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TM 9-2320-363-10 - Liberated Manuals

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1. Drive Train Principles of Operation e ir Dowd debet NE NEG Driving TIps cede Re eR DR kamina Driving With a Damaged Tire M917A1 and 917 1 WIMCS Electrical System Principles of Operation Engine Shut Equipment Characteristics Capabilities and Features Data Inte raa et eed ce bese Exhaust System Principles of Operation Extreme Cold Operate in Extreme Heat Operate zac Sete Rohde da Ve Dade Front Wheel and Tire Assembly Replacement M917A1 and 917 1 w MCS Fuel System Principles of Operation General PMCS Procedures Index 2 Change 1 Paragraph 2 13 2 46 1 12 1 4 1 11 1 14 2 19 2 18 2 46 2 20 2 14 1 9 1 12 1 16 2 39 2 40 2 42 3 10 1 15 2 82 2 140 1 16 1 2 1 15 1 26 2 96 2 93 2 140 1 29 2 97 0 2 85 1 5 1 16 1 28 2 127 2 131 2 133 3 28 1 27 2 34 Subject Heater and Defroster Operate Hydraulic System All Except M915A2 Principles of Operation Initial Adjustments at ka S k unai i uquna Initial Adjustments Daily Checks and Self Tests Instrumen
2. AR 385 55 Change 1 A 3 A 4 Blank TM 9 2320 363 10 APPENDIX B COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS Section INTRODUCTION B 1 SCOPE This appendix lists Components of End Item and Basic Issue Items for the M915 Family of Vehicles to help you inventory items required for safe and efficient operation B 2 GENERAL The Components of End Item and Basic Issue Items Lists are divided into the following sections a Section Il Components of End Item This listing is for informa tional purposes only and is not authority to requisition replacements These items are part of the end item but are removed and separately packaged for transportation or shipment As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Illustrations are furnished to assist you in identifying the items b Section Ill Basic Issue Items These are the minimum essential items required to place the truck in operation to operate it and to perform emer gency repairs Although shipped separately packaged BII must be with the truck dur ing operation and whenever it is transferred between property accounts The illustrations will assist you with hard to identify items This manual is your authority to request requisition replacement based on TOE MTOE authorization of end item B 3 EXPLANATION OF COLUMNS Below is an explanation
3. eras rau a TE aCe ance ae Dictate ME Ea Fahrenheit aot dee eui dus Gross Combination Weight Rating GVWR E Gross Vehicle Weight Rating Kg ueri wayurkuma U awia w UR RUPES Kilogram sicui ayah Te Me be ROC RARO a UR Kilometers per Hour i EUER Yakumama Caguana ar RENE Phew RISE Liters per Hour MOS uo tdi d stan ck A eU Material Control System PMCS Zuma E Preventive Maintenance Checks and Services ioc ETE Power Take Off 1 4 TM 9 2320 363 10 Section Il EQUIPMENT DESCRIPTION AND DATA Paragraph Page Number Paragraph Title Number Equipment Characteristics Capabilities and Features Location and Description of Major Components Differences Between Models 1 15 Equipment 1 16 1 9 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES a Characteristics 1 The M915A2 is used to transport M871 M872 and M1062 semitrailers on line haul missions It has a Gross Vehicle Weight Rating GVWR of 52 000 Ib 23 608 kg and is equipped with a two way oscillating sliding fifth wheel compatible with a two inch kingpin Maximum towed load on kingpin is 30 000 Ib 13 620 kg 2 The M916A1 and M916A2 are used to transport M172 and M870 semitrailers loaded with heavy engineer equipment and 60PRS and W
4. 3 9 Winch Controls 916 1 and 916 2 2 7 Winch Operate M916A1 and M916A2 2 28 Woods or Rocky Terrain Operate in 2 44 Page 2 134 2 24 2 82 2 97 0 2 122 2 98 2 100 2 136 2 85 2 20 1 32 2 93 3 19 2 123 2 88 2 87 3 4 2 105 1 3 3 23 2 29 2 110 2 135 Change 1 Index 5 Index 6 Blank By Order of the Secretary of the Army DENNIS J REIMER General United States Army Official Chief of Staff 4 L B HUDSON Administrative Assistant to the Secretary of the Army 04419 Distribution To be distributed in accordance with IDN number 380850 Operator maintenance requirements for TM9 2320 363 10 U S GOVERNMENT PRINTING OFFICE 1998 646 039 60040 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS PRINT YOUR UNITS COMPLETE ADORESS Your Mailing Address THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL eT TITLE TITLE Operator s Manual VAT Puree wr IN THIS SPACE TELL WHAT IS WRONG WHAT SHOULD 8 DONE ABOUT IT Item 1 Item reads break pedal 1 Should read brake pedal 1 We PRINTED GRADE OR TITLE AND TELEPHONE NUMBER Your Name Rank and Phone Number DA PORE 2028 2 PREVIOUS EDIT ONS 8 YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 JUL 79 ARE OBSOLETE
5. 1 20 BRAKES Con b Loss of air pressure in the primary system causes the rear service brakes to become inoperative front brakes will continue to be operated by secondary System air pressure In addition trailer brakes will be operated by the secondary sys tem Loss of secondary system air pressure causes the front axle brakes to become inoperative rear service brakes and trailer brakes will be operated by the primary system C The warning light and buzzer inside the cab come on if air pressure drops below 64 psi 441 kPa in either system If this happens check the air pressure gages to determine which system has low air pressure Although the vehicle s speed can be reduced using the foot brake control pedal either the front or rear service brakes will not be operating causing a longer stopping distance Bring the vehicle to a safe stop and have the air system repaired before continuing d On tractor trailer vehicles if both the primary and secondary sys tems become inoperative the trailer service brakes or spring parking brakes will automatically apply when air pressure drops to 35 45 psi 241 310 kPa The tractor spring parking brakes will automatically apply when air pressure drops below 45 psi 310 kPa e All vehicles have a four channel anti lock brake system ABS and cam operated service brakes with non asbestos brakeshoes f All vehicles except M915A2 and M916A1 have automatically adjust ing slack adjuster
6. 12 proper torque 13 14 14 15 16 17 18 Position bracket 9 with wheel valve 10 and hoses attached Install two hub nuts 11 and have Unit Maintenance apply Connect inner wheel valve stem hose 15 to tee connector Connect hose 19 to outer wheel valve stem 16 Connect hub port connector 6 to hub air port 5 Connect hose 8 to hub port connector 6 Remove wheel blocks Inflate tires using CT S paragraph 2 17 or manual tire infla tion procedure paragraph 3 8 3 36 TM 9 2320 363 10 3 11 REAR WHEEL AND TIRE ASSEMBLY REPLACEMENT 917 1 AND 917 1 W MCS Con t 3 37 TM 9 2320 363 10 3 12 BATTERY BOX COVER REPLACEMENT a from battery box 3 38 To avoid eye injury eye protection is required when working around batteries Do not smoke use open flame make sparks or create other ignition sources around batteries If a battery is giving off gases it can explode and cause injury to personnel Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery ter minal a direct short will result in instant heating damage to equipment and injury to personnel Sulfuric acid contained in batteries can cause seri ous burns If battery corrosion or electrolyte makes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may result
7. 2 Description CAGEC amp Part Number Analyzer Charger Battery 09GZ5 VC 5 Axe Single Bit 4 16 HD wt 35 5 36 5 in long 19207 6150925 Block Jack Support Wood 4X8X9 in 19207 CPR103023 1 Block Jack Support Wood 7X8X9 in 19207 CPR103023 2 Chains Tire 80535 2245 Chains Tire 80535 002 2749 Clevis Part of Tow Bar 2540 00 378 2012 19207 8724449 Gloves Welders 58536 A A 50022 Handle Mattock 35 5 36 5 in long 19207 11677021 Kit Arctic Engine Heater 64678 681 830 10 K1 Kit Arctic Personnel Heater 64678 681 830 12 K1 Kit Arctic Personnel Heater 64678 681 830 11 K1 Kit First Aid 19207 11677011 Kit M13 Apparatus 81361 E5 51 527 ADDITIONAL AUTHORIZATION LIST Usable On Code TM 9 2320 363 10 Section Ill ADDITIONAL AUTHORIZATION LIST Con t 1 2 National Description Usable Stock Number CAGEC amp Part Number On Code 5340 01 345 4676 Kit M13 Decontamination Mounting 64678 681 899 01 KO 005 01 345 8880 Kit Rifle Mounting 64678 681 816 00 KO 005 01 439 9229 Kit Rifle Mounting 64678 681 816 00 K2 5340 00 158 3805 Padlock 96906 MS35647 10 5340 00 158 3805 Padlock 96906 MS35647 10 5120 00 243 2395 Pick Mattock 5 lb Without Handle 19207 11677022 5315 00 539 9174 Pin Part of Tow Bar 2540 00 378 2012 19207 10929861 5315 00 350 4326 Pin Locking Part of Tow Bar 2540 00 378 2012
8. Brakes 2 38 2 125 Central Tire Inflation System CTIS M917A1 and M917A1 w MCS Principles of Operation 1 24 1 34 Characteristics Capabilities and Features Equipment 1 9 1 5 Cleaning Vehicle 3 5 3 17 Controls and Indicators Additional 2 8 2 30 CTIS M917A1 and 917 1 85 2 6 2 26 Instrument Panel 2 2 2 2 Controls Cab Floor Mounted 2 4 2 21 OAL 54 erimus ds aug 2 5 2 24 Steering Wheel Column Mounted 2 3 2 20 Winch 916 1 and M916A2 2 7 2 29 Cooling System Principles of Operation 1 17 1 28 Corrosion Prevention and Control CPC 1 3 1 2 Couple to Truck All Except M917A1 and M917A1 W MGS editus te eet ea c NI MR dS 2 23 2 102 CTIS M917A1 and M917A1 w MCS Controls and Indicators 2 6 2 26 Operates RB RA up hun dne 2 17 2 89 Index 1 TM 9 2320 363 10 Subject Daily Checks Damaged Tire Driving With M917A1 and M917A1 5 Data Equipment Destruction of Army Materiel to Prevent Enemy Use Differences Between Models
9. Winch Cable All Temperatures M916A1 and M916A2 F 6 TM 9 2320 363 10 67 F to Lubricant Refill oF UE 432 F Component Capacity 20 C to 10 C 55 C to 0 Expected Temperatures Intervals ANTIFREEZE MIL A 46153 Ethylene Glycol Inhibited Heavy Duty ANTIFREEZE MIL A 11755 Ethylene Glycol Arctic Grade Engine Radiator 65 Qt See Chart E 61 5 L For Arctic Operation refer to FM 9 207 CHART A ENGINE POWER STEERING AND OIL CAN POINTS EXPECTED TEMPERATURES Lubricating Oil ICE L Tactical Lubricating Oil ICE L Arctic OE HDO 15 40 0 1236 OE HDO 30 0 238 OE HDO 40 N A S p peel OEA lubricant is required to meet the low expected temperature range lubricant is to be used in lieu of OE HDO 10 lubricant for all expected temperatures where OE HDO 10 is specified F 7 TM 9 2320 363 10 CHART B TRANSMISSION EXPECTED TEMPERATURES Lubricating Oil ICE Tactical Lubricating Oil ICE Arctic If OEA lubricant is required to meet the low expected temperature range lubricant is to be used in lieu of OE HDO 15 40 lubricant for all expected temperatures where OE HDO 10 and OE HDO 15 40 are specified CHART M16A1 AND M916A2 WINCH RESERVOIR EXPECTED TEMPERATURES EE ER ED Lubricating Cil ICE Tactical Lubricating Oil ICE Arctic If OEA lubricant is required to meet the low expected temperature rang
10. bue Sep ete paka eae deep Shut Down Operate Sliding Fifth Wheel M915A2 Operate Sliding Fifth Wheel M916A1 and M916A2 Couple to Truck All Except 917 1 and M917A1 w MCS Uncouple from Truck All Except M917A1 and M917A1 W MGS ua bets b o Ee et bee eed CRT a a Pintle Towing Procedures Mud Flap Stowage All Except M917A1 and M917A1w MCS Operate Power Take Off PTO All Except 915 2 Operate Winch 916 1 and 916 2 Operate Air Conditioner All Except M915A2 and M916A1 Operate Portable Fire Operate Llghis Rifle Mounting Operate Heater and Defroster Preparation for Movement DININ NIOJ ro f mi Change 1 2 81 TM 9 2320 363 10 2 12 GENERAL WARNING These vehicles have been designed to operate safely and efficiently within the limits specified in this TM Operation beyond these limits is prohibited in accor dance with AR 70 1 without written approval from Com mander U S Army Tank automotive and Armaments Command ATTN AMSTA DSA CS Warren MI 48397 5000 NOTE For operation of the M917A1 and M917A1 w MCS dump truc
11. w MCS 22 5 x 8 25 22 5 x 9 in 22 5 x 9 in 22 5 x 9 in in 10 1 125 in 10 1 125 in 10 1 125 in 10 1 125 in tubeless radial on highway tubeless radial on off road tubeless radial on off road tubeless radial on off road 11R22 5 80R22 5 80R22 5 Front XZY 1 65R22 5 XZY Rear 80R22 5 XZY 1 14PR 18PR 18PR 18PR H L L Front J Rear L 105 psi 115 psi 115 psi 724 kPa 793 kPa 793 kPa 90 psi 100 psi 90 psi 90 psi 690 kPa 621 kPa 621 kPa 621 kPa 105 psi 115 psi 115 psi 90 psi 724 kPa 793 kPa 793 kPa 621 kPa Single gear Single gear Single gear Single gear 1 21 TM 9 2320 363 10 1 12 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t M917A1 M917A1 w MCS Steering Con t Actuation hydraulic hydraulic hydraulic hydraulic power power power power booster booster booster booster Power Steering Eaton B165R Eaton B165R Eaton B165R Eaton B165R Pump Turning Diameter 53 ft 9 in 80 ft 24 4 m 80 ft 24 4 m 38 9 ft 76 4 m 11 9 m Towing Attach ments Pintle Hook Manufacturer Holland Holland Holland Holland Model No 760 No 760 No 760 No 760 Rated Capacity 30 tons 30 tons 30 tons 30 tons 27 2 metric 27 2 metric 27 2 metric 27 2 metric tons tons tons tons Towing Eyes Quantity 2 front 2 rear 2 front 2 rear 2 front 2 rear 2 front 2 rear Maximum Load 60 000 Ib 60 000 Ib 60 000 Ib 60 000 Ib Capacity
12. M817A1 W MCS Exhaust Muffler Deadens noise of engine exhaust Fuel Tank Holds fuel Steps mounted to tank provide access to cab TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS Storage Box Provides stowage area for BII and other items Mud Flaps Prevent water and debris from spraying up on passers by or dump body Pintle Hook Coupling device for trailers with lunettes Taillights Composite tail stop backup and turn signal lights on vehicle chassis Taillights Dump Include tail stop and turn signal lights Instead of Body backup lights dump body has an audible backup warning signal Dump Body Holds aggregate hot mix asphalt or similar materials Body Props Used to support raised EMPTY dump body for inspection and maintenance MCS Tailgate Has four electro pneumatically controlled gates which allow for controlled spreading of material Can also operate like a standard tailgate TM 9 2320 363 10 1 11 DIFFERENCES BETWEEN MODELS Vehicle Model M917A1 M917A1 w MCS Engine Model DDEC II Engine Model DDEC Ill Manual Ether Quick Start Automatic Ether Quick Start Transfer Case Driving Front Axle Highway Tires On Off Road Tires CTIS Spare Wheel and Tire 2 Way Sliding Fifth Wheel 4 Way Oscillating Fifth Wheel Hydraulic Winch Tachograph Datalogger Air Conditioner px x Eg ET X Initially built M916A2 and
13. REVERSE OF DA FORM 2028 2 AMSMC OP 103 85 FRL IN YOUR UNITS ADDRESS DEPARTMENT OF THE ARMY OFFICIAL BUSINESS BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 82 ROCK ISLAND IL POSTAGE WILL BE PAID BY ROCK ISLANO ARSENAL Director Armament and Chemical Acquisition and Logistics Activity ATTN AMSTA AC NML Rock Island IL 61201 9948 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES VOUT SNOW VEL PIN 069047 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did 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 US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov
14. 1 Keep It Clean Dirt grease oil and debris get in the way and may cover up a serious problem Clean as you work and as needed Use dry clean ing solvent Item 17 Appendix Dj on all metal surfaces Use detergent Item 4 and water when you clean rubber plastic and painted surfaces 2 Rust and Corrosion Check metal parts for rust and corro sion If any bare metal or corrosion exists clean and apply a light coat of lubricating oil Item 14 Appendix D Report it to your supervisor 3 Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose tighten it 4 Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to your supervisor 5 Electric Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and ensure that the wires are in good condition 6 Hoses and Fluid Lines Look for wear damage and signs of leaks Ensure that clamps and fittings are tight Wet spots indicate leaks but a stain around a fitting or connector can also mean a leak If a leak comes from a loose fitting or connector tighten it If something is broken or worn out report it to your supervisor 7 Fluid Leakage It is
15. Item To Not Fullv Missi Check ot Fully Mission Interval ERG Procedure Capable If Before Perform this check with trailer after trac tor traller are coupled a Listen for air leaks at interve Any air leaks are hicular connecting hoses present relay valve and air reser voirs b Apply trailer brakes only and b Brakes fail to hole attempt to move tractor tractor trailer com trailer combination bination from mov ing a Monitor all gages and indica a Any temperature tor and warning lights or pressure gage Check that engine coolant does not register transmission oil and transfer indicates abnor case all except M915A2 oil mal reading temperature gages register within normal range green band b On M915A2 and M916A1 b Gage reads less check that fuel pressure than 35 psi 241 gage reads 35 65 psi 241 kPa 448 kPa During Brakes Check brakes for pulling or Brakes pull or grabbing grab b Check that brake pedal is b Brake pedal is firm and does not fully spongy or de depress to floor presses fully to floor 2 45 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con Item To Not Fullv Missi Check ot Fully Mission Interval Procedure Capable If Check for smooth steering Steering is erratic without pulling to one side or pulls or has exces excessive play more than 212 sive p
16. On all vehicles except M915A2 916 1 check for proper operation of lumbar adjustment knob 21 seat back adjustment lever 22 and seat tilt knob 23 2 42 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Check Not Fully Mission Li Procedure Capable If Before Side Mir Adjust side mirrors as required rors paragraph 2 13 Before Instru ment Panel Gages and Indi cator and Warning Lights At 1760 2100 rpm minimum engine oil pressure for safe operation is 12 psi 83 kPa If gage does not show at least 12 psi 83 kPa shut down engine and notify supervisor Failure to follow this caution will damage engine a Check oil pressure gage a Gage reading is Reading should be 12 50 psi not within limits 83 295 kPa at idle b Check primary and b Gage reads less ary air pressure gages for than 65 psi 441 90 120 psi 621 827 kPa kPa yellow green band band warning buzzer stays on or gage is no operating c Check that voltmeter regis c Needle is in yellow ters within green band or red band d On M915A2 and 916 1 d Reading is below check fuel pressure gage 7 psi 48 kPa reading Reading should be no lower than 7 psi 48 kPa 2 43 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS Interval Before Before 2 44
17. TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To tem Interval Check Not Fully Mission West Service Procedure Capable If 50 Weekly Batteries Check for missing broken c Cables are miss Con t split or frayed cables 69 ing broken split or frayed d Check for damaged terminal d Terminal posts are posts 67 damaged e Check for rust and corrosion f Check for cleanliness g Report any problems to Unit Maintenance 2 69 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con Location Item To Not Fully Mission cee Procedure Capable If a Check pressure in tires and adjust as required Weekly Spare ig Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result a Check pressure in tire and adjust as required M915A2 105 psi 724 kPa M916A1 M916A2 115 psi 793 kPa M917A1 M917A1 w MCS 90 psi 621 kPa b Check wheel for cracks b Wheel is cracked breaks or bends broken or bent Weekly Forward R and Tires Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result NOTE M917A1 and M917A1 w MCS CTIS must b
18. 12 7 liter 400 horsepower in line diesel engine built by Detroit Diesel g Allison HT 740 four speed automatic transmission 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPON ENTS 8 M915A2 M916A1 and M916A2 Marker Clearance Indicate outline of truck Lights Air Horn Provides an audible alert TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS M916A1 AND M916A2 Component Side Mirrors Provide driver with a view of sides of truck Grabhandles Provide a hand hold for personnel climbing on truck Utility Power Supplies power for work lights Located on both Receptacle sides of truck Spare Wheel and Tire Extra wheel and tire used in case of a flat tire TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS Con t Component Battery Box and Steps Front Service Lights Sling Points Blackout Lights 1 8 0 M916A1 AND M916A2 Description Holds vehicle batteries and provides steps to access cab Include headlights and turn signals Provide attachment point for slings Used during blackout conditions Include marker and drive lights TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS Con t Towing Eyes Provide attachment points for towing device Brush Guard Protects front of hood and components under hood from damage Spotting Mirrors Provide added visibility to sides of truck
19. 2 34 2 114 2 109 2 118 1 34 1 30 1 30 1 34 1 28 1 26 1 29 1 28 1 27 1 32 1 32 3 32 3 18 1 3 2 117 TM 9 2320 363 10 Subject Paragraph S Sandy or Dusty Conditions Operate in 2 43 Seal Controls usum ba Teta ede 2 5 GIBT CR 2 13 Shut Down Engine 2 20 Slave Start TTUCK space E x Rd 2 36 Sliding Fifth Wheel Operate M915A2 dr irin ea re e MER RR NL da 2 21 Operate M916A1 916 2 2 22 Snow and Ice Operate on 2 45 Start ENJINS aegre era RP ee 2 14 Steering Wheel and Column Mounted Controls 2 3 Steering Principles of Operation 1 21 T Tips Driving 2 18 Tire Inflation Manual 3 7 TOW TUCK aged petty BS een eae ES 2 37 Transfer Case All Except M915A2 Operate 2 16 Transmission Operate 2 15 Troubleshooting Symptom Index 3 4 U Uncouple From Truck All Except M917A1 and M917A1 85 2 24 W Warranty Information 1 6 Wheel and Tire Assembly Replacement All Except M917A1 917 1 w MCS
20. 2 9 TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con 21 19 20 M915A2 M916A1 22 26 25 24 ALL EXCEPT M915A2 AND M916A1 Control or Indicator Mechanical Switch Spring loaded two position switch Operates the All Except M915A2 same as mechanical switch on other model trucks and M916A1 Refer to item 17 in subparagraph a 3 Auxiliary Switch Four position switch Operates the same as auxil All Except M915A2 iary switch on other model trucks Refer to item 18 and M916A1 in subparagraph a 3 Engine Jake Brake Selects number of engine cylinders desired for Selection Switches braking action two four or six cylinders Turn on left switch for two cylinders right switch for four cyl inders and both switches for all six cylinders TM 9 2320 363 10 INSTRUMENT PANEL Con t Control or Indicator Fifth Wheel Slide M915A2 Tachograph M915A2 and M916A1 All Wheel Drive Control Valve Lever All Except M915A2 Tailgate Release Control Valve Lever M917A1 and M917A1 w MCS PTO Indicator Light All Except M915A2 PTO Switch All Except M915A2 Parking Brake Control Function Permits repositioning of sliding fifth wheel from inside cab LOCK position deactivates control valve and locks fifth wheel to baseplate UNLOCK position activates control valve to allow changes to total length of tractor trailer and changes to axle loads Registers truck ground speed mph
21. 298 3 kW Maximum Gov 2100 rpm 2100 rpm 2100 rpm 2100 rpm erned Speed Oil Filter Type DDEC Il DDEC Il DDEC Ill DDEC Il 1 bypass 2 1 bypass 2 2 full flow 2 full flow full flow full flow replaceable replaceable replaceable replaceable elements elements elements elements Fuel System Type diesel fuel diesel fuel diesel fuel diesel fuel injected injected injected injected Fuel Tank Air Cleaner Sedi 1 18 TM 9 2320 363 10 1 12 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t M917A1 M917A1 w MCS Cooling System Radiator Working 10 psi 10 psi 10 psi 10 psi Pressure 69 kPa 69 kPa 69 kPa 69 kPa Electrical System dual 12 24 dual 12 24 dual 12 24 dual 12 24 volt volt volt volt Batteries Quantity 4 4 4 Voltage 12 volt 12 volt 12 volt 12 volt Transmission Manufacturer Allison Allison Allison Allison Model HT 470 HT 470 HT 470 HT 470 Type 4 speed 4 speed 4 speed 4 speed automatic automatic automatic automatic Transfer Case Manufacturer N A Oshkosh Oshkosh Oshkosh Front Axle Manufacturer Rockwell Oshkosh Oshkosh Oshkosh Type I beam Hypoid FDS Hypoid FDS Hypoid FDS FF961 1807 1807 1807 Rated Capacity 12 000 Ib 16 000 Ib 16 000 Ib 16 000 Ib 5448 kg 7264 kg 7264 kg 7264 kg Maximum Steering 28 28 28 Angle TM 9 2320 363 10 1 12 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t M917A1 M917A1 M916A1 w MCS Rear A
22. 917 1 917 1 w MCS have manual ether quick start system TM 9 2320 363 10 1 12 EQUIPMENT DATA Table 1 1 Equipment Data M917A1 M917A1 M916A1 M916A2 w MCS Manurere Freightliner Freightliner Freightliner Freightliner Dimensions Length Overall 275 5 in 289 in 289 in 303 8 in 700 cm 734 cm 734 cm 771 7 cm 316 8 in 804 7 cm Height Overall 119 in 128 in 128 in 135 5 in 302 cm 325 cm 325 cm 343 cm Width Overall 98 in 98 in 98 in 103 8 in 249 cm 249 cm 249 cm 267 cm Wheelbase 162 in 174 in 174 in 174 in 411 cm 442 cm 442 cm 442 cm Ground Clearance 9 23 cm 9 in 23 9 in 23 9 in 23 cm 18 680 Ib 27 740 Ib 27 860 29 454 8481 kg 12 594 kg 12 684 kg 31 472 13 360 14 288 kg 52 000 Ib 68 000 Ib 68 000 Ib 68 000 Ib 23 608 kg 30 872 kg 30 872 kg 30 872 kg GCWR 105 000 lb 120 000 Ib 130 000 Ib 68 000 Ib 46 670 kg 59 020 kg 59 020 kg 80 872 kg Front Axle Loaded 12 000 Ib 16 000 Ib 16 000 Ib 16 000 Ib 5448 kg 7264 kg 7264 kg 7264 kg Rear Axle Loaded 40 000 Ib 52 000 Ib 52 000 Ib 52 000 Ib 18 160 kg 23 608 kg 23 608 kg 23 608 ko 1 16 TM 9 2320 363 10 1 12 EQUIPMENT DATA Table 1 1 Equipment Data Con t M917A1 M917A1 M916A1 w MCS Capacities Engine Oil 41 qt 41 qt 41 qt 41 qt Refill w Filters 38 8 1 38 8 1 38 8 1 38 81 Engine Oil
23. Combustion Engine OE HDO 40 81349 MIL L 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum RAG Wiping 64067 7920 00 205 1711 50 Pound Bale SOLVENT Dry Cleaning Type Il 81348 P D 680 1 Pint Can 1 Quart Can 1 Gallon Can 5 Gallon Can 55 Gallon Drum TM 9 2320 363 10 Section Il EXPENDABLE AND DURABLE ITEMS LIST Con t 3 4 National Description Number Level Stock Number CAGEC Part Number TAPE Reflective 2 Inches Wide 81346 ASTM D4956 9390 00 174 2322 1800 Inch Roll D 5 D 6 Blank TM 9 2320 363 10 APPENDIX E STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE E 1 SCOPE a This appendix shows the location for stowage of equipment and material required to be carried on the M915 Family of Vehicles This appendix also includes illustrations showing the location of all decals data plates and stencils b Items related to the M917A1 and M917A1 w MCS chassis are included in this appendix Items related to the M917A1 and M917A1w MCS dump body are in TM 5 3805 264 14 amp P E 1 TM 9 2320 363 10 E 2 DECALS AND PLATES OVER ALL WIDTH E 2 SHIPPING DATA MSI7AI DVER ALL LENGTH OVER ALL HEIGHT SHIPPING VOLUME SHIPPING WEIGHT 305 25 IN SHIPPING TONNAGE 16 TONS 26 1 FRONT AXLE WEIGHT 13 554 LBS 100 00 IN FRONT REAR AXLE WEIGHT 8 416 LBS 2 261 CULFT BACK REAR AXLE WEIGHT 8 520 LBS 30 790
24. Part Number GREASE Automotive and Artillery GAA 81349 MIL G 10924 14 Ounce Cartridge 2 1 4 Ounce Tube 1 3 4 Pound Can 6 1 2 Pound Can 35 Pound Pail 120 Pound Drum OIL Lubricating GO 75 81349 MIL L 2105 1 Quart Can 5 Gallon Can OIL Lubricating Gear Multipurpose GO 80 90 81348 MIL L 2105 1 Quart Can 5 Gallon Can 55 Gallon Drum 16 Gage OIL Lubricating GO 85 140 81349 MIL L 2105 55 Gallon Drum OIL Lubricating Internal Combustion Engine Arctic OEA 81349 MIL L 46167 1 Quart Can 5 Gallon Drum 55 Gallon Drum OIL Lubricating Internal Combustion Engine OE HDO 10 81349 MIL L 2104 D 3 TM 9 2320 363 10 Section Il Number Level D 4 EXPENDABLE AND DURABLE ITEMS LIST Con t 3 National Stock Number 9150 00 189 6727 9150 00 186 6668 9150 00 191 2772 9150 01 151 4117 9150 01 151 4118 9150 01 151 4118 9150 00 186 6681 9150 00 188 9858 9150 00 189 6729 9150 00 189 6730 9150 00 188 9860 9150 00 188 9862 7920 00 205 1711 6650 00 110 4498 6650 00 664 5685 6650 00 281 1985 6850 00 274 5421 6850 00 285 801 1 4 Description CAGEC Part Number 1 Quart Can 5 Gallon Can 55 Gallon Drum OIL Lubricating Engine OE HDO 15 W 40 81349 MIL L 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum OIL Lubricating Internal Combustion Engine OE HDO 30 81349 MIL L 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum OIL Lubricating Internal
25. Press key to check tire pressures and to inflate damaged tire every 15 seconds Annunciator light will flash on and off in this mode Run flat operation is limited to ten minutes unless re selected Press key a second time to de select TM 9 2320 363 10 2 6 CTIS CONTROLS AND INDICATORS M917A1 AND M917A1 W MCS Con t EMER Emergency Mode Key SAND Mode Key X C Cross Country Mode Key HWY Highway Mode Key Electronic Control Unit ECU Press key to select 30 psi 207 kPa tire pressures for operation in extreme terrain conditions where maximum traction is required up to a maximum speed of 10 mph 16 kph Reduce MPH indicator light will always illuminate in this mode Operation in EMER mode is limited to 10 minutes After ten minutes CTIS will inflate to SAND setting unless driver re selects EMER Press key to select 40 psi 276 kPa tire pressures for operation in sand snow and mud up to a maximum speed of 25 mph 40 kph If 25 mph overspeed is exceeded for more than one minute reduce MPH indicator light will flash If exceeded for more than two minutes CTIS will automatically inflate to cross country X C setting There is no time limit for operation in this mode Press key to select 55 psi 379 kPa tire pressures for operation on non paved secondary roads and unimproved surfaces up to a maximum speed of 40 mph 64 kph If 40 mph overspeed is exceeded for more than one minute reduce MPH indicator
26. Senses vehicle speed and sig nals the ECU to automatically inflate tires when vehicle speed exceeds by 10 mph 16 kph the top speed setting for the selected mode Quick Release Valves Allow air from PCU to inflate or vent air during deflation Wheel Valves Isolate air pressure in tire during normal operation and for tire removal Air valve on wheel valve allows for inflation and deflation using standard manual inflation equipment 1 36 TM 9 2320 363 10 1 24 CENTRAL TIRE INFLATION SYSTEM CTIS M917A1 AND M917A1 W MCS Con t OPERATOR ELECTRONIC CONTROLS CONTROL UNIT PNEUMATIC CONTROL EXHAUST TO ATMOSPHERE PRESSURE SWITCH XS AIR LINES AIR VALVE 1 37 1 38 Blank TM 9 2320 363 10 CHAPTER 2 OPERATING INSTRUCTIONS Section DESCRIPTION AND USE OPERATOR S CONTROLS AND INDICATORS Paragraph Page Number Paragraph Title Number General Instrument Steering Wheel and Column Mounted Controls Cab Floor Mounted Controls Seat Controls CTIS Controls and Indicators M917A1 and M917A1 w MCS Winch Controls 916 1 and M916A2 Additional Controls and Indicators 2 1 GENERAL Do not attempt to operate the M915 Family of Vehicles until becoming familiar with the
27. Shut Down Check Engine Engine Temperature Engine Oil or Low Air Pressure warning lights come on stop vehicle shut down engine and investigate cause Check gages and indicators frequently Operate engine brakes as required paragraph 2 2 Operate interaxle lockout all wheel drive as required paragraph 2 Stop vehicle by applying long even pressure to service brakes Do not pump brakes After vehicle is at a complete stop place transmission in Neutral N transfer case in Neutral N and pull parking brake control knob OU T Change 1 2 97 TM 9 2320 363 10 2 20 SHUT DOWN ENGINE 2 97 0 CAUTION Shutting down engine without performing step a could damage turbocharger Run engine at idle for four to five minutes Turn all accessories off paragraph 2 2 Move ignition switch to OFF position Perform After operation PMC Chapter P Section II p Change 1 TM 9 2320 363 10 THIS PAGE INTENTIONALLY LEFT BLANK Change 1 2 97 1 TM 9 2320 363 10 2 21 OPERATE SLIDING FIFTH WHEEL 915 2 CAUTION M915A2 is designed to be used with M871 M872 and M1062 semitrailers only Other semitrail ers may cause equipment damage Trailer must be blocked and trailer brakes locked to prevent damage to tractor or trailer by uncontrolled sliding of fifth wheel If towing M872 trailer rear mud flaps must be removed and stowed in br
28. and DO NOT breathe vapors DO NOT use near open flame or excessive heat The solvents flash point is 100 138 F 38 C 59 C If you become dizzy while using cleaning solvent immediately get fresh air and medical help If solvent contacts eyes imme diately wash your eyes and get medical aid Weekly or on condition apply GAA to top plate latch mechanism slider rails locking plungers and all lubrication fit tings Clean and lubricate moving parts on underside with dry cleaning solvent and OE HDO 4 RADIATOR F 16 Let radiator cool before remov ing cap Remove cap in two steps First place thick cloth over cap and slowly turn cap left to its first stop pause and allow pressure to escape from cooling system Then turn cap further left until you can remove it Failure to follow this procedure can result In serious burns Daily with engine cool remove radia tor cap Check level of coolant in radia tor Coolant must be within 2 1 2 in 6 4 cm below filler neck Add coolant to correct level Install radiator cap 5 ENGINE CRANKCASE Daily check level of lubricating oil Wait 10 minutes after shutting down engine to allow oil to drain back into crankcase To ensure an accurate reading vehi cle must be parked on level ground Safe operating level is between ADD and FULL marks on dipstick As required add OE HDO through filler opening DO NOT overfill 6 TRANSMISSION COLD OIL CHECK COLD RUN B
29. axle all vehicles except M915A2 are equipped with No Spin on both rear axles The No Spin differen tial eliminates individual wheel spinout for better traction When locking system is engaged driving axles receive equal torque Maintain steady even movement with transmission in lower gears and lockout all wheel drive LOCK ENGAGE position Try to keep vehi cle rolling without straining engine and powertrain b For all vehicles except M917A1 and M917A1 w MCS if vehicle gets Stuck reduce tire pressure to gain additional traction Reduce pressure in front tires to 50 psi and pressure in rear tires to 45 psi 302 kPa Inflate tires to normal pres sures once vehicle is freed When resuming operation on highway surfaces be sure to reset CTIS selector panel to higher tire pres sures Operating vehicle with underinflated tires will cause premature tire wear or damage to tires Failure to follow this warning may result in death or injury to per sonnel C For M917A1 and M917A1 w MCS select SAND mode key on CTIS selector panel d If M917A1 or M917A1 w MCS gets stuck select emergency EMER on CTIS selector panel to reduce tire pressures to 30 psi 207 kPa Do NOT exceed 10 mph 16 kph Operation in this mode is limited to 10 minutes unless rese lected Remember to reset to higher tire pressures when vehicle is freed e If vehicle bogs down after tire pressure has been reduced place boards brush canvas
30. b You are operating the truck for the first time This PMCS describes preventive mainte nance checks and services for the chas sis of an M917A1 and M917A1 w MCS Dump Truck Refer to TM 5 3805 264 14 amp P for PMCS on the dump truck body Before Overall a Check under truck for evi a Class Ill oil cool View dence of fluid leakage such ant or hydraulic as oil coolant fuel or leaks or Class Il hydraulic fluid fuel leaks are evi dent b Check truck for obvious b Damage that damage that would impair would impair oper operation ation is evident c Visually check for missing or c Any tire is missing damaged tires Check lug or damaged Lug nuts to ensure they are at nuts are loose or least finger tight missing TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Check Not Fully Mission Interval Service Procedure Capable If Before Cab Check for damage to lights 9 Damage that would Exterior spotting mirrors 1 side mirror interfere with visibil 4 windshield 2 windshield ity and impair opera wipers and blades 3 cab tion is evident door 8 grabhandle 5b and battery box 7 and steps Check for presence and condi Spare wheel and tire tion of spare wheel and is missing or dam tire 6 aged P Before Overall Check truck for obvious a Damage that View damage that would im
31. change oil if oil appears milky or con tains metallic particles TM 9 2320 363 10 Always wear heavy gloves when you handle winch wire rope Never allow wire rope to run through your hand as broken wires can cause injury Hearing protection is required for operator and all personnel working on or around winch station dur ing operation WINCH CABLE On condition clean and lubricate cable Unwind cable and soak in clean OE HDO overnight Clean with a brush Wipe off excess oil Coat with GAA before rewinding cable on drum 8 OIL CAN POINTS On conditior or weekly lubricate sparingly with OE HDO door hinges and latches View driver and passenger seat adjuster and sliding tracks View J and spare wheel and tire carrier ratchet gear shaft View K F 17 F 18 Blank TM 9 2320 363 10 Subject Paragraph A Abbreviations List 0 1 8 1 3 Additional Controls and Indicators 2 8 2 30 Air Conditioning System All Except M915A2 and M916A1 Principles of Operation 1 23 1 34 Air System Principles of Operation 1 19 1 30 B Battery Box Cover Replacement 3 12 3 38 Brakes Cage and 2 38 2 125 Brakes Principles of Operation 1 20 1 30 C Cab Floor Mounted Controls 2 4 2 21 Cage and
32. for M915 Family of Vehicles Con t Item To Check Service Procedure Instru ment Panel Gages and Indi cator and Warning Lights e Check that fuel supply gage registers and indicates ade quate fuel for mission Check air cleaner restriction indicator g Check that ABS warning light is lit h On M917A1 and M917A1 w MCS verify that CTIS sys tern is operational with no malfunctions indicated on selector panel paragraph 2 17 Parking Brake With service brake pedal depressed transmission in Drive D and engine at idle pull out on parking brake valve then release service brake pedal Vehicle should not move With transmission in Drive D release parking brake and apply service brakes Vehicle should not move Trans mission Controls With service brakes applied move transmission selector lever through all gears and check for smooth operation binding gears Not Fully Mission Capable if f On M915A2 indi cator window shows yellow On all other models indicator window shows 20 in of water Mission requires use of CTIS and CTIS does not have System power or is mal functioning Vehicle moves with parking brake ap plied Vehicle moves with service brakes ap plied Operation is smooth or there is no between 15 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location
33. immediately get fresh air and medical help If solvent contact eyes immediately wash your eyes and get medical aid WARNING FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher in the cab may result in temporary breathing difficulty during and immediately after the discharge event If at all possible discharge fire extinguisher from outside the cab Ventilate cab thoroughly prior to reentry WARNING HAZARDOUS WASTE DISPOSAL When servicing this vehicle performing maintenance or disposing of materials such as engine coolant transmission fluid lubricants battery acids or batteries and CARC paint consult your unit local hazardous waste disposal center or safety office for local regulatory guidance If further information is needed please contact The Army Environmental Hotline at 1 800 872 3845 WARNING HEARING PROTECTION Hearing protection is required when operating vehicle at more than 35 mph 56 kph with windows open for an extended period of time Hearing protection is also required when working around truck with engine running for an extended period of time and when performing loading or dumping operations Failure to follow this warning may result in hearing damage d Change 1 TM 9 2320 363 10 WARNING NBC EXPOSURE If NBC exposure is suspected all air cleaner media should be handled by
34. or similar materials under and in front of tires after shoveling a clear path ahead of each tire This should improve traction f If these efforts fail and it becomes evident that vehicle will not free itself use winch M916A1 M9164A2 if possible or have another vehicle tow stuck vehicle 2 134 TM 9 2320 363 10 2 43 OPERATE IN SANDY OR DUSTY CONDITIONS Con t g Whenever operating in sandy or dusty areas you should 1 Make sure each tire has a valve cap 2 Check engine and transmission temperature and engine oil pressure frequently 3 If vehicle overheats stop and find out why Service or notify Unit Maintenance as necessary 4 Make sure engine oil filler tube and transmission fluid filler tube are cleaned before dipsticks are removed to check fluid levels Clean accumula tions of sand and dirt from around any fluid filler locations before checking or adding fluids Clean spouts of fuel containers and areas around filler caps on fuel tanks before adding fuel Under extremely sandy or dusty conditions filter fuel when filling tanks 6 Cover window glass to protect against sand blasting 2 44 OPERATE IN WOODS OR ON ROCKY TERRAIN NOTE M915A2 is equipped with No Spin automatic lock ing positive traction differential on the forward rear axle all vehicles except M915A2 are equipped with No Spin on both rear axles The No Spin differen tial eliminates individual wheel spinout for better
35. traction When locking system is engaged driving axles receive equal torque For all vehicles except M915A2 shift transfer case selector to LOW range if operating in extremely slip pery conditions or while climbing steep inclines a Ensure vehicle can clear any obstructions and try to avoid low hang ing tree limbs which might cause damage 2 135 TM 9 2320 363 10 2 44 OPERATE IN WOODS OR ON ROCKY TERRAIN Con t b Ensure spare wheel and tire assembly is available For M916A1 and M916A2 release fifth wheel oscillating travel lockout by removing locking pin 1 lowering lockout 2 and reinserting locking pin 1 This allows fifth wheel to oscillate side to side d For M917A1 and M917A1 w MCS select cross country X C mode on CTIS selector panel paragraph 2 17 p HAUL M172 M916A1 AND M916A2 2 45 OPERATE ON SNOW OR ICE NOTE M915A2 is equipped with No Spin automatic lock ing positive traction differential on the forward rear axle all vehicles except M915A2 are equipped with No Spin on both rear axles The No Spin differen tial eliminates individual wheel spinout for better traction When locking system is engaged driving axles receive equal torque For all vehicles except M915A2 shift transfer case selector to LOW range if operating in extremely slip conditions or while climbing steep inclines a General 1 Driving a Accelerate slowl
36. 11 Drive approxi mately 1 2 mile and readjust chains as required 2 139 TM 9 2320 363 10 2 46 DRIVING WITH A DAMAGED TIRE M917A1 AND M917A1 W MCS a Press RUN FLAT key on CTIS selector panel b After ten minutes RUN FLAT light will flash and key may be pushed again to reactivate the feature After the RUN FLAT feature has been activated it may be shut off by pressing RUN FLAT key during the ten minute activation period 2 140 TM 9 2320 363 10 CHAPTER 3 MAINTENANCE INSTRUCTIONS Section I LUBRICATION INSTRUCTIONS 3 1 GENERAL Lubrication instructions are in Appendix F of this manual NOTE For M917A1 and M917A1 w MCS dump body lubrication Instructions refer to TM 5 3605 264 14 amp P b All lubrication instructions are mandatory 3 1 3 2 Blank TM 9 2320 363 10 Section Il TROUBLESHOOTING PROCEDURES Paragraph Page Number Paragraph Number Number General 2s exer NUR Explanation of Columns Troubleshooting Symptom Index Troubleshooting s Ree 3 2 GENERAL NOTE Refer to TM 5 3805 264 14 amp P for M917A1 and M917A1 W MCS dump body troubleshooting a This section provides information for identifying and correcting mal functions which may develop while operating the M915 Family of Vehicles b The Troubleshooting Symptom index in paragraph 3 4 lists common malfunctions which may occur and re
37. 19207 11676920 Bag Tool BII storage box 19204 7541507 Beacon Warning Light Kit 12 volt 66654 SY22011H A Binder Looseleaf 19207 11677003 Cable Assy Power NATO in BII storage box 19207 11682336 1 TM 9 2320 363 10 BASIC ISSUE ITEMS 4 Usable on Code EA EA EA EA EA Change 1 B 3 TM 9 2320 363 10 1 Illus Number Section Ill 2 National Stock Number 6150 01 478 6510 2540 00 678 3469 4210 01 338 6064 4910 01 003 9599 5120 00 242 3915 B 4 Change 1 BASIC ISSUE ITEMS Con t 3 Description CAGEC Part Number Cable Assy 12 volt Tractor Tri 12 ft BII storage box 64678 PHM 42FL40 144 Chock Wheel storage box 58536 A A 52475 1 Extinguisher Fire on cab floor 54905 447 Gauge Tire in cab glove box 19207 7974576 1 Hammer 2 Ib storage box 80063 SMC133095 4 Usable on Code TM 9 2320 363 10 Section BASIC ISSUE ITEMS Con t 11 12 2 National Description Stock Number CAGEC Part Number 5120 00 243 2419 Handle 30 in long in BII storage box 71282 44201 12 5120 01 084 3298 Handle Wrench EA 1 in BII storage box 34623 967556 13 6150 00 772 8814 Harness Assy 12 ft 24 5A2 EA 1 volt 6A1 BII storage box 6A2 19207 7728814 14 5340 01 328 444 Hook 6A1 EA 1 n side of 5th w
38. 2 113 and 2 114 2 113 and P 114 2 117 thru 2 119 2 120 Blank thru 2 119 2 120 Blank 2 121 and 2 122 2 122 Approved for public release distribution is unlimited TM 9 2320 363 10 C1 Remove Pages Insert Pages 2 137 and 2 138 and 2 138 3 27 and 3 28 and 3 28 3 31 and 3 32 and 3 32 A 1 and A 2 A 1 and 2 A 4 Blank B 3 thru B 8 LE ME 1 and 2 C 1land C E 3 and E 4 E 3Jand E 4 E 4 Y E 4 2 Blank Index 1 and Index 2 and Index 5 Index 6 Blank Index 5 Index 6 Blank Front Cover Front Cover Pin 3 File this change sheet in front of the publication for reference purposes By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Chief of Staff Official SANDRA R RILEY Administrative Assistant to the Secretary of the Army 0508908 DISTRIBUTION To be distributed in accordance with the initial distribution number IDN 380850 requirements for TM 9 2320 363 10 Approved for public release distribution is unlimited TM 9 2320 363 10 LIST OF EFFECTIVE PAGES Dates of issue for original and change pages work packages are Original 30 December 1997 Change 1 15 February 2006 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 42 AND TOTAL NUMBER OF PAGES IS 306 CONSISTING OF THE FOLLOWING Page Change No No Cover Back Blank atoh A and B i and ii iii iv Blank 1 1 and 1 2 1 3 1 4 thru 1 37 1 38 Blank 2 1 thru 2 10 2 11
39. 3 and connect pneumatic hose 1 to valve stem 4 e Add air until desired pressure is reached f Remove pneumatic hose 1 from valve stem 4 and install valve stem cap 3 Pull out OFF trailer air supply control valve and shut down engine paragraph 2 20 h Disconnect pneumatic hose 1 from emergency gladhand 2 and return to stowage 3 ALL EXCEPT M917A1 M917A1 AND M917A1 AND M917A1 W MCS W MCS 3 20 TM 9 2320 363 10 3 8 OPERATION OF SPARE WHEEL AND TIRE ASSEMBLY CARRIER a Remove Spare Wheel and Tire Assembly from Carrier 1 Ensure pawl 2 engages gear shaft 1 and remove two nuts 5 2 Turn gear shaft 1 clockwise slightly and disengage pawl 2 from gear shaft Swing pawl 2 out of way Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improp erly lifted or if it falls on you 3 Slowly rotate gear shaft 1 counterclockwise one notch M916A1 AND M915A2 M916A2 TM 9 2320 363 10 3 8 OPERATION OF SPARE WHEEL AND TIRE ASSEMBLY CARRIER Con t 4 For M915A2 M917A1 and M917A1 w MCS support spare wheel and tire assembly 6 and remove wheel clamp plate 7 For M916A1 and M916A2 support spare wheel and tire assembly 6 and disengage D ring 4 on upper end of support strap 8 b Repeat steps 2 and 3 until spare wheel and tire assembly is lowered to ground b Install Spare Wheel and Tire Assembly on
40. 9 2320 363 10 CENTRAL TIRE INFLATION SYSTEM CTIS M917A1 AND 1 24 M917A1 W MCS Con t OPERATOR ELECTRONIC CONTROLS CONTROL UNIT PNEUMATIC CONTROL D UNIT SPEED SENSOR EXHAUST TO _ PRESSURE SWITCH 2 AIR LINES AIR VALVE 1 35 TM 9 2320 363 10 1 24 CENTRAL TIRE INFLATION SYSTEM CTIS M917A1 AND M917A1 W MCS Con t d Four terrain settings may be selected HIGHWAY HWY CROSS COUNTRY X C SAND EMERGENCY EMER and the RUN FLAT mode If tire damage is minimal e g a minor puncture or slow leak selecting RUN FLAT causes CTIS to monitor tire pressure every fifteen seconds and re inflate the tire e Tire pressure can be manually checked and air added to tires through a conventional air valve located at each wheel valve f Major components of the CTIS are COMPONENT FUNCTION Electronic Control Unit Contains microprocessor that controls the system and ECU Operator Selec operator selector panel tor Panel Pneumatic Control Unit Directs air pressure through air lines to the wheel valves according to ECU commands Air Dryer Separates moisture and filters impurities from compressed air system before air enters the CTIS Pressure Switch Acts as a brake priority switch by preventing CTIS from consuming air until the air brake system has a minimum of 85 psi 586 kPa of air Speed Sensor Mounted at transfer case
41. BEAM 5 00075 FORWARO REAR AXLE DIFF 5 000 5 REAR REAR AXLE DIFF 5 00075 FRONT AXLE DIFFERENTIAL 5 00075 FRONT AXLE SPRING 5 000 TRANSFER CASE 5 000 71E 10 000 FUEL FILTER PRIMARY 10 000 FUEL FILTER SECONDARY 10 000 TRANSFER CASE 20 000 A 1 oIL FILTER FUL FLOW 20 000 4 9 O1L FILTER BYPASS 20 00070 20 TRANSMISSION 20 000 21 TRANSMISSION FILTER 20 000 4 1 PWR STRG RESERVOIR 20 000 A 1 PwR STRG FILTER 20 0075 24 ROLLER JOURNALS AND BUSHINGS 20 000 5 25 DRIVELINE UNIVERSAL JOINT L SLIP YOKES AND SPLINE 75 000 26 WHEEL BEARINGS Val 75 000 4 27 FORWARD REAR AXLE OIL FILTER 75 000 4 12 FORWARO REAR AXLE DIFF 75 00074 12 REAR REAR AXLE DIFF 75 0004A 14 FRONT AXLE DIFFERENTIAL 75 00074 29 PULLEY FAN DRIVE L 75 000 4 5 TACH DRIVE ra NO LUBRICATION DATA 91741 A SS LUBRICATION KEY 0 GAA C CHECK QOE HDO LUBRICATING OIL INTERNAL COMBUSTION TACTICAL SERVICE F FILL MIL L 2104 D DRAIN GAA GREASE AUTOMOTIVE AND ARTILLERY HIL G 10924 GAA l LUBRICATE GO LUBRICATING DIL GEAR MULTIPURPOSE 0 2105 CH CHANGE B ITEM APPEARS ON BOTH SIDES OF TRUCK 50 1 INSPECT OC lt QN CONDITION GO B ADJUST SEE OPERATORS MANUAL FO DETAILS GC CL CLEAN OF AQE P 24 00641 000 NOTE TO VALIDATE WARRANTY INITIAL SERVICE HUST BE PERFORMED AT 5 000 MIL
42. Handle Air Horn Cable Door Opening Handle Door Window Glass Regulator Handle Door Lock Button 2 30 Push button and raise lever to unlock window Push out on handle to open window Pull handle in to close window Lower lever to lock window Pull cable to activate air horn Release cable to deactivate air horn Pull handle to open cab door Turn left handle clockwise to lower left window and counterclockwise to raise left window Turn right handle counterclockwise to lower right window and clockwise to raise right window Push button down to lock door To unlock either pull door opening handle or unlock from outside with ignition key TM 9 2320 363 10 2 8 ADDITIONAL CONTROLS AND INDICATORS Con t Control or Indicator 336 008 Function Transport Lock M917A1 and M917A1 w MCS Locks dump body to truck frame when dump truck is being transported Locked position is at six o clock Normally left at three o clock unlocked position Do NOT raise dump body if body transport lock indicator light on instrument panel indicates dump body is locked TM 5 3805 264 14 amp P Change1 2 31 TM 9 2320 363 10 2 8 ADDITIONAL CONTROLS AND INDICATORS Con t Control or Indicator Function Stroke Alert Indicator Bright orange band painted on service pushrod of All Except M915A2 all brake chambers When visible notify Unit and M916A1 Maintenance to perfor
43. M915A2 Pintle Towing Procedures PMCS Procedures Portable Fire Extinguisher Operate Power Take Off Operate All Except M915A2 Preparation for Movement Principles of Operation Air Conditioning All Except M915A2 and M916A1 ee unt ex tego PU e BrakeS sca ett ncque we XP CRT ie a Sa ds Central Tire Inflation System CTIS M917A1 and 917 1 5 Cooling Drive Trails seda bebe e baa au ap Tau ERAS uS Electrical 5 Exhaust System Fuel System Hydraulic System All Except M915A2 cri Rear Wheel and Tire Assembly Replacement 917 1 917 1 5 Refueling Reporting Equipment Improvement Recommendations EIRs Rifle Mounting Index 4 Transmission Paragraph 2 31 2 30 2 27 2 43 2 21 2 22 2 45 2 16 2 15 2 28 3 8 2 25 2 11 2 30 2 27 2 34 1 23 1 19 1 20 1 24 1 17 1 14 1 18 1 16 1 15 1 22 1 21 3 11 3 6 1 5 2 32 Page 2 116 2 114 2 109 2 134 2 98 2 100 2 136 2 88 2 87 2 110 8 21 2 107
44. M916A1 Con t f Turn fan switch 1 to 4 highest speed g As soon as cool air is flowing from dashboard outlets close win dows h Adjust temperature control lever 3 and fan switch 1 as required MAX A C VENT HEAT HEAT DEF DEF coo ww 4 2 30 OPERATE PORTABLE FIRE EXTINGUISHER WARNING Discharging large quantities of dry chemical fire extin guisher in the cab may result in temporary breathing dif ficulty during and immediately after the discharge event If at all possible discharge fire extinguisher from out side the cab Ventilate cab thoroughly prior to reentry NOTE This is a type B and C fire extinguisher Use on oil and electrical fires only a Remove fire extinguisher 3 from bracket 5 located between pas senger seat and shift tower b Hold fire extinguisher 3 upright Point nozzle 4 toward base of fire and pull safety pin 1 Squeeze lever 2 discharging chemical at base of fire Use side to side motion to spread chemical d After using fire extinguisher notify Unit Maintenance 2 114 Change 1 TM 9 2320 363 10 2 30 OPERATE PORTABLE FIRE EXTINGUISHER Con t 1 2 115 TM 9 2320 363 10 2 31 OPERATE LIGHTS NOTE If engine is not running ignition switch must be in ON position for lights to operate a Operate Beacon Warning Light 1 Move beacon light switch up to turn on beacon warning li
45. Modes are MAX A C VENT HEAT HEAT DEF and DEF b Vehicles without air conditioning Modes are VENT HEAT HEAT DEF and DEF Temperature Control Allows selection of a full range of temperatures Lever from COOL to WARM TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t e Indicator and Warning Lamps 44 45 46 47 48 49 50 44 FASTEN SEAT BELT Turn Signal Indicators Left right green light flashes whenever outside turn signal lights are flashing Both lights flash when four way flashers are on Engine Oil Warning Red light comes on and warning buzzer sounds Light when engine oil pressure is below 5 psi 34 kPa Check Engine CHK Yellow light comes on for approximately five ENG Light seconds when ignition switch is turned on Light stays on if there is an engine malfunction Engine Temperature Red light comes on and a warning buzzer sounds Warning Light when engine coolant temperature is above 225 F 107 C SHUT DOWN Light Red light comes on for approximately five seconds when ignition switch is turned on Light stays on when problems such as low oil pressure low cool ant or overheating occur in engine making it unsafe for further operation High Beam Indicator Green light comes on when high beam headlights Light are on AXLE LOCK Light Amber light comes on when interaxle differential lockout all wheel drive control valve lever is set to LOCK ENGAGE position or when transfer case selector
46. PRINT YOUR UNIT S COMPLETE ADORESS THEN JOT DOWN THE DOPE ABOUT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL o ANIA PREVIOUS EOITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR lt ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 AMSMC 103 85 FILL IK YOUR UNITS ADORESS DEPARTMENT OF THE ARMY I NO POSTAGE OFFICIAL BUSINESS NECESSARY IF MAILED IN THE UNITED STATES mw wasa BUSINESS REPLY MAIL AERA w FIRST CLASS PERMIT t2 ROCK ISLAND ww POSTAGE WILL BE PAJO BY ROCK ISLAND ARSENAL wr r wa war Director Armament and Chemical Acquisition and Logistics Activity ATTN AMSTA AC NML Rock Island IL 61201 9948 Q31vuO3H3d ONOW vat RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG wre mis FROM PRINT YOUR UNITS COMPLETE ADORESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL PUBLICATION NUMBER PUBLICATION TITLE TM La N De Operator s Manual ERO WHAT S WRONG PAINTED ORADE OR TITLE AMO TELEPHONE NUMBER PREVIOUS OITIONS 85 1 YOUR OUTFIT WANTS TO KNOW ABOUT YOUR DA 1 JUL 79 2028 2 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS
47. Pam 738 750 U S Army Equipment Index of Modification Work Orders DA Pam 750 10 A 3 FORMS Refer to DA Pam 738 750 The Army Maintenance Management System TAMMS for instructions on the use of maintenance forms Equipment Inspection and Maintenance Worksheet DA Form 2404 Product Quality Deficiency SF Form 368 Recommended Changes to Equipment Technical Publications DA Form 2028 2 Recommended Changes to Publications and Blank Forms DA Form 2028 A 4 FIELD MANUALS Basic Cold Weather 20 FM 31 70 Camoutlage de bred aded ed agente FM 5 20 Cold Weather Operations FM 9 207 Desert Operations u oi uiai e FM 90 3 Driver 0 00 21 300 First Aid Manual i tee ite et re FM 4 25 11 Manual for the Wheeled Vehicle FM 21 305 NBC Contamination Avoidance 2 2 a FM 3 3 Change 1 1 TM 9 2320 363 10 A 4 FIELD MANUALS Con t NBC Decontamination essent FM 3 5 NBC Protection au ns ree eee Ln ded inet Leste ib Dora E dv av FM 3 4 Northern Operations a FM 31 71 RIQQING euo neto Gye a dee dete i en a te a FM 5 725 Vehicle Recovery Oper
48. RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS OFFICIAL con PENALTY FOR PRIVATE USS 8300 REVERSE OF OA FORM 2039 2 POSTAGE AND FEES PAID DEPARTMENT OF THE ARMY O00 314 ATTN AMSTA AC NML Commander U S Army Tank automotive and Armaments Command Rock Island IL 61201 9948 vani 7 7707777007 SOMETHING WRONG wr ms THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT N SS OUT FOLD IT AND DROP IT IN THE MAIL TION DATE _ TM een 35558 30 Dec 97 Operator s Manual HAMM E 2028 2 PREVIOUS OITIONS P S YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 179 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 AMSMC OP 102 85 FILL IN YOUR UNITS ADDRESS DEPARTMENT OF THE ARMY Ea ARS NO POSTAGE OFFICIAL BUSINESS NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 82 POSTAGE WILL BE BY ROCK ISLAND ARSENAL ROCK ISLAND IL Director Armament and Chemical Acquisition and Logistics Activity ATTN AMSTA AC NML Rock Island IL 61201 9948 hl de O31vuO JH3d Yva RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG wire mus ruscicanov FROM
49. TOW eee We aca ean ce prier ue 123 Cage Brakes Operate in Extreme Operate in Extreme Operate Mud or Soft Surfaces asuy EET Operate in Sandy or Dusty Conditions Operate in Woods or On Rocky Terrain Operate on Snow Driving with a Damaged Tire 917 1 and M917A1 WIMGS sebo abd deed eae ee 2 140 pfe 6 OFT 1 1 ine 9 A A 2 40 Pu 9 h ER gt S ee Oyo 2 35 GENERAL WARNING These vehicles have been designed to operate safely and efficiently within the limits specified in this TM Operation beyond these limits is prohibited in accor dance with AR 70 1 without written approval from Commander U S Army Tank automotive and Arma ments Command ATTN AMSTA DSA CS Warren MI 48397 5000 a This section contains instructions for safely operating the M915 Family of Vehicles under unusual conditions In addition to normal preventive mainte nance special care must be taken to keep truck operational in extreme temperatures and other environmental conditions b Refer to FM 21 300 and FM 21 305 for additional
50. VIEW G M916A1 AND M916A2 WINCH RESERVOIR FILLER CAP SEE ier i POL D BREATHE SIGHT INDICATORS AOAP OIL SAMPLING VALVE VIEW H M916A1 AND M916A2 FIFTH WHEEL SLIDING RAILS GREASE FITTINGS AND LOCKING BOTH SIDES PLUNGERS LOCK SHAFT PLUNGER FIFTH WHEEL JAWS CLEAN AND COAT LIGHTLY 7 JAW PINS ROCKER SHAFT CLEAN AND COAT LIGHTLY LATERAL SHAFT FROM UNDEBNEATH F 13 TM 9 2320 363 10 VIEW I CAB DOOR OIL CAN POINTS VIEW J SEATS OIL CAN POINTS TM 9 2320 363 10 VIEW K SPARE WHEEL AND TIRE CARRIER OiL CAN OIL CAN POINTS POINTS TUR ol SSRI J CY NCM U Y TI M915A2 OIL CAN POINTS M917A1 AND M917A1 WIMCS F 15 TM 9 2320 363 10 1 M915A2 FRONT AXLE WHEEL BEARINGS Daily check that level of gear lubricating oil is visible in sight glass If oil is not visible remove rub ber plug and add GO until level is even with plug opening Install rubber plug 2 POWER STEERING RESER VOIR Daily with engine running and fluid at operating temperature remove dipstick from reservoir and check level of lubricating oil on dipstick Add OE HDO to bring level above the ADD mark on dipstick 3 FIFTH WHEEL ALL EXCEPT M917A1 AND 917 1 W MCS Dry cleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid con tact with skin eyes and clothes
51. Wipe all washed areas dry 3 6 REFUELING Fuel tank cap may become hot during vehicle opera tion Use hand protection when removing fuel cap DO NOT smoke or permit any open flame in area of truck while you are servicing diesel fuel system Be sure hose nozzle is grounded against filler tube dur ing refueling to prevent static electricity Failure to follow this warning may result tin injury to person nel or equipment damage Place portable fire extinguisher within reach prior to refueling DO NOT overfill fuel tank f fuel starts foaming from fuel tank stop immedi ately to avoid fuel spillage Failure to follow this warning could result in injury to personnel Shut down engine paragraph 2 20 Wipe off dirt on and around fuel filler cap 1 Remove filler cap 1 by rotating cap counterclockwise Fill tank 2 to holes approximately 3 in 7 6 cm in filler neck p Install filler cap 1 by rotating cap clockwise as far as it will go TM 9 2320 363 10 3 6 REFUELING Con t 3 7 MANUAL TIRE INFLATION a Remove pneumatic hose 1 with gauge from BII storage box b rear of vehicle Start paragraph 2 14 and push ON trailer air supply control valve 3 19 TM 9 2320 363 10 3 7 MANUAL TIRE INFLATION Con t NOTE For M917A1 and M917A1 w MCS valve stem is located on CTIS wheel valve d Remove valve stem cap
52. and unlocks driveline based on changing driving conditions a LOCK In poortraction conditions stop vehicle and place lever in LOCK position to lock up driveline b UNLOCK When conditions are back to normal move left to UNLOCK while vehicle is moving TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t C Lower Control Panel lt M915A2 AND ALL EXCEPT M916A1 M915A2 AND M916A1 Ignition Switch Operates gages switches sending units instru ment panel lights and engine start Turn key in switch to right for ON position Turn key fully counterclockwise to activate accessories Turn key to center vertical position to turn all systems OFF Engine Start Button Press to energize starter solenoid Release button as soon as engine starts Utility Light Switch All ON OFF toggle switch controls utility lights Except M917A1 and mounted on back of cab Up position is ON Down 917 1 w MCS is OFF Ether Quick Start Press and release button to manually inject ether Button for starting in cold weather Button is removed on vehicles with automatic ether injection systems Panel Lights Control Brightens or dims instrument panel lights Turn Knob clockwise to brighten and counterclockwise to dim Turn fully counterclockwise to shut off panel lights TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t pens Bar a pana 9 0909 M915A2 AND ALL EXCEPT M916A1 M915A2 AND M916A1
53. b Slide mode control lever 2 to desired position C Slide temperature control lever 3 to desired temperature range d Rotate fan switch 1 to adjust fan speed from slower to faster as desired e Press FRESH RECIRC air button 4 to desired setting 2 34 PREPARATION FOR MOVEMENT WARNING Lifting cables chains hooks and slings used for lifting truck must be in good condition and of suit able capacity Failure to follow this warning may result in injury or death to personnel and damage to equipment Improper use of lifting equipment and improper attachment of cables to vehicle can result in serious personnel injury and equipment damage Observe all standard rules of safety a For M917A1 and M917A1 w MCS place transport lock 1 in LOCKED position b To lift vehicle attach suitable lifting device to lifting shackles Lift vehicle slowly and have observers watch for any signs of cable failure unusual load shifts and obstructions During transport secure vehicle by attaching cables to tiedown points 2 118 Change 1 TM 9 2320 363 10 2 34 PREPARATION FOR MOVEMENT Con t 336 008 Change 1 2 119 2 120 Blank TM 9 2320 363 10 Section IV OPERATION UNDER UNUSUAL CONDITIONS Paragraph Page Number Paragraph Number Number 35 General 121 Slave Start TRUCK urere ret rete ec e
54. d Uu HYDRAULIC CONTROL VALVES 1 33 TM 9 2320 363 10 1 23 AIR CONDITIONING SYSTEM ALL EXCEPT M915A2 AND M916A1 a The air conditioning unit is part of the heater and is mounted under the glove compartment It is a single unit consisting of heater core air conditioning evaporator coil blower motor control valves and air ducts b The system is turned on by the mode control lever and the four speed blower switch which also controls flow rate C An even cab temperature is maintained by controlling the coolant flow through the heater core or refrigerant flow through the evaporator coil BLOWER SWITCH MODE CONTROL LEVER TEMPERATURE CONTROL LEVER 1 24 CENTRAL TIRE INFLATION SYSTEM CTIS M917A1 AND M917A1 W MCS a The operator uses CTIS to regulate tire pressure at all wheels This allows operation of the dump truck on all road surfaces and across a wide variety of terrain including off road when the vehicle is stuck due to extreme conditions ice snow mud and when a tire has a slow leak due to a minor puncture or other dam age b CTIS uses air from the vehicle air system paragraph 1 19 Air is routed to the wheels via a dedicated pneumatic system plumbed from the vehicle s wet tank C An Electronic Control Unit ECU is mounted to the shift tower inside the cab An operator selector panel is built into the ECU allowing operator entry of System commands instructions 1 34 TM
55. e For M916A1 and M916A2 when coupling to M870 semitrailer pay out winch cable paragraph 2 28 and attach to gooseneck on trailer Release vehicle parking brake to allow vehicle to be pulled back under trailer until king pin locks into fifth wheel Disconnect and stow winch cable paragraph 2 25 NOTE One 12 volt light cable and one 24 volt light cable are stored in tool box f Connect air hoses and light cables Push trailer air supply control knob paragraph 2 2 IN open trailer supply valve and set trailer control valve hand brake Backing SLOWLY helps to prevent hitting too hard in coupling and damaging king pin g Back up slowly until fifth wheel locks firmly to king pin h Check king pin connection and fifth wheel slide locks by pulling trac tor gently forward against locked trailer brakes or blocked wheels As resistance is felt put transmission selector lever in reverse and gently back tractor to verify fifth wheel slide locks in both directions When resistance is felt put transmission selector lever in Neutral N and set parking brake i Verify that lock release handles are in j Check semitrailer lights k Stow wheel blocks l Lift and secure semitrailer landing gear and stow float pads 2 104 TM 9 2320 363 10 2 24 UNCOUPLE FROM TRUCK ALL EXCEPT M917A1 AND M917A1 W MCS gear e 5 p Use caution when uncoupling from truck BE ALERT for personnel in area Ensure that
56. hands arms and body are clear of potential pinch points Failure to follow this warning may result in injury to personnel NOTE Truck and trailer must be aligned Use ground guide if one is available Stop truck and trailer Shift transmission into Park P paragraph 2 15 Block wheels as required Pull trailer air supply valve OUT Apply parking brake paragraph 2 2 Place float pads under semitrailer landing gear and lower landing Set trailer hand brake control valve and close trailer air supply valve Disconnect and stow trailer air supply lines and intervehicular cable 2 105 TM 9 2320 363 10 2 24 UNCOUPLE FROM TRUCK ALL EXCEPT M917A1 AND M917A1 W MCS Con t NOTE Steps i through m apply to M915A2 Pull secondary lock release handle 4 out and lift to engage catch j Pull primary lock release handle 3 out k Release parking brake and slowly pull forward until trailer clears fifth wheel l Stop and set parking brake m Pull trailer air supply valve OUT and disconnect and secure trailer air hoses and cables NOTE Steps n through q apply to M916A1 and M916A2 n Pull secondary lock release handle 1 out and raise to engage hooks on fifth wheel housing 0 Pull primary lock release handle 2 out and hook on fifth wheel housing Secure trailer with winch cable paragraph 2 28 to prevent trailer from pushing tractor from beneath it q Slowly pull truck forward until semitraile
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58. hydraulic controls lines and ponents are loose tern fittings for looseness leaks or leaking or damaged M916A1 signs of other damage and M916A2 Monthly Spare a Check spare wheel and tire a Spare tire is miss Wheel for cuts gouges cracks or ing or damaged and Tire uneven wear and Vehicle Tires b Check for secure mounting of spare wheel and tire c Check all vehicle tires for c Any tire is missing cuts gouges cracks or or damaged uneven wear Monthly Radiator Remove dirt and debris from Ail Mod cooling fins els and Con denser All Except M915A2 and M916A1 Monthly Air Con Check air conditioner opera ditioner tion Operate for at least five Ail minutes to help prevent drying Except and cracking of tubing seals M915A2 and reduce refrigerant leaks in and the system M916A1 2 80 TM 9 2320 363 10 Section OPERATION UNDER USUAL CONDITIONS Paragraph Page Number Paragraph Number Number m General ee Deis ad bw Gr Dok de a ac RO a aC ER ewes Initial Adjustments Daily Checks and Self Tests Start Operate no no AAS Operate Transfer Case All Except M915A2 Operate CTIS M917A1 917 1 w MCS 2 18 Driving DPS sees emen Ea 2 19 Driving iex
59. in rack teeth 6 If lowered raise landing gear to fully retracted position M870 LOAD HAUL M172 2 101 TM 9 2328 363 10 2 23 COUPLE TO TRUCK ALL EXCEPT M917A1 AND M917A1 W MCS Do not use trailer handbrake as primary brake to keep tension on coupling system This will cause undue tension on brakes and coupling which could result in injury to personnel or damage to equip ment Prevent problems with slack in fifth wheel by using good braking habits and adjusting coupling and braking systems properly DO NOT tow 6 000 gallon water distributors with a partial load except when in use on construction sites and a maximum speed of 10 mph When towing outside of construction sites TRAILERS MUST BE EMPTY OR FULL Either drain water distributor empty preferred or fill to capacity MAXIMUM SPEEDS FOR BOTH TRAILERS ARE HIGHWAY 55 MPH GRAVEL DIRT 30 MPH OFF ROAD 5 MPH Failure to follow this warning could result in unsafe driving conditions causing serious injury or death to personnel and damage to equipment When towing model WD6S 6 000 gallon water dis tributor fifth wheel must be in rear setting LOAD HAUL M172 For model 60PRS fifth wheel must be at rear setting LOAD HAUL M172 to load and front setting HAUL M870 to tow For all models travel lockout must be engaged to prevent side to side oscillation of water distributor Failure to follow this warning could result in unsafe driving condi
60. in vehicle ensure there is adequate clearance at maximum upward travel of seat Adjust seat paragraph 2 5 Adjust seat belt paragraph 2 13 Turn on lights as necessary paragraph 2 2 Select transmission gear paragraph 2 15 Select transfer case position paragraph 2 16 For M917A1 and M917A1 w MCS select CTIS setting paragraph 2 Q 2 96 TM 9 2320 363 10 2 19 DRIVING Con t l m n 18 ABS warning light blinks when interaxle lockout all wheel drive is engaged 0 B Move truck gradually by depressing accelerator Ensure ABS indicator light goes off after 4 mph 6 kph is exceeded NOTE During long engine idling periods engine coolant tem perature will fall below normal operating range The incomplete combustion of fuel in a cold engine will cause crankcase dilution formation of lacquer or gummy deposits on valves pistons and rings and rapid accumulation of engine sludge Avoid unnecessary engine idling CAUTION Care must be exercised if tractor or trailer ABS light comes on while driving possibly indicating an ABS mal function Although the regular normal vehicle system is still fully operational you should continue in a safe manner and reduce speed to 40 mph 64 kph until the mission is complete When the mission is complete report to Unit Maintenance to clear the ABS fault and restore full ABS capabilities NOTE If during operation
61. in death or serious injury to personnel a Eyes Flush with cold water for no less than 15 minutes and seek medical attention immediately b Skin Flush with large amounts of cold water until all acid Is removed Seek medical attention as required c Internal If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magnesia beaten egg or vegetable oil Seek medical attention immediately d Clothing Equipment Wash area with large amounts of cold water Neutralize acid with baking soda or household ammonia Unfasten two latches 3 and slide battery box cover 2 outboard 4 TM 9 2320 363 10 3 12 BATTERY BOX COVER REPLACEMENT Con t b Slide battery box cover 2 on battery box 4 with step 1 outboard and fasten two latches 3 1 3 39 3 40 Blank TM 9 2320 363 10 APPENDIX A REFERENCES A 1 SCOPE This appendix lists all forms field manuals technical manuals and other publications referenced in this manual and which apply to the operation of the M915 Family of Vehicles A 2 PUBLICATION INDEXES The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to material covered in this technical man ual Consolidated Index of Army Publications and Blank Forms DA Pam 25 30 Functional User s Manual for the Army Maintenance Management DA
62. information 2 121 TM 9 2320 363 10 2 36 SLAVE START TRUCK WARNING When slave starting truck use NATO slave cables that DO NOT have loose or missing insulation DO NOT proceed if suitable cables are not available DONOT use civilian type jumper cables Failure to follow this warning could result in injury CAUTION If dead truck s engine does not start within 30 sec onds release engine start button Wait three to five minutes before repeating procedure to prevent over heating the starter and damaging batteries of live vehicle If engine does not start after several attempts Unit Maintenance must perform additional maintenance Under no circumstances can the truck be started by being towed or pushed Failure to follow this caution will cause damage to transmission NOTE Before slave starting ensure that checks have been made to determine whether problem is low or dead battery If vehicle other than another M915 family vehicle is used to slave start truck refer to Operator s Manual for that vehicle for any special slave starting proce dures a Normal Slave Starting 1 Connect NATO slave cable to receptacle 1 on dead vehi cle 2 Connect other end of NATO slave cable to receptacle on live vehicle 3 Start engine of live vehicle and run at 1000 rpm for 15 20 minutes Stop engine and remove NATO slave cable from receptacle
63. kph hand engine speed rpm hand and distance traveled odometer Other two hands are clock hands With a tachograph disk installed data is recorded on a seven day graph for a permanent record Engages and disengages front driving axle based on changing driving conditions a ENGAGE In poor traction conditions stop vehicle and move lever to left position to lock up driveline and engage front driving axle b DISENGAGE When conditions are back to normal move lever to right position and let up on accelerator to disengage Unlocks and locks dump body tailgate TM 5 3805 264 14 amp P Indicates when PTO is turned on Positions are ON and OFF Engages PTO PTO will not operate unless main light switch is in SER DRIVE or STOP LIGHT position M917A1 and M917A1 w MCS Yellow diamond shaped knob operates parking brake valve Pull out to apply and push in to release parking brake Change 1 2 11 TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t 2 12 27 28 M915A2 27 916 1 ALL EXCEPT M915A2 AND M916A1 Control or Indicator Trailer Air Supply Control Interaxle Lockout Control Valve Lever M915A2 Function Red octagonal shaped knob supplies air to trailer air reservoirs Push in to charge trailer air supply and release trailer spring brakes Pull out to shut off air supply Locks
64. of fuel in fuel tank when ignition switch is turned on Indicates oil temperature in transfer case a GREEN BAND Range of 100 275 F 38 135 C is normal b YELLOW BAND Range of 275 300 F 135 149 indicates oil temperature is too high and gage must be closely monitored c RED BAND Above 300 F 149 C Disengage all wheel drive and perform troubleshooting Registers engine speed in rom Maximum gov erned speed is 2100 rpm Idle speed is 600 rpm Registers vehicle ground speed in mph kph speedometer and distance traveled seven digit odometer in miles TM 9 2320 363 10 2 2 2 6 INSTRUMENT PANEL Con t 3 Right Gage Panel Transmission Oil Temperature Gage All Except M915A2 and M916A1 Air Cleaner Restriction Indicator Gage All Except M915A2 and M916A1 Fuel Gage All Except M915A2 and M916A1 Indicates oil temperature in transmission Normal range in green band is 100 299 F 38 148 C If needle goes into yellow band 300 324 F 149 162 C or red band 325 F 163 C or above stop and investigate cause Indicates air cleaner air flow is adequate if gage is clear If restricted indicator window will show up to 20 inches of water Push yellow reset button to reset after air cleaner has been serviced Indicates amount of fuel in fuel tank when ignition switch is turned on TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t 11 Transfer Case Oil Indicates
65. oil temperature in transfer case Temperature Gage a GREEN BAND Range of 100 275 F 38 All Except M915A2 135 C is normal and M916A1 b YELLOW BAND Range of 275 300 F 135 149 C indicates oil temperature is too high and gage must be closely monitored c RED BAND Above 300 F 149 C Disengage all wheel drive and perform troubleshooting Primary Air Pressure Registers air pressure in psi in rear brake sys Gage tern Normal operating range is 90 120 psi 621 827 kPa Secondary Air Registers air pressure in psi in front brake sys Pressure Gage tern Normal operating range is 90 120 psi 621 827 kPa Main Light Switch Five position switch To engage mechanical M915A2 and switch must be held in UNLOCK position up M916A1 Switch positions are a BO DRIVE Same as BO MARKER position but blackout drive light and trailer circuit will also function BO MARKER Blackout marker tail lights and blackout stop lights will function No other lights or electrical horn will function OFF No lights or electrical horn will function STOP LIGHT Electrical horn and all separately controlled lights will function except blackout stop lights No marker tail lights or drive headlights will function SER DRIVE Same as STOP LIGHT position but headlight and non blackout marker tail lights will function 2 7 TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t 89 y lo M915A2 AND M916A1 Mechanical S
66. panel 2 26 MUD FLAP STOWAGE ALL EXCEPT M917A1 AND M917A1 W MCS If towing M172 or M672 trailer rear mud flaps must be removed and stowed in brackets Failure to follow this caution may result in equipment damage 8 Remove lock pin 1 b Pull up on mud flap 3 and remove Tap spring upward with hammer as required Place mud flap 3 stowage bracket 2 and insert lock 1 d When towing operations are complete remove lock pin 1 and mud flap 3 from stowage bracket 2 e Position mud flap 3 on vehicle and install lock pin 1 2 108 TM 9 2320 363 10 2 26 MUD FLAP STOWAGE ALL EXCEPT M917A1 AND M917A1 W MCS Con t F M916A1 AND M916A2 2 27 OPERATE POWER TAKE OFF PTO ALL EXCEPT M915A2 a Engage PTO CAUTION Do not shift transmission with PTO engaged Gears stop during shifting which could cause excessive loading of PTO 1 Place transmission selector lever in neutral N 2 Operate engine at low idle and set parking brake 3 On M917A1 and M917A1 w MCS place main light switch in STOP LIGHT or SER DRIVE position 4 Place PTO switch in ON position PTO indicator light should come on 2 109 TM 9 2320 363 10 2 27 OPERATE POWER TAKE OFF PTO ALL EXCEPT M915A2 Con t 5 On M916A1 and M916A2 operate winch paragraph 2 28 6 On M917A1 and M917A1 w MCS operate hydraulic control lever TM 5 3805 264 14 amp P b Shut Down
67. reduce MPH indicator light will come on Vehicle speed should be reduced at this time 4 Press X C Cross Country mode key to operate on non paved secondary roads and unimproved surfaces Do not exceed 40 mph 64 kph or reduce MPH indicator light will come on Vehicle speed should be reduced at this time If overspeed is exceeded for more than one minute CTIS will automatically inflate to highway setting 5 Press SAND mode key to operate in sand snow and mud Do not exceed 25 mph 40 kph or reduce MPH indicator light will come on Vehicle speed should be reduced at this time If overspeed is exceeded for more than one minute CTIS will automatically inflate to cross country setting When resuming operation on highway surfaces be sure to reset CTIS selector panel to higher tire pressures Operating vehicle with underinflated tires will cause pre mature tire wear or damage to tires causing unsafe driv ing conditions Failure to follow this warning may result in death or injury to personnel 6 Reset CTIS to higher tire pressures as required 2 92 TM 9 2320 363 10 2 18 DRIVING TIPS BE ALERT for personnel in area while operating truck Always check to ensure area is clear of personnel and obstructions before moving out Failure to follow this warning may result in serious injury or death to person nel Governed speed is 2100 rpm If engine is allowed to exceed governed speed serious engine or transmission damage may
68. side of vehicle are right hand threads turn left to loosen turn right to tighten If replacing inner rear tire loosen both outer and inner wheel nuts 9 Loosen but do not remove wheel nuts 3 33 TM 9 2320 363 10 3 11 REAR WHEEL AND TIRE ASSEMBLY REPLACEMENT M917A1 AND M917A1 W MCS Con t Hydraulic jack is intended only for lifting truck not for supporting vehicle to perform maintenance Do not get under truck after it is raised unless it is properly sup ported with blocks or jackstands Failure to observe this warning may result in death or injury to personnel 10 Raise jack until tires clear ground Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improperly lifted or if it falls on you 11 Remove outer tire wheel nuts and wheel and tire assembly 12 If replacing inner rear tire remove spacer wheel nuts and wheel and tire assembly Remove hose 15 from valve stem 18 b Install Rear Wheel and Tire Assembly 1 Obtain a deflated replacement wheel and tire assembly ensuring valve stem cap and valve stem core are removed 3 34 TM 9 2320 363 10 3 11 REAR WHEEL AND TIRE ASSEMBLY REPLACEMENT 917 1 AND 917 1 W MCS Con t 2 If replacing inner tire connect hose 15 to inner wheel valve stem 18 3 Rotate wheel hub 20 until hub air port 5 is at 12 o clock position Use caution when lifting or handlin
69. switch 2 in ON position AUX HTR light 1 will light when heater burner is lit NOTE If Hi LO switch is set to HI position heater will automati cally switch to low heat when temperature of coolant at heater inlet reaches 160 F LO position is suitable when heater operates over an extended period 2 Place HI LO switch 3 to desired setting 3 To turn heater off place AUX HTR switch 2 to OFF position Heater burner will stop and AUX HTR light will go out within a few minutes but blower will continue to run for approximately one minute C Operate Arctic Swing Fire Heater Kit 1 Check fuel level in heater 7 Add fuel as required 2 Check air shutoff valve by pushing pressure pin 10 Pres sure pin is spring loaded and must bounce back 3 Loosen wing nut 9 fully and check gasket for proper posi tion 4 Push heater 7 in heat exchanger 8 and tighten wingnut 9 2 128 TM 9 2320 363 10 2 39 OPERATE IN EXTREME COLD Con t Battery voltage must be the same as voltage indicated on heater hand pump lever Incorrect voltage may cause damage to equipment 5 Connect cable 11 to connector 12 and batteries 6 Close fuel regulator 6 7 Squeeze ignition switch 4 on pump lever 5 and actuate pump 8 After three or four strokes open fuel regulator 6 1 2 to 1 turn while continuing to pump 9 Adjust fuel regulator 6 until pulsating sounds come in equal intervals St
70. v d I m m m jm z z Z Z gt gt TABLE CONTENTS Page 1 1 General 1 1 Equipment Description and 1 5 Principles of Operation 1 25 OPERATING INSTRUCTIONS 2 1 Description and Use of Operator s Controls and IBdiGal0rS u ua 2 1 Preventive Maintenance Checks and Services PMCS 2 33 Operation Under Usual Conditions 2 81 Operation Under Unusual Conditions 2 121 OPERATOR 222 3 1 Lubrication Instructions 3 1 Operator Troubleshooting Procedures 3 3 Operator 3 17 REFERENGES tete dr Exit nata COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS B 1 ADDITIONAL AUTHORIZATION LIST C 1 EXPENDABLE AND DURABLE ITEMS LIST D 1 STOWAGE AND DECAL DATA PLATE AND STENCIL a E 1 LUBRICATION INSTRUCTIONS F 1 INDEX Index 1 TM 9 2320 363 10 HOW TO USE THIS MANUAL T
71. yards 91 4 m Be alert for signs that tires may have flat spots or that one or more brake shoes may be frozen and require preheating Notify Unit Maintenance as required 5 Parking a If vehicle will be parked for a short period park in a shel tered area out of wind If shelter is not available park vehicle so it does not face into the wind b If vehicle will be parked for a long shutdown period try to park on high ground and use planks or brush to make a raised and relatively dry surface Keep tires out of snow water ice and mud if possible c Clean snow ice and mud from vehicle as soon as pos sible after shutdown d lf vehicle will be parked for a long period of time have Unit Maintenance remove and store batteries Fill fuel tank to guard against conden sation and drain any accumulated water from air reservoirs and fuel filters e Ensure tires are properly inflated 2 127 TM 9 2329 363 10 2 39 OPERATE IN EXTREME COLD Con t f Have Unit Maintenance check and service cooling sys tem to ensure truck is adequately protected against extreme cold Ensure transmis sion is in NEUTRAL N position and vehicle tires are blocked b Operate Artic Personnel Heater Kit NOTE Auxiliary heater AUX HTR indicator light illuminates only when burner is lit Indicator light turns on and off automatically Initial time required for indicator light to light depends on outside temperature 1 Place AUX HTR
72. 1 2 Ton M871 MS 7141 iiie e TM 9 2330 359 14 amp P Operator s Unit Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Semitrailer Tank Fuel 7500 Gallon M1062 ee en t teo o ricette aur TM 9 2330 384 14 amp P TM 9 2320 363 10 A 5 TECHNICAL MANUALS Con t Operator s Unit Direct Support and General Support Maintenance Manual with RPSTL for 6 000 Gallon Semitrailer Water Distributor Model WD6S TM 5 3825 225 14 amp P Operator s Unit Direct Support and General Support Maintenance Manual with RPSTL for 6 000 Gallon Water Distributor Model 60 PRS TM 5 3825 255 14 amp P Principles of Automotive TM 9 8000 A 6 TECHNICAL BULLETINS Rust Proofing Procedures for Truck Utility TB 43 0213 inu ein 9 2320 363 15 A 7 OTHER PUBLICATIONS Abbreviations and Acronyms sseeee ASME Y14 38 1999 Army Medical Department Expendable Durable Items CTA 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic CTA 50 970 Prevention of Motor Vehicle Accidents
73. 19207 5213744 5120 00 293 3336 Shovel Hand Rd Pt D Hdl Short Size 2 19207 11655784 2540 01 267 2912 Tow Bar Medium Duty 19207 12322663 C 3 C 4 Blank TM 9 2320 363 10 APPENDIX D EXPENDABLE AND DURABLE ITEMS LIST Section 1 INTRODUCTION D 1 SCOPE This appendix lists expendable and durable items you will need to operate and maintain the M915 Family of Vehicles This listing is for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items D 2 EXPLANATION OF COLUMNS a Column 1 Item Number This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the item e g Use dry cleaning solvent Item 17 Appendix D b Column 2 Level This column identifies the lowest level of main tenance that requires the listed item C Operator Crew C Column 3 National Stock Number This is the National Stock Number assigned to the item which you can use to requisition it d Column 4 Item Name Description Commercial and Govern ment Entity Code and Part Number This provides the other information you need to identify the item e Column 5 Unit of Measure U M Unit of Issue U I This col umn shows the physical m
74. 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t mr ec Not Fully Mission Interval Service Procedure Capable If Engine To ensure an accurate reading vehicle must be parked on level ground Wait 10 minutes after shutting down engine to allow oil to drain into crankcase Remove dipstick 60 and check level of lubricating oil Safe operating level is between ADD and FULL marks on dipstick If level is low add oil through filler open ing 59 until level on dipstick is correct Appendix F TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Not Fully Mission Interval Check Procedure Capable If 43 After Radiator DO NOT remove radiator cap unless engine is cold Remove cap in two steps First place thick cloth over cap and slowly turn cap left to first stop Pause and allow pressure to escape Turn cap further left until it can be removed This is a pressurized cooling system and escap ing steam hot water or coolant will cause serious burns Remove radiator cap 61 and check coolant level in radiator 62 Coolant must be within 21 6 4 cm below filler neck Add coolant as required 2 63 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Interval Check Service Not Fully Mis
75. 2 12 thru 2 30 2 31 2 32 thru 2 80 2 81 2 82 thru 2 96 2 97 2 97 0 and 2 97 1 2 98 thru 2 117 2 118 thru 2 119 2 120 Blank 0frt O 0 O 4 2 121 2 122 2 123 thru 2 137 2 138 2 139 and 2 140 3 1 thru 3 27 3 28 3 29 thru 3 31 3 32 3 33 thru 3 39 3 40 Blank A 1 A 2 A 3 A 4 Blank B 1 and B 2 Zero in this column indicates an original page or work package A TM 9 2320 363 10 Page Change No No B 3 and B 4 B 5 B 6 thru B 8 C 1 C 2 C 3 C 4 Blank D 1 thru D 5 D 6 Blank E 1 thru E 3 E 4 E 4 1 E 4 2 Blank E 5 thru E 9 E 10 Blank F 1 thru F 17 F 18 Blank Index 1 Index 2 Index 3 and Index 4 Index 5 Index 6 Blank Authentication Page Back Blank Sample DA Form 2028 2 Blank DA Form 2028 2 Blank Back Cover Back Cover PIN Number O O O O O O O O O O O O O Zero in this column indicates an original page or work package TM 9 2320 363 10 TECHNICAL MANUAL HEADQUARTERS TM 9 2320 363 10 DEPARTMENT OF THE ARMY Washington D C 30 December 1997 OPERATOR S MANUAL FOR TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A2 NSN 2320 01 272 5029 EIC B4E TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A1 NSN 2320 01 272 5028 EIC B4F TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A2 NSN 2320 01 431 1163 E
76. 2 122 Change 1 TM 9 2320 363 10 2 36 SLAVE START TRUCK Con t 4 Start engine of dead vehicle paragraph 2 14 If engine will not start Notify Unit Maintenance b Emergency Slave Starting 1 Connect NATO slave cable to receptacle 1 on dead vehi cle 2 Connect other end of NATO slave cable to receptacle on ive vehicle 3 Start engine of live vehicle and run at 700 rpm 4 Start engine of dead vehicle paragraph 2 14 and allow both vehicles to idle for five to ten minutes If engine will not start notify Unit Mainte nance 5 Remove NATO slave cable from receptacle on live vehicle 6 Remove NATO slave cable from receptacle 1 on dead vehicle 2 37 TOW TRUCK a General 1 Notify Unit Maintenance to send tow vehicle TM 9 2320 363 20 and tools required to remove propeller shafts 2 Refer to FM 21 305 for general guidelines on vehicle recov ery and use of warning kits and signals Refer to FM 21 305 and FM 20 22 for addi tional information 2 123 TM 9 2320 363 10 2 37 TOW TRUCK 3 When towing vehicle with front axle and rear tandem on ground ensure that interaxle lockout all wheel drive control valve switch is in UNLOCK DISENGAGE position Ensure that universal joint on rear of propeller shaft at the input to the forward rear axle is disconnected and tied up to vehicle undercarriage 4 When front axle of vehicle being tow
77. 3 STEERING WHEEL AND COLUMN MOUNTED CONTROLS Turn Signal Lever Electric Horn Steering Wheel Trailer Brake Hand Control Valve Lever Hazard Signal Switch Headlight Dimmer Switch 2 20 Move lever forward for right turn signal rearward for left turn signal and center for off Push to activate Used instead of air horn in normal city driving Turn clockwise to turn vehicle right and counterclockwise to turn vehicle left Spring loaded lever when pulled rearward activates trailer brakes Located under the turn signal Move switch out left to activate hazard lights Move turn signal lever forward or rearward to deactivate hazard lights On vehicles with serial numbers 6R 170696 and below push button at end of turn signal lever to turn on high beams Push button a second time to turn high beams off On vehicles with serial numbers 6R 170697 and above lift end of turn signal lever to turn on high beams Lift lever again to turn high beams off TM 9 2320 363 10 2 4 CAB FLOOR MOUNTED CONTROLS f pod Control or Indicator Function Accelerator Pedal Depress to increase engine speed Release to decrease engine speed Brake Pedal Depress to apply service brakes on truck and if properly coupled to a trailer trailer service brakes Release to release service brakes TM 9 2320 363 10 2 4 CAB FLOOR MOUNTED CONTROLS Con t 3 M915A2 AND M916A1 M917A1 AND M917A1 W MCS
78. 320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION DRIVELINE LOCKING SYSTEM 8 DRIVELINE WILL NOT DISENGAGE INDICATOR LIGHT STAYS ON WHEN INTERAXLE LOCKOUT ALL WHEEL DRIVE CONTROL VALVE IS MOVED TO UNLOCK DISENGAGE POSITION Step 1 Ensure system has had enough time to disengage Leave interaxle lockout all wheel drive in UNLOCKED DISENGAGE position and wait for light to go off Step 2 If indicator light remains on excessive driveline windup have occurred Back truck up slowly and check if indicator light goes off If indicator light remains on notify Unit Maintenance ELECTRICAL SYSTEM 9 ONE OR MORE LIGHTING SYSTEMS NOT WORKING Step 1 Check position of switch es If vehicle is coupled to semitrailer and problem is with semitrailer lighting system check interve hicular cable connection Place switch es in ON position and blackout light switch to NORMAL position Connect intervehicular cable Step 2 Perform semitrailer troubleshooting ENGINE 10 ENGINE COOLANT TEMPERATURE GAGE INDICATES ENGINE IS OVER HEATING DO NOT remove radiator cap unless engine is cold Remove radiator cap in two steps First place a thick cloth over cap and slowly turn cap left to first stop Pause and allow pressure to escape Turn cap further left until it can be removed This is a pressurized cool ing system and escaping steam hot water or coolant will cause seri
79. 7 NOMENCLATURE CROSS REFERENCE LIST Common Name Official Nomenclature Sable esit bete Wire Rope Cold Start Ether Quick Start System Differential Lock Unlock Interaxle Lockout M915A2 All Wheel Drive All Except M915A2 Engine Coolant Antifreeze Ethylene Glycol Mixture ater urea x ark ages dow beads Quick Disconnect Coupling Jake wit oy secede te T AAA OE ae has Engine Brake LOC Sup y MD Seat Belt Adjustment No SplnB ee Automatic Locking Positive Traction Differential 1 8 LIST OF ABBREVIATIONS NOTE Refer to ASME Y14 38 1999 for standard abbreviations Abbreviation Definition AAE 22 AL tits papu Additional Authorization List ABS rd teta palu NER RUE Anti Lock Brake System 22 aa u nt tee Dac utet Basic Issue Items soweit o RA ah d idt Sapa DE ast detur Centigrade or Celsius Change 1 1 3 TM 9 2320 363 10 1 8 LIST OF ABBREVIATIONS Con t Abbreviation Definition CID eii toe eh ss grt ha mel POR Cubic Inch Displacement CIV Ai ok pe EE Qich vi e eae e e act e ris iex Me bag Rte Centimeter gat e Components of End Item C TIS factos Central Tire Inflation System ECU ned e ele Sains Electronic Control Unit
80. AND Run engine for one minute at 1000 rpm to charge the system Idle engine until transmission reaches 60 120 F 16 49 C With engine idling and transmission in Neutral N remove dipstick from oil filler tube and check oil level Oil registering in the COLD RUN band indicates a sufficient quantity of oil to safely operate the transmission until temperature reaches 160 200 F 71 93 C When temperature reaches 160 200 F 71 93 C a hot oil check must be performed HOT OIL CHECK HOT RUN BAND Be sure temperature has reached 160 200 F 71 93 C With engine idling and transmission in Neutral N remove dipstick from oil filler tube and check oil level If oil registers in the HOT RUN band quantity of oil in transmission is safe for operating the vehicle If it registers on or below the bottom line of the HOT RUN band add the required amount of oil to bring oil level to the middle of the HOT RUN band Approximately 1 quart 0 95 liter of oil is required to move the oil level from the bottom line to the middle line of the HOT RUN band 7 M916A1 AND M916A2 WINCH HYDRAULIC RESERVOIR Daily check level of lubricating oil in reser voir Level is low if not visible or just visible in lower sight indicator To add oil remove filler cap and add OE HDO until level is visible in top sight indica tor Before reinstalling filler cap remove any debris from filler cap strainer Notify Unit Maintenance to
81. Beacon Light Switch ON OFF toggle switch controls beacon warning light on top of vehicle Check Engine CHK Used by maintenance personnel for engine diag ENG Button nostic purposes ONLY TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t d Lower Right Dash Panel 36 37 Wiper Washer Control Auxiliary Heater Indicator Light Auxiliary Heater Control Switch HI LO Switch FRESH RECIRC Air Button Fan Switch 38 39 40 41 Turns windshield wipers on off Clockwise is ON Counterclockwise is OFF To wash windshield press knob in to spray water and to turn wipers on Lights up when heater burner is lit Operates arctic personnel heater Positions are ON and OFF Controls rate of heating for arctic personnel heater If set at HI heater burner will go on when coolant temperature at inlet to heater is 160 F 71 C LO is suitable for standby operation Allows A C M916A2 M917A1 and M917A1 w MCS VENT and HEAT modes to be used with recirculated or fresh air When mode control lever is at HEAT DEF or DEF system draws in fresh air regardless of button setting When MAX A C is selected system draws recirculated air regardless of button setting Controls four speed fan Positions are OFF 1 2 3 and 4 All the way clockwise is maximum fan speed 2 15 TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t Mode Control Lever Allows selection of modes of operation a Vehicles with air conditioning
82. CTION A procedure to correct the problem 3 4 TROUBLESHOOTING SYMPTOM INDEX Troubleshooting Procedure Page AIR SYSTEM AND BRAKES Air Reservoir Pressure Low Warning Light and Buzzer are ON System Loses Pressure During Vehicle Operation or Low Air Pressure Warning Light and Buzzer Come On During Vehicle Operation 2 Trailer Brakes Will Not Apply When Pedal or Hand Control on Steering Column is Used aD CTIS M917A1 and M917A1 wMCS CTIS Selector Panel indicates Five Lights Flashing Four Mode Lights Flashing Two Mode Lights On Solid DRIVELINE LOCKING SYSTEM Driveline Will Not Disengage Indicator Light Stays On When Interaxle Lockout All Wheel Drive Control Valve is Moved to UNLOCK DISENGAGE ELECTRICAL SYSTEM One or More Lighting Systems 2 2 4 3 4 TM 9 2320 363 10 3 4 TROUBLESHOOTING SYMPTOM INDEX Con t Troubleshooting Procedure Page ENGINE Engine Coolant Temperature Gage indicates Engine is Overheating Cranks but Fails to Start 3 10 Does Not Develop Full Power essent dle Properly 3 11 Ex
83. Carrier 1 For M915A2 M917A1 and M917A1 w MCS secure hoist cable 3 by inserting wheel clamp plate 7 through wheel opening 2 For M916A1 and M916A2 wrap support strap 8 around spare wheel and tire assembly 6 and attach D ring 4 to hook on frame rail 3 Turn gear shaft 1 clockwise until spare wheel and tire assembly 6 is raised to stowed position 4 Engage pawl 2 on gear shaft 1 5 Install two nuts 5 M916A1 AND M916A2 3 22 TM 9 2320 363 10 3 9 WHEEL AND TIRE ASSEMBLY REPLACEMENT ALL EXCEPT 917 1 AND M917A1 W MCS NOTE When changing tires DO NOT substitute type or size tire unless all tires on the vehicle can be converted Keep all tires the same size and type a Placement of Jack 1 M915A2 a For front tire replacement place jack 4 so jack ram 3 is under first small leaf spring 1 just forward of axle 2 1 b For rear tire replacement place jack 4 so jack ram 3 is under equalizing beam 6 inboard of equalizing beam end adapter 5 3 23 TM 9 2320 363 10 3 9 WHEEL AND TIRE ASSEMBLY REPLACEMENT ALL EXCEPT M917A1 AND M917A1 W MCS Con t 2 916 1 and M916A2 a For front tire replacement place jack 4 so jack ram 3 is under front axle steering arm 7 a lt s 7 4 2 b For rear tire replacement place jack 4 so jack ram 3 is under equalizing beam 6 inboard of equalizing beam end adapte
84. Control or Indicator Transmission Shifts automatic transmission into gear Positions Selector Lever are reverse R neutral N drive D third gear 3 second gear 2 and first gear 1 Lever must be in neutral N to start truck On M916A2 M917A1 and M917A1 w MCS reverse R activates an audio alarm when light switch is in any service position 2 22 TM 9 2320 363 10 2 4 CAB FLOOR MOUNTED CONTROLS Con t M917A1 AND 917 1 W MCS Transfer Case Shifts transfer case between LOW and HIGH Selector Lever All range Lever is normally left in HIGH If left in Except M915A2 Neutral N position truck will not move Truck must be completely stopped with transmission in Neutral N before transfer case shifting is possible Shifting selector lever to LOW also engages all wheel drive Hydraulic Control Controls raising and lowering of dump body TM 5 Lever M917A1 and 3805 264 14 amp P 917 1 w MCS MCS Control Unit Controls operation of MCS tailgate TM 5 3805 917 1 w MCS 264 14 amp P 2 23 TM 9 2320 363 10 2 5 SEAT CONTROLS y ANVE qu Li aree 7 I DS li 2 ie m IU oo 4 915 2 916 1 L 2 5 ALL EXCEPT M915A2 AND M916A1 Fore and Aft Seat Three position lever moves seat forward or Adjustment Lever backward Right position locks seat in place Moving lever all the way left adjusts seat Traveling p
85. D6S 6 000 gallon water distributors over primary and secondary roads and off road They have a GVWR of 68 000 Ib 30 872 kg and are equipped with a 45 000 Ib 20 430 kg winch a tail roller and a four way oscillating sliding fifth wheel compatible with a 3 1 2 inch kingpin Maximum towed load on kingpin is 40 000 Ib 18 160 kg The M917A1 and M917A1 w MCS have a GVWR of 68 000 lb 30 872 kg a 14 cu yd 10 7 m dump body capacity and an 18 5 ton 16 8 metric ton load capability They are equipped with a Central Tire Inflation System CTIS which allows operation across a wide variety of terrain b Capabilities and Features 1 While operating on Class roads the fully loaded M915A2 can maintain a speed of 55 mph 88 kph on level roads and 29 mph 47 kph while ascending a 3 percent grade It has a minimum turning diameter curb to curb of 53 ft 9 in 16 4 m 2 While operating on Class roads all other trucks can main tain a speed of 55 mph 88 kph on level roads and 25 mph 40 kph while ascending a 3 percent grade 3 Average cruising ranges at Gross Combination Weight Rat ing GCWR with a full tank of fuel will vary based on conditions e g varying loads prolonged idle PTO usage off road driving and climatic conditions Cruising range is optimally 300 miles 483 km TM 9 2320 363 10 1 9 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES 4 The M916A1 and M916A2 have a transmission
86. EPLACEMENT ALL EXCEPT M917A1 AND M917A1 W MCS Con t Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improp erly lifted or if it falls on you NOTE Wheel nuts on left side of vehicle are left hand threads turn right to loosen turn left to tighten Wheel nuts on right side of vehicle are right hand threads turn left to loosen turn right to tighten Valve stems on inner and outer rear tires should be positioned 180 apart 2 If replacing inner rear tire position wheel and tire assembly on wheel hub and install and handtighten wheel nuts 3 For front or outer rear tire position wheel and tire assembly on wheel hub and install and handtighten wheel nuts 4 Lower and remove jack 3 26 TM 9 2320 363 10 3 9 WHEEL AND TIRE ASSEMBLY REPLACEMENT ALL EXCEPT M917A1 AND M917A1 W MCS Con t WARNING Whenever inner and or outer wheel lug nuts require tightening or a wheel has been removed and replaced lug nuts must be torqued to the required torque Failure to follow this warning may result in serious injury to personnel and damage to equipment Tighten wheel nuts with wheel wrench After 25 miles 40 km retighten wheel nuts Within next 75 miles 121 km have Unit Maintenance torque wheel nuts to proper torque Tightening pattern is identical for all wheel assem blies 5 For front outer rear tire tight
87. ES SERVICE INTERVALS SHOWN ABOVE BEGIN THEREAFTER REFER TO INSTRUCTIONAL MANUAL FOR COMPLETE INFORMATION REGARDING LUBRICATION T lt ep T TIRE AND DATA pom 16 000 3A565R225XIY 22 5 x 12 25 90 Fond 533 96 000 MCH 31580R225K2Y 22 5 X 9 0 so ALL VEHICLES TM 9 2320 363 10 E 2 DECALS AND PLATES Con t THIS VEHICLE IS EQUIPPED WITH A BACK UP ALARM WHEN BACKING THE UND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE TRAVEL LOCK OPERATION m LU UNLOCKED LOCKED e 0 M917A1 AND M917A1 W MCS E 4 Change 1 TM 9 2320 363 10 E 3 5 AND STENCILS PERSONNEL GEAR STORAGE BOX TIRE CHAIN STORAGE BOX M13 DECONTAMINATION KIT MOUNTING TIEDOWN TP100 LIFT BASIC ISSUE ITEMS TIEDOWN BII STORAGE BOX M915A2 Change 1 E 4 1 E 4 2 Blank TM 9 2320 363 10 E 3 STOWAGE AND STENCILS Con t TIE DOWN TP 105 TP100 M915A2 LOAD purses CLASSIFICATION sch a LL el us zU 2 TOW M915A2 E 5 TM 9 2320 363 10 E 3 STOWAGE AND STENCILS Con t TIE DOWN PERSONNEL GEAR STORAGE BOX TIRE CHAIN TIRE CHAIN STORAGE BOX STORAGE BOX M915A2 PERSONNEL GEAR STORAGE BOX M13 DECONTAMINATION KIT MOUNTING TP115 TIRE CHAIN STORAGE BOX EE i TP90 v
88. Each 27 240 kg 27 240 kg 27 240 kg 27 240 kg Up to 45 Angle Front Long Axis Fifth Wheel Manufacturer Holland Holland Holland Type 36 in 91 4 in 91 4 _ in 91 4 cm 1 4 1 ter 2 way p 4 way 4 oscillating oscillating oscillating Pitch Fwd Aft 15 10 15 10 15 10 1 22 TM 9 2320 363 10 1 12 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t M917A1 M917A1 Towing Attach ments Con t Kingpin Size 2 in 5 1 cm Manufacturer D P Winch D P Winch Model u DP45BD DP45BD N A Rated Capacity 45 000 Ib 45 000 Ib 20 430 kg 20 430 kg Drum Capacity 150 ft 45 7 150 ft 45 7 N A m of e m of cable Cable Diameter 7 8 in 7 8 in 2 2 cm 2 2 cm High 26 ft 7 9 m 26 ft 7 9 m per per minute Low 13 n 3 96 13 ft 3 96 per m per d minute Cab Manufacturer Freightliner Freightliner Freightliner Freightliner Construction Aluminum Aluminum Aluminum Aluminum Type 2 passen 2 passen 2 passen 2 passen ger tilt ger tilt ger tilt ger tilt forward hood forward hood forward hood forward hood Accessories Utility Lights 2 fixed 2 fixed 2 fixed N A Air Horn 1 top of cab 1 top of cab 1 top of cab 1 23 TM 9 2320 363 10 1 12 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t e M917A1 M916A1 w MCS Military Load Classification Vehicle w o Trailer Vehicle w Trailer M871 14 35 unloaded loa
89. Filter 4 at 4 qt 4 qt 4 qt Refill 3 8 1 3 8 1 3 8 1 3 8 1 Engine Bypass Oil 1 4 qt 1 4 qt N A N A Filter Refill 1 3 I 1 3 I Cooling System 65 qt 65 qt 65 qt 65 qt 61 5 I 61 5 1 61 5 1 61 5 1 Fuel Tank 80 gal 100 gal 100 gal 100 gal 302 8 1 378 5 378 5 1 378 5 1 Power Steering 2 qt 2 qt 2 gt 2 at Reservoir 1 91 1 9 1 1 9 1 9 1 Winch Drum Winch Reservoir N A 42 gal 42 gal N A 159 0 I 159 0 1 N A 5 gt 5 at 4 71 4 7 1 Front Axle 27 pt 27 pt 27 pt 12 8 1 12 8 1 12 8 I Transmission 33 qt 33 qt 31 21 31 21 Transfer Case N A 5 gt 5 qt 5 qt 4 7 1 4 7 1 4 71 Rear Axle 13 14 5 qt 22 23 qt 22 23 at 22 23 gt Forward Rear 12 3 13 7 1 20 8 21 8 1 20 8 21 8 1 20 8 21 8 1 Engine Manufacturer Detroit Diesel Detroit Diesel Detroit Diesel Detroit Diesel Type 4 stroke in 4 stroke in 4 stroke in 4 stroke in line diesel line diesel line diesel line diesel TM 9 2320 363 10 1 12 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t M917A1 M917A1 M915A2 M916A1 w MCS Engine Con t Model DDEC II lI II DDEC 111 Cylinders Displacement 775 CID 775 775 775 CID 12 7 1 127 1 12 7 1 12 7 1 Torque 1200 rpm 1400 Ib ft 1400 Ib ft 1400 Ib ft 1400 lb ft 86 Ne m 1898 m 1898N m 1808 N m Maximum 400 400 400 400 power 2100 rpm 298 3 kW 298 3 kw 298 3 kw
90. For M917A1 and M917A1 w MCS select appropriate tire pressure on CTIS selector panel paragraph 2 17 C Maintain steady pressure on accelerator pedal to keep vehicle rolling until solid ground is reached Do not accelerate to point where wheels spin and do not stop if possible d If vehicle gets stuck try to pull out slowly in a low gear Boards brush or similar materials may be placed under tires to provide traction When resuming operation on highway surfaces be sure to reset CTIS selector panel to higher tire pressures Operating vehicle with underinflated tires will cause pre mature tire wear or damage to tires Failure to follow this warning may result in death or injury to personnel e If M917A1 or M917A1 w MCS gets stuck select emergency EMER on CTIS selector panel to reduce tire pressures to 30 psi 207 kPa Do NOT exceed 10 mph 16 kph Operation in this mode is limited to 10 minutes unless reselected Reset to higher tire pressures when vehicle is freed f If M916A1 or M916A2 gets stuck and is not coupled to trailer winch may be used Attach winch cable to another vehicle or heavy object that will not move under load When vehicle reaches hard surface place interaxle lockout all wheel drive in UNLOCK DISENGAGE position 2 132 TM 9 2320 363 10 2 42 FORDING a General 1 Maximum fording depth is 20 in 50 8 cm 2 Ford to maximum depth for short periods and short distances only Vehicles
91. IC B4J TRUCK DUMP HEAVY CHASSIS 68 000 GVWR 6 X 6 14 CU YD ON OFF HIGHWAY M917A1 NSN 3805 01 431 1165 EIC E5C M917A1 W MCS NSN 3805 01 432 8249 EIC EBD REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any mistakes or if you know of a way to improve the procedures please let us know Submit your DA Form 2028 Recommended Changes to Equipment Technical Publications through the Internet on the Army Elec tronic Product Support AEPS website The Internet address is https aeps ria army mil The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page 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 pro gram You may also mail fax or e mail your letter or DA Form 2028 direct to AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 The e mail address is TACOM TECH PUBS ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited Change 1 i TM 9 2320 363 10 CHAPTER 1 Section l Section Il Section lll CHAPTER 2 Section l Section Il Section lll Section IV CHAPTER u Section l Section ll Section lll APPENDIX APPENDIX D gt gt gt gt TU TU 0 0
92. INES WHEN YOU USE THIS MANUAL Read through this manual and become familiar with its contents before attempt ing to operate or maintain the truck A warning summary is provided at the beginning of this manual and should be read before attempting to operate or maintain the truck ii iv Blank TM 9 2320 363 10 CHAPTER 1 INTRODUCTION Section I GENERAL INFORMATION Paragraph Page Number Paragraph Title Number SCOPE sed ca hie Maintenance Forms and Procedures Corrosion Prevention and Control CPC Destruction of Army Materiel to Prevent Enemy Use Reporting Equipment Improvement Recommendations EIRs Warranty Information Nomenclature Cross Reference List List of Abbreviations 1 1 SCOPE 1 This manual is for use in operating and maintaining the M915 Family of Vehicles to include the chassis of the M917A1 and 917 1 w MCS Mate rial Control System dump truck 2 For operation and maintenance of the M917A1 and M917A1 w MCS dump truck body refer to TM 5 3805 264 14 amp P b Equipment Name and Model Number 1 Truck Tractor Line Haul 52 000 GVWR 6 X 4 M915A2 2 Truck Tractor Light Equipment Transporter LET 68 000 GVWR 6 X 6 w Winch M916A1 and M916A2 3 Truck Dump Heavy Chassis 68 000 GVWR 6 X 6 14 Cu Yd On Off Highway M917A1 and M917A1 w MCS C P
93. ION CORRECTIVE ACTION 15 ENGINE STARTS BUT MISFIRES OR RUNS ROUGH AFTER PROPER WARMUP PERIOD Check air cleaner restriction indicator If indicator is not clear notify Unit Maintenance 16 EXCESSIVE ENGINE OIL CONSUMPTION Check for loose oil lines and oil leaks If oil lines are loose or leaks are found notify Unit Mainte nance 17 EXCESSIVE EXHAUST SMOKE AT NORMAL ENGINE OPERATING SPEED Step 1 Check air cleaner restriction indicator If indicator is not clear notify Unit Maintenance Step 2 Check for water in fuel Drain fuel water separator Table 2 1 18 LOW OR NO ENGINE OIL PRESSURE Check engine oil level If engine oil is low fill to correct level Appendix F POWER TAKE OFF PTO M916A1 AND M916A2 19 PTO DOES NOT ENGAGE Check position of PTO switch and that indicator light is ON Place PTO switch in ON position and ensure indicator light comes ON STEERING 20 HARD STEERING SHIMMY OR WANDERING NOTE Check tire pressure when tires are cold Step 1 Check that tires are properly inflated Inflate tires to proper pressure Table 2 1 3 12 TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2 Check for loose lug nuts Tighten loose lug nuts and notify Unit Maintenance to apply proper torque Step 3 Check for worn loose or damaged parts on front axle or sus pension Check steering linkage wheels and vehicle fr
94. LBS m et ALL VEHICLES TM 9 2320 363 10 E 2 DECALS AND PLATES Con t COMPONENT DATA MS1I7AI MANUFACTURED BY FREIGHTLINER CORP CONTRACT DAAEO7 96 C X076 VEHICLE MODEL NUMBER M917AI ENGINE MODEL OETROIT DIESEL SERIES 60 TRANS MODEL MAIN ALLISON AUTOMATIC HT 740 FRT AXLE MODEL OSHKOSH 18K REAR AXLE MODEL ROCKWELL RT 52 160P GVWR 68 000 LBS TRANSFER CASE OSHKOSH 55000 SERIES T NOTE USE VEHICLE IDENTIFICATION NUMBER WHEN ORDERING PARTS WHEELBASE 175 00 INCHES ENGINE NO 501 23563 000 TRANS NO S07 13402 000 FRT AXLE NO SIO 12482 000 REAR AXLE NO 511 18234 489 RATIO 4 89 TO TRANSFER CASE 2205810 U VEHICLE NOISE EMISSION CONTROL INFORMATION THIS VEHICLE 15 EXEMPT FROM THE PROHIBITEONS OF SECTION 0 A 0 2 3 ANO 5 OF THE NOISE CONTROL ACT OF 1972 2400847 GED maar aeneo PDD rm DAILY RSVR DIPSTICK DAILY 2 FLEL FILTER PRIMARY DAILY 3 LeveL oresticK DAILY TRAMSISSION DIPSTIOK DAILY 29 RADIATOR COOLANT oc 16 CRANKCASE s 22 STRG GEAR SHAFT BUSHING 5 00075 PINDLE HOK 5 00075 CAMMASTER SLACK ADJUSTERS 5 000 5 TRUNNION U JOINT 5 00079 DRAG LINK 5 000 5 STRG SHAFT U JOINT SPLINE 5 000 5 REAR AXLE SPRING AND WALKING
95. O to perform winching operations TM 9 2320 363 10 LOCATION AND DESCRIPTION OF MAJOR COMPO 1 10 NENTS Con t b M917A1 and M917A1 w MCS NOTE Refer to TM 5 3805 264 14 amp P for more information on the location and description of major components of the dump truck body 1 12 Component Marker Clearance Lights Side Mirrors Grabhandles Utility Power Receptacle Spare Wheel and Tire Battery Box and Steps Front Service Lights Blackout Lights M917A1 Description Indicate outline of dump truck Provide driver with a view of sides of dump truck Provide a hand hold for personnel climbing on dump truck Supplies power for work lights Located on both sides of dump truck Extra wheel and tire used in case of a flat tire Holds vehicle batteries and provides steps to access cab Include headlights and turn signals Used during blackout conditions TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS Con t Brush Guard Protects front of hood and components under hood from damage Spotting Mirrors Provide added visibility to sides of truck and trailer if towing Beacon Warning Amber rotating light alerts other vehicles of Light presence of truck Cargo Cover Controls Extend and retract cargo cover Transport Lock Locks dump body to truck frame when transporting dump truck Lif Tie Down Provides lift and tie down points Shackles
96. PTO 1 On M916A1 and M916A2 release winch controls If engine rom was raised reduce rom using throttle control switch On M917A1 and M917A1 w MCS place hydraulic control in Neutral N TM 5 3805 264 14 amp P 3 M917A1 M917A1 w MCS place main light switch to OFF position 4 Place PTO switch to OFF position PTO indicator light will go out 2 28 OPERATE WINCH 916 1 AND 916 2 a General 1 M916A1 and M916A2 tractors are equipped with a full hydraulic winch mounted on the frame behind the cab The winch has a fail safe spring loaded brake that automatically sets any time the winch control valve is in neu tral or there is a power failure hydraulic pressure drops to less than 200 psi 2 The winch operates at 2100 psi hydraulic pressure from a dual pump driven by a PTO on the transmission The rated capacity of the winch is 45 000 Ib 20 250 kg For more information refer to TM 5 725 OIL RESERVOIR BRAKE DRUM CONTROL PANEL WIRE ROPE 2 110 TM 9 2320 363 10 2 28 OPERATE WINCH M916A1 AND M916A2 Con t 3 The winch operator s station is located on left side of the trac tor behind the cab The operator stands on the platform provided and operates the winch using the controls on top of the control panel Always wear heavy gloves when handling winch cable Never allow cable to run through hands frayed cables can cut you Never operate winch with less than four turns of ca
97. T M917A1 AND M917A1 W MCS NOTE When changing tires DO NOT substitute type or tire size unless all tires can be converted a Remove Rear Wheel and Tire Assembly 1 Stop engine paragraph 2 20 and drain vehicle air system Table 2 1 2 Position jack 4 so jack ram 3 is under equalizing beam 2 inward of equalizing beam end adapter 1 08 9 lt re 3 Remove valve stem cap 12 from wheel valve 10 and deflate both tires by pressing on valve stem core 13 WARNING Always wear eye protection and drain all air from wet tank before disconnecting CTIS air lines hoses or fit tings Residual air in tire s and air line s will be expelled even though tire s is flat Failure to follow this warning could cause serious eye injury 4 Disconnect hose 8 from hub air port connector 6 and remove hub air port connector from hub air port 5 5 Disconnect hose 19 from outer wheel valve stem 16 3 32 Change 1 TM 9 2320 363 10 3 11 REAR WHEEL AND TIRE ASSEMBLY REPLACEMENT 917 1 AND 917 1 W MCS Con t 6 Disconnect inner wheel valve stem hose 15 from tee con nector 14 7 Remove two hub nuts 11 and bracket 9 with wheel valve 10 and hoses attached 8 Block wheels 19 16 NOTE Wheel nuts on left side of vehicle are left hand threads turn right to loosen turn left to tighten Wheel nuts on right
98. TEMS Con t 26 1 2 3 4 Illus National Description Usable Number Stock Number CAGEC Part Number On Code 5120 00 293 1289 Wrench Lug in storage box 03683 18806 B 8 Change 1 TM 9 2320 363 10 APPENDIX C ADDITIONAL AUTHORIZATION LIST Section INTRODUCTION C 1 SCOPE This appendix lists additional items that you are authorized for the support of the M915 Family of Vehicles C 2 GENERAL This list identifies items that do not have to accompany the truck and that do not have to be turned in with it These items are authorized to you by CTA MTOE TDA or JTA C 3 EXPLANATION OF LISTING National Stock Numbers descriptions and quantities are provided to help you identify and request the additional items you require to support this equipment If the item required differs for different models of this equipment see the Usable On Code column for the applicable model or models Usable On Codes for the M915 Family of Vehicles are Usable On Code Model 5A2 M915A2 6A1 M916A1 6A2 M916A2 TAI M917A1 7E1 M917A1 w MCS C 1 TM 9 2320 363 10 Section Il 1 National Stock Number 6130 01 449 7594 5110 00 293 2336 5510 00 491 0306 5510 00 491 0307 2540 01 396 1914 5340 00 545 2337 8415 00 268 7859 5120 00 288 6574 2540 01 345 8896 2540 01 345 8898 2540 01 347 6249 6545 00 922 1200 4230 01 133 4124 C 2 Change 1
99. TM 9 2320 363 10 OPERATOR S MANUAL FOR TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A2 NSN 2320 01 272 5029 EIC B4E TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A1 NSN 2320 01 272 5028 EIC B4F TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A2 NSN 2320 01 431 1163 EIC B4J TRUCK DUMP HEAVY CHASSIS 68 000 GVWR 6 X 6 14 CU YD ON OFF HIGHWAY M917A1 NSN 3805 01 431 1165 EIC E5C M917A1 W MCS NSN 3805 01 432 8249 EIC EBD Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY DECEMBER 1997 TM 9 2320 363 10 FOR INFORMATION ON FIRST AID REFER TO FM 4 25 11 WARNING CARBON MONOXIDE EXHAUST GASES CAN KILL Carbon monoxide is a colorless odorless deadly poison which when breathed deprives the body of oxygen and causes suffocation Exposure to air containing car bon monoxide produces symptoms of headache dizziness loss of muscular control apparent drowsiness and coma Permanent brain damage or death can result from Severe exposure Carbon monoxide occurs in exhaust fumes of internal combustion engines Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation The following precautions must be observed to ensure safety of person nel when engine of truck is ope
100. When desired amount of line has been payed out stop winch by releasing both control levers Set throttle control 5 to LOW 2 112 TM 9 2320 363 10 2 28 OPERATE WINCH M916A1 AND M916A2 Con t 6 Direct crew member to disconnect wire rope from payload 7 Have crew member pull on wire rope and keep fairly taut and start rewinding drum by pushing down on winch line control lever 4 8 Ensure that wire rope winds neatly onto drum without tan gling kinking twisting or overlapping Ensure that coils on drum are tight and close together 9 Direct crew member to signal when enough slack has been taken up to anchor the eye 10 Have a crew member anchor wire rope eye 1 to anchor 2 11 Shut down paragraph 2 27 2 29 OPERATE AIR CONDITIONER ALL EXCEPT M915A2 AND M916A1 a If cab is hot inside open windows and allow hot air to vent b Move mode control lever 2 to VENT and turn fan switch 1 to OFF position c Start engin paragraph 2 14 NOTE If outside air is dusty or smoky mode control lever should be set to MAX A C and windows and vent closed to prevent drawing dust or smoke into cab d Move mode control lever 2 to A C With control at A C fresh air is drawn into cab With control at MAX A C air inside cab is recirculated e Move temperature control lever 3 to COOL 2 113 TM 9 2320 363 10 2 29 OPERATE AIR CONDITIONER ALL EXCEPT M915A2 AND
101. acement All Except M917A1 and 917 1 9 Front Wheel and Tire Assembly Replacement M917A1 and 917 1 86 3 28 Rear Wheel and Tire Assembly Replacement M917A1 917 1 5 3 12 Battery Box Cover 3 38 3 5 CLEANING VEHICLE Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to person nel DO NOT use high pressure water to clean inside of cab or engine compartment Damage to electrical system may result a Exterior 1 Never wipe dirt off when vehicle is dry 2 Never wash vehicle in direct sunlight or if vehicle exterior is hot to touch 3 Wash vehicle often using cold or lukewarm water never use hot water or any strong detergent Do not use abrasives to remove mud and dirt from your vehicle 3 17 TM 9 2320 363 10 3 5 CLEANING VEHICLE Con t 4 While cleaning vehicle look closely for evidence of rust or corrosion bare metal or other exterior damage If any problems are found notify Unit Maintenance to treat affected areas b Interior 1 Remove loose dust and dirt from cab interior components 2 Clean upholstery and seat belts using a mild solution of warm water and soap never use solvents or abrasives
102. ackets provided Failure to do so will cause equipment damage The tractor trailer combination is not capable of turning more than a 90 angle The M915A2 M916A1 and M916A2 truck tractors have the capability to turn greater than 90 Care must be taken to avoid hitting semitrailer with trac tor when turning more than 90 Operator must use caution when cresting hills which cause the truck tractor to have a nose down angle greater than 4 with respect to towed semi trailer Damage to vehicle or loss of control could occur a Pull secondary lock 1 release handle 1 before releasing pri mary lock release handle 2 to uncou ple the trailer 2 98 TM 9 2320 363 10 2 21 OPERATE SLIDING FIFTH WHEEL M915A2 Con t b Place fifth wheel slide control valve lever 3 in UNLOCK position to release two slide locking plungers 5 Ensure that plungers release If plungers did not release lower landing gear to relieve pressure and allow fifth wheel to slide more easily C Drive tractor slowly forward or backward to position fifth wheel d After sliding to desired position engage two slide locking plungers 5b by placing fifth wheel slide control valve lever 3 in LOCK position CAUTION Do not operate vehicle if slide locking plungers are not fully engaged and landing gear is not fully retracted This could result in damage to tractor trailer and land ing gear e Visually check that two slid
103. ailers may cause equipment damage Trailer must be blocked and trailer brakes locked to prevent damage to tractor or trailer by uncontrolled sliding fifth wheel f towing M172 trailer rear mud flaps must be removed and stowed Failure to do so will cause equipment damage a Pull secondary lock release handle 1 before releasing the primary lock release handle 4 2 100 TM 9 2320 363 10 2 22 OPERATE SLIDING FIFTH WHEEL 916 1 AND 916 2 Con t b When operating off road release fifth wheel oscillating travel lockout by removing locking pin 2 lowering lockout 3 and reinserting locking pin allowing fifth wheel to oscil late side to side Handle must be used when operating release lever Fail ure to do so could result in injury to personnel C Using handle 7 pull locking release lever 5 and release two slide locking plungers 8 Ensure that plungers release If plungers did not release lower landing gear to relieve pressure and allow fifth wheel to slide more easily d Drive tractor slowly forward or backward to position fifth wheel e After sliding to desired position engage two slide locking plung ers 8 by using handle 7 to trip release lever 5 and allow plungers to retract f Visually check that two slide locking plungers 8 are retracted and fully engaged It may be necessary to leave trailer brakes locked and move tractor slightly to engage plungers
104. ale x I _ WEE MA ALLE v dy Tr ha Sp V i s BASIC ISSUE ITEMS HEBOWI TOW TIE DOWN STORAGE BOX IE DOWN M916A1 AND M916A2 E 6 TM 9 2320 363 10 E 3 STOWAGE AND STENCILS Con t TIRE CHAIN STORAGE BOX LOAD CLASSIFICATION SIGN TOW ETD TE i au 916 1 916 2 7 TM 9 2320 363 10 E 3 STOWAGE AND STENCILS Con t REFLECTIVE REFLECTIVE TAPE M916A2 TAPE 916 2 PERSONNEL GEAR d roi E STORAGE BOX L AN Iru PRESSE S REFLECTIVE TAPE M916A2 item 18 Appendix D M916A1 AND M916 2 SIDES LIFT TIE DOWN BOTH SIDES FRAME OF FRAME M917A1 AND M917A1 W MCS E 8 TM 9 2320 363 10 E 3 STOWAGE AND STENCILS Con t TP90 M13 DECONTAMINATION LIFT KIT MOUNTING BOTH SIDES OF FRAME BASIC ISSUE ITEMS STORAGE BOX TOW TIE DOWN BOTH SIDES OF FRAME M917A1 AND M917A1 W MCS 9 10 Blank TM 9 2320 363 10 APPENDIX F LUBRICATION INSTRUCTIONS F 1 GENERAL NOTE These instructions are mandatory This equipment Is enrolled in the Army Oil Analysis Program AOAP Engine oil transmission oil and hydraulic fluid must be sampled every 90 days as prescribed by DA Pam 738 750 For lubrication instructions for the M917A1 and M917A1 w MCS Dump Truck Bod
105. alert indicator 71 Check pintle hook 73 for looseness damaged locking mechanism and presence of cotter pin Lubricate at all four grease fittings 72 F if pintle hook does not rotate freely by hand 2 74 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t heck Not Fully Mission Interval Service Procedure Capable If Weekly Pintle 58 Weekly Rear and For ward Rear Wheels and Tires Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result NOTE M917A1 and M917A1 w MCS CTIS must be in highway HWY mode for this check a Check pressure in tires and adjust as required 2 75 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Che W Not Fully M ec ot Fully Mission Interval Service Procedure Capable If 58 Weekly Con t M915A2 Empty 80 psi 652 kPa M915A2 Loaded 100 psi 690 kPa M916A1 M916A2 Empty 90 psi 621 kPa M916A1 M916A2 Loaded 90 psi 621 kPa M917A1 M917A1 w MCS 90 psi 621 kPa b Ensure all wheel stud lug b Any wheel stud is nuts are tight using wheel missing or lug nut stud lug nut wrench and is loose handle c Check wheel for cracks c Wheel is cracked breaks or bends broken or ben
106. ame for worn loose or damaged parts If worn loose or damaged parts are found notify Unit Main tenance 21 VEHICLE STEERING SLOW OR INTERMITTENT TO RESPOND Step 1 Check power steering fluid level If power steering fluid is low fill to correct level Appendix F Step 2 Check for proper operation of power steering With vehicle at halt turn steering wheel in either direction until steer limit is reached Hold steering wheel in position for five seconds Turn steering wheel in other direction until steering limit is reached Repeat cycling a number of times TRANSMISSION 22 SLOW OR ERRATIC TRANSMISSION CLUTCH ENGAGEMENT Check transmission fluid level If transmission fluid is low fill to correct level Appendix F 23 TRANSMISSION FLUID TEMPERATURE GAGE INDICATES FLUID IS OVERHEATING DURING NORMAL OPERATION Step 1 Check transmission fluid level If transmission fluid is low fill to correct level Appendix F Step 2 Check transmission fluid dipstick for discoloration that would indicate water coolant in fluid If dipstick is discolored notify Unit Maintenance WHEELS AND TIRES 24 TIRES WORN UNEVENLY OR EXCESSIVELY Step 1 Check tires for proper pressure Inflate tires to proper pressure Table 2 1 TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2 Check for bent wheel rims If rim is bent replace wheel and tire assembly Not
107. and semitrailer if towing Winch Controls Operate winch M916A1 and M916A2 TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS Con t Component Description Grabhandles Provide a hand hold for personnel climbing on truck Ramp Sloped surface serves as an approach to fifth wheel and facilitates coupling of semitrailer Fifth Wheel Coupling device for semitrailers with kingpins TM 9 2320 363 10 1 10 LOCATION AND DESCRIPTION OF MAJOR COMPO NENTS Hosetenna Utility Lights Beacon Warning Light Exhaust Muffler Hood Latch Fuel Tank Storage Boxes Mud Flaps Trailer Gladhands Pintle Hook Taillights Tail Roller M916A1 and M916A2 Hydraulic Winch M916A1 and M916A2 Mounting and stowage location for intervehicular air lines Illuminate area in back of cab There is one light on each side of cab Amber rotating light alerts other vehicles of presence of truck Deadens noise of engine exhaust Locks hood closed Located on both sides of hood Holds fuel Steps mounted to tank provide access to cab Provide stowage area for BIl and other items Prevent water and debris from spraying up on passers by or towed semitrailer Provide air supply for brakes of trailer Coupling device for trailers with lunettes Contain composite tail stop backup and turn signal lights Facilitates coupling and uncoupling operations Powered by PT
108. ater separator 31 Turn knob clockwise to 2 51 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Ur Procedure o abdo i 28 Interve Check for presence and gen Air hose gladhand hicular eral condition of intervehicular or electrical connec Air air hoses 33 gladhands 34 tor is damaged Hoses gladhand preformed packings and 35 and electrical connectors Electri 36 cal Con nectors All Except M917A1 and M917A1 w MCS 2 52 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Not Fully Mission Interval i Procedure Capable If 29 Winch a Inspect winch reservoir a Damage that M916A1 38 lines and fittings drum would impair oper and 39 and controls 37 for ation or Class Ill 916 2 leaks or damage leaks are evident b Check level of lubricating oil in reservoir 38 Level is low if not visible or if just visible in lower sight indicator 40 Add oil as required by removing filler cap 42 and adding oil until visible in top sight indicator 41 Ensure that strainer 43 is clean before installing filler cap 2 53 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Not Fullv M ot Fully Mission Inter
109. ations sse FM 20 22 A 5 TECHNICAL MANUALS Batteri Su saa ha en L ea elle TM 9 6140 200 14 Care Maintenance Repair and Inspection of Pneumatic Tires and Inner Tubes TM 9 2620 200 14 Destruction of Army Materiel to Prevent Enemy Use TM 750 244 6 Operator s Unit Direct Support Maintenance Manual with RPSTL for M917A1 and M917A1 w MCS Dump Tr cke Body A u u tte en TM 5 3805 264 14 amp P Operator s Unit Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Semitrailer Flatbed Breakbulk Container Transporter 34 Ton M872 M872A1 M872A2 M872AG TM 9 2330 359 14 amp P Operator s Unit Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Semitrailer Lowbed 25 Ton 4 Wheel MTZ2 MTZ2A1 uu Susu eet cete TM 9 2330 211 14 amp P Operator s Unit Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Semitrailer Lowbed 40 Ton Construction Equipment Transporter 870 870 1 TM 5 2330 360 14 amp P TM 5 2330 378 14 amp P Operator s Unit Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Semitrailer Tactical Dual Purpose Breakbulk Container Transporter 22
110. blackout lights accesso ries and trailer connectors b The Dual Voltage Alternator Control DUVAC mounted on the fire wall in the engine compartment regulates the distribution of 12 and 24 volts 12 VOLT BATTERIES SERIES PARALLEL SWITCH TO CAB 1 29 TM 9 2320 363 10 1 19 AIR SYSTEM a The air system consists of the air compressor air dryer air reser voirs and various air lines Also included in the air system are the air pressure gages located on the dashboard which are used for monitoring air pressure for safe opera tion of all air operated components of the vehicle b On the M917A1 and M917A1 w MCS the chassis air system sup plies air to operate the Central Tire Inflation System CTIS and the tailgate release air cylinder TM 5 3805 264 14 amp P On the M917A1 w MCS the chassis air system interfaces with the MCS air system to operate the MCS tailgate TM 5 3805 264 14 amp P AIR GAGES SECONDARY PRIMARY gt oo COMPRESSOR HOLDING TANKS 1 20 BRAKES a The dual air brake system consists of two independent air brake sys tems that use a single set of brake controls Each system has its own reservoirs plumbing and brake chambers The primary system operates the service brakes on the rear axle the secondary system operates the service brakes on the front axle On tractor trailer configurations service brake signals from both systems are sent to the trailer 1 30 TM 9 2320 363 10
111. ble on drum Keep cable coils tight and close together on drum while winch ing Failure to follow this warning may result in injury to personnel Hearing protection is required for operator and per sonnel working around winch station during opera tion DO NOT use winch for moving or lifting people Seri ous injury could result Keep trailer air supply hoses away from wire rope to prevent damage to hoses NOTE Rated winch pull is set by limiting hydraulic system relief valve pressure to maximum of 2500 psi which pro vides 45 000 Ib 20 250 kg pull on bare drum As winch drum is loaded with wire rope effective line pull is reduced The line per cable layer with 7 8 inch wire rope is 1 st layer 45 000 Ib 20 250 kg 2nd layer 39 265 Ib 17 810 kg 3rd layer 34 775 Ib 15 773 kg 4th layer 31 210 Ib 14 156 kg 5th layer 28 310 Ib 12 841 kg b Operate Winch 1 Engage PTO paragraph 2 27 2 111 TM 9 2320 363 10 2 28 OPERATE WINCH M916A1 AND M916A2 Con t 2 Have a crew member disconnect wire rope eye 1 from anchor 2 3 To pay out wire rope pull up and hold line control lever 4 in LINE OUT position Winch unwinds in low speed Have crew member walk end of wire rope out NOTE High speed winch operation is only recommended for paying out wire rope or taking up slack 4 To run winch at high speed set throttle control 5 to HIGH and push down and hold speed control lever 3 5
112. can ford to maximum depth for five minutes without requiring mainte nance to continue operation b Before Fording 1 Check bottom surface of water to ensure it is hard enough to be forded without exceeding maximum fording depth 1 Ensure that engine is operating properly 2 Lubricate unpainted surfaces to guard against rust and dete rioration Place interaxle lockout all wheel drive control valve in LOCK ENGAGE position c During Fording 1 Place transmission in a low gear paragraph 2 15 and enter water slowly 2 Ford at speeds of 3 4 mph 5 6 kph d After Fording 1 When vehicle emerges from water apply brakes a few times to dry brake linings Ensure that brakes are working properly before driving at normal speeds 2 Allow engine to run for awhile to drive out any accumulated water 3 Drain or dry any area where water has accumulated 4 Check all fluids for signs of contamination and for proper lev els Appendix F 5 If vehicle has been operated in salt water rinse undercar riage immediately Allow exterior to dry and check for evidence of salt accumulation Use a clean damp cloth to immediately remove all salt accumulation 6 Notify Unit Maintenance that after fording lubrication is required 2 133 TM 9 2320 363 10 2 43 OPERATE IN SANDY OR DUSTY CONDITIONS NOTE M915A2 is equipped with No Spin automatic lock ing positive traction differential on the forward rear
113. cation wipe off excess lubricant to prevent accumulation of for eign matter d Refer to FM 9 207 for lubrication instructions in cold weather F 1 TM 9 2320 363 10 LUBRICATION CHART TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A2 NSN 2320 01 272 5029 TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A1 NSN 2320 01 272 5028 TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A2 NSN 2320 01 431 1163 TRUCK DUMP HEAVY CHASSIS 68 000 GVWR 6 X 6 14 CU YD ON OFF HIGHWAY M917A1 NSN 3805 01 431 1165 M917A1 W MCS NSN 3805 01 432 8249 This Lubrication Chart is for the opera tor crew C Lubrication intervals on condition or hard time are based on normal operation Lubricate more dur ing constant use and less during inac tive periods Use correct grade of lubricant for seasonal temperature expected For equipment under manufacturers warranty hard time oil service inter vals shall be followed Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions e g longer than usual operating hours extended idling periods extreme dust etc Dry cleaning solvent P D 680 is toxic and flammable Always wear protective goggles and F 2 gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near op
114. cessive Engine Oil Consumption Exhaust Smoke At Normal Engine Operating Speed Fails to Crank When Starter Button is Pressed Starts but Misfires or Runs Rough After Proper Warmup Period Low or No Engine Oil Pressure Lascia dicte e d 3 12 POWER TAKE OFF PTO M916A1 AND M916A2 PTO Does Not STEERING Hard Steering Shimmy or Wandering gt lt mm Vehicle Steering Slow or Intermittent to Respond 3 13 TRANSMISSION Slow or Erratic Transmission Clutch Engagement Transmission Fluid Temperature Gage Indicates Fluid is Overheating During Normal Operation 3 13 WHEELS AND TIRES Tires Worn Unevenly or Excessively Vehicle Wanders or Pulls to One Side on Level Pavement Wheel Wobbles 3 14 WINCH M916A1 and M916A2 Winch Drum Will Not Operate 3 15 Unusually Noisy When Operating 2 2 3 15 3 5 TM 9 2320 363 10 Table 3 1 Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION AIR SYSTEM AND BRAKES 1 AIR RESERVOIR PRESSURE LOW WARNING LIGHT AND BUZZER ARE ON Step 1 Check whether air reservoir draincocks are closed Close draincocks Step 2 If vehicle is not coupled to a semitrail
115. cracks breaks nent is cracked bro nents loose connections or other ken or loose damage 2 72 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To n Interval Check Not Fully Mission Service Procedure Capable If Weekly Axle Dry cleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat The solvent s flash point is 100 138 38 C 59 C if you become dizzy while using cleaning solvent immediately get fresh air and medical help if solvent contacts eyes immediately wash your eyes and get medi cal aid NOTE Perform the following service at all axles except the M915A2 front axle Without removing breather vent 70 check for a clogged vent Clean with dry cleaning solvent Item 17 Appendix DJ as required to remove dirt and grease 2 73 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con Item To Check Not Fully Mission interval Service Procedure Capable If Weekly Brake Cham bers All Except M915A2 and M916A1 Perform the following check at all axles Check brake chamber service Stroke alert indicate pushrod for showing of stroke is visible
116. d against tires freezing to the ground or becoming pocketed in ice and will provide some traction when vehicle is started and moving again b Install Tire Chains 1 Lay out chains flat on ground alongside tire to be mounted Untangle any cross chains 2 Open all cams 4 open meaning longest spacing 3 Pick up rear side chains 1 no cams and place over top of tire 4 Tuck last cross member 2 against bottom of tire with loose side chain 3 sticking out away from tire 5 Roll vehicle in direction of last crossmember 2 approximately 1 4 tire revolution 2 138 TM 9 2320 363 10 2 45 OPERATE ON SNOW OR ICE Con t 6 Pull inside side chain 5 snug and hook into appropriate link to hold snug 7 Pull outside side chain 6 snug and hook NOTE Hooks must be even Same number of loose links must appear on each side of chain If not even loosen outside hook and rehook both inside and outside hooks until they are even 8 Close cams 4 by inserting key 7 in slot and rotate 180 degrees clockwise Start with cam closet to side chain hook NOTE All four cams should not have to be locked for chain to be tight 9 If additional tightening is required tighten cam on opposite side of tire Continue tightening cams as required 10 If all four cams are tight loosen all four cams and resnug side chain at fastener hook until no more than three cams require adjust ment
117. ded unloaded loaded 14 46 unloaded loaded 11 34 unloaded loaded unloaded unloaded loaded loaded 17 54 unloaded unloaded loaded loaded 23 23 unloaded unloaded loaded loaded 23 23 unloaded unloaded loaded loaded 1 24 TM 9 2320 363 10 Section Ill PRINCIPLES OF OPERATION Paragraph Page Number Paragraph Title Number 0 SR Rn 1 25 Drive Evel SYSt6M teed nd aa wad etl ua 1 27 Exhaust Cooling System 2 22 2224 44 Electrical System Air System Brakes Steeriti sues secre aching segs Hane ee eA ee eS Hydraulic System All Except 915 2 Air Conditioning System All Except M915A2 and M916A1 Central Tire Inflation System CTIS M917A1 and M917A1 WIMOS 22226 edere cea dela etn dea ok 1 34 1 13 INTRODUCTION a All vehicles consist of eight functional systems drive train fuel sys tem exhaust system cooling system electrical system air system brakes and steering b All vehicles except the M915A2 have a hydraulic system C All vehicles except the M915A2 and 916 1 have an air condition ing system d An additional system on the M917A1 and M917A1 w MCS is the Central Tire Inflation System CTIS e This s
118. e In highway HWY mode for this check 2 70 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To 1 2 Check Not Fully Mission Interval Service Procedure Capable If 52 Weekly Forward Con t Rear and Rear Rear Wheels and Tires M915A2 Empty 80 psi 552 kPa M915A2 Loaded 100 psi 690 kPa M916A1 M916A2 Empty 90 psi 621 kPa M916A1 M916A2 Loaded 90 psi 621 kPa M917A1 M917A1 w MCS 90 psi 621 kPa b Ensure all wheel stud lug b Any wheel stud is nuts are tight using wheel missing or lug nut stud lug nut wrench and is loose handle c Check wheel for cracks c Wheel is cracked breaks or bends broken or bent 2 71 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Interval Check Service 53 Weekly Fifth Wheel All Except M917A1 and M917A1 w MCS Not Fully Mission Procedure Capable If Failure to keep fifth wheel plate lubricated could cause erratic steering due to bind ing of plate between tractor and trailer This could result in an accident causing injury to personnel Coat fifth wheel plate 44 and sliding rails 46 liberally with grease Lubricate at all grease fittings Appendix 54 Steering Check front axle steering corn Any steering compo Compo ponents for
119. e OEA lubricant is to be used in lieu of OE HDO 10 lubricant for all expected temperatures where OE HDO 10 is specified TM 9 2320 363 10 CHART D M915A2 FRONT AXLE WHEEL BEARINGS EXPECTED TEMPERATURES w E L Lubricating Oil Gear Multipurpose 2105 GO 75 0 186 0 226 85 140 0 Ll l l l l CHART E ANTIFREEZE EXPECTED TEMPERATURES oe ee hits MIL A Antifreeze Ethylene 46153 Glycol Inhibited Heavy Duty MIL A Arctic 11755 MIL A 46153 11 pope TM 9 2320 363 10 oc lt oc lt N oc m lt oc m 2 u lt gt SECONDARY FUEL FILTER PRIMARY FUEL FILTER WATER SEPARATOR WATER DRAIN VIEW B M915A2 FRONT AXLE WHEEL BEARINGS WHEEL BEARINGS F 10 TM 9 2320 363 10 VIEW C POWER STEERING RESERVOIR FILL AND LEVEL CHECK POWER STEERING RESERVOIR VIEW D M915A2 FIFTH WHEEL GREASE FITTING SLID R RAILS r D me an PLUNGER FIFTH WHEEL PLATE LATCH MECHANISM TOP AND BOTTOM LATCH MECHANISM FROM UNDERNEATH ANGLED TOP SURFACE F 11 TM 9 2320 363 10 VIEW E ENGINE CRANKCASE AOAP OIL 3 SAMPLING ENGINE OIL SAMPL OIL LEVEL DIPSTICK VIEW F TRANSMISSION DIPSTICK AND FILL TUBE AOAP OIL SAMPLING VALVE F 12 TM 9 2320 363 10
120. e of debris and other material that could interfere with air venting Install filler cap Check that lubricating oil is vis ible in sight glass 28 and rub ber plug 27 is installed If oil is not visible in sight glass remove plug and add until level is even with plug opening Appendix Not Fully Mission Capable If 2 59 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Interval Check Service Trans mission 2 60 Procedure Start engine and run at idle with transmission in Neutral N until transmission oil tem perature gage registers 60 120 F 16 49 C Perform cold oil check Appendix F When temperature has reached 160 200 F 71 93 C perform hot oil check Tora Add transmission fluid as required through fill tube 57 until level on dipstick 56 is correct Appendix F Shut down Not Fully Mission Capable if TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Check Not Fully Mission Interval Service Procedure Capable if Air Res ervoirs Perform the following service at ail air res ervoirs Open air reservoir drain valve 58 using cable pulls if present and allow all air and liquid condensation to drain When fully drained close drain 2 61 TM 9 2320 363 10 Table
121. e immediate action to stop the corrosive burning effects Failure to follow these procedures may result in death or serious injury to personnel a Eyes Flush with cold water for no less than 15 minutes and seek medical attention immediately b Skin Flush with large amounts of cold water until all acid is removed Seek medical attention as required C Internal If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magnesia beaten egg or vegeta ble oil Seek medical attention immediately d Clothing Equipment Wash area with large amounts of cold water Neutralize acid with baking soda or household ammonia WARNING BRAKES Do not use trailer handbrake to prevent trailer from jackknifing because this may cause trailer to jackknife Modern airbrake systems are designed to deliver the right amount of air to all wheels to stop vehicle without jackknifing Failure to fol low this warning may result in death or injury to personnel or damage to equip ment Do not use trailer handbrake as primary brake to keep tension on coupling sys tem This will cause undue tension on brakes and coupling which could result in injury to personnel or damage to equipment Prevent problems with slack in fifth wheel by using good braking habits and adjusting coupling and braking systems properly When caging brakes block wheels to keep truck from moving when brakes are released Fai
122. e locking plungers 5 are retracted and fully engaged It may be necessary to leave trailer brakes locked and aor slightly to engage plungers in rack teeth 4 f If lowered raise landing gear to fully retracted position 2 99 TM 9 2320 363 10 2 22 OPERATE SLIDING FIFTH WHEEL M916A1 AND 916 2 DO NOT tow 6 000 gallon water distributors with a partial load except when in use on construction sites and a maximum speed of 10 mph When towing outside of construction sites TRAILERS MUST BE EMPTY OR FULL Either drain water distributor empty preferred or fill to capacity MAXIMUM SPEEDS FOR BOTH TRAILERS ARE HIGHWAY 55 MPH GRAVEL DIRT 30 MPH OFF ROAD 5 MPH Failure to follow this warning could result in unsafe driving conditions causing serious injury or death to personnel and damage to equipment e When towing model WD6S 6 000 gallon water dis tributor fifth wheel must be in rear setting LOAD HAUL M172 For model 60PRS fifth wheel must be at rear setting LOAD HAUL M172 to load and front setting HAUL M870 to tow For all models travel lockout must be engaged to prevent side to side oscillation of water distributor Failure to follow this warning could result in unsafe driving conditions causing serious injury or death to personnel and damage to equipment The M916A1 and M916A2 is designed to be used with M870 and M172 semitrailers and models 60PRS and WD6S water distributors Other semitr
123. ear of potential pinch points Failure to follow this warning may result in injury to personnel Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equipment or injury to personnel may result These vehicles have been designed to operate safely and efficiently within the limits specified in this TM Operation beyond these limits is prohibited in accor dance with AR 70 1 without written approval from Commander U S Army Tank automotive and Armaments Command ATTN AMSTA DSA CS Warren MI 48397 5000 f Change 1 TM 9 2320 363 10 WARNING WINCH OPERATION M916A1 AND M916A2 Always wear heavy gloves when handling winch cable Never allow cable to run through hands frayed cable can cut you Never operate winch with less than four turns of cable on drum Keep cable coils tight and close together on drum while winching Failure to follow this warning may result in injury to personnel Hearing protection is required for operator and personnel working around winch station during operation DO NOT use winch for moving or lifting people Serious injury could result WARNING WORK SAFETY Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improperly lifted or if it falls on you Hydraulic jack is intended only for lifting truck not for supporting vehicle to per for
124. easurement or count of an item such as gallon dozen gross etc D 1 TM 9 2320 363 10 Section Il D 2 EXPENDABLE AND DURABLE ITEMS LIST 3 National Stock Number 6850 00 174 1806 6850 00 181 7929 6850 00 181 7933 6850 00 181 7940 6850 00 926 2275 7930 00 282 9699 9140 00 286 5295 9140 00 286 5296 9140 00 286 5297 9140 00 286 5286 9140 00 286 5287 9140 00 286 5288 9140 00 286 5289 4 Description CAGEC Part Number ANTIFREEZE Arctic Grade 81349 MIL A 11755 55 Gallon Drum ANTIFREEZE Permanent Ethylene Glycol Inhibited Heavy Duty 81349 MIL A 46153 1 Gallon Can 5 Gallon Can 55 Gallon Drum Cleaning Compound Windshield 81348 O C 1901 DETERGENT General Purpose Liquid 81348 7930 00 282 9699 1 Gallon Can FUEL DIESEL DF 2 Grade 81348 VVF800GRADEDF2RE 5 Gallon Can 55 Gallon Drum 16 Gage 55 Gallon Drum 18 Gage FUEL Diesel Winter 81348 VVF800GRADEDF1W1 Bulk 5 Gallon Can 55 Gallon Drum 16 Gage 55 Gallon Drum 18 Gage Section Il Number Level TM 9 2320 363 10 EXPENDABLE AND DURABLE ITEMS LIST Con t 3 National Stock Number 9150 01 197 7693 9150 01 197 7688 9150 01 197 7690 9150 01 197 7609 9150 01 197 7692 9150 01 197 7691 9150 01 035 5390 9150 01 035 5391 9150 01 035 5392 9150 01 035 5393 9150 01 035 5394 9150 01 035 5396 9150 00 402 4478 9150 00 402 2372 9150 00 491 7197 4 Description CAGEC
125. eck amp Fill C See View E amp Note 5 Transmission Check amp Fill C See View F amp Note 6 Winch Reservoir Check amp Fill C See View G amp Note 7 Winch Cable See Note 7 C Fifth Wheel See View H amp Note 3 C TM 9 2320 363 10 M917A1 AND M917A1 W MCS LUBRICANT INTERVAL INTERVAL LUBRICANT Primary Fuel Fil ter Water Separator Drain Moisture C See View A Power OE Steering Reser HDO voir Check amp Fill C See View C amp Note 2 Radiator Check amp Fill C See Note 4 Engine Crank case Check amp Fill C See View E amp Note 5 Transmission Check amp Fill C See View F amp Note 6 F 5 TM 9 2320 363 10 Expected Temperatures 6 to x 67 F to Lubricant Refill 122 SET ID F30 32 F Component Capacity 14 C to gere 55 C to 50 C 0 Lubricating ICE OEA MIL L 46167 Lubricating Oil ICE Arctic Engine Crankcase 41 Qt See Chart A w Filters 38 8 L Transmission 33 Qt See Chart B 31 2 L Power Steering 2 Qt See Chart A Reservoir 19 3 L Winch Reservoir 42 Gal See Chart C M916A1 amp 159 L M916A2 Oil Can Points As Reqd See Chart A GO MIL L 2105 Lubricating Oil Gear Multipurpose Front Axle Wheel As Reqd See Chart D Bearings M915A2 GAA MIL G 10924 Grease Automotive and Artillery Intervals OE HDO MIL L 2104 Fifth Wheel All Temperatures All Except M917A1
126. ection explains the overall operation of these systems 1 25 TM 9 2320 363 10 1 14 DRIVE TRAIN a The drive train of the M915A2 consists of a 60 Series Detroit Diesel engine and an Allison 4 speed automatic transmission connected to RT 40 145P rear tandem axles b The M916A1 and M916A2 have RT52 160P rear tandem axles and an Oshkosh front drive axle The axles receive power through an Oshkosh transfer case from the transmission and engine C The M917A1 and M917A1 w MCS drive train is similar to the M916A2 It differs in that all axles are modified to incorporate CTIS plumbing REAR REAR AXLE FORWARD REAR AXLE TRANSFER CASE ALL EXCEPT M915A2 FRONT ORIVE AXLE 1 26 TM 9 2320 363 10 1 15 FUEL SYSTEM a Fuel to power the engine is pumped out of the fuel tank by an engine mounted fuel pump The engine fuel system consists of one electronic unit injector per cylinder a transfer pump low pressure fuel lines and primary and sec ondary filters b The engine is governed by an electronic control system The system controls idle speed and limits engine maximum speed The driver controls engine speed through the position of the electric foot pedal assembly C Fuel filters are spin on types The primary fuel filter has a hand fuel primer pump and a water drain d Fuel may be drained from the tank through the drain port located on the bottom of the tank e There is an ether quick start system for
127. ed is lifted off the ground disconnect universal joint on propeller shaft at the input to the forward rear axle and tie it up to vehicle undercarriage b When rear tandem axles of vehicle being towed are lifted off ground ensure interaxle lockout all wheel drive control valve switch is in UNLOCKED DISENGAGE position Place transfer case selector lever in Neutral N position Propeller shafts must be disconnected to prevent opera tion of transfer case and interaxle lockout all wheel drive control valve switch must be in UNLOCK DISEN GAGE position before towing vehicle Failure to follow this caution may result in transmission damage NOTE Towing vehicle speed should not exceed 15 mph on pri mary roads and 8 mph on secondary roads For cross country towing all tires of disabled vehicle should be on ground b Towing Procedures 1 Install medium duty tow bar at towing vehicle pintle and dis abled vehicle towing eyes Ensure tow bar is long enough to allow complete turning radius 2 Connect air pressure hoses between disabled vehicle and towing vehicle Quick disconnect gladhands are located behind rear bumper 3 Release parking brakes and turn appropriate lights on 2 124 TM 9 2320 363 10 2 38 CAGE AND UNCAGE BRAKES a Cage Brakes In the event of an air pressure loss spring brakes on the tandem rear axles will apply the brakes If the vehicle must be towed and there is not enough air system pressu
128. eels 2 48 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Not Fully Mission Capable If 22 FRONT Front Check that lubricating oil is vis Axle ible in sight glass 28 and rub Wheel ber plug 27 is installed If oil Bear is not visible in sight glass ings remove plug and add until 915 2 level is even with plug opening Appendix F 2 49 TM 9 2320 363 10 2 50 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Check Service Power Steering Reser voir Procedure With fluid at operating temper ature and engine running remove dipstick 29 and check level of power steering fluid in reservoir 30 Add fluid as required if level is below add mark Appendix F Not Fully Mission Capable If TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To E Interval Check Not Fully Mission Service Procedure Capable if DO NOT perform fuel system checks inspections or maintenance while smok ing or near fire flames or sparks Fuel may ignite causing damage to vehicle and injury or death to personnel NOTE Ensure that a suitable container is used to catch fluid Turn drain knob 32 counter clockwise and drain all water from fuel filter w
129. el and tire from carrier paragraph 3 8 3 28 Change 1 TM 9 2320 363 10 3 10 FRONT WHEEL AND TIRE ASSEMBLY REPLACEMENT 917 1 AND 917 1 W MCS Con t NOTE Wheel nuts on left side of vehicle are left hand threads turn right to loosen turn left to tighten Wheel nuts on right side of vehicle are right hand threads turn left to loosen turn right to tighten 8 Loosen wheel nuts on wheel to be removed Hydraulic jack is intended only for lifting truck not for supporting vehicle to perform maintenance Do not get under truck after it is raised unless it is properly sup ported with blocks or jackstands Faliure to observe this warning may result in death or injury to personnel 9 Raise jack until tire clears ground Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improp erly lifted or if it fails on you 10 Remove wheel nuts and wheel and tire assembly 3 29 TM 9 2320 363 10 3 10 FRONT WHEEL AND TIRE ASSEMBLY REPLACEMENT 917 1 AND M917A1 W MCS b Install Front Wheel and Tire Assembly Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improp erly lifted or if it falls on you 1 Position wheel and tire assembly on wheel hub ensuring hole in wheel aligns with hub air port 4 NOTE Wheel nuts on left side of vehicle are left hand threads turn right to loosen tu
130. em 3 as required Weekly CTIS a With engine running select RUN FLAT key 76 Check system for air leaks b With engine running select b Mission requires one inflate and one deflate use of CTIS and mode on selector panel 75 CTIS is malfunc Check that tires inflate and tioning deflate c While driving select EMER mode key 77 and check that instrument panel reduce MPH indicator light comes on 2 78 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Not Fully Mission Interval Procedure Capable if Monthly a Check for obvious damage a Any loose or bro to frame and undercarriage ken frame side rails crossmem bers broken welds or broken bolts are found b Check propeller shafts and b Mounting bolts U joints for loose or broken and nuts are loose bolts and nuts or missing Monthly Check all air lines fittings and Any air lines fittings valves for looseness or dam or valves are loose age or damaged Monthly Check exhaust system for cor Any exhaust leak rosion looseness or damage are suspected 2 79 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location item To Not Fullv M Check ot Fully Mission Interval Service Procedure Capable if Monthly Hydrau Check winch reservoir drum Any hydraulic com lic Sys
131. en flame or excessive heat The solvent s flash point is 100 F 138 F 38 C 59 C If you become dizzy while using cleaning sol vent immediately get fresh air and medical help If solvent contacts eyes immediately wash your eyes and get medi cal aid Clean area around lubrication points with dry cleaning solvent Item 17 Appendix D or equivalent before lubri cating equipment After lubrication wipe off excess lubricant to prevent accumulation of foreign matter Dashed leader line indicates lubrica tion on both sides of vehicle TM 9 2320 363 10 M915A2 LUBRICANT INTERVAL INTERVAL LUBRICANT Primary Fuel Filter Water Separator Drain Moisture C See View A Wheel Bearings Check and Fill C See View B amp Note 1 Power Steering Reser voir Check amp Fill C See View C amp Note 2 Fifth Wheel Clean amp Grease C See View D and Note 3 Radiator Check amp Fill C See Note 4 Engine Crank case Check amp Fill C See View E amp Note 5 Transmission Check amp Fill C See View F amp Note 6 F 3 TM 9 2320 363 10 LUBRICANT Radiator Check amp Fill C See Note 4 Primary Fuel Fil ter Water Separator Drain Moisture C See View A Power Steering Reser voir Check amp Fill C See View C amp Note 2 F 4 M916A1 AND INTERVAL M916A2 INTERVAL LUBRICANT OE HDO Engine Crank case Ch
132. en wheel nuts according to tightening pattern WHEEL NUT TIGHTENING PATTERN 6 If replacing inner rear tire alternately tighten inner wheel nuts by removing outer wheel nut according to tightening pattern and tighten inner wheel nut After tightening inner wheel nut reinstall outer wheel nut and tighten according to tightening pattern 7 Notify Unit Maintenance as soon as possible to apply proper torque 8 Stow defective tire in spare wheel and tire carrier paragraph 3 8 and have it replaced or repaired as soon as possible 9 Remove wheel blocks 3 27 TM 9 2320 363 10 3 10 FRONT WHEEL AND TIRE ASSEMBLY REPLACEMENT M917A1 AND M917A1 W MCS a Remove Front Wheel and Tire Assembly NOTE When changing tires do not substitute type or tire size unless all tires can be converted 1 Stop engine paragraph 2 20 and drain vehicle air system Table 2 1 2 Block wheels 3 Position jack 1 so jack ram 3 is under front steering axle WARNING Always wear eye protection and drain all air from wet tank before disconnecting CTIS air lines hoses or fit tings Residual air in tire s and air line s will be expelled even though tire s is flat Failure to follow this warning could cause serious eye injury 4 Disconnect hose 6 from elbow 5 5 Disconnect connector 7 from wheel valve 8 6 Remove elbow 5 from hub air port 4 7 Remove spare whe
133. er form ether quick start system checks or inspections while smoking or near fire flame or sparks Failure to follow this warning may cause a fire and explosion causing serious Injury or death to personnel Step 4 If operating a vehicle with automatic ether injection system check red indicator light on ether control relay paragraph 2 8 If red light is on notify Unit Maintenance 12 ENGINE DOES NOT DEVELOP FULL POWER Step 1 Check whether power take off PTO is disengaged Disengage PTO Step 2 Check air cleaner restriction indicator If indicator is not clear notify Unit Maintenance 13 ENGINE DOES NOT IDLE PROPERLY Step 1 Check air cleaner restriction indicator If indicator is not clear notify Unit Maintenance Step 2 If operating M915A2 or 916 1 in temperature below 32 F 0 check that cold weather starting procedure was used Perform cold weather starting procedure paragraph 2 14 14 ENGINE FAILS TO CRANK WHEN STARTER BUTTON IS PRESSED Step 1 Check position of ignition switch Place ignition switch in ON position Step 2 Check position of transmission selector lever Place transmission selector lever to Neutral N position Step 3 Check for dirty loose or broken battery cables Clean dirty cables Tighten loose connections at batteries ground and starter If cable is broken notify Unit Maintenance 3 11 TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECT
134. er check position of trailer air supply control knob Pull knob out OFF Step 3 Start engine paragraph 2 14 and check for air leaks at air reservoirs hoses fittings and intervehicular air hose connec tions If air leaks are present notify Unit Maintenance Step 4 Perform semitrailer troubleshooting 2 AIR SYSTEM LOSES PRESSURE DURING VEHICLE OPERATION OR LOW AIR PRESSURE WARNING LIGHT AND BUZZER COME ON DURING VEHICLE OPERATION NOTE Any change in pressure on brake pedal will cause a change in air pressure reading Step 1 Ensure trailer air supply control knob is pulled out OFF Operate engine until warning light and buzzer go off and release parking brake Stop engine and note reservoir pres sure Fully press and hold service brake pedal for two minutes Have crewmember check for leaks Reservoir pressure loss during two minute period should not exceed 5 psi 34 kPa Close air reservoir draincocks If leaks are present notify Unit Maintenance NOTE Any change in pressure on brake pedal will cause a change In air pressure reading Step 2 Push trailer air supply control knob in ON to charge semi trailer air reservoirs and repeat step 1 Have crewmember check semitrailer for leaks Pressure loss should not exceed 5 psi 34 kPa in two minutes 3 6 TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION If air leaks are present or reservoir
135. f engine still fails to start notify Unit Maintenance DO NOT run engine above idle speed until oil pressure gage indicates at least 12 psi 83 kPa at idle speed i Monitor gages and indicators If after ten seconds there is no indica tion of oil pressure and SHUT DOWN light engine oil warning light or CHK ENG light remains on shut down perd 72 and perform troubleshooting Chap ter 3 Section Il NOTE Perform steps j through m if outside temperature is at or below 32 F 0 C Vehicles not equipped with a manual ether quick start system are equipped with an automatic ether injection system for cold weather starting j Perform steps a through h 2 86 TM 9 2320 363 10 2 14 START ENGINE Con t For vehicles equipped with manual ether quick start system never press ether quick start button unless cranking engine simultaneously Buildup of ether fumes may result in combustion in intake manifold DO NOT operate starter motor for more than 30 sec onds at a time After 30 seconds allow starter motor to cool for at least two minutes before attempting to start engine again Excessive heating of starter motor may result in damage or early starter failure k For manual ether quick start system press engine start button and at the same time press ether quick start button once l When engine starts release engine start button DO NOT run engine above idle speed until oil pressure gage indica
136. fers you to the proper page in Table 3 1 for a troubleshooting procedure C If you are unsure of the location of an item mentioned in trouble shooting refer to paragraph 1 10 Chapter 2 Section d Before performing troubleshooting read and follow all safety instruc tions found in the Warning Summary at the front of this manual e This section cannot list all malfunctions that may occur nor all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by the listed corrective actions notify your supervisor f When troubleshooting a malfunction 1 Locate the symptom or symptoms i that best describe the malfunction 2 Turn to the page in Table 3 1 where the troubleshooting pro cedures for the malfunction in question are described Headings at the top of each page show how each troubleshooting procedure is organized MALFUNCTION TEST OR INSPECTION in step number order and CORRECTIVE ACTION 3 Perform each step in the order listed until the malfunction is corrected DO NOT perform any maintenance task unless the troubleshooting proce dure tells you to do so 3 3 TM 9 2320 363 10 3 3 EXPLANATION OF COLUMNS The columns in Table 3 1 are defined as follows a MALEUNCTION A visual or operational indication that something is wrong with the equipment b IEST OR INSPECTION procedure to isolate the problem in a system or component C CORRECTIVE A
137. for presence and gen eral condition of mud flaps 51 Not Fully Mission Capable If Damage that vents coupling pre Damage that vents coupling pre Taillights are dam aged Damage that vents air from apply ing trailer brakes when coupled Mud flaps are miss ing 2 57 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Check Not Fully Mission Service Procedure Capable If Interval WARNING 1 I DO NOT smoke or permit any open flame in area of truck while servicing diesel fuel system Be sure hose nozzle is grounded against filler tube during refueling to pre vent static electricity Failure to follow this warning may result in injury to personnel or equipment damage a Check for presence and a Filer cap is miss condition of fuel filler cap ing or damaged 55 b Check fuel tank 54 for b Class III fuel leaks leaks damage and security are evident of mounting 2 58 Change 1 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Check Service Front Axle Wheel Bear ings M915A2 Procedure c Remove fuel tank filler cap 55 and fill fuel tank 54 to holes approximately 3 in 7 6 cm in filler neck Ensure that filler cap is fre
138. fy supervisor Be alert for evidence of fluid leakage a Check under truck for evi dence of fluid leakage such as oil coolant fuel or hydraulic fluid b Check front gladhands for damage Ensure that glad hand vent holes are not plugged Ensure that dummy couplings are installed Class IIl oil coolant or hydraulic leaks o Class 11 fuel leak are evident a Class Ill oil cool ant or hydrauli leaks or Class Il fuel leaks are evi dent 2 47 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t nd Not Fully Missi e ot Fully Mission Interval service Procedure Capable If 23 After c Check truck for obvious c Damage that Con t damage that would impair would impair oper operation ation is evident d Check for damage to front d Lights are dam service and blackout lights aged and marker clearance lights Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result a Visually check all left side a Tire is missing tires for defects underinfla deflated unser tion or loose or missing viceable or two or wheel studs or lug nuts more wheel studs or lug nuts are missing b For M917A1 and M917A1 w b CTIS components MCS check for damage to are damaged CTIS hoses 25 wheel valves 26 and fittings 24 at wh
139. g Force The vehicle is equipped with an engine braking system that enables the engine to act as a brake The engine brake should be used for descending grades and is most effective between 1750 2100 rpm a If maximum engine braking is required turn both engine brake selection switches up to engage six cylinders b If less than maximum engine braking is required turn left engine brake selection switch up and right engine brake selection switch down to engage two cylinders or left engine brake selection switch down and right engine brake selection switch up to engage four cylinders 5 Downhill Braking a Select a gear that allows engine with engine brake applied to control vehicle speed with engine rpm at or below 2100 rpm without apply ing service brakes As downgrade is approached progressively select a gear that when combined with engine brake will allow you to maintain engine speed of 1750 2100 rpm b As engine speed exceeds 2100 rpm use one positive application of service brakes to slow engine speed to 1650 rpm release engine brake downshift one gear and apply engine brake Repeat this procedure until engine speed can be maintained at 1750 2100 rpm Excessive use of service brake to control downhill speed will result in loss of braking power due to heat build up c If you experience a total loss of braking due to heat build up apply engine brake six cylinders upshift as engine speed approaches 2100 rp
140. g conditions causing serious injury or death to personnel and damage to equipment When towing 6 000 gallon water distributor fifth wheel must be in rear setting LOAD HAUL 172 and travel lockout must be engaged to prevent side to side oscillation of water distributor Failure to follow this warning could result in unsafe driving conditions causing serious injury or death to personnel and damage to equipment TM 9 2320 363 10 C1 CHANGE HEADQUARTERS NO 1 DEPARTMENT OF THE ARMY Washington D C 15 February 2006 OPERATOR S MANUAL TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A2 NSN 2320 01 272 5029 EIC B4E TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A1 NSN 2320 01 272 5028 EIC B4F TRUCK TRACTOR LIGHT EQUIPMENT TRANSPORTER LET 68 000 GVWR 6 X 6 W WINCH M916A2 NSN 2320 01 431 1163 EIC B4J TRUCK DUMP HEAVY CHASSIS 68 000 GVWR 6 X 6 14 CU YD ON OFF HIGHWAY M917A1 NSN 3805 01 431 1165 EIC B5C M917A1 W MCS NSN 3805 01 432 8249 EIC EBD TM 9 2320 363 10 dated 30 December 1997 is changed as follows 1 Remove old pages and insert new pages 2 New or changed material is indicated by a vertical bar in the margin Remove Pages Insert Pages A B Blank a thru h hri i and ii i Bind iij 1 3 and 1 4 1 4 2 11 2 12 2 11 2 12 2 31 2 32 and 2 32 2 57 and 2 58 and 2 81 and 2 82 and 2 97 thru 2 98 thru 2 98
141. g wheel and tire assembly It is heavy and could cause injury if improp erly lifted or if it falls on you NOTE Wheel nuts on left side of vehicle are left hand threads turn right to loosen turn left to tighten Wheel nuts on right side of vehicle are right hand threads turn left to loosen turn right to tighten 4 If replacing inner tire position wheel and tire assembly on wheel hub 20 with hand hold 7 not containing valve stem aligned with hub air port 5 Install wheel nuts and handtighten 5 Install spacer 6 Position outer wheel and tire assembly on wheel hub 20 with hand hold 7 not containing valve stem aligned with hub air port 5 Install wheel nuts and handtighten 7 Route inner wheel valve stem hose 15 through outer wheel hand hold 17 8 Lower and remove jack 3 35 TM 9 2320 363 10 3 11 REAR WHEEL AND TIRE ASSEMBLY REPLACEMENT 917 1 AND 917 1 W MCS Con t Whenever inner and or outer wheel lug nuts require tightening or a wheel has been removed and replaced lug nuts must be torqued to the required torque Failure to follow this warning may result in serious injury to personnel and damage to equipment NOTE Tightening pattern is identical for ail wheel assemblies 9 tenance apply proper torque to wheel nuts 10 Have Unit Main Remove two WHEEL NUT TIGHTENING PATTERN hub nuts 11 at 4 and 5 o clock position 11 on wheel hub studs
142. ght 1 BCN LT indicator 4 should come on 2 Move beacon light switch down to turn off beacon warning light 1 b Operate Work Lights 1 Connect work light plug into receptacle 3 2 Place ignition key in ON position and main light switch in STOP LIGHT or SER DRIVE position 3 Position ignition key in OFF position and disconnect work light plug from receptacle 3 C Operate Utility Lights All Except M917A1 and M917A1 w MCS 1 Place ignition key in ON position and move utility light switch up to turn utility lights 2 on UTLY light indicator 5 should come on 2 Move utility light switch down and place ignition key in OFF position FASTEN SEAT BELT esoceseoseqeo TUN 5 4 2 116 TM 9 2320 363 10 2 32 RIFLE MOUNTING KIT a For M915A2 and M916A1 rifle mounting kit 1 is located next to shift control b For all except M915A2 and 916 1 rifle mounting kit 1 is located behind shift tower against back wall of cab M915A2 AND M916A1 ALL EXCEPT M915A2 AND M916A1 2 33 OPERATE HEATER AND DEFROSTER NOTE Heater and defroster obtain heat from engine as it runs If engine is not running heat will not be available for these functions a Start engie paragraph 2 14 and bring truck to normal operating temperature 2 117 TM 9 2320 363 10 2 33 OPERATE HEATER AND DEFROSTER Con t
143. heel 6A2 74410 XA 0756 15 4910 01 407 2953 Hose Pneumatic Tire EA 1 Inflation with Gauge 40 ft in BII storage box 19207 11677140 7 B 5 TM 9 2320 363 10 Section Ill BASIC ISSUE ITEMS Con t 1 2 3 4 Illus National Description Usable Number Stock Number CAGEC Part Number On Code 16 5120 01 146 8096 Jack Hydraulic 20 Ton w EA 1 Handle BII storage box 63704 28961 17 6220 01 327 3225 Lamp Work Portable 12 EA 2 volt 25 ft Cord storage box 78422 1401152 18 5120 00 181 6819 Pliers Combination Gen EA 1 eral Purpose in BII storage box 72368 J26 19 5120 00 227 7356 Screwdriver Flat Tip EA 1 storage box 64067 5120 00 227 7356 20 5120 00 234 8913 Screwdriver Crosstip EA 1 BII storage box 75347 BD122 B 6 Change 1 TM 9 2320 363 10 Section Ill BASIC ISSUE ITEMS Con t 21 22 336 037 2 3 National Description Stock Number CAGEC Part Number 4030 01 187 0964 Shackles Towing in BII storage box 19207 12328579 3990 01 327 1278 Tie Down Hood Molded Rubber BII storage box 0C1E6 CR15A 9905 00 148 9546 Triangle Folding Reflective in BII storage box 19207 11669000 5120 00 240 5328 Wrench Adjustable 8 in long in BII storage box 19207 11655778 3 Change 1 B 7 TM 9 2320 363 10 Section Ill BASIC ISSUE I
144. his manual is designed to help you operate and maintain the M915 Family of Vehicles FEATURES OF THIS MANUAL A table of contents is provided at the beginning of this manual An index of all paragraphs contained within a section is found at the beginning of each section WARNINGs CAUTIONs NOTEs subject headings and other important infor mation are highlighted in BOLD print as a visual aid A WARNING indicates a hazard which can result in death or serious injury A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment NOTE A NOTE is a statement containing information that will make the procedure easier to perform Statements and words of particular importance are printed in CAPITAL LET TERS to create emphasis Instructions are located with illustrations that show the specific task on which the operator is working Dashed leader lines used in illustrations indicate that called out items are not vis ible i e they are located within the structure Dashed leader lines in the Lubri cation Chart indicate that lubrication is required on BOTH sides of the equipment Technical instructions include metric units in addition to standard units A metric conversion chart is provided on the inside back cover An alphabetical index is provided at the end of the manual to assist in locating information not readily found in the table of contents FOLLOW THESE GUIDEL
145. icle must be stopped completely and transmission must be in Neutral N position before transfer case can be shifted into position 1 High High is the normal operating position 2 Neutral N Neutral N is the normal position when vehicle is not in use Vehicle will not move if transfer case is in Neutral N 3 Low Low engages all wheel drive which is normally used when transmission gear selection is other than Drive D b Operation 1 Stop vehicle and place transmission in Neutral N position 2 88 TM 9 2320 363 10 2 16 OPERATE TRANSFER CASE ALL EXCEPT M915A2 Con t Ensure that transfer case selector lever is fully engaged Failure to follow this caution may result in equipment damage NOTE An air leak may be heard if transfer case selector lever is not fully engaged 2 Move transfer case selector lever to desired position 2 17 OPERATE CTIS M917A1 AND M917A1 W MCS a CTIS Selector Panel Display Summary 1 Single Mode Light A solid single mode light indi cates pressure has been achieved for that mode CTIS is inactive and wheel valves are closed A flashing single mode light indicates CTIS is working to achieve pressure associated with that mode 2 89 TM 9 2320 363 10 2 17 OPERATE CTIS M917A1 AND M917A1 W MCS Con t 2 Two Mode Lights on Solid CTIS has shut off with tire pressure between two mode set tings perform troubleshooting Section II 3 Fo
146. ify Unit Maintenance to apply proper torque Step 3 Check for loose lugs nuts and worn loose or damaged sus pension components Tighten loose lug nuts and notify Unit Maintenance to apply proper torque If suspension components are worn loose or damaged notify Unit Maintenance 25 VEHICLE WANDERS OR PULLS TO ONE SIDE ON LEVEL PAVEMENT Step 1 Check tires for proper pressure Inflate tires to proper pressure Table 2 1 Step 2 Check that tires are proper size and type If one tire is mismatched and spare matches replace mis matched tire with spare If one or more tires are mis matched notify Unit Maintenance Step 3 Check for loose or damaged steering gear linkage If steering gear linkage is loose or damaged notify Unit Maintenance 26 WHEEL WOBBLES Step 1 Check for loose or missing lug nuts Tighten loose lug nuts and notify Unit Maintenance to apply proper torque If lug nuts are missing notify Unit Maintenance Step 2 Check for bent wheel rims If rim is bent replace wheel and tire assembly Notify Unit Maintenance to apply proper torque Step 3 Check for loose worn or damaged steering and suspension components If steering or suspension components are damaged notify Unit Maintenance TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION WINCH M916A1 AND M916A2 27 WINCH DRUM WILL NOT OPERATE Step 1 Check position of PTO sw
147. ine to return to idle speed Shift transmission to R REVERSE Again apply light steady throttle and allow vehicle to move rearward as far as it will go Apply service brakes and allow engine to return to idle speed This procedure can be continued as long as each directional shift moves vehicle a greater distance If not vehicle should be towed from its position 2 Stopping a Ease up on accelerator leaving vehicle in gear b Apply service brakes lightly and evenly Do NOT pump service brake pedal 2 137 TM 9 2320 363 10 2 45 OPERATE ON SNOW OR ICE Con t Do not use engine brake if road surfaces are slippery Using engine brake on wet icy or snow covered roads could result of loss of vehicle control Failure to follow this warning could result In death or injury to personnel or damage to equipment c Always avoid sudden braking and use of engine brake on slick roads d All vehicles have Anti Lock Brake System ABS and have the advantage of easier handling and controllability during emergency stops During emergency or reduced traction stops press brake pedal fully until vehicle comes to a safe stop DO NOT PUMP brake pedal With brake pedal fully depressed ABS will control all wheels to provide steering control and a reduced braking dis tance 3 Parking If parking on icy slushy wet or muddy surfaces place boards brush or other materials that will provide traction underneath tires This will guar
148. is in LOW range all except M915A2 2 17 TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t 51 52 53 e 9e36 0 6 60 O 8 9 51 8 FASTEN SEAT BELT Utility UTLY Light All Except M917A1 and M917A1 w MCS Beacon Light BCN LT Low Air Pressure Warning Light Parking Brake Indicator Light All Except M915A2 and M916A1 Tractor ABS TRAC ABS Indicator Light All Except M915A2 and M916A1 Amber light comes on when utility lights are turned on Amber light comes on when beacon warning light is turned on Red light comes on and warning buzzer sounds when air pressure in either section of dual system falls below 65 psi 448 kPa Red light comes on when parking brakes are activated Red light comes on when ignition is turned ON Once vehicle moves faster than 4 mph 6 kph light goes out if ABS components are working Light blinks when vehicle is in all wheel drive TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t M916A2 M917A1 AND M917A1 W MCS Body Up Indicator Red light comes on when dump body is raised Light M917A1 and M917A1 w MCS Body Transport Red light comes on when dump body transport lock Lock Indicator Light is locked M917A1 and M917A1 w MCS Reduce MPH Red light comes on when dump truck is traveling Indicator Light too fast for tire pressure selected by CTIS para M917A1 and graph 2 6 M917A1 w MCS 2 19 TM 9 2320 363 10 2
149. itch and that PTO indicator light is ON Place PTO switch in ON position and ensure PTO indicator light is lit Step 2 Check position of engine speed switch on winch control con sole Place engine speed switch to HIGH position Step 3 Check if winch drum is free from any debris that would prevent it from turning Remove any debris that blocks winch drum DO NOT remove fill cap when hydraulic fluid is hot Hydraulic tank is pressurized to 5 psi 34 kPa Remove cap slowly to prevent burns Step 4 Check hydraulic fluid level If hydraulic fluid is low fill to correct level Appendix F 28 WINCH UNUSUALLY NOISY WHEN OPERATING Always wear heavy gloves when handling winch cable Never allow cable to run through hands frayed cable can cut you Never operate winch with less than four turns of cable on drum Keep cable coils tight and close together on drum while winching Failure to follow this warning may result in injury to personnel Check that cable is not twisted tangled or causing drum to bind Pay out or take up cable and straighten 3 15 3 16 Blank TM 9 2320 363 10 Section MAINTENANCE PROCEDURES Paragraph Page Number Paragraph Title Number Cleaning Vehicle Manual Tire Inflation 3 19 Operation of Spare Wheel and Tire Assembly Carrier Wheel and Tire Assembly Repl
150. its primary mission If you make check and service procedures that show faults listed in this column the equipment is not mission capable Follow standard operating proce dures for maintaining the equipment or reporting equipment failure 2 11 GENERAL PMCS PROCEDURES a Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If the truck does not perform as required refer to the appropriate troubleshooting procedure in Chapter 3 Section Il b If anything looks wrong and you can t fix it write it on your DA Form 2404 If you find something seriously wrong IMMEDIATELY report it to your supervi sor C Before performing preventive maintenance read all the checks required for the applicable interval and prepare all the tools you need to make all the checks You ll always need a rag Item 16 Appendix D or two 2 34 TM 9 2320 363 10 2 11 GENERAL PMCS PROCEDURES Con t Dry cleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ven tilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat The solvent s flash point is 100 F 130 F 38 C 59 C If you become dizzy while using cleaning solvent immediately get fresh air and medical help If solvent contacts eyes immedi ately wash your eyes and get medical aid
151. k body refer to TM 5 3805 264 14 amp P This section contains instructions for safely operating the M915 Family of Vehicles under usual conditions Unusual conditions are defined and described in Section IV of this chapter 2 13 INITIAL ADJUSTMENTS DAILY CHECKS AND SELF TESTS a Perform Before operation Preventive Maintenance Checks and Ser vices PMCS Chapter 2 Section II b Change military load classification paragraph 1 12 if necessary Adjust side mirrors 3 by loosening two nuts 2 and moving side mirror to proper position Tighten two nuts CAUTION DO NOT attempt to adjust spotter mirrors without loos ening screws Attaching screw may become loose and result in loss of spotter mirror d Adjust spotter mirrors 1 by loosening three screws 4 and moving spotter mirror to proper position Tighten three screws 2 82 TM 9 2320 363 10 2 13 INITIAL ADJUSTMENTS DAILY CHECKS AND SELF TESTS Con t Use of seat belts while operating vehicle is mandatory Fasten belt BEFORE driving Trying to fasten three point seat belt while driving creates a hazardous condi tion Failure to follow this warning may result in death or injury to personnel e Adjust tether belt 1 Loosen tether belt 6 and turn buckle 5 at a right angle to webbing Pull buckle away from inner webbing 2 Tighten tether belt 6 to proper tension Ensure that movement of seat suspension is not
152. lay in 6 4 cm in steering wheel a Check for unusual noise or a Unusual noise or vibration from engine trans vibration is pre mission transfer case all sent except 915 2 drive shafts axles and wheels b Check for smooth operation b Selector shifts with of transfer case selector all difficulty or there is except M915A2 unusual noise During Winch M916A1 and M916A2 Always wear heavy gloves when handling winch wire rope Never allow cable to run through hands as injury may result a Check cable for kinks frays a Cable is damaged and breaks in wire Check missing for inadequate lubrication or corrosion As required clean and lubricate cable when mission is complete Appen dix F b Check winch for proper con b There is no control trol response response 2 46 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Interval Check Service During Air Con ditioner All Except M915A2 and M916A1 Procedure Not Fully Mission Capable If Perform the following inspection only if air conditioner is required due to climatic conditions Overall Leakage Overall View Turn air conditioner on and set blower to maximum cooling speed settings Wait five min utes to allow temperature to stabilize Check outlet ducts for cool air If air is not cooler than ambient temperature noti
153. light will flash If exceeded for more than two minutes CTIS will automatically inflate to highway setting There is no time limit for operation in this mode Press key to select 90 psi 621 kPa tire pressures for normal operation on improved paved surfaces up to a maximum speed of 60 mph 97 kph There is no time limit for operation in this mode The control center for CTIS 2 27 TM 9 2320 363 10 2 6 CONTROLS AND INDICATORS M917A1 AND M917A1 W MCS Reduce MPH Red light indicates when vehicle is traveling too fast Indicator Light for selected mode The following overspeed values cause light to come on Highway 60 mph 97 kph Cross Country 40 mph 64 kph Sand 25 mph 40 kph Emergency Light always on Run Flat No light 2 28 TM 9 2320 363 10 2 7 WINCH CONTROLS 916 1 AND 916 2 Speed Control Controls winch speed Push lever down for fast winch operation Release lever for slow operation Line Control Place lever in STOP position to apply drum brake and stop winch Move lever to LINE OUT position to release drum brake and pay out winch cable Move lever to LINE IN position to reel in cable Throttle Control Two position toggle switch controls engine speed Move toggle switch to HIGH to increase engine Speed to a maximum of 1000 rpm Move switch to LOW to decrease engine speed 2 29 TM 9 2320 363 10 2 8 ADDITIONAL CONTROLS AND INDICATORS Cab Vent Window
154. ll not 14 Verify that engine oil start Engine oil warning light 15 CHK ENG warning light light 16 SHUT DOWN light CHK ENG SHUT 17 low air pressure warn DOWN or low ail ing light 18 and warning pressure warning buzzer turn off light and warning buzzer stay on 2 40 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t cheek Not Fully Mission Interval cervice Procedure Capable If Before Engine 18 fo 8 FASTEN SEAT BELT DO NOT run engine above idle speed until oil pressure gage indicates at least 12 psi 83 kPa at idle speed b Check engine rpm on tacho b At idle engine meter all except M915A2 speed is not at and M916A1 or on tacho 600 rpm graph M915A2 and M916A1 Before a Check seats and seat belts a Seat belts are not for security of mounting and serviceable damage TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Not Fully Mission Interval Service Procedure Capable If 9 Before Seats All adjustments should be made while seated Primary air pressure gage must indicate a minimum of 60 psi 414 kPa to adjust height of seat b Check for proper operation b Seat missing or of seat height adjustment inoperative valve lever 20 and fore and aft seat adjustment lever 19
155. location and use of all controls and indicators The following section describes all operator controls and indicators 2 1 TM 9 2320 363 10 2 2 INSTRUMENT PANEL a Instrument Cluster 1 Left Gage Panel Air Vent Engine Water Temperature Gage Engine Oil Pressure Gage Function Vents air into cab from heater ventilator defroster and air conditioner if equipped Louvered openings are adjustable Registers engine coolant temperature in degrees Fahrenheit Normal range is in green band 190 210 F 88 99 C If needle goes into yellow band 210 215 F 99 120 C or red band 216 250 F 102 121 C stop and investigate cause Registers engine oil pressure in psi kPa Normal pressure at rated speed 1200 rpm is 50 psi 345 kPa Pressure at idle speed 600 rpm is 12 psi 83 kPa minimum TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t Voltmeter Indicates rate of battery charge or discharge in volts a RED BAND Below 11 volts indicates a possible malfunction Stop and report problem to Unit Maintenance YELLOW BAND 11 12 volts indicates battery is undercharged Turn off all electrical circuits if possible and run engine at highest rpm permitted for existing conditions If reading is still not in green band notify Unit Maintenance GREEN BAND 13 15 volts indicates normal operating range RED BAND Above 15volts indicates batteries are being overcharged Notify Unit Maintenance Tu
156. low vehicle to cool down 2 Check cooling system air cleaner air cleaner restriction indi cator engine oil level and radiator fins frequently Perform necessary services and notify Unit Maintenance of any unusual gage readings or problems 3 Notify Unit Maintenance to shorten differential oil change interval c Parking Vehicle 1 Park vehicle under cover if possible If shelter is not avail able cover vehicle with tarpaulins If there aren t enough tarps to cover entire vehicle arrange tarps around engine compartment and over radiator to keep sand and dust out Cover window glass to protect against sand blasting 2 Ensure all tires are inflated to proper pressure 3 Check frequently for rust and fungus growth Clean and lubri cate vehicle to help prevent deterioration 2 131 TM 9 2320 363 10 2 41 OPERATE IN MUD OR SOFT SURFACES NOTE M915A2 is equipped with No Spin automatic lock ing positive traction differential on the forward rear axle all vehicles except M915A2 are equipped with No Spin on both rear axles The No Spin differen tial eliminates individual wheel spinout for better traction e When locking system is engaged driving axles receive equal torque a Before entering mud or other soft surfaces check conditions and select appropriate transmission gear range LOCK ENGAGE interaxle lockout all wheel drive Enter soft area at a medium speed for gear range selected b
157. lure to follow this warning may result in death or injury to personnel or damage to equipment TM 9 2320 363 10 DO NOT use engine brake if road surfaces are slippery Use of engine brake on wet icy or snow covered roads could result in loss of vehicle control Failure to follow this warning could result in death or injury to personnel or damage to equipment Brake chamber contains spring under great pressure To prevent personnel injury never work directly behind chamber If caging bolt will not engage properly spring may be broken Do not remove clamp ring around spring brake chamber It is under tension and can cause personnel injury if released When spring brakes are applied vehicle will stop quickly which could result in injury to personnel Also vehicle cannot be driven again until malfunction is repaired and enough air supply is present for operation of service brakes WARNING COMPRESSED AIR Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to personnel WARNING CTIS OPERATION M917A1 AND M917A1 W MCS When resuming operation on highway surfaces be sure to reset CTIS selector panel to higher tire pressures Operating vehicle with underinflated tires will cause premature tire wear or damage to tires cau
158. m and in Drive D position continue to apply engine brake and maintain directional control of vehicle 2 94 TM 9 2320 363 10 2 18 DRIVING TIPS Con t d The anti lock brake system ABS will help in controlling wheel lockup and tire skidding during an emergency d On M915A2 engage interaxle lockout as required DO NOT actuate interaxle lockout control valve while tires are slipping DO NOT operate vehicle continuously with interaxle lockout control valve locked during extended good road conditions Damage to axle gearing and excessive tire wear could result NOTE ABS warning light blinks when interaxle lockout is engaged 1 To lock interaxle ease up on accelerator pedal momentarily and move interaxle lockout control valve lever to LOCK position while maintaining vehicle speed Axle lock indicator light comes on Proceed over poor road conditions with caution Do not wait until traction is lost and tires are spinning before locking interaxle 2 To unlock interaxle place interaxle lockout control valve lever in UNLOCK position and remove foot from accelerator Observe that axle lock indica tor light goes off System is now unlocked e For all except M915A2 engage ail wheel drive as required DO NOT actuate all wheel drive control valve while vehi cle is in motion Do not operate vehicle continuously with all wheel drive control valve engaged during extended good road conditions Damage to axle gearing and exces
159. m maintenance Do not get under truck after it is raised unless it is properly supported with blocks or jackstands Failure to observe this warning may result in death or injury to personnel Ether is highly flammable and explosive DO NOT perform ether quick start sys tem checks or inspections while smoking or near fire flame or sparks Failure to follow this warning may cause a fire and explosion causing serious injury or death to personnel Handle must be used when operating release lever Failure to do so could result in injury to personnel Failure to completely turn ON or OFF air cutoff valve will cause loss of brakes on trailer or truck Lifting cables chains hooks and slings used for lifting truck must be in good condition and of suitable capacity Failure to follow this warning may result in injury or death to personnel and damage to equipment Improper use of lifting equipment and improper attachment of cables to vehicle can result in serious personnel injury and equipment damage Observe all stan dard rules of safety Change 1 g TM 9 2320 363 10 WARNING WATER DISTRIBUTOR TOWING DO NOT tow 6 000 gallon water distributors with a partial load except when use on construction sites and at a maximum speed of 10 mph When towing out side of construction sites either drain water distributor empty preferred or fill to capacity Failure to follow this warning could result in unsafe drivin
160. m stroke adjustment or major brake service Ex dust Control or Indicator Function Ether Control Relay Red light comes on when automatic ether injection Indicator Light All system fuel canister is empty Except M915A2 and M916A1 2 32 TM 9 2320 363 10 Section Il PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS Paragraph Page Number Paragraph Title Number 2 33 Explanation of Table Entries 2 33 General PMCS Procedures 2 34 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles 2 37 2 9 GENERAL To ensure that the truck is ready for operation at all times it must be inspected on a regular basis so that defects may be found and corrected before they result in serious damage equipment failure or injury to personnel Table 2 1 contains Systematic instructions on inspections adjustments and corrections to be performed by the operator crew to keep your equipment in good operating condition and ready for its primary mission 2 10 EXPLANATION OF TABLE ENTRIES a Item Number Item No Column Numbers in this column are for reference When completing DA Form 2404 Equipment Inspection and Maintenance Worksheet include the item number for the check service indicating a fault Item numbers also appear in the order that you m
161. mounted PTO which powers the winch The PTO on the M917A1 and M917A1 w MCS powers the dump body controls TM 5 3805 264 14 amp P b The M915A2 and M916A1 are equipped with an instrument panel mounted tachograph which registers and records data related to truck ground Speed engine speed and distance traveled This data is stored on a 7 day graph for a permanent record All other models are equipped with a Datalogger which is a data processing module that provides data storage capability and records in detail the per formance and utilization of the vehicle Datalogger memory can store over a month of data for use by maintenance and management personnel There is no operator inter ference with the Datalogger 6 The following capabilities and features are common to all models a air activated front and rear non asbestos cam brakes with a four channel anti lock brake system ABS to provide significantly improved handling and braking during emergency stops b operation in temperatures from 25 F 32 C to 125 F 52 C and to 40 F 40 C with arctic kit installed c start and climb capability of a 20 percent grade at GCWR in both forward and reverse directions d fording capability up to 20 in 51 cm deep for 5 minutes without damage or requiring maintenance before operations can continue e two passenger aluminum corrosion proof cab with a 90 degree tilt forward hood for service accessibility f six cylinder
162. n of release stud 2 shows above nut Spring brake is fully released b Uncage Brakes 1 Block wheels 2 Remove nut 4 and washer 5 from release stud 2 3 Turn release stud 2 to left 1 4 turn and remove release stud from spring chamber 6 4 Install cap 3 in spring chamber 6 5 Insert release stud 2 into stowage pocket 1 and install washer 5 and nut 4 on release stud 2 126 TM 9 2320 363 10 2 39 OPERATE IN EXTREME COLD a X General 1 Extreme cold causes many problems a Lubricants thicken or congeal b c d Various materials will become hard brittle and easily Batteries may freeze or lose their electrical efficiency Fuel may not readily atomize for combustion damaged e The cooling system requires adequate protection from extreme cold f Fuels lubricants and antifreeze compounds require Special storage handling and use 2 Refer to FM 9 207 for additional information 3 Winterization Kit All vehicles assigned to arctic regions are equipped with a winterization kit which protects vehicle systems from freeze damage and enables easier starting 4 Starting Out a Be careful when you first start your vehicle Use cold weather starting procedure paragraph 2 14 and allow engine time to reach operat ing temperature range of 120 140 F 48 59 C Be alert that tires may be frozen to ground b Start driving very slowly for about 100
163. necessary for you to know how fluid leakage affects the status of your truck The following are definitions of the types classes of leakage you need to know to be able to determine the status of your truck Learn and be familiar with them and remember when in doubt notify your supervi sor 2 35 TM 9 2320 363 10 2 11 GENERAL PMCS PROCEDURES Con t Operation is allowable with Class 1 and Class leakage WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with Class or Class II leaks check fluid lev els more frequently Class leaks must be reported immediately to your supervisor Failure to do this will result in damage to vehicle and or components Leakage Definitions for PMCS Class Leakage indicated by wetness or discolor ation but not great enough to form drops Class 11 Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class Ill Leakage great enough to form drops that fall from the item being checked inspected 2 36 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Item To Check Not Fully Mission Sevice Procedure Capable If NOTE Review all WARNINGs CAUTIONs and NOTEs before performing PMCS and operating the truck Perform all PMCS checks If a You are the assigned operator but have not operated the truck since the last weekly inspection
164. of columns found in the tabular listings a Column 1 Illustration Number Illus Number This column indi cates the number of the illustration that shows the item b Column 2 National Stock Number Indicates the National Stock Number NSN assigned to the item and will be used for requisitioning purposes B 1 TM 9 2320 363 10 B 3 EXPLANATION OF COLUMNS Con t C Column 3 Description and Usable On Code Indicates the Fed eral item name and if required a minimum description in parentheses to identify and locate the item The entry for each item ends with the Commercial and Government Entity Code CAGEC in parentheses followed by the part number Usable On Code indicates the vehicle to which the item is assigned Usable on codes for the M915 Family of Vehicles are Usable On Code Model 5A2 M915A2 6A1 M916A1 6A2 M916A2 7M M917A1 7E1 M917A1 w MCS d Column 4 Unit of Issue U I Indicates how the item is issued for the National Stock Number shown in Column 2 e Column 5 Quantity Required Qty Red Indicates the quantity of the item authorized to be used with the equipment Section Il COMPONENTS OF END ITEM There are currently no COEI assigned B 2 1 Illus Number Section Ill National Stock Number 2540 00 670 2459 5140 00 356 847 1 6220 01 495 2851 7510 00 889 3494 6150 01 022 6004 3 Description CAGEC Part Number Bag Pamphlet In cab glove box
165. op pumping 10 After three to five minutes adjust fuel regulator 6 until pul sating evens out 11 Disconnect cable 11 from connector 12 and batteries 2 129 TM 9 2320 363 10 2 39 OPERATE IN EXTREME COLD Con t 12 To turn heater off close fuel regulator 6 completely When pulsating stops heater is off Allow heater enough time to cool Failure to do so could result in injury to personnel 13 Loosen wing nut 9 and remove heater 7 from heat exchanger 8 2 130 TM 9 2320 363 10 2 39 OPERATE IN EXTREME COLD Con t d Operate Winch Avoid winching operations that cause sudden shock loads In extremely cold temperatures metals become brittle and sudden shock loads can cause equipment damage 1 Before operating winch warm up hydraulic system by turning PTO switch ON and operating engine at approximately 1000 rpm for ten minutes 2 When hydraulic system is warmed up operate winch in no load condition by paying out approximately 25 ft 7 6 m of cable at low speed 3 Take up cable at low speed 4 Winch should be ready for normal operation 2 40 OPERATE IN EXTREME HEAT a General During very hot weather driving procedures may require altering to prevent vehicle overheating Avoid continuous high speeds long hard pulls and continuous operation in soft terrain b Driving Vehicle 1 Check water temperature gage and stop if temperature is unusually high Al
166. osition is center position which provides a shock absorbing effect Seat Height On M915A2 and M916A1 push in to inflate Adjustment Control suspension and raise seat To lower seat pull lever Valve Lever out Vehicle air pressure must be above 60 psi 414 kPa to operate lever On all other vehicles push lever up to raise seat and down to lower seat Lumbar Adjustment Controls lumbar support in seat Rotate knob Knob All Except forward to increase and rearward to decrease M915A2 and lumbar support M916A1 2 24 TM 9 2320 363 10 2 5 SEAT CONTROLS Con t Seat Back Adjusts seat back angle Apply or remove pressure Adjustment Lever All from seat back and hold lever rearward to adjust Except M915A2 and M916A1 Seat Cushion Tilt Rotate knob to increase or decrease seat tilt Adjustment Knob All Except M915A2 and M916A1 Seat Belt Three point belt locks into tether belt Tether Belt Adjustable belt located on both sides of seat TM 9 2320 363 10 2 6 Key 2 26 CTIS CONTROLS AND INDICATORS M917A1 AND M917A1 W MCS Selector Panel RUN FLAT Selector Displays CTIS information and allows entry of System commands Has four preset tire pressure mode keys and a run flat selector Each selector push button is back lit and has an annunciator or System status light This light flashes while pressures are being checked or changed and is lit steadily when selected pressure has been reached
167. ous burns Step 1 Check engine coolant level in radiator Add engine coolant as required Appendix TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2 Step 3 Step 4 Step 5 Step 6 Check system for leaks If leaks are found notify Unit Maintenance Check if radiator cooling fins are free of mud snow ice or debris Remove anything that blocks or impedes cooling fins Check cooling fan drive belts for looseness If belts are loose notify Unit Maintenance Check engine oil level If engine oil is low fill to correct level Appendix F Check transmission fluid level If transmission fluid level is low fill to correct level Appendix F 11 ENGINE CRANKS BUT FAILS TO START Fuel tank cap may become hot during vehicle operation Use hand protection when removing fuel cap Step 1 Step 2 Step 3 3 10 Check fuel gage with ignition switch in ON position If empty add fuel paragraph 3 6 Check air cleaner restriction indicator If indicator is not clear notify Unit Maintenance If operating M915A2 or M916A1 in temperature below 32 F 0 C check that cold weather starting procedure was used Perform cold weather starting procedure paragraph 2 14 TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Ether is highly flammable and explosive DO NOT p
168. pair would impair oper operation ation is evident b Visually check for missing or b Any tire is missing damaged tires Check lug or damaged Lug nuts to ensure they are at nuts are loose or least finger tight missing 2 38 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Check Not Fully Mission Interval Service Procedure Capable If Cab Check for damage to lights 9 Damager that would Exterior side mirror 10 cab door 8 interfere with visibil grabhandles 5 and steps ity and impair opera 11 tion is evident Before Instru ment Panel NOTE Refer to Chapter 2 Section for the loca tion of all gages switches and indicator lights Check for damage to gages gage is broken switches and indicator and unreadable warning lights 2 39 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Check Not Fully Mission Interval Service Procedure Capable If Before Fire a Check for missing or dam a Fire extinguisher is aged fire extinguisher 12 missing or dam aged b Check gage 13 for proper b Presure gage presure of approximately needle is in 150 psi 1034 kPa recharge area c Check for damaged or miss c Seal is broken or ing seal 14 missing Before a Start engine paragraph 2 a Engine wi
169. personnel wearing protective equipment Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures WARNING gt IF NBC EXPOSURE IS SUSPECTED ALL AIR FIL TER MEDIA WILL BE HANDLED BY PERSONNEL WEARING FULL NBC PROTECTIVE EQUIPMENT SEE OPERATOR MAINTENANCE MANUAL 7690 01 114 3702 To order this NBC decal use National Stock Number NSN 7690 01 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 WARNING PRESSURIZED COOLING AND HYDRAULIC SYSTEMS DO NOT remove radiator cap unless engine is cold Remove in two steps First place thick cloth over cap and slowly turn cap left to first stop Pause and allow pressure to escape Turn cap further left until it can be removed This is a pressurized cooling system and escaping steam hot water or coolant will cause serious burns DO NOT remove fill cap when hydraulic fluid is hot Hydraulic tank is pressurized to 5 psi 34 kPa Remove cap slowly to prevent serious burns TM 9 2320 363 10 WARNING SLAVE STARTING When slave starting truck use NATO slave cables that DO NOT have loose or missing insulation DO NOT proceed if suitable cables are not available DONOT use civilian type jumper cables Failure to follow this warning could result in injury WARNING TIRE CHANGING Whenever inner and o
170. pressure loss exceeds 5 psi 34 kPa in two minutes troubleshoot semitrailer 3 TRAILER BRAKES WILL NOT APPLY WHEN PEDAL OR HAND CONTROL ON STEERING COLUMN IS USED Check intervehicular air hoses for proper connections to semitrailer Connect air hoses 4 TRAILER BRAKES WILL NOT RELEASE Step 1 Check position of trailer brake hand control Move control to forward OFF position Step 2 Check position of trailer air supply control knob Push knob in ON Step 3 Check intervehicular air hoses for proper connections Connect air hoses Step 4 Check vehicle air system for leaks If leaks are found notify Unit Maintenance If leaks are not found and vehicle components are not dam aged troubleshoot semitrailer CTIS M917A1 AND M917A1 W MCS 5 CTIS SELECTOR PANEL INDICATES FIVE LIGHTS FLASHING Step 1 Check whether air reservoir draincocks are closed and posi tion of trailer air supply control valve Close air reservoir draincocks and pull valve out OFF Step 2 Check condition of tires If tire has a slow leak or minor puncture select RUN FLAT on CTIS selector panel and continue operation Change tire as soon as tactical situation permits Step 3 Check for broken or kinked air lines If air lines are broken or kinked notify Unit Maintenance TM 9 2320 363 10 Table 3 1 Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4 Excessive air seal leakage during cold weather star
171. r 5 D t 3 x 4 b Remove Wheel and Tire Assembly 1 Block wheels 2 Remove spare wheel and tire assembly from carrier para graph 3 8 3 24 TM 9 2320 363 10 3 9 WHEEL AND TIRE ASSEMBLY REPLACEMENT ALL EXCEPT M917A1 AND M917A1 W MCS Con t NOTE If replacing inner rear tire loosen both outer and inner wheel nuts Wheel nuts on left side of vehicle are left hand threads turn right to loosen turn left to tighten Wheel nuts on right side of vehicle are right hand threads turn left to loosen turn right to tighten 3 Remove wheel nuts on wheel to be removed 4 Place jack in position step a Hydraulic jack is intended only for lifting truck not for supporting vehicle to perform maintenance Do not get under truck after it is raised unless it is properly sup ported with blocks or jackstands Failure to observe this warning may result in death or injury to personnel 5 Raise jack until tire s clears ground Use caution when lifting or handling wheel and tire assembly It is heavy and could cause injury if improp erly lifted or if it falls on you 6 For front or outer rear tire remove wheel nuts and wheel and tire assembly 7 If replacing inner rear tire remove wheel nuts and wheel and tire assembly Install Wheel and Tire Assembly 1 Manually inflate spare tire to proper pressure paragraph 3 3 25 TM 9 2320 363 10 3 9 WHEEL AND TIRE ASSEMBLY R
172. r is supported by landing gear 2 106 TM 9 2320 363 10 2 24 UNCOUPLE FROM TRUCK ALL EXCEPT M917A1 AND M917A1 W MCS Con t r Have a crew member observe semitrailer king pin to ensure that it clears during separation of tractor and semitrailer Ensure king pin clears rear frame crossmember or tail roller when tractor is pulled forward M870 trailers have a ten dency to swing forward into rear of truck when king pin clears tail roller S Pull tractor slowly forward allowing semitrailer king pin plate or gooseneck and king pin to slide down fifth wheel and ramps until semitrailer landing gear touches ground t Disconnect and stow winch cable paragraph 2 28 2 25 TOWING PROCEDURES a Remove cotter pin 3 engage latch 4 and lift lock 5 to open posi tion b Connect trailer to pintle hook 6 c Push lock 5 down ensuring latch 4 engages and install cotter pin 3 d Connect intervehicular electric cable from receptacle 1 on rear of vehicle to trailer e Connect air hoses from quick disconnect couplings 2 at rear of vehicle to trailer 2 107 TM 9 2320 363 10 2 25 PINTLE TOWING PROCEDURES Con t Failure to completely turn ON or OFF air cutoff valve will cause loss of brakes on trailer or truck NOTE Sed paragraph 2 22 for use of trailer handbrake f Open trailer air supply valve on hosetenna behind cab all tractors and push in trailer air supply knob on instrument
173. r outer wheel lug nuts require tightening or a wheel has been removed and replaced lug nuts must be torqued to the required torque Failure to fol low this warning may result in serious injury to personnel and damage to equipment WARNING TRUCK OPERATION BE ALERT for personnel in area while operating truck Always check to ensure area is clear of personnel and obstructions before moving out Failure to follow this warning may result in serious injury or death to personnel Use of seat belts while operating vehicle is mandatory Fasten belt BEFORE driv ing Trying to fasten three point belt while driving creates a hazardous condition Failure to follow this warning may result in death or injury to personnel Serious injury may result if head clearance is not adequate while sitting in seat Before driving or riding in vehicle ensure there is adequate clearance at maxi mum upward travel of seat e Check Engine button is used for diagnostic purposes only DO NOT push Check Engine button during vehicle operation because engine will slow down to an idle which could cause hazardous operating conditions Return to operating mode by releasing accelerator pedal and allowing engine to return to idle speed Failure to follow this warning may result in death or injury to personnel Use caution when coupling to or uncoupling from tractor truck Be alert for per sonnel in area Ensure that hands arms and body are cl
174. rated 1 DO NOT operate truck engine in enclosed areas 2 DONOT idle truck engine without adequate ventilation DO NOT drive truck with inspection plates or cover plates removed 4 BE ALERT for exhaust poisoning symptoms They are e Headache Dizziness Sleepiness e Loss of muscular control 5 f you see another person with exhaust poisoning symptoms e Remove person from area Expose to fresh air Keep person warm Do not permit physical exercise Administer cardiopulmonary resuscitation CPR if necessary Notify a medic 6 BE AWARE The field protective mask for nuclear biological chemical NBC protection will not protect you from carbon monoxide poisoning The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation Change 1 a TM 9 2320 363 10 WARNING BATTERIES To avoid eye injury eye protection is required when working around batteries Do not smoke use open flame make sparks or create other ignition sources around batteries If a battery is giving off gases it can explode and cause injury to per sonnel Remove all jewelry such as rings ID tags watches and bracelets If jew elry or a tool contacts a battery terminal a direct short will result in instant heating damage to equipment and injury to personnel Sulfuric acid contained in batteries can cause serious burns If battery corrosion or electrolyte makes contact with skin eyes or clothing tak
175. rbo Boost Gage Measures pressure in intake manifold in excess of M915A2 and atmospheric pressure being created by M916A1 turbocharger Normal pressure is 28 psi 193 kPa at full load 2 3 TM 9 2320 363 10 2 2 2 4 INSTRUMENT PANEL Con t 2 Center Gage Panel 9 ABS Warning Light M915A2 and M916A1 Fuel Pressure Gage M915A2 and M916A1 Transmission Oil Temperature Gage M915A2 and M916A1 10 M916A1 Lights when ignition switch is turned on If ABS components are working light goes out when vehicle speed exceeds 4 mph 6 kph Light blinks when vehicle is in interaxle lockout all wheel drive Indicates output fuel pressure of fuel pump Normal range is 35 65 psi 241 448 kPa Indicates oil temperature in transmission Normal range in green band is 100 299 F 38 148 C If needle goes into yellow band 300 324 F 149 162 C or red band 325 F 163 C or above stop and investigate cause TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t Air Cleaner Restriction Indicator Gage M915A2 Fuel Gage M915A2 and M916A1 Transfer Case Oil Temperature Gage M916A1 Tachometer All Except M915A2 and M916A1 Speedometer Odometer All Except M915A2 and M916A1 Indicates air cleaner air flow is adequate if gage is clear If restricted indicator window will show yellow Push yellow reset button to reset after air cleaner has been serviced Indicates amount
176. re to compress the power spring in the spring brake chambers to release the brakes compress them manually Each vehicle has four spring brakes Brake chamber contains spring under great pres sure To prevent personnel injury never work directly behind chamber If caging bolt will not engage properly spring may be broken e Do not remove clamp ring around spring brake chamber It is under tension and can cause person nel injury if released When spring brakes are applied vehicle will stop quickly which could result in injury to personnel Also vehicle cannot be driven again until malfunc tion is repaired and enough air supply is present for operation of service brakes When caging brakes block wheels to keep truck from moving when brakes are released Failure to follow this warning may result in death or injury to personnel or damage to equipment 1 Block wheels 2 125 TM 9 2320 363 10 2 38 CAGE AND UNCAGE BRAKES Con t 2 Remove nut 4 washer 5 and release stud 2 from stow age pocket 1 3 Remove cap 3 from spring chamber 6 4 Insert cross pin end of release stud 2 into opening where cap 3 was removed b To engage cross pin rotate release stud 2 until cross pin end goes into slot inside of spring chamber 6 Turn release stud right 14 turn cross pin is now engaged 6 Install washer 5 and nut 4 on release stud 2 7 Tighten nut 4 until approximately 3 i
177. restricted TM 9 2320 363 10 2 13 INITIAL ADJUSTMENTS DAILY CHECKS AND SELF TESTS Con t f Fasten seat belt 1 Slowly pull link 9 out of retractor 10 and across lap far enough to engage buckle 5 If retractor locks too soon allow belt to retract slightly and then pull slowly 2 Push link 9 into buckle 5 3 Position shoulder strap 8 diagonally across chest NOTE if engaging Komfort Loc allow no more than 1 in 2 5 cm between chest and shoulder strap Komfort Loc will automatically release if pressure is applied to shoulder strap 4 If desired engage Komfort Loc 7 by pulling on shoulder strap 8 and pressing Komfort Loc lever up 5 To release seat belt press release button on buckle 5 if Komfort Loc 7 was engaged give shoulder strap 8 a quick downward tug to release 2 84 TM 9 2320 363 10 2 14 START ENGINE a Ensure that parking brake is applied paragraph 2 2 NOTE The M915 Family of Vehicles are equipped with a neutral safety switch which prevents the engine from being started if transmission is not in Neutral N b Place transmission selector lever in Neutral N Ensure that all accessories are off and engine brake system Switches are in OFF position Check Engine button is used for diagnostic purposes only DO NOT push Check Engine button during vehicle operation because engine will slow down to an idle which could cause hazardo
178. result a Check gages and indicators frequently If gage or indicator shows an abnormal reading or warning light comes on bring vehicle to a safe stop shut down engine paragraph 2 20 and investigate cause CAUTION Steering wheel should not be held at full steer for more than 10 seconds This could result in overheating of oil loss of oil from power steering reservoir and pump gear damage b Avoid over steering Become familiar with steering characteristics of vehicle before attempting maneuvers in limited space c Drive efficiently and economically 1 Driving at Highway Speed Recommended normal highway cruising range is 1800 1900 rpm If operating on hilly terrain in high winds or in other conditions that make it impractical to operate without reserve power operate vehicle in lower gear 2 Driving in City When slowing for posted speed zones remain in Drive D position and reduce engine rpm 3 Driving Uphill under load Proper use of gears shortens time on hills and minimize amount of shifting As vehicle starts uphill press accelera tor pedal as required to maintain speed 2 93 TM 9 2320 363 10 2 18 DRIVING TIPS Con t DO NOT use engine brake if road surfaces are slippery Use of engine brake on wet icy or snow covered roads could result in loss of vehicle control Failure to follow this warning could result in death or injury to personnel or damage to equipment 4 Use Engine as a Brakin
179. rn left to tighten Wheel nuts on right side of vehicle are right hand threads turn left to loosen turn right to tighten 2 Install and handtighten wheel nuts 3 Lower and remove jack 4 Connect elbow 5 to hub air port 4 with open elbow port perpendicular to outer edge of wheel 3 30 TM 9 2320 363 10 3 10 FRONT WHEEL AND TIRE ASSEMBLY REPLACEMENT M917A1 AND M917A1 W MCS Con t 5 Remove protective plug from wheel valve 8 and install on wheel valve of defective tire 6 Connect connector 7 to wheel valve 8 NOTE Ensure hose is not kinked after connecting to elbow Rotate elbow if necessary 7 Connect hose 6 to elbow 5 NOTE Tighten wheel nuts with wheel wrench After 25 miles 40 km retighten wheel nuts Within next 75 miles 121 km have Unit Maintenance torque wheel nuts to proper torque Tightening pattern is identical for all wheel assem blies 8 Tighten wheel nuts according to wheel tightening pat tern WHEEL NUT TIGHTENING PATTERN 9 Stow defective tire in spare wheel and tire carrier paragraph 3 8 and have it replaced or repaired as soon as possible 10 Notify Unit Maintenance as soon as possible to apply proper torque 11 Inflate tire to desired pressure using CTIS paragraph 2 17 or manual inflation procedure paragraph 3 7 12 Remove wheel blocks 3 31 TM 9 2320 363 10 3 11 REAR WHEEL AND TIRE ASSEMBLY REPLACEMEN
180. s On all axles brake chambers have a stroke alert indicator which allows the operator to monitor brakeshoe wear AIR GAGES SECONDARY PRIMARY BRAKE REAR AXLE SPRING CONTROL BRAKE CHAMBERS FRONT AXLE BRAKE CHAMBERS COMPRESSOR TM 9 2320 363 10 1 21 STEERING The power steering system consists of an integral steering gear which includes a manual steering mechanism and hydraulic control valve hydraulic hoses power steering pump reservoir and other components b The power steering pump driven by the engine provides the power assist for the steering system POWER STEERING PUMP STEERING GEAR RESERVOIR 1 22 HYDRAULIC SYSTEM ALL EXCEPT M915A2 a The M916A1 and M916A2 have a hydraulic system that is used to supply hydraulic power to the winch motor The hydraulic system is comprised of a 50 gallon frame mounted tank and a hydraulic pump driven by a transmission mounted PTO b On the M916A1 and M916A2 with the engine running and the PTO engaged the hydraulic pump takes fluid from the tank and delivers it to the winch control valve bank The valve bank consists of a two speed control valve and a direc tion control valve The M917A1 and M917A1 w MCS hydraulic system is used to raise and lower the dump body TM 5 3805 264 14 amp P 1 32 TM 9 2320 363 10 1 22 HYDRAULIC SYSTEM ALL EXCEPT 915 2 Con t WINCH DRUM WINCH HYDRAULIC TANK M916A1 2 5 m
181. sing unsafe driving conditions Failure to follow this warning may result in death or injury to personnel Always wear eye protection and drain all air from wet tank before disconnecting CTIS air lines hoses or fittings Residual air in tire s and air line s will be expelled even though tire s is flat Failure to follow this warning could cause seri ous eye injury WARNING DIESEL FUEL HANDLING DO NOT smoke or permit any open flame in area of truck while you are servicing diesel fuel system Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity Failure to follow this warning may result in injury to personnel or equipment damage DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing damage to vehicle and injury or death to personnel Change 1 c TM 9 2320 363 10 Fuel tank cap may become hot during vehicle operation Use hand protection when removing fuel cap WARNING DRY CLEANING SOLVENT Dry cleaning solvent P D 680 is toxic and flammable Always wear protective gog gles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or exces sive heat The solvent s flash point is 100 F 138 F 38 C 59 C If you become dizzy while using cleaning solvent
182. sion Procedure Capable If Vehicle operation with Inoperative horn may violate AR 385 55 If tactical situation permits check operation of electrical and air horns Acces Verify that windshield wipers sory and heater ventilator or air Items conditioner if equipped oper ate Lights NOTE Vehicle operation with damaged or inoper ative headlights or stoplights may violate AR 385 55 a Check for presence and operation of service drive turn signal blackout marker marker blackout drive and marker clearance lights b Check operation of tail stop lights Depress brake pedal approximately 1 4 in 6 4 mm Tail stoplights should come on TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Not Fullv M ot Fully Mission Interval Reo Procedure Capable If 47 Weekly Drive a Check for loose missing a Any drive belt is Belts broken frayed or cracked loose missing drive belts 64 Notify broken cracked supervisor if loose drive to the belt fiber belts are suspected has more than one crack 1 8 in 3 2 mm in depth or has frays more than 2 in 5 1 cm long b Check for damaged pulleys b Pulley is dam aged 2 65 TM 9 2320 353 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Not Fully Missi Check ot Fully Mission Interval Sonica Proced
183. sive tire wear could result NOTE All wheel drive may be engaged in two ways Perform either step 1 or step 2 to engage 1 With vehicle stopped and transfer case selector in HIGH range place all wheel drive control valve lever to ENGAGE position Axle lock indica tor light will come on and all wheel drive is now engaged 2 95 TM 9 2320 363 10 2 18 DRIVING TIPS Con t 2 With vehicle stopped shift transfer case selector into LOW range Axle lock indicator light will come on and all wheel drive is now engaged NOTE All wheel drive may be disengaged in two ways Per form either step 3 or step 4 to disengage operate vehicle if axle lock indicator light stays on Notify Unit Maintenance 3 To disengage all wheel drive when transfer case selector is in LOW range stop vehicle and move transfer case selector to HIGH range All wheel drive is disengaged and axle lock indicator light will go off 4 To disengage all wheel drive when transfer case selector is in HIGH range and all wheel drive control valve lever is in ENGAGE position move all wheel drive control valve lever to DISENGAGE position and remove foot from accelerator 2 19 DRIVING a Perform initial adjustments daily checks and self tests paragraph 2 13 b Start engihe paragraph 2 14 and allow truck to warm up Serious injury may result if head clearance is not ads quate while sitting in seat Before driving or riding
184. t 59 Weekly Front Wheel and Tire Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result NOTE M917A1 and M917A1 w MCS CTIS must be in highway HWY mode for this check 2 76 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Not Fully Missi Check ot Fully Mission Interval Procedure Capable If 59 Weekly Front a Check pressure in tires and Con t Wheel adjust as required and Tire M915A2 Empty 80 psi 552 kPa M915A2 Loaded 100 psi 690 kPa M916A1 M916A2 Empty 90 psi 621 kPa M916A1 M916A2 Loaded 90 psi 621 kPa M917A1 M917A1 w MCS 90 psi 621 kPa b Ensure all wheel stud lug b Any wheel stud is nuts are tight using wheel missing or lug nut stud lug nut wrench and is loose handle c Check wheel for cracks Wheel is cracked breaks or bends broken or bent CAB INTE RIOR 60 Weekly Doors Check operation and general and Win condition of cab doors and dows windows 2 77 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Not Fully Mission Interval Procedure Capable if Weekly Check level of fluid in reservoir 74 located behind driver s seat Add windshield washer cleaning compound It
185. t Panel Controls and Indicators Lights Operate ax AE sae nan SAEI La ea List of Abbreviations Location and Description of Major Components Maintenance Forms and Procedures Major Components Location and Description Manual Tire Inflation Mud Flap Stowage All Except M917A1 and M917A1 CUL Sic EN EE Mud or Soft Surfaces Operate in Nomenclature Cross Reference List Operate CTIS M917A1 and M917A1 w MCS Operate Air Conditioning All Except M915A2 and M916A1 Heater and Defroster In Extreme Cold In Extreme Heat In Mud or Soft Surfaces In Woods or On Rocky Terrain TM 9 2320 363 10 Paragraph 2 33 1 22 2 13 2 13 2 2 1 8 1 10 1 2 1 10 3 7 2 26 2 41 2 17 2 29 2 33 2 39 2 40 2 41 2 44 Page 2 117 2 82 2 82 2 2 2 116 1 3 1 6 1 2 1 6 3 19 2 108 2 132 2 89 2 113 2 117 2 127 2 131 2 132 2 135 Index 3 TM 9 2320 363 10 Subject Operate Con t Eighteen TES Portable Fire Extinguisher Power Take Off PTO All Except M915A2 Sandy or Dusty Conditions Sliding Fifth Wheel M915A2 cosa Su Ee Se a Ae tes M916A1 and M916A2 Snow and Ice Transfer Case All Except
186. tes at least 12 psi 83 kPa at idle speed m Do not run engine above 600 rpm until normal oil pressure is indi cated on engine oil pressure gage 2 15 OPERATE TRANSMISSION a General The transmission may be placed in six different gears 1 Reverse R Reverse R is used to back up the vehicle Vehicle must be brought to a complete stop before shifting from a forward gear to reverse gear or visa versa 2 87 TM 9 2320 363 10 2 15 OPERATE TRANSMISSION Con t Do not allow truck to coast in Neutral N This can result in severe transmission damage and engine braking is not available 2 Neutral N Neutral N is normal transmission position when vehicle is not in use Use this gear to start engine 3 Drive D When placed in Drive D the transmission starts out in 1st gear and automatically progresses to 4th gear During slowdown transmis sion automatically downshifts 4 Gears 2 and 3 Use 2nd or 3rd gears when road load or traffic conditions make it preferable to use lower gears When conditions improve return to Drive D 5 Gear 1 1st gear is the low gear used for pulling through mud snow or going up steep grades This position also offers maximum engine braking power b Operation 1 Depress brake pedal and hold 2 Release parking brake paragraph 2 2 3 Move transmission selector lever to desired gear 2 16 OPERATE TRANSFER CASE ALL EXCEPT 915 2 a General Veh
187. tions causing serious injury or death to personnel and damage to equipment If towing M172 or M872 trailer rear mud flaps must be removed and stowed Failure to follow this caution may result In equipment damage a On M916A1 and M916A2 make sure secondary lock release handle is pulled OUT paragraph 2 22 2 102 TM 9 2320 363 10 2 23 COUPLE TO TRUCK ALL EXCEPT M917A1 AND M917A1 W MCS Con t b Ensure that fifth wheel ramps are level with or are slightly below the angle of the pickup ramps Use caution when coupling to truck BE ALERT for per sonnel in area Ensure that hands arms and body are clear of potential pinch points Failure to follow this warning may result in injury to personnel Be careful not to run king pin up fifth wheel ramps as this can damage king pin and or fifth wheel NOTE Truck and trailer must be aligned Use a ground guide if one is available PROPER ALIGNMENT WITH SEMITRAILER C Slowly back tractor under semitrailer king pin plate or gooseneck Stop when king pin plate or gooseneck is touching guide ramps Semitrailer king pin should be centered as closely as possible in throat of fifth wheel d Ensure that semitrailer is picked up with fifth wheel ramps If king pin comes in too high it will not engage in fifth wheel correctly Adjust semitrailer if needed 2 103 TM 9 2320 363 10 2 23 COUPLE TO TRUCK ALL EXCEPT M917A1 AND 917 1 W MCS
188. tup occur If tires are not damaged continue operation Continue to operate vehicle Condition should correct itself as seals warm up If condition does not correct itself notify Unit Maintenance 6 CTIS SELECTOR PANEL INDICATES FOUR MODE LIGHTS FLASHING Step 1 Check condition of tires If tire has a slow leak or minor puncture select RUN FLAT on CTIS selector panel and continue operation Change tire as soon as tactical situation permits Step 2 Check whether air reservoir draincocks are closed and posi tion of trailer air supply control valve Close air reservoir draincocks and pull valve out OFF Step 3 Check for broken or kinked air lines If air lines are broken or kinked notify Unit Maintenance Step 4 Excessive air seal leakage during cold weather startup can occur If tires are not damaged continue operation Continue to operate vehicle Condition should correct itself as seals warm up If condition does not correct itself notify Unit Maintenance 7 CTIS SELECTOR PANEL INDICATES TWO MODE LIGHTS ON SOLID Step 1 Press any mode key and attempt a pressure change If pressure change is successful continue mission Step2 Check whether air reservoir draincocks are closed and posi tion of trailer air supply control valve Close air reservoir draincocks and pull valve out OFF Step 3 Check for broken or kinked air lines If air lines are broken or kinked notify Unit Maintenance 3 8 TM 9 2
189. ubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion prob lem If a corrosion problem is identified it can be reported using SF Form 368 Prod uct Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA Pam 738 750 1 4 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use refer to TM 750 244 6 1 2 TM 9 2320 363 10 1 5 REPORTING EQUIPMENT IMPROVEMENT RECOMMEN DATIONS EIRs If your truck 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 Form 368 Product Quality Deficiency Report Mail it to us at Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island Illinois 61299 7630 We ll send you a reply 1 6 WARRANTY INFORMATION The vehicles are warranted by Freightliner Corporation in accordance with TB 9 2320 363 15 Warranty starts on the date found in block 23 DA Form 2408 9 in the logbook Report all defects in material or workmanship to your supervisor who will take appropriate action through your Unit Maintenance shop 1
190. uld impair oper ation is evident d Lights are dam aged e Exhaust system components are damaged 2 55 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Item To Not Fully M ot Fully Mission miseva Procedure Capable if Wheels and Tires Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result a Visually check all right side a Tire is missing tires for defects underinfla deflated unser tion or loose or missing viceable or two or wheel studs or lug nuts more wheel studs or lug nuts are missing b For M917A1 and M917A1 w b CTIS components MCS check for damage to are damaged CTIS hoses 25 wheel valves 26 and fittings 24 at wheels 2 56 Table 2 1 TM 9 2320 363 10 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Interval Item To Check Service Fifth Wheel Ramps All Except M917A1 and M917A1 w MCS Fifth Wheel Roller M916A1 and M916A2 Taillights Trailer Glad hands Mud Flaps Procedure Check for damage to fifth wheel ramps 53 Check for damage to roller 52 Check for damage to taillights 49 Check for presence of dummy couplings 50 and damage to trailer gladhands 48 Check
191. ur Mode Lights Flashing CTIS has shut off and is waiting for operator instruction per form troubleshooting Chapter 3 Sec tion li 2 90 TM 9 2320 363 10 2 17 OPERATE CTIS M917A1 AND M917A1 W MCS Con t 4 Five Mode Lights Flashing CTIS has shut off due to fault detection of a CTIS component perform troubleshooting Chapter 3 Section Il RUN FLAT Flashing with a mode light RUN FLAT is selected Tire pressures are checked at more frequent intervals 6 No Mode Lights Inadequate vehicle power perform trouble shooting Chapter 3 Section 11 7 Lights Sequentially Flashing Configuration error perform troubleshooting Section 11 2 91 TM 9 2320 363 10 2 17 OPERATE CTIS M917A1 AND M917A1 W KS Con t b CTIS Operation NOTE Before operating CTIS become familiar with CTIS prin ciples of operatior Chapter 1 Section and CTIS con trols and indicators Chapter 2 Section 1 1 When engine is started tire pressures are pressures LAST ACHIEVED when vehicle was operated i e cross country pressures achieved HWY selected and pressures not achieved vehicle shut down Upon restart system will default to cross country 2 Tire pressures may be checked at any time by pressing mode key for selected mode CTIS automatically performs inflation or deflation as required 3 Press HWY Highway mode key to operate on improved road surfaces Do not exceed 60 mph 97 kph or
192. ure Capable if Weekly Ether Ether is highly flammable and explosive DO NOT perform ether quick start system checks or inspections while smoking or near fire flame or sparks Failure to fol low this warning may cause a fire and explosion causing serious injury or death to personnel a Check for loose connec a Damage or leak tions and damage to lines age is evident fittings and canister Be alert for the odor of leaking ether b On vehicles equipped with b Red indicator light an automatic ether quick is on start system check that red indicator light on ether con trol relay is not on when vehicle has power TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location dem Not Fully Missi ot Fully Mission Interval MEE Procedure Capable If Weekly Front Wheel and Tire Ir Operating truck with an underinflated or defective tire may lead to tire failure and loss of steering control Damage to equip ment or injury to personnel may result NOTE M917A1 and M917A1 w MCS CTIS must be in highway HWY mode for this check a Check pressure in tires and adjust as required M915A2 Empty 85 psi 586 kPa M915A2 Loaded 105 psi 724 kPa M916A1 M916A2 Empty 100 psi 690 kPa M916A1 M916A2 Loaded 115 psi 793 kPa M917A1 M917A1 w MCS 90 psi 621 kPa b Ensure all wheel stud lug b Any wheel stud is nuts are tight
193. urpose of Equipment 1 The M915A2 truck tractor is a 6 X 4 prime mover of semitrail ers used primarily to transport containers bulk cargo and petroleum products over primary and secondary roads under worldwide climatic conditions in a military envi ronment TM 9 2320 363 10 1 1 SCOPE Con t 2 The M916A1 and M916A2 truck tractors are 6 X 6 prime movers of low bed semitrailers used primarily to transport heavy engineer equipment over primary and secondary roads and off road under worldwide climatic conditions in a military environment 3 The M917A1 and M917A1 w MCS are 6 X 6 dump trucks used to transport dump or spread asphalt aggregate dirt and similar materials over primary and secondary roads and off road 1 2 MAINTENANCE FORMS AND PROCEDURES Department of the Army forms and procedures used for the equipment will be those prescribed by DA Pam 738 750 Functional User s Manual for the Army Maintenance Management System TAMMS as contained in the Maintenance Man agement Update 1 3 CORROSION PREVENTION AND CONTROL CPC 8 Corrosion Prevention and Control CPC of Army materiel is a con tinuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items b While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as r
194. us operating condition Return to operating mode by releasing accelerator pedal and allowing engine to return to idle speed Failure to follow this warning may result in injury to personnel d Turn ignition switch to ON position CHK ENG light and SHUT DOWN light come on and then turn off after approximately five seconds Engine oil warning light low air pressure warning light TRACTOR ABS light PARK BRAKE light if applied and warning buzzer come on For M917A1 and M917A1 w MCS CTIS selector panel illuminates and should display a single solid mode light or a single flashing mode light e For M915A2 ensure that interaxle lockout control valve lever is in UNLOCK position f For all models except M915A2 ensure that all wheel drive control valve lever is in DISENGAGE position and power take off PTO switch is in OFF position DO NOT operate starter motor for more than 30 seconds at a time After 30 seconds allow starter motor to cool for at least two minutes before attempting to start engine again Excessive heating of starter motor may result in damage or early starter failure g Press engine start button 2 85 TM 9 2320 363 10 2 14 START ENGINE Con t h When engine starts release engine start button If engine fails to start prime fuel system by pumping fuel water separator valve 1 for one minute Press engine start button If engine still fails to start pump valve for 20 seconds Press engine start button i
195. use in cold weather On the M915A2 M916A1 and initially built M916A2 M917A1 and M917A1 w MCS it is manually controlled via a push button on the instrument panel in the cab On newer M916A2 M917A1 and M917A1 w MCS models the ether quick start system is com puter controlled CYLINDER HEAD RESTRICTED FITTING UPPER FITTING FUEL PUMP PRIMARY FUEL FILTER WITH HAND PRIMER P SECONDARY FUEL FILTER DRAIN FUEL TANK 1 27 TM 9 2320 363 10 1 16 EXHAUST SYSTEM The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger The gases flow into exhaust pipes and a muffler to the atmosphere above the cab EXHAUST MANIFOLD TURBOCHARGER MUFFLER EXHAUST PIPES 1 17 COOLING SYSTEM The cooling system consists of one circulating pump a coolant filter two 190 F thermostats for controlling fluid flow a transmission oil cooler a radiator and a belt driven fan The cooling system cools the engine by means of circulating pressur ized ethylene glycol based coolant through the engine and radiator TM 9 2320 363 10 1 17 COOLING SYSTEM Con t TWO THERMOSTATS TWO THERMOSTATS CIRCULATING PUMP RADIATOR W PAL INLET MODEL DDEC 11 ENGINE Ri FROM RADIATOR MODEL DDEC III ENGINE 1 18 ELECTRICAL SYSTEM a Four 12 volt batteries connected in series parallel supply the 12 volt electrical system and provide 24 volts for the starter motor
196. using wheel missing or lug nut stud lug nut wrench and is loose handle c Check wheel for cracks c Wheel is cracked breaks or bends broken or bent 2 67 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Location Item To Not Fully Missi Check ot Fully Mission Hem Service Procedure Capable It Weekly Batteries To avoid eye Injury eye protection Is required when working around batteries Do not smoke use open flame make sparks or create other Ignition sources around batteries If a battery Is giving off gases It can explode and cause injury to personnel Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery termi nal a direct short will result In an instant heating damage to equipment and injury to personnel To reduce battery damage do not remove batteries from vehicle equipment battery compartment unless the battery compart ment Is corroded greenish white powder Do not jerk or pull on battery cables dur ing visual inspection Battery replacement will be performed by Unit Maintenance personnel a Release latches 68 and One or more bat remove cover 65 Check teries are dam battery compartment for aged or missing damaged or missing batter ies b Check for damaged or miss b One or more filler ing filler caps 66 caps are damaged or missing
197. ust perform checks and services for the interval listed b Interval Column This column tells you when you must perform the procedure in the procedure column 1 Before procedures must be done immediately before you operate the truck 2 During procedures must be done while you are operating the truck 3 After procedures must be done immediately after you have operated the truck 4 Weekly procedures must be done once each week 5 Monthly procedures must be done once each month C Location Item to Check Service Column This column provides the location and item to be checked or serviced The item location is underlined 2 33 TM 9 2320 363 10 2 10 EXPLANATION OF TABLE ENTRIES Con t NOTE The WARNINGs and CAUTIONSs appearing your PMCS table should always be observed WARNINGs and CAUTIONs appear before applicable procedures You must observe these WARN INGS to prevent serious injury to yourself and others and CAU TIONS to prevent your equipment from being damaged d Procedure Column This column gives the procedure you must per form to check or service the item listed in the Item to Check Service column to know if the equipment is ready or available for its intended mission or for operation You must perform the procedure at the time stated in the interval column e Not Fully Mission Capable If Column Information in this column tells you what faults will keep your equipment from being capable of performing
198. val Procedure Capable if Fifth Wheel All Except M917A1 and M917A1 w MCS Failure to keep fifth wheel plate lubricated could cause erratic steering due to binding of plate between tractor and trailer This could result in an accident causing injury to personnel a Check that fifth wheel plate 44 is coated with grease b Check for operation and dam b Lock release age to lock release levers levers do not oper 45 slide locking plungers ate Locking jaw 47 sliding rails 46 and fifth mechanism is wheel plate 44 cracked or worn 2 54 Item No 31 TM 9 2320 363 10 Table 2 1 Preventive Maintenance Checks and Services PMCS for M915 Family of Vehicles Con t Interval Location Item To Check Service Procedure a Check under truck for evi dence of fluid leakage such as oil coolant fuel hydraulic fluid b Check rear gladhands for damage Ensure that glad hand vent holes are not plugged Ensure that dummy couplings are installed c Check truck for obvious damage that would impair operation d Check for damage to rear service and blackout lights and marker clearance lights e Check for damage to exhaust system compo nents Ensure that compo nents are securely mounted and are not leaking Not Fully Mission Capable if a Class 111 oil cool ant or hydraulic leaks or Class Il fuel leaks are evi dent c Damage that wo
199. witch Spring loaded two position switch Switch posi M915A2 and tions are M916A1 a LOCK Down position prevents movement of main light switch b UNLOCK position Up position enables movement of main light switch Hold lever in UNLOCK position and move main light switch to desired position Auxiliary Switch Four position switch Will not function if main light M915A2 and switch is OFF Switch positions are M916A1 PANEL BRT Bright panel lights will function except if main light switch is in OFF BO DRIVE or BO MARKER positions PANEL DIM Same as PANEL BRT position but panel lights dimmer switch may dim lights PANEL OFF Panel lights will not function PARK When main light switch is in SER DRIVE position headlights will be deactivated leaving all service marker tail lights functioning 2 8 TM 9 2320 363 10 2 2 INSTRUMENT PANEL Con t M915A2 Air Vents Air Cleaner Restriction Indicator Gage M916A1 Main Light Switch All Except M915A2 and M916A1 Vent air into cab from heater ventilator defroster and air conditioner if equipped Louvered openings are adjustable Indicates air cleaner air flow is adequate if gage is clear If restricted indicator window will show up to 20 inches of water Push yellow reset button to reset after air cleaner has been serviced Five position switch Operates the same as main light switch on other model trucks Refer to item 16 in subparagraph a 3
200. xle Tan dem Manufacturer Rockwell Rockwell Rockwell Rockwell RT40 145P RT52 160P RT52 160P RT52 160 w CTIS Rated Capacity 40 000 Ib 52 000 Ib 52 000 Ib 52 000 Ib 18 160 kg 23 608 kg 23 608 kg 23 608 kg Ratio 4 56 1 4 89 1 4 89 1 4 89 1 Automatic Locking forward rear both rear both rear both rear Positive Traction differential differentials differentials differentials Differential only Brake System Actuation Air mechani Air mechani Air mechani cal cal cal cal Pressure Range 60 120 psi 60 120 psi 60 120 psi 60 120 psi 414 827 414 827 414 827 414 827 kPa kPa kPa kPa Airbrake Chambers Service 2 on front 2 on front 2 on front 2 on front axle axle axle axle Failsafe Spring 4 on forward 4 on forward 4 on forward 4 on for rear and rear and rear and ward rear rear rear rear rear rear rear and rear axles axles axles rear axles ABS Anti Lock Brake System Type 4 channel 4 channel 4 channel 4 channel Location front axle and front axle and front axle and front axle and rear rear axle rear rear axle rear rear axle rear rear axle 1 20 1 12 Wheels Size Number of Studs Stud Size Ply Rating Load Range Inflation Pressure Maximum Load Front Rear Spare Steering Manufacturer Steering Gear Type TM 9 2320 363 10 EQUIPMENT DATA Con t Table 1 1 Equipment Data Con t M917A1 M917A1
201. y refer to TM 5 3805 264 14 amp P a The M915 family of vehicles must receive lubrication with approved lubricants at recommended intervals in order to be mission ready at all times b The Lubrication Chart shows lubrication points items to be lubri cated the required lubricants and recommended intervals for lubrication by the oper ator crew Any special lubrication instructions required for specific components are contained in the NOTES section of the chart C The KEY and CHARTS A through E provide information needed to select the proper lubricant for various temperature ranges and uses and identify the interval d Recommended intervals are based on normal conditions of opera tion temperature and humidity When operating under extreme conditions lubri cants should always be changed more frequently When in doubt notify your supervisor F 2 SPECIFIC LUBRICATION INSTRUCTIONS a Keep all lubricants in a closed container and store in a clean dry place away from extreme heat Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep lubrication equipment clean and ready for use b Maintain a record of lubrication performed and report any problems noted during lubrication Refer to DA Pam 738 750 for maintenance forms and proce dures to record and report any findings C Keep all external parts of equipment not requiring lubrication free of lubricants After lubri
202. y to avoid spinning tires b Drive at slower speeds 2 136 TM 9 2320 363 10 2 45 OPERATE ON SNOW OR ICE Con t c Give signals sooner d Apply brakes sooner to give early warning of intention to stop This will also help to avoid skidding e Maintain double the normal distance from the vehicle ahead f Keep windshields windows mirrors headlights stop lights and body lights clean and free of snow and ice Use defroster to help keep glass free of snow and ice g Descend moderate grades in gear normally used for ascending same grade On steep or very slippery grades LOCK ENGAGE Interaxle Lockout All Wheel Drive Control Valve and use at least one gear lower h After driving through slush or water drive slowly and test brakes Keep driving slowly maintaining moderate pressure on service brake pedal to create a slight drag When brakes are dry and operating properly resume normal Speed i If a difficult stretch of road approaches stop and inspect it carefully before driving on it Select transmission gear range that best suits road condition and LOCK ENGAGE Interaxle Lockout All Wheel Drive If vehicle becomes stuck or tires start spinning it may be possible to rock vehicle out LOCK ENGAGE Interaxle Lockout All Wheel Drive and shift transmission to D DRIVE Apply light steady throttle never full throttle When vehicle has moved as far as it will go apply service brakes and allow eng

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