System Manifolds CLUTCH SYSTEM GROUP MAINTENANCE Scope Clutch Assembly FUEL SYSTEM GROUP MAINTENANCE Scope Fuel Injector Turbocharger Fuel Tanks Cold Start System COOLING SYSTEM GROUP MAINTENANCE Scope Radiator Water Pump Fan Assembly ELECTRICAL SYSTEM GROUP MAINTENANCE Scope Charging System Starting System Instrument Panel Lighting System Horn Assembly Battery System Cab and Chassis Wiring Harnesses TRANSMISSION SYSTEM GROUP MAINTENANCE Scope Transmission Assembly TRANSMISSION TRANSFER SYSTEM GROUP MAINTENANCE Scope Transmission Transfer Assembly Transmission Transfer Controls and Linkages.. FRONT AXLE GROUP MAINTENANCE Scope Front Axle Assembly Differential Carrier Assembly Steering Mechanism REAR AXLE GROUP MAINTENANCE Scope Rear Axle Assemblies Paragraph Page iv

7 TABLE OF CONTENTS-CONT Part 2 of 4 CHAPTER 11. Section I. Section II. Section III. CHAPTER 12. Section I. Section II. CHAPTER 13. Section I. Section II. Section III. Section IV. Section V. CHAPTER 14. Section I. Section II. Section III. Section IV. CHAPTER 15. Section I. Section II. Section III. CHAPTER 16. Section I. Section II. Section III. Section IV. Section V. Section VI. Section VII. CHAPTER 17. Section I. Section II. Section III. BRAKE SYSTEM GROUP MAINTENANCE Scope Handbrake and Service Hydraulic Brake System WHEEL SYSTEM GROUP MAINTENANCE Scope Tires STEERING SYSTEM GROUP MAINTENANCE Scope Mechanical Steering Gear Power Steering Gear Assembly Steering Hydraulic System Steering System Valves FRAME AND TOWING ATTACHMENTS GROUP MAINTENANCE Scope Frame Assembly Pintles Fifth Wheel Assembly SPRINGS AND TORQUE AND STABILIZER RODS GROUP MAINTENANCE Scope Springs Torque and Stabilizer Rods BODY, CAB, AND HOOD GROUP MAINTENANCE Scope Body, Cab, and Hood Components Fenders, Running Boards, and Windshield Assembly Seats Tool and Stowage Boxes Cargo Bodies Special Purpose Bodies Part 3 of 4 WINCH, HOIST, CRANE, AND POWER TAKEOFF ASSEMBLIES GROUP MAINTENANCE Scope Winch, Hoist, and Crane Assemblies Power Takeoff and Swivel Valve Assemblies.... Paragraph Page v

8 TABLE OF CONTENTS-CONT Part 4 of 4 Paragraph Page CHAPTER 18. BODY ACCESSORY ITEMS GROUP MAINTENANCE Section I. Scope Section II. Canvas Accessory Items CHAPTER 19. MAINTENANCE OF MATERIAL USED IN CONJUNCTION WITH MAJOR ITEMS Section I. Scope Section II. Winterization Kits Section III. Special Purpose Kits vi

9 CHAPTER 1 GENERAL INFORMATION 1-1. SCOPE. This volume shows you how to do troubleshooting at the direct support level of maintenance. The amount of troubleshooting you can do is based on what the Maintenance Allocation Chart says you can fix. Because of this, the only trouble symptoms you will find here are those that could be caused by faulty things you can fix ORGANIZATION. When you do PMCS, or when you drive the truck and find that something is wrong, write down what is wrong. Then check the fault symptom index to see if the trouble (fault symptom) you noted is in the index. If it is, you can do troubleshooting to find the fault and fix it TROUBLESHOOTING APPROACH. In order to find out what is causing the problem in the truck, you must use a good approach. A good approach just means a way of doing troubleshooting so you can find the problem and not get confused or lost. The following chapter describes how you can use the materials in this volume to troubleshoot with a good approach. 1-1/(1-2 blank)

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11 CHAPTER 2 TROUBLESHOOTING APPROACH 2-1. GENERAL APPROACH. This chapter gives you instructions on how to use the troubleshooting material to help you find and fix the trouble. In every system of the truck there can be faults or problems which will cause certain symptoms. Symptoms can be such things as unusual noise, vibration or even complete failure of a system. This volume gives information for each system on which you can do troubleshooting to find faults and fix them. Before you troubleshoot a system, you should look at the troubleshooting indexes which will lead you to the information you need to help make your troubleshooting faster and easier. If you follow the instructions the right way, you will find those troubles you can fix. But, if you fix something and the trouble is still there, it means there is more than one trouble. If this happens, start all over again to find the other trouble TROUBLESHOOTING INDEX. The troubleshooting index, and instructions on how to use it are in chapter 3. Go to this index first because it tells you where to find troubleshooting roadmaps, fault symptom indexes, summary troubleshooting charts and support diagrams for each system TEST EQUIPMENT PROCEDURES INDEX. The test equipment procedures index, and instructions on how to use it are in chapter 4. This index tells you where to find electrical and mechanical tests which you can use to do your troubleshooting. It also tells you what equipment you will need to do the tests. If you have a STE/ICE (Simplified Test Equipment/Internal Combustion Engine) Set (NSN ), you may use it, where applicable, to do your troubleshooting. Refer to TM & P TROUBLESHOOTING ROAD MAPS. Troubleshooting roadmaps for each system are in chapter 5. If the system is made up of subsystems, these subsystems are also on the roadmap. Under the subsystem is a list of things which are the most likely causes of a fault symptom in that subsystem. If you have enough skill, you can troubleshoot these things on the truck without using the detailed troubleshooting procedures. So if you know enough about the truck to work on your own, use the roadmap for the system with the problem before you check the fault symptom index FAULT SYMPTOM INDEX. Fault symptom indexes and instructions on how to use them are in chapter 6. For each system of the truck, there is an index which gives you a list of the fault symptoms for that system. The index also tells you where to find the detailed troubleshooting procedures and what resources (tools/people) you need to do each procedure SAMPLE TROUBLESHOOTING PROCEDURE. A sample troubleshooting procedure is in chapter 7. This sample procedure will help you see the way detailed troubleshooting procedures are to be used. 2-1/(2-2 blank)

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13 CHAPTER 3 TROUBLESHOOTING INDEX 3-1. GENERAL. This chapter has a troubleshooting index which covers every system of the truck on which you can do troubleshooting. The index tells you where to find all the other information you need to do your troubleshooting procedures INDEX. The troubleshooting index (figure 3-1) is divided into five columns that list systems, troubleshooting roadmaps, fault symptoms, summary troubleshooting procedures, and system support diagrams. The following breakdown tells you what is in each column. a. System Column. This column gives a list of systems on the truck for which troubleshooting can be done at the direct support maintenance level. b. Troubleshooting Roadmaps Column. This column tells you where to find the troubleshooting roadmap for each listed system. These roadmaps are given in chapter 5. c. Fault Symptom Index Column. This column tells you where to find the troubleshooting fault symptom index for each listed system. Fault symptom indexes are given in chapter 6. d. Summary Troubleshooting Procedures Column. This column tells you where to find the summary troubleshooting procedure for each listed system. Some systems do not have summary troubleshooting procedures, so the column will be left blank for those systems. e. System Support Diagrams Column. This column tells you where to find support diagrams for each listed system. Some systems do not have support diagrams, so the column will be left blank for those systems. 3-1

14 SYSTEM SUMMARY TROUBLE- FAULT SYSTEM TROUBLE- SHOOTING SYMPTOM SUPPORT SHOOTING ROADMAPS INDEXES PROCEDURES DIAGRAMS 1 ENGINE Figure 5-1 Table FUEL Figure 5-2 Table 6-2 Figure COOLING Figure 5-3 Table ELECTRICAL Figure 5-4 Table FRONT AXLE Figure 5-5 Table REAR AXLE Figure 5-6 Table STEERING Figure 5-7 Table FRONT WINCH Figure 5-8 Table REAR WINCH Figure 5-9 Table M543A2 WRECKER Figure 5-10 Table DEEP WATER FORDING Figure 5-11 Table 6-11 Figure 3-1. Troubleshooting Index 3-2

15 CHAPTER 4 TEST EQUIPMENT PROCEDURES INDEX 4-1. GENERAL. This chapter has a test equipment procedures index which tells you where to find the tests you need to do your troubleshooting INDEX. The test equipment procedures index is divided into three columns that list test equipment, tests, and figure numbers. The following breakdown tells you what is in each column. a. Test Equipment Column. This column tells you what kind of equipment you need to do your troubleshooting tests. b. Tests Column. This column tells you what tests are given in this manual. Next to each piece of test equipment are listed the tests that you can do with that equipment. This column also gives troubleshooting tests which can be done without using test equipment. c. Figure Column. This column tells you where you can find the tests in this manual. 4-1

16 TEST EQUIPMENT TESTS FIGURE COMPRESSION GAGE TESTER Engine Cylinder Compression 9-1 MULTIMETER AN/URM-105C Refer to TM DIAL INDICATOR GAGE Steering Knuckle End Play 17-1 OIL PRESSURE TEST SET Power Steering Pump Pressure 19-1 Power Cylinder Pressure 19-1 PRESSURE GAGE Swing Motor Swivel valve pressure 23-1 Fuel Injector Nozzle Figure 4-1. Test Equipment Procedures Index

17 CHAPTER 5 TROUBLESHOOTING ROADMAPS 5-1. GENERAL. This chapter gives troubleshooting roadmaps for every system of the truck for which you have detailed troubleshooting procedures. Figures 5-1 through 5-11 cover all the roadmaps for the detailed procedures ROADMAPS. Each roadmap gives a list of things which are most likely to cause a fault symptom in a system or subsystem. At least one of the items listed will be found to be bad when you do the detailed troubleshooting procedures for that system. 5-1

18 ENGINE SYSTEM I Oil pressure regulator valve Pressure oil pump pickup tube screen Pressure oil pump pickup tube mounting bolts Pressure oil pump outlet tube mounting bolts Oil pump Valve springs Pushrods Tappets Engine valves Figure 5-1. Troubleshooting Roadmap, Engine System FUEL SYSTEM Fuel injector nozzles Fuel injection pump Turbocharger Figure 5-2. Troubleshooting Roadmap, Fuel System COOLING SYSTEM Expansion plugs Engine block Cylinder head TA Figure 5-3. Troubleshooting Roadmap, Cooling System 5-2

19 ELECTRICAL SYSTEM ENGINE COOLANT HEATER FUEL BURNING HEATER ELECTRIC BRAKES Overheat temperature Overheat switch ---- Voltage regulator control Fuel valve assembly Diode Motor resistor Heater blower motor Overheat thermostat Fuel valve assembly Lead 53A Heater resistor Lead 53D Blower assembly motor --- Rheostat Heater control switch Rear harness Circuit breaker switch Lead from circuit breaker to heater Fuel control valve control switch Circuit breaker Harness from heater control box to heater Lead from circuit breaker to heater HEATER VOLTAGE REGULATOR control switch Heater control switch Harness from heater control box to heater Figure 5-4. Troubleshooting Roadmap, Electrical System 5-3

20 FRONT AXLE SYSTEM Steering knuckles Axle shafts and universal joints Steering gear Differential Figure 5-5. Troubleshooting Roadmap, Front Axle System REAR AXLE SYSTEM Forward rear axle differential Rear rear axle differential Figure 5-6. Troubleshooting Roadmap, Rear Axle System STEERING SYSTEM Steering knuckle Power steering pump Power cylinder Power steering rack assembly Steering gear sector shaft adjustment Steering gear TA Figure 5-7. Troubleshooting Roadmap, Steering System 5-4

21 FRONT WINCH SYSTEM Power takeoff Drag brake Figure 5-8. Troubleshooting Roadmap, Front Winch System REAR WINCH SYSTEM Drag brake linings Rear winch Figure 5-9. Troubleshooting Roadmap, Rear Winch System 5-5

22 M543A2 WRECKER SYSTEM, HOIST WINCH SWING MOTOR CONTROLS Hoist winch motor assembly Swivel valve Gondola boom control valve Cable drum assembly Swing motor Boom elevating cylinder assembly Automatic brake adjustment Drive gear assembly Gondola crowd control valve Automatic brake linings Drive pinion gear Relief valve assembly Drive pinion idler gear Figure Troubleshooting Roadmap, M543A2 Wrecker System DEEP WATER FORDING SYSTEM Fuel tank cap Air cleaner assembly Clutch housing Figure Troubleshooting Roadmap, Deep Water Fording System 5-6

23 CHAPTER 6 FAULT SYMPTOM INDEXES 6-1. GENERAL. This chapter gives troubleshooting fault symptom indexes for every system of the truck for which you have detailed troubleshooting procedures. These indexes are in table form (tables 6-1 through 6-11) which gives you a quick way to check what material you have to use to do your troubleshooting INDEXES. Each index is divided into columns which give you information you need to help you do troubleshooting procedures. The following breakdown tells you what is in each column. a. Subsystem Column. If the main system is divided into subsystems, the subsystems will be listed in this column. b. Symptom Column. This column lists the symptoms, or problems for which detailed troubleshooting procedures are given. c. Summary Column. This column tells you where to find the summary troubleshooting procedures for each symptom. d. Detailed Column. This column tells you where to find the detailed troubleshooting procedure for each symptom. e. Persons Column. This column tells you how many people are needed to do the troubleshooting procedure. f. Special Tools Column. Any tools needed to do the troubleshooting procedure which are not included in your common tool kit are listed in this column. g. Standard Tools Column. A dot in this column means that tools found in your common tool kit are needed to do the troubleshooting procedure. h. Materials Column. This column tells you what troubleshooting procedure. These materials and how decided by your maintenance officer. i. Time Column. This column tells you how much detailed troubleshooting procedure. The time will be officer. materials are needed to do the they will be issued will be time you will need to do the decided by your maintenance 6-1

24 FAULT SYMPTOM INDEX TABLE 6-1. ENGINE SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Low oil pressure Figure Engine runs rough Figure Checking cylinder compression gage assembly 3. Hard starting Figure Checking cylinder compression gage assembly TABLE 6-2. FUEL SYSTEM FAULT SYMPTOM INDEX TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Engine cranks but does not start Figure Engine runs rough and lacks power Figure Poor fuel mileage Figure TA

25 TABLE 6-3. COOLING SYSTEM TS PROCEDURE FAULT SYMPTOM INDEX RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Engine temperature gage reads above 195 F while running Figure 13-1 FAULT SYMPTOM INDEX TABLE 6-4. ELECTRICAL SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED ENGINE COOLANT HEATER FUEL BURNING HEATER Engine coolant heater overheats and continues burning Engine coolant heater does not give off enough heat Engine coolant heater does not start Fuel burning heater overheats and continues burning Fuel burning heater does not give off enough heat Figure 14-1 Figure 14-2 Figure 14-3 Figure 14-4 Figure 14-5 ELECTRIC BRAKES Fuel burning heater does not start When hydraulic brakes are applied, towed load does not have enough braking action Figure 14-6 Figure 14-7 TA

26 TM TABLE 6-5. FRONT AXLE SYSTEM TS PROCEDURE FAULT SYMPTOM INDEX SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Front axle makes noise Figure Shimmy Figure Dial indicator Dial indicator FAULT SYMPTOM INDEX TABLE 6-6. REAR AXLE SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Rear axle makes noise Figure Too much backlash when driving Figure 18-2 TA

27 TABLE 6-7. STEERING SYSTEM TS PROCEDURE FAULT SYMTOM INDEX.. RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Hard steering Figure Power steering oil pressure test set 2. Shimmy Figure FAULT SYPMTOM INDEX TABLE 6-8. FRONT WINCH SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SYMTOM SUBSYSTEM SUMMARY DETAILED 1. Winch does not pull load Figure Winch does not hold load Figure Winch drum spins too fast Figure when unwinding cable TA

28 FAULT SYMPTOM INDEX TABLE 6-9. REAR WINCH SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Winch does not hold load Figure TA

29 FAULT SYMTOM INDEX TABLE M543A2 WRECKER SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED HOIST WINCH 1. Hoist winch does not pull Figure load 2. Hoist winch pulls load Figure slowly 3. Hoist winch does not hold Figure load 4. Jerky operation as hoist Figure winch pulls load SWING MOTOR 5. Crane does not swing Figure Pressure gage 6. Crane swings slowly Figure Pressure gage 7. Jerky operation as crane Figure Pressure gage swings CONTROLS 8. Boom comes down too Figure fast 9. Boom does not extend Figure or extends and retracts slowly 10. Jerky operation as boom Figure extends or retracts TA

30 FAULT SYMTOM INDEX TABLE DEEP WATER FORDING SYSTEM TS PROCEDURE RESOURCES REQ D TEST EQUIPMENT SUBSYSTEM SYMPTOM SUMMARY DETAILED 1. Engine stalls while fording Figure Clutch slips after leaving Figure water TA

31 CHAPTER 7 SAMPLE TROUBLESHOOTING PROCEDURES 7-1. GENERAL. This chapter gives a sample troubleshooting procedure. The purpose of the sample procedure is to help you see how detailed troubleshooting procedures, test equipment procedures, and summary troubleshooting procedures are used to find faults in a system SAMPLE DETAILED PROCEDURE. (See figure 7-1.) The sample detailed procedure given is the fuel system troubleshooting procedure for the symptom, STARTER MOTOR WILL NOT CRANK ENGINE. This symptom is one you will have when you try to start your truck and certain parts on the truck are not working correctly. In each numbered box, instructions are given which tell you what to do, and how to do it. A large dot is placed next to the what-to-do instructions, and small dots next to the "how-to-do-it" instructions. a. Box number 1 gives start to troubleshoot. general instructions on getting the truck ready before you b. Box number 2 gives fault isolation test instructions. In this case you are told to check starting system circuit for loose, burned, or broken leads and connections. These tests or checks, are often referred to in detailed troubleshooting procedures to help you find the problem and fix it. After you do the tests or checks you read the question at the bottom of box number 2. If the starter system is not okay, the answer to the question is so you go to the next box. c. Box number 3 gives you a corrective action. In this case the fault is burned or broken leads or connectors. The corrective action is what you do to fix the fault, which is to replace any burned or broken leads or connectors. If the engine still doesn t start after you do this, it could mean that there are other faults in the system. When this happens, go back to the beginning of the procedure and do each step again until you find the other faults. d. Sometimes the corrective actions given for a fault will tell you what to do to fix the fault, but will not give you detailed instructions on how to fix it. Instead, you will be told to refer to another volume in this manual for these instructions. Box number 4 is an example of this. 7-1

32 STARTER SYSTEM TROUBLESHOOTING chapter 6 Vol 2 chapter 6 para 6-15 Vol 2 para 6-6 TM Figure 7-1. Sample Troubleshooting Procedure 7-2

33 CHAPTER 8 ENGINE SYSTEM TROUBLESHOOTING 8-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Engine System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 8-1

34 ENGINE SYSTEM TROUBLESHOOTING chapter 2 para 2-23 TM TM TM TM chapter 2 para 2-23 Figure

35 chapter 2 para 2-21 chapter 1 para 1-3 Figure 8-1 (Sheet 2 of 4) 8-3

36 chapter 2 para 2-20 chapter 2 para 2-21 LO Figure 8-1 (Sheet 3 of 4) 8-4

37 TM Figure 8-1 (Sheet 4 of 4) 8-5

38 TM chapter 2 para 2-14 Figure 8-2 (Sheet 1 of 2) 8-6

39 chapter 2 para 2-19 chapter 2 para 2-19 chapter 2 para 2-19 TM TM Figure 8-2 (Sheet 2 of 2) 8-7

40 TM TM chapter 2 para 2-6 TM Figure

41 CHAPTER 9 ENGINE SYSTEM TEST PROCEDURES 9-1. GENERAL. This chapter gives test procedures for the tests given in chapter 8, for the Engine System TEST SET-UP. Instructions for setup of test equipment and parts to be tested are given before the test procedures. Illustrations are used, when needed, to show you how to hook up the test equipment to the part to be tested TEST PROCEDURE. Detailed step-by-step instructions, in flow chart form, are given for each test. The procedure calls out the type of test and the condition of the truck system for each part of testing. The step-by-step test will lead you to the bad component or to a fault symptom within a related system. Reference is made to the fault symptom index, chapter 6, if the test shows a fault in another system. 9-1

42 ENGINE SYSTEM TEST PROCEDURES chapter 4 para 4-3 Figure 9-1 (Sheet 1 of 2) 9-2

43 Figure 9-1 (Sheet 2 of 2) 9-3/(9-4 blank)

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45 CHAPTER 10 FUEL SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Fuel System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 10-1

46 FUEL SYSTEM TROUBLESHOOTING Figure 10-1 (Sheet 1 of 3) 10-2

47 chapter 4 para 4-4 TM TM TM TM Figure 10-1 (Sheet 2 of 3) 10-3

48 figure 11-1 figure 11-1 chapter 4 para 4-4 chapter 4 para 4-5 Figure 10-1 (Sheet 3 of 3) 10-4

49 TM Figure 10-2 (Sheet 1 of 2) 10-5

50 chapter 4 para 4-4 chapter 4 para 4-4 Figure 10-2 (Sheet 2 of 2) 10-6

51 TM Figure 10-3 (Sheet 1 of 3) 10-7

52 TM TM Figure 10-3 (Sheet 2 of 3) 10-8

53 TM chapter 4 para 4-5 Figure 10-3 (Sheet 3 of 3) 10-9/(10-10 blank)

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55 CHAPTER 11 FUEL SYSTEM SUPPORT DIAGRAMS GENERAL. This chapter gives the diagrams you need when doing troubleshooting procedures in chapter 10. Figure 3-1 is a complete listing of all support diagrams used in this manual. 11-1

56 11-2 Figure Fuel Injectors and Fuel Lines

57 CHAPTER 12 FUEL SYSTEM TEST PROCEDURES GENERAL. This chapter gives test procedures for the tests given in chapter 10, for the Fuel System TEST SET-UP. Instructions for setup of test equipment and parts to be tested are given before the test procedures. Illustrations are used, when needed, to show you how to hook up the test equipment to the part to be tested TEST PROCEDURE. Detailed step-by-step instructions, in flow chart form, are given for each test. The procedure calls out the type of test and the condition of the truck system for each part of testing. The step-by-step test will lead you to the bad component or to a fault symptom within a related system. Reference is made to the fault symptom index, chapter 6, if the test shows a fault in another system. 12-1

58 FUEL SYSTEM TEST PROCEDURES Figure

59 CHAPTER 13 COOLING SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Cooling System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 13-1

60 COOLING SYSTEM TROUBLSHOOTING TM TM Figure 13-1 (Sheet 1 of 2) 13-2

61 chapter 2 para 2-6 chapter 2 para 2-6 chapter 2 para 2-5 Figure 13-1 (Sheet 2 of 2) 13-3/(13-4 blank)

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63 CHAPTER 14 ELECTRICAL SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Electrical System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 14-1

64 ELECTRICAL SYSTEM TROUBLESHOOTING chapter 19 para TM Figure 14-1 (Sheet 1 of 2) 14-2

65 chapter 19 para para chapter 19 chapter 19 para Figure 14-1 (Sheet 2 of 2) 14-3

66 chapter 19 para Figure 14-2 (Sheet 1 of 6) 14-4

67 chapter 19 para chapter 19 para Figure 14-2 (Sheet 2 of 6) 14-5

68 TM chapter 19 para TM chapter 19 para Figure 14-2 (Sheet 3 of 6) 14-6

69 chapter 19 para chapter 19 para chapter 19 para Figure 14-2 (Sheet 4 of 6) 14-7

70 TM Figure 14-2 (Sheet 5 of 6) 14-8

71 chapter 19 para chapter 19 para Figure 14-2 (Sheet 6 of 6) 14-9

72 TM TM Figure 14-3 (Sheet 1 of 5) 14-10

73 TM Figure 14-3 (Sheet 2 of 5) 14-11

74 TM TM Figure 14-3 (Sheet 3 of 5) 14-12

75 Check harness from heater control box to heater for continuity Set heater control switch to OFF Unscrew and take off harness plug from control box receptacle Unscrew and take off harness plug from heater Set multimeter to measure continuity Place multimeter - lead on control box harness plug contact A Place multimeter + lead on heater harness plug contact A Read multimeter. Multimeter should indicate continuity Do this test for contacts B, C, D, and E of both harness plugs Read multimeter after each contact tested. Multimeter should measure zero ohms for each test Does multimeter measure zero ohms for each contact tested? Figure 14-3 (Sheet 4 of 5) 14-13

76 chapter 19 para chapter 19 para TM Figure 14-3 (Sheet 5 of 5) 14-14

77 chapter 19 para Figure 14-4 (Sheet 1 of 2) 14-15

78 chapter 19 para 19-9 chapter 19 para 19-9 chapter 19 para 19-9 Figure 14-4 (Sheet 2 of 2) 14-16

79 Figure

80 TM chapter 19 para 19-9 chapter 19 para 19-9 Figure 14-5 (Sheet 2 of 4) 14-18

81 chapter 19 para 19-9 chapter 19 para 19-9 Figure 14-5 (Sheet 3 of 4) 14-19

82 chapter 19 para 19-9 TM Figure 14-5 (Sheet 4 of 4) 14 20

83 TM Figure 14-6 (Sheet 1 of 6) 14-21

84 TM TM Figure 14-6 (Sheet 2 of 6) 14-22

85 TM Figure 14-6 (Sheet 3 of 6) 14-23

86 TM Figure 14-6 (Sheet 4 of 6) 14-24

87 chapter 19 para 19-9 chapter 19 para 19-9 chapter 19 para 19-9 Figure 14-6 (Sheet 5 of 6) 14-25

88 TM Figure 14-6 (Sheet 6 of 6) 14-26

89 Figure 14-7 (Sheet 1 of 8) 14-27

90 Figure 14-7 (Sheet 2 of 8) 14-28

91 TM Figure 14-7 (Sheet 3 of 8) 14-29

92 TM Figure 14-7 (Sheet 4 of 8) 14-30

93 TM TM Figure 14-7 (Sheet 5 of 8) 14-31

94 Figure 14-7 (Sheet 6 of 8) 14-32

95 TM Figure 14-7 (Sheet 7 of 8) 14-33

96 TM TM TM Figure 14-7 (Sheet 8 of 8) 14-34

97 CHAPTER 15 ELECTRICAL SYSTEM TEST PROCEDURES TEST PROCEDURES. Test procedures for using voltmeters. procedures for the electrical system Refer to TM for these consist of procedures. 15-1/(15-2 blank)

98

99 CHAPTER 16 FRONT AXLE SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Front Axle System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 16-1

100 FRONT AXLE SYSTEM TROUBLESHOOTING chapter 9 para 9-5 Figure 16-1 (Sheet 1 of 2) 16-2

101 chapter 9 para 9-5 chapter 9 para 9-5 chapter 13 para 13-5 Figure 16-1 (Sheet 2 of 2) 16-3

102 chapter 9 para 9-5 Figure 16-2 (Sheet 1 of 2) 16-4

103 chapter 9 para 9-5 chapter 9 para 9-5 chapter 9 para 9-5 chapter 9 para 9-5 Figure 16-2 (Sheet 2 of 2) 16-5/(16-6 blank)

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105 CHAPTER 17 FRONT AXLE SYSTEM TEST PROCEDURES GENERAL. This chapter gives test procedures for the tests given in chapter 16, for the Front Axle System TEST SET-UP. Instructions for setup of test equipment and parts to be tested are given before the test procedures. Illustrations are used, when needed, to show you how to hook up the test equipment to the part to be tested TEST PROCEDURE. Detailed step-by-step instructions, in flow chart form, are given for each test. The procedure calls out the type of test and the condition of the truck system for each part of testing. The step-by-step test will lead you to the bad component or to a fault symptom within a related system. Reference is made to the fault symptom index, chapter 6, if the test shows a fault in another system. 17-1

106 FRONT AXLE SYSTEM TEST PROCEDURES Figure 17-1 (Sheet 1 of 2) 17-2

107 Figure 17-1 (Sheet 2 of 2) 17-3/(17-4 blank)

108

109 CHAPTER 18 REAR AXLE SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Rear Axle System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 18-1

110 REAR AXLE SYSTEM TROUBLESHOOTING TM TM chapter 10 para 10-3 chapter 9 para 9-4 chapter 10 chapter 9 para 9-4 para 10-3 Figure

111 TM chapter 10 para 10-3 chapter 9 para 9-4 chapter 9 para 9-4 chapter 10 para 10-3 Figure /(18-4 blank)

112

113 CHAPTER 19 STEERING SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Steering System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 19-1

114 STEERING SYSTEM TROUBLESHOOTING chapter 9 para 9-5 Figure 19-1 (Sheet l of 7) 19-2

115 LO Figure 19-1 (Sheet 2 of 7) 19-3

116 Figure 19-1 (Sheet 3 of 7) 19-4

117 chapter 13 para 13-7 Figure 19-1 (Sheet 4 of 7) 19-5

118 LO Figure 19-1 (Sheet 5 of 7) 19-6

119 chapter 13 para 13-5 Figure 19-1 (Sheet 6 of 7) 19-7

120 chapter 13 para 13-5 chapter 13 para 13-5 Figure 19-1 (Sheet 7 of 7) 19-8

121 chapter 13 para 13-5 chapter 13 para 13-5 chapter 13 para 13-5 Figure /(19-10 blank)

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123 CHAPTER 20 FRONT WINCH SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Front Winch System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 20-1

124 FRONT WINCH SYSTEM TROUBLESHOOTING TM chapter 17 para chapter 17 para Figure

125 TM Figure 20-2 (Sheet l of 2) 20-3

126 TM chapter 17 para Figure 20-2 (Sheet 2 of 2) 20-4

127 TM Figure 20-3 (Sheet 1 of 2) 20-5

128 TM chapter 17 para Figure 20-3 (Sheet 2 of 2) 20-6

129 CHAPTER 21 REAR WINCH SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Rear Winch System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 21-1

130 REAR WINCH SYSTEM TROUBLESHOOTING TM chapter 17 para Figure

131 CHAPTER 22 M543A2 WRECKER SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the M543A2 Wrecker System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 22-1

132 M543A2 WRECKER SYSTEM TROUBLESHOOTING chapter 17 para chapter 17 para chapter 17 para Figure

133 chapter 17 para chapter 17 para chapter 17 para TA Figure

134 Symptom chapter 17 para Figure 22-3 (Sheet 1 of 2) 22-4

135 chapter 17 para chapter 17 para Figure 22-3 (Sheet 2 of 2) 22-5

136 chapter 17 para chapter 17 para chapter Figure 22-4

137 chapter 17 para Figure 22-5 (Sheet 1 of 2) 22-7

138 chapter 17 para chapter 17 para chapter 17 para chapter 17 para Figure 22-5 (Sheet 2 of 2)

139 chapter 17 para Figure 22-6 (Sheet 1 of 2) 22-9

140 chapter 17 para chapter 17 para chapter 17 para chapter 17 para Figure 22-6 (Sheet 2 of 2) 22-10

141 chapter 17 para Figure 22-7 (Sheet 1 of 4) 22-11

142 chapter 17 para chapter 17 para Figure 22-7 (Sheet 2 of 4) 22-12

143 chapter 17 para chapter 17 para chapter 17 para chapter 17 para chapter 17 para chapter 17 para chapter 17 para chapter 17 para Figure 22-7 (Sheet 3 of 4) 22-13

144 chapter 17 para chapter 17 para chapter 17 para chapter 17 para chapter 17 para Figure 22-7 (Sheet 4 of 4) 22-14

145 chapter 17 para chapter 17 para chapter 17 para Figure

146 chapter 17 para chapter 17 para chapter 17 para chapter 17 para Figure

147 chapter 17 para chapter 17 para chapter 17 para Figure

148 chapter 17 para chapter 17 para Figure (Sheet 2 of 2) 22-18

149 CHAPTER 23 M543A2 WRECKER SYSTEM TEST PROCEDURES GENERAL. This chapter gives test procedures for the tests given in chapter 22, for the M543A2 Wrecker System TEST SET-UP. Instructions for setup of test equipment and parts to be tested are given before the test procedures. Illustrations are used, when needed, to show you how to hook up the test equipment to the part to be tested TEST PROCEDURE. Detailed step-by-step instructions, in flow chart form, are given for each test. The procedure calls out the type of test and the condition of the truck system for each part of testing. The step-by-step test will lead you to the bad component or to a fault symptom within a related system. Reference is made to the fault symptom index, chapter 6, if the test shows a fault in another system. 23-1

150 M543A2 WRECKER SYSTEM TEST PROCEDURES Figure 23-1 (Sheet 1 of 3) 23-2

151 Figure

152 Figure 23-1 (Sheet 3 of 3) 23-4

153 CHAPTER 24 DEEP WATER FORDING SYSTEM TROUBLESHOOTING EQUIPMENT ITEMS COVERED. This chapter gives equipment troubleshooting procedures for the Deep Water Fording System, for which there are authorized corrective maintenance tasks at the direct support and general support maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the direct support and general support maintenance level are covered in this chapter. 24-1

154 DEEP WATER FORDING SYSTEM TROUBLESHOOTING Figure 24-1 (Sheet 1 of 2) 24-2

155 TM TM TM Figure 24-1 (Sheet 2 of 2) 24-3

156 TM TM Figure 24-2 (Sheet 1 of 2) 24-4

157 TM Figure 24-2 (Sheet 2 of 2) 24-5/(24-6 blank)

158

159 By Order of the Secretaries of the Army and the Air Force: Official: E. C. MEYER General, United States Chief of Staff Army J. C. PENNINGTON Major General, United States Army The Adjutant General Official: LEW ALLEN, JR., General, USAF Chief of Staff VAN L. CRAWFORD, JR., Colonel, USAF Director of Administration Distribution: To be distributed in accordance with DA Form 12-38, Direct and General Support Maintenance requirements for 5-Ton Truck Chassis: 5-Ton, 6x6, M39A2. *U.S. Government Printing Office /44893

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