TM 9-2320-302-20
Contents
1. 0133 00 1 WP 013400 Brake Pedal 0134 00 1 Front Brakeshoe 0135 00 1 WP 0136 00 Front Brake Spider and Brake Chamber Bracket Replacement Rear Brakeshoe 0137 00 1 Rear Brake Spider and Brake Chamber Bracket Replacement Slack Adjuster Adjustment 0139 00 Slack Adjuster and 5 Replacement 0140 00 1 Front Air Brake Chamber 0141 00 1 Rear Air Brake Chamber 0142 00 1 Primary I Air Tank and Fittings 0143 00 1 Primary II Air Tank and Fittings 0144 00 T Secondary Air Tank and Fittings Air Supply Tank And Fittings Replacement Air Tube 0147 00 1 Constant Air Junction Block Replacement 0148 00 1 Cab Air Junction Block Replacement 0149 00 1 Tractor Protection Valves2. WP 0048 00 Fan Clutch Solenoid WP 0049 00 Fan Clutch and Drive Pulley Replacement Water Filter Element Replacement Water Filter Adapter and Bracket Replacement Water Pump Maintenance 1 WP 0053 00 Spindle and Housing Replacement WP 0054 00 Alternator Belt Replacement and WP 0055 04 Alternator WP 0056 00 Starter 1 WP 0057 00 Voltage Regulator WP 0058 00 Battery Equalizer WP 0059 00 Starter Relay i Uu a y cl Iellie Soo ay CAI N S Iellie cei iie em em 0022 00 1 0024 00 1 0026 00 1 0035 00 1 0037 00 1 0041 00 T 0045 00 T 0049 00 1 0050 00 1 0051 00 1 0052 00 1 0053 00 1 0055 00 1 0056 00 1 0058 00 1 0059 00 1 9 2320 302 20 Table of Contents Continued Page Number Left Panel Gages and Lamps Replacement 0060 00 1 C
3. 0168 00 1 Pitman Arm and Drag Link Maintenance 0169 00 1 Power Steering Reservoir and Hose 0170 00 1 Right Step 0171 00 1 Left Step 0172 00 1 Left Side Platform Replacement 0173 00 1 Right Rear Step Replacement 0174 00 1 Front Bumper 0175 00 1 Spare Wheel Hoist 0176 00 1 Rear Tie Down 0177 00 1 Fifth Wheel 4 0178 00 1 Pintle Hook Replacement and 0189 00 1 WP 0180 00 Towing Bracket Replacement 10180 00 Taillight Bracket 0181 00 1 Front Shock Absorber Replacement 0182 00 1 Rear Shock Absorber 0183 00 1 Brush Guard 0184 00 1 Engine Hood Assembly Replacement 0185 00 1 Hood As
4. 0221 00 1 Air Conditioner Resister Block Replacement Air Conditioner Thermostatic Switch Replacement Air Conditioner Binary Switch Air Conditioner Leak 0225 00 1 Air Conditioner Compressor Magnetic Clutch Replacement M13 Decontamination Kit Mounting Bracket Replacement General Maintenance Instructions 2 0228 00 1 Arctic Heater Replacement 0229 00 1 Illustrated List of Manufactured 0230 00 1 WP 0231 00 Torque 0231 00 1 SUPPORTING INFORMATION R ferenGes sour esr eh bad GEE ee T OE oA TEES 0232 00 1 Maintenance Allocation Chart MAC Introduction Maintenance Allocation Chart Expendable and Durable Items 464 0235 00 1 Tool Identification 0236 00 1 vcrc Index 1 DDEC Wiring 1 OEM Responsibility RPSAR Geek ee tle ih t END de ak ee RE vi 9 2320 302 20 HOW USE THIS MANUAL This manual is designed to help you
5. 0079 00 1 Water Level Module Water Level Probe 0081 00 1 Headlamp 0082 00 1 Headlamp and Headlight Replacement 0083 00 1 Blackout Drive Marker Light and Wiring Harness Replacement Right Front Blackout Marker 0085 00 Rear Blackout Marker Replacement 0086 00 1 Taillight Maintenance sack did IRURE UPS RE PORE E 0087 00 1 Side Marker Turn Signal Light Clearance Light Replacement 0089 00 1 Utility Light Maintenance 0090 00 1 Interior Light Unit and Bulb 0091 00 1 Fuel Pressure Sensor Replacement 0092 00 1 Fuel Temperature Sensor 0093 00 1 Fuel Level Sending Unit 0094 00 1 Oil Pressure Sensor Replacement 0095 00 1 Oil Temperature Sensor 0096 00 1 Oil Pressure Sending Unit Replacement
6. 0150 00 1 Rear Relay Valve 0151 00 1 Front Service Brake Relay Valve Front Gladhands 0153 00 1 Rear Gladhand Replacement 0154 00 1 9 2320 302 20 Table of Contents Continued Page Number Front Quick release Valve 0155 00 1 Rear Quick release Valve Air Dryer Replacement cisco eR t ES UR RU RR 0157 00 1 Air Dryer Canister Replacement 0158 00 1 Trailer Hand Brake 0159 00 1 Parking Brake and Trailer Air Supply Valve Replacement Foot Brake Valve 0161 00 1 Front Anti lock Brake System ABS Air Solenoid Replacement j Rear Anti lock Brake System ABS Air Solenoid Replacement Front and Dual Rear Wheel Lug Nut Installation 0164 00 1 Front Hub Drum Wheel Bearings and Seal Replacement Rear Hub Drum Wheel Bearings and Seal Replacement Steering Wheel 0167 00 Universal Shaft Replacement and
7. 9 2320 302 20 UNIT MAINTENANCE MANUAL FOR TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A3 NSN 2320 01 432 4847 e QE E i Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY May 2001 9 2320 302 20 TECHNICAL MANUAL HEADQUARTERS TM 9 2320 302 20 DEPARTMENT OF THE ARMY Washington D C 28 May 2001 UNIT MAINTENANCE MANUAL FOR TRUCK TRACTOR LINE HAUL 52 000 GVWR 6 X 4 M915A3 NSN 2320 01 432 4847 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 pro cedures please let us know Submit your DA Form 2028 Recommended Changes to Equipment Technical Publications through the Internet on the Army Electronic Product Support AEPS website The Internet address is http aeps ria army mil If you need a password scroll down and click on ACCESS REQUEST FORM The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your com ments and better manage the DA Form 2028 program You may also mail fax or e mail your letter DA Form 2028 direct to AMSTA LC CI 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 309 782 072
8. maintain the M915A3 Tractor Truck FEATURES OF THIS MANUAL A Table of Contents is provided at the beginning of this manual WARNINGs CAUTIONs NOTEs subject headings and other important information are highlighted in BOLD print as a visual aid WARNING A WARNING indicates a hazard which results in death or serious injury CAUTION 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 procedures easier to perform Statements and words of particular importance are printed in CAPITAL LETTERS to create empha sis Instructions are located with illustrations that show the specific task on which the mechanic is work ing Dashed leader lines used in illustrations indicate that called out items are not visible i e they are located within the structure Dashed leader lines in the Lubrication 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 GUIDELINES WHEN YOU THIS MANUAL Read through this manual and become familiar with its contents before attempting to maintain the vehicle
9. 0097 00 1 Water Temperature Sensor 0098 00 1 Water Level Sensor Replacement 0099 00 1 Fan Temperature Sensor 0100 00 1 Air Temperature Sensor 0101 00 1 Turbo Boost Sensor TBS 0102 00 1 Timing Reference Sensor 0103 00 1 Synchronous Reference Sensor 0104 00 1 Air Pressure Sending Units Primary Secondary Replacement WP 0106 00 Front Anti lock Brake System ABS Sensor Replacement 0106 00 1 9 2320 302 20 Table of Contents Continued Page Number Rear Anti lock Brake System ABS Sensor Replacement Anti lock Brake System ABS Electronic Control Unit Replacement 0108 00 1 Brake Light Trailer Brake Light Sending Unit Replacement Collision Warning System CWS Antenna Alignment 0110 00 1 Collision Warning System CWS 0111 00 1 Electric Horn Replacement 0112 00 1 Battery Replacement 0113 00 1 Battery Box
10. 0114 00 1 Battery Cables Replacement 0115 00 1 Stop Tail Backup Lights Wiring Harness Replacement 0116 00 1 Automatic Ether Starting Aid Wiring Harnesses Replacement Cab to Frame Ground Wire 0118 00 1 Electrical Connectors Maintenance 0119 00 T Shift Selector and Shift Tower 0120 00 1 Transmission Fill Level Check Tube Transmission Oil Cooler Lines and Fittings Replacement Transmission Oil Filter Elements Transmission Electronic Control Unit ECU Replacement Transmission Electronic Control Unit ECU Wiring Harness Replacement Transmission Speed Sensor Replacement 0126 00 1 Transmission Oil Cooler Replacement 0127 00 1 Transmission Breather Replacement 0128 00 1 Driveline 0129 00 1 Driveline U Joints and Bearings Replacement 0130 00 1 Front Axle in 0131 00 1 Front Axle Stop Cushion 0132 00 1 Rear Axle Breather
11. 6 Table of Contents Page Number Warning Summary eene ebbe eue hs pu EE VERUS Si RS E H How to Use This 1 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION WP 0001 00 General 1 0001 00 1 WP 0002 00 Equipment Description and 0002 00 1 WP 0003 00 Theory of 0003 00 1 CHAPTER 2 UNIT TROUBLESHOOTING PROCEDURES 000400 Troubleshooting 0004 00 WP 0005 00 Troubleshooting Symptom Index 0005 00 1 WP 000600 Engine Troubleshooting 0006 00 1 WP 0007 00 DDEC Engine Troubleshooting 0007 00 1 WP 0008 00 Exhaust System Troubleshooting 0008 00 1 WP 0009 00 Cooling System Troubleshooting 0009 00 1 WP 0010 00 Electrical System Troubleshooting 0010 00 1 WP 0011 00 Transmission and Driveline Systems Troubleshooting 0011 00 1 WP 001200 Brake System Troubleshooting 0012 00 1 WP 0013 00 Anti lock Brake System ABS Troubleshooting and Test
12. A Warning Summary is provided at the beginning of this manual and should be read before attempting to maintain the vehicle vii 9 2320 302 20 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION 9 2320 302 20 GENERAL INFORMATION 0001 00 SCOPE 1 Type of Manual This manual is for use in performing Unit Maintenance on the M915A3 Tractor Truck 2 Equipment Name Model Number Truck Tractor Line 52 000 GVWR 6 X 4 M915A3 3 Purpose of Equipment The M915A3 Tractor Truck is a 6 X 4 prime mover of semitrailers used primarily to transport containers bulk cargo and petroleum products over primary and secondary roads under worldwide climatic conditions in a military environment MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance 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 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS 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 LC CIP WT Rock Island Illin
13. all defects in material or workmanship to your supervisor who will take appropriate action 0001 00 1 9 2320 302 20 GENERAL INFORMATION CONTINUED 0001 00 NOMENCLATURE CROSS REFERENCE LIST COMMON NAME OFFICIAL NOMENCLATURE Cold Stare System CERE RR eR ERR EE UE REM Ether Quick start System Engine Coolant zt ARENA dsc MSS EMEN TS Sales Antifreeze Ethylene Glycol Mixture Gladhande fea Quick Disconnect Coupling A US Komfort LOC 2 EN NES BID NEUE Seat Belt Adjustment TAC eios tutos hae s toten nido d ton euis furious bero sacs vga RON ee Rear Suspension System LIST OF ABBREVIATIONS NOTE Refer to MIL STD 12D for standard abbreviations ABBREVIATION DEFINITION ABS etam Ne et e e La en ad o ER Rede Anti lock Brake System usu uses nS eU UN EM A C E Centigrade or Celsius UP ATO S EIC UR MN Check Engine Light CID eere e en PRICE e qoe erede PE ear agence Cubic Inch Displacement CI iens Deu eR LR Rec ER ax er ede ER esce ipd Centimeter COWS Mu E p P Collision Warning System DDEC ERASMUS eb ONE Dre UA NERA NM AA RESI RAN S VAR ES Detroit Diesel Electronic Controlled DDLI LE EAERISeex
14. ciespeq env ea ueniet oue LES Men sq ent baee e VAT Diagnostic Data Link de ub dne ee ula dete Re A ERE RE ES Diagnostic Data Reader EGUS VERE ER ER UR RR RR S QOEM RU UNI E E RARE Electronic Control Unit rt dI cr M m n RS Fahrenheit e n ue oa Sa gun Mond gus dime roue eodd rr vt Gross Combination Weight Rating Ln Gross Vehicle Weight Rating ee e e RE S MR RE E Kilogram ki ote dte Csesar ete M ti xA dd Kilometer AP RU e edi e e bene qe ns AL Kilopascal op d Manuele ue Kilometers per Hour IW a el a PR ER EP CREME GR ES ROC ICE EORR ER RR SOURCE Kilowatt Aue eid Abas Bue dq ete RA eret eie p Ete ARE EA eto Liter jn Pound ER re RR REPRE NUR EE MEM Pound foot mM nir Md ca IM ru MEE Liters per Hour Iuris di jue ete state wood aca AG NOLAN dd ee ate NAR ie Mele dedere piel d Meter Oum Millimeter MIS eei leva rela o lese ara Movement Tracking System 0001 00 2 9 2320 302 20 GENERAL INFORMATION CONTINUED 0001 00 LIST OF ABBREVIATIONS CONTINUED ABBREVIATION DEFINITION INTE ood eese po
15. enter Gage Panel Maintenance 0061 00 1 Right Gage Panel and Lamps Upper Right Dash Panel 0063 00 1 Left Hand Switch Panel 0064 00 1 Right Hand Switch Panel 0065 00 1 Control Module Replacement 1 Heater and Air Conditioning Control Panel Replacement 12V Power Receptacle 0068 00 1 Fiber Optic Light Source 0069 00 1 Check Engine Switch and Jumper Harness Fuse Relay Circuit Breaker and Holder Replacement Master Battery Switch Replacement 0072 00 1 Turn Signal Switch Electronic Throttle Replacement 0074 00 1 Electronic Control Module NATO Slave Receptacle Replacement Utility Power Receptacle Trailer Electrical Receptacles Parking Brake Pressure Switch Replacement
16. er epe rapa nan cee a PO dba rico Newton Meter PMCS e BEN ne MEAE RD A ERI ike ata ARENA Preventive Maintenance Checks and Services png pP Pounds per Square Inch TDI 44d edo edem d ec ER do emet eb ded aue dado eb edel pta Revolutions per Minute 0001 00 3 9 2320 302 20 EQUIPMENT DESCRIPTION AND DATA 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES 1 Characteristics a The M915A3 Tractor Truck 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 oscillat ing sliding fifth wheel compatible with two inch kingpin Maximum towed load on kingpin is 30 000 13 620 kg Capabilities and Features While operating on Class I roads the fully loaded M915A3 can maintain a speed of 65 mph 105 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 Average cruising ranges at Gross Combination Weight Rating GCWR with a full tank of fuel will vary based on conditions e g varying loads prolonged idle and climatic conditions Cruising range is optimally 400 miles 640 km The M915A3 is equipped with an instrument panel mounted speedometer and tachometer which register truck ground speed and engine speed The M915A3 has the following capabilities and featu
17. ing 0013 00 1 9 2320 302 20 Table of Contents Continued Air System Troubleshooting Steering System Troubleshooting Chassis and Fifth Wheel Troubleshooting Air Conditioning System Troubleshooting and Testing WP 0018 00 Collision Warning System CWS CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS WP 001900 Service Upon Receipt Page Number 0014 00 1 0015 00 1 0016 00 1 0017 00 1 0019 00 1 WP 0020 00 Unit Preventive Maintenance Checks and Services PMCS Introduction 0020 00 1 WP 0021 00 Unit Preventive Maintenance Checks and Services PMCS Oil Fill Tube Oil Level Dipstick Tube and Adapter Replacement Oil Filter Element Oil Cooler and Oil Filter Adapter Oil Sample Valves Replacement Air Compressor Discharge Hose Air Compressor Governor Replacement and Air Compressor Replacement WP 0030 00 Fuel Hoses and Fittings Replacemen
18. nt 0203 00 1 Cab Overhead Storage Compartment Steering Column Cover Replacement 0205 00 1 Cab Door 0206 00 1 Transmission Tunnel Access Cover Rear View Mirror 0208 00 1 Spotter Mirror 0209 00 1 Windshield Wiper Motor and Linkage 0210 00 T Windshield Washer Reservoir 0211 00 1 Windshield Wiper and Wiper Arm Replacement Vehicle Jack Mounting Bracket Replacement Air Horn and Valve Replacement 0214 00 1 Data and Instruction Plates 0215 00 1 M16 Rifle Mounting Bracket Cup Holder 0217 00 1 Cab Roof Air Deflector Replacement 0218 00 1 HVAC Air Cylinder 0219 00 T HVAC Blower Motor 0220 00 1 HVAC Heater Core Replacement
19. ois 61299 7630 We will send you a reply CORROSION PREVENTION AND CONTROL CPC l Corrosion Prevention and Control CPC of Army materiel is a continuing 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 2 While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem 3 If a corrosion problem is identified it can be reported using SF Form 368 Product 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 OZONE DEPLETING SUBSTANCES ODS Listing to be provided by requiring activity DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use refer to TM 750 244 6 PREPARATION FOR STORAGE OR SHIPMENT For preparation for storage or shipment procedures refer to TM 740 90 1 and MIL V 62038D WARRANTY INFORMATION The vehicle is warranted by Freightliner Corporation in accordance with TB 9 2320 302 15 Warranty starts on the date found in block 23 DA Form 2408 9 in the logbook Report
20. ors Heated Grabhandles Utility Power Receptacle Air Horn Master Battery Switch Spare Wheel and Tire Battery Box and Steps Front Service Lights Bumper Extensions Blackout Lights Towing Eyes 342 001 Indicate outline of truck Provide driver with a view of sides of truck and semitrailer if towing Provide a hand hold for personnel climbing on truck Supplies power for work lights Located on both sides of truck Provides an audible alert Provides battery power to 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 Provide adjustable attachment point for slings Used during blackout conditions Include marker and drive lights Provide attachment points for towing device 0002 00 2 9 2320 302 20 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED COMPONENT DESCRIPTION CWS Antenna Forward looking collision warning system antenna Brush Guard Protects front of hood and components under hood from damage Spotting Mirrors Provide added visibility to sides and front of truck 0002 00 3
21. res 1 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 2 operation in temperatures from 25 F 32 C to 125 F 452 C and to 40 F 40 C with arctic kit installed 3 start and climb capability of a 20 percent grade at GCWR in both forward and reverse directions 4 fording capability up to 20 in 51 cm deep for 5 minutes without damage or requiring maintenance before operations can continue 5 two passenger aluminum corrosion proof cab with a 90 degree tilt forward hood for service accessibility 6 six cylinder 12 7 liter 430 horsepower in line turbocharged diesel engine built by Detroit Diesel 7 Allison HD 4560P six speed automatic transmission 8 Collision Warning System CWS that warns the driver of potentially dangerous driving situations by acti vating visual and audible alerts For operation in arctic conditions the M915A3 can be equipped with an arctic heater mounted under the cab above the battery box This provides heat for the cab and engine cooling system The arctic heater may be operated prior to starting the engine to provide preheating of engine block 0002 00 1 9 2320 302 20 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS A E fes un 4 hoe m S EI 2 79 Marker Clearance Lights Side Mirr
22. sembly Repair 0186 00 1 Hood Adjustment crece De reser tU p Cx Rr a epe RU E cg Rai en 0187 00 1 Hood Latch 7 4 0188 00 1 Hood Liner 0189 00 1 Hood Prop and Mount Replacement 0190 00 1 Seat 0 0191 00 1 DR RP RE SERA 0192 00 1 Seat Belt 2 0193 00 1 Front Splash Guard and Fender Extension 0194 00 1 Rear Fender Replacement 0195 00 1 Mud Flap Assembly 0196 00 1 Personal Gear Storage Box and Mounting Bracket Replacement Basic Issue Items BII Storage Box and Mounting Bracket Replacement 0198 00 1 Storage Box Latch Replacement 0199 00 1 Rear Platform 0200 00 1 Floor Mats Replacement 0201 00 1 9 2320 302 20 Table of Contents Continued Page Number Cab Liners Replacement 2 2eik eme hes Rhe RR ROTER UA ER 0202 00 1 Head Liners Replaceme
23. t WP 0031 00 Fuel Strainer and Filter Element Replacement WP 0032 00 Fuel Filter Adapters Replacement WP 0033 00 Fuel Tank and Mounting Brackets WP 003400 Fuel Pump 2 WP 0035 00 Automatic Ether Starting Aid Air Cleaner Air Intake Duct and Turbo Bypass Valve Maintenance WP 0037 00 Air Intake Tubes and Hoses WP 0038 00 Charge Air Cooler and Air Recirculation Shield Replacement WP 0039 00 Exhaust System Muffler Stack and Heat Shield Replacement WP 0040 00 Exhaust System Flex Pipe Clamps and Heat Shield Replacement WP 0041 00 Drain and Fill Cooling WP 0042 00 Coolant Hoses Pipes and Clamps WP 0043 00 Thermostat and Thermostat Housing Cover Replacement WP 0044 00 Radiator Support Rod WP 004500 Radiator WP 0046 00 Fan Belt Replacement and WP 0047 00 Fan Impeller and Shroud
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