3229-206 do TM9-2320-206-20 TECHNICAL MANUAL ORGANIZATIONAL MAINTENANCE MANUAL FOR TRUCK TRACTOR, 10-TON, 6x6 M123 (2320-395-1875) M123C (2320-294-9552) e MI23A1C (2320-226-6081) M123E2 (2320-879-6177) & Md . AND a TRUCK CARGO, 10-TON, 6x6 M125 (2320-219-7340) This reprint includes all changes in effect at the time of publication ~ Changes 5 and 6. @ teavauantens, DEPARTMENT OF THE ARMY e init = OCTOBER 1971 | iin Google BiWARNING CARBON MONOXIDE POISONING CAN BE DEADLY CARBON MONOXIDE IS A COLORLESS, ODORLESS, DEADLY POISONOUS GAS, WHICH, WHEN BREATHED, DEPRIVES THE BODY OF OXYGEN AND CAUSES SUFFOCATION. EXPOSURE TO AIR CONTAMINATED WITH CARBON MONOXIDE PRODUCES SYMPTOMS OF HEADACHE. DIZi INESS, Lt ‘OP MUSCULAR CONTROL, APPARENT DROWSIN BRAIN DAMAGE OR DEATH CAN RESULT FROM SEVERE EXPOSURE. IT OCCURS IN THE EXHAUST FUMES OF FUEL-BURNING HEATERS AND INTERNAL-COMBUSTION ENGINES AND BE- COMES DANGEROUSLY CONCENTRATED UNDER CONDITIONS OF INADEQUATE VENTILATION. THE FOLLOWING PRE- CAUTIONS MUST BE OBSERVED TO INSURE THE SAFETY OF PERSONNEL WHENEVER THE PERSONNEL HEATER, MAIN OR AUXILIARY ENGINE OF ANY VEHICLE IS OPERATED POR MAINTENANCE PURPOSES OR TACTICAL USE. 1, DO NOT OPERATE HEATER OR ENGINE OF VEHICLE IN AN ENCLOS LATED. 2,DO NOT IDLE ENGINE FOR LONG PERIODS WITHOUT MAINTAININ COMPARTMENTS, 3,DO NOT DRIVE ANY VEHICLE WITH INSPECTION PLATES, COVER PLATES, ENGINE COMPARTME! i$ NECESSARY FOR MAINTENANCE PURPOSE: 4. BE ALERT AT ALL TIMES DURING VEHICLE OPERATION FOR EXHAUST ODORS AND EXPOSURI EITHER IS PRESENT, IMMEDIATELY VENTILATE PERSONNEL COMPARTMENTS. IF SYMPTOMS PERSIST. RE- MOVE AFFECTED PERSONNEL FROM VEHICLE AND TREAT AS FOLLOWS MOVED UNL COMA, PERMANENT D AREA UNLESS IT IS ADEQUATELY VENTI- (G ADEQUATE VENTILATION IN PERSONNEL. DOORS RE- YMPTOMS. IF EXPOS ‘TO PRESH AIR; KEEP WARM: DO NOT PERMIT PHYSICAL EXERCISE: If NECESSARY. ADMINISTER ARTIFICIAL RESPIRATION, ‘THE BEST DEFENSE AGAINST CARBON MONOXIDE POISIONING IS ADEQUATE VENTILATION, WARNING. When disconnecting or connecting vehicle battery eable the sround cable (s) must be disconnected first and connected last. Remove ground cable from terminal clamp on M123A1C and M123E2 vehicles. Do not remove clamp from running board battery as underseat battery would still be grounded. Non-compliance could result in personal injury and vehicle damage. WARNING. Exhaust gases are dangerous. Troubleshoot exhaust systems in well ventilated area to preclude injury to personnel WARNING Remove rings, watches, ete. prior to performing any electrical troubleshooting, to prevent accidental short circuits and/or electri shock. WARNING Do not permit a “hot” wire to touch metal parts of the vehicle at any time. Testing by striking a hot wire ‘against a ground (flash testing) will ereate an are that ‘ean cause personal injury and destroy the connector on the lead, WARNING Before checking or draining radiator. turn filler eap to the left until stop is reached. Cap is then in vented position to allow pressure to escape. Non-compliance ‘could result in serious burns. WARNING Explosive fumes. Before performing any fuel pump ‘operations, disconnect (cable No. 77 when working on left tank or cable No, 78 when working on right fuel tank? from electrical connector and wrap it with insulating tape to prevent the possibility of an electrical spark igniting fumes inthe fuel tank, WARNING Make certain locking. ring is seated properly: against rim of wheel through its entire circumference, before inflating tire. Do not stand in front of wheel when inflating it. If wheel is not mounted, turn ring side down shen inflating it to reduce chance of ring being dislodged, Safety chains ean be loosely wrapped arvund two different points of the tire and rim to safewuard against injury should the side ring release during inflation. Failure to observe this warning can result in personal injury WARNING: Explosive fumes. When draining tanks, atach a xround wire from vehicle fuel tank to fuel receptacle to carry off static eletricit WARNING. If vehicle is used to transport flammable or explosive ‘material, be sure to install spark arrestor mufflers GoogleChanges in force: C 5 ‘TM 9-2320-206-20 cs @ CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, DC, 28 January 1975 Organizational Maintenance Manual TRUCK, TRACTOR, 10-TON, 6X6, M123 (2320-00-395-1875) M123C (2320-00-294-0552), M123A1C (2320-00-226-6081) M123E2 (2320-00-879-6177) AND TRUCK, CARGO 10-TON, 6X6, M125 (2320-00-219-7340) Current as of 1 October 1974 ‘TM 9-2820-206-20, 22 October 1971, is changed as follows: Page i, Section XIV. Cooling system. Change ‘MI23E1 to Mi23E2. Page 1-1, Paragraph 1-4 Line 2. Change TM 750-2443 to, TM 750-244-6, Paragraph 1-76(4) Cooling System. Change Radiator operating pressure for M123A1C, M123E2 from 12 pai to 4 pei. Paragraph 1-76(10) Azles. Change front axle ratio for M128, M128C, M125 from 9.019:1 to, “8.02:1". Paragraph 1-7H(15) Steering System. Add the following under Hydraulic pump: ‘Outflow rate (at 1200 rpm. ‘speed, full wheel turn)... gpm 6 gpm Pressure (at 1200 rpm engine ‘speed, full wheel turn) .. 1000 pai Paragraph 1-76(16) Fifth wheel entry is superse- ded as follows: Pith wheel: M123, M1230, M125 MI2RA1C, MI23E2 Make: ... Military Standard Military Standard Size: 96in. 36 in. ‘Ord Number: 6578254 578284 King Pin Size: ... 85 in. 35 in. Page 2-1, paragraph 25, line 6. Add the following: Refer to figure 2-2.1 for Fabricated Special Tool for Oil Cooler Element Removal. Fabricate as follows: Use serap stock (such as aluminum or steel) 2/4 inch wide, 1/4 inch thick and make to dimensions shown. Drill two 1/4 inch holes in stock. Two 10-32NF x 3/4 screws are required for use of this tool. Refer to paragraph 2-45 for use. Page 2-2. Add figure 2-2.1 as follows: ‘This change supersedes C2, 20 Apt 1973; C 2, © September 1973; and C4, 11 March 1074.NOTE: ALL DIMENSIONS SHOWN ARE ARE IN INCHES a Va 41/16 TA021437 Figure 24.1. Fabricated special tool for oil cooler element removal. Pages 2-5, 2-6, 2-7, Table 22 title. Change “Monthly Schedule (or quarterly)” to, “Semiannual”. Page 2-6, Add Sequence No. 20.1 as follows: Under Items to be inspected, add, “Air Brake Hoses.” Under Procedure, add, “Examine all brake hoses installed on the vehicle; if any of the following deficiencies are revealed it is mandatory to replace or reposition the hose as appropriate, prior to operating the vehicle.” 4. Surface cracking or seepage at any point. 6, Pinching of brake hose. ¢. Evidence or wear due to rubbing or contact with vehicle structure. @. Brake hose stress due to improper installa- tion, Under paragraph reference, add, “Para 2-183a, b,c, and 2-184." Page 2-12, Chart 2-1, Corrective action 24c. Change (fig. 2-130) to, “(figs. 2-127 and 2-128).” Page 2-19, Chart 2-8, Malfunction 43. Delete entries fora, b, andc in Probable cause and Corrective action columns. ‘Manfunetion 45, Delete entries for b in Probable cause and Corrective action columns. Page 2-21, Chart 2-4, Corrective action 8. Change (para 2-166) to (para 2-247). Page 2-86, Figure 2-26, In title, change M124 to M125, Page 2-49, Add figure 2-41.1 as follows:@ INSTRUMENT CIRCUIT BREAKER WIRING DIAGRAM pean 27—TO PANEL INSTRUMENTS 2 7 8 Dare gre TOPIN K TRALLER SWITCH © RECEPTACLE Bs] RELAY SWITCH 18-22-18 TO DIMMER SWITCH (—16 A TO LIGHT SWITCH TAO11639 ‘Figure £:411. Lighting cite for Mts tractors equipped ‘0 prime mover forthe M747 semitrailerPage 2-55. Paragraph 2-48 is superseded as follows: 2-43. Full-flow Oil Fitter (figs. 2-49, 2-49.1 and 2-49.2) NOTE Inlet and outlet lines do not have to be removed to service the full-flow oil filters. 4. Filter Element, (1) Removal. (a) Drain oil filter. (b) Remove four filter flange capscrews and lockwashers. (c) Remove oil filter body and filter bag. (d) Discard filter bag and filter head gasket. (e) Clean filter body with dry-cleaning solvent or mineral spirits palnt thinner. (2) Installation (fig. 249.1). (a) Place ring in filter bag with studs protruding. Fold top of bag inward over ring about ‘U2inch and firmly seat bag around ring stud bases. (b) Install gasket over studs and against bag. () Install retainer attached to wire mesh spacer over studs. (d) Install second gasket over studs and ‘against spacer retainer. (©) Insert ring studs into spool through oil channel. Install wing nuts on studs and tighten. Make sure nut wings are parallel to length of spool. (9) Place filter bag assembly on clean flat surface with wire mesh spacer on top and filter bag ‘on bottom. Roll bag and spacer around spool so that spacer is between bag and studs. (h) Insert filter bag assembly into filter body. () Install filter body and new filter head gasket and secure to filter flange with four capecrews and lockwashers. Do not overtighten. Fill engine with oil (LO 9-2320-206-12), @) Start engine and check for leaks. Stop ‘engine and check oil level in cylinder block. (&) Add oil until the level reads FULL on the oo 0, Filter Body Bracket, (1) Removal. (a) Disconnect inlet and discharge lines from filter body. (b) Remove three capscrews and self-locking nuts which secure the filter bracket to the frame bracket. (@) Installation. (a) Position the filter body bracket and secure with three capscrews and self-locking nuts. (b) Connect inlet and outlet lines at filter and quick-disconnect points as shown in figure 249.2. CAUTION To prevent oil filter restriction, mount the oil filter inlet quick-disconnect coupling with the nut on the filter side and mount the oil filter outlet quick-disconnect coupl- ing with the nut on the hose side. (c) Start engine and run until operating temperature is reached. Check filter body and lines for tightness and leaks. (d) Stop engine and check cylinder block oil level. Add oil as necessary. ‘Add figures 2-49.1 and 249.2 as follows:SY £/ ys K WIRE MESH SPACER ‘020087 Fou, Figure £491. Installating full-flow filter bag. FULL FLOW OIL FILTER (MOUNTED ON TRUCK) MOUNT THIS COUPLING WITH NUT (ON FILTER SIDE MOUNT THIS COUPLING WITH N on cour 1UT ON HOSE SIDE (MOUNTED ON ENGINE V8-300) ‘CORRECT CONNECTION 8 OIL COOLER OUTLET TO OIL FILTER INLET OIL FILTER OUTLET TO OIL COOLER INLET Figure 24492. Full flow oil filter hove connections. ‘TAO09566Page 2-55. Paragraph 2-45 is superseded as follows: 2-45. Oll Cooler (fig. 2-58) a, Removal. (2) Drain radiator and remove dipstick. @) Disconnect lines and fittings from oil cooler. (8) Disconnect dipstick holder from block. (4) Remove bolts and washers. (® Remove oil cooler from engine. 6. Oil Cooler Element Removal. (2) Remove bolts and separate housing sections. (2) Remove retainer. @)Connect fabricated special tool (fig. 2-2.1) with two 10-32NF x 9/4 screws from element removal. (4) Remove element with twisting and pulling motion. ¢. Oil Cooler Element Installation. 2) Install rear seal. @ Install element. ) Install front seal. (4) Install retainer. (®) Connect cil cooler sections and secure with bolts. . Testing. ) Plug oil outlet and attach 700/100 pei ai to oil outlet. @ Immerse unit in water and apply air pressure. The slightest leak will be indicated by the appearance of bubbles. (8) Assemble front and rear heads to cooler. (@) Plug either inlet or outlet connection and check for leaks as described in (1) and (2) above. ¢. Installation. (2)Position oil cooler with new gaskets toleft side of engine. Hold in place by installing lockwashers and bolts, (2) Tighten bolts to 30 to 50 Ibe-ft torque. (8) Connect diptstick holder to block. (4) Connect lines and fittings to oil cooler. (©) Fill cooling system and bring oil to proper level. Page 2-60. Paragraph 2-60 is superseded as follows: 2-50. Clutch Controls and Linkage NOTE Free pedal travel should be two inches; if free pedal travel is less than one inch, an adjustment in the control linkage, or removal of spacers, is necessary. a. Free Pedal Travel Check. (1) Mark clutch pedal level (chalk mark) two inches from floor, as shown in figure 2-60.1. @ Depress pedal until meeting resistance other than that caused by returning spring. (Chalk mark should be even with floorboard). line 6 (8) Observe chalk mark. If above or below floor board, make minor adjustment. , Minor Adjustment (fig. 2-60.1). (1) Loosen locknut and turn adjusting bolt out to inerease, or in to decrease, and achieve desired twoinch travel. One half turn will adjust clutch ‘approximately one inch. @ Tighten locknut without further movement of adjusting bolt. ¢. Linkage Adjustment. If free pedal travel cannot be restored by minor adjustment, proceed with the following: (2) Remove six bolts and lockwashers securing lower inspection cover to clutch housing. Remove cover. @ Loosen adjusting bolt locknut and remove adjusting bolt. (@) Remove nut on release level retaining screw and remove screw. (@ Remove release lever from clutch cross shaft (fig. 260.1), (8) Take adjusting bolt and run locknut down until approximately five threads are showing below locknut. © Reinstall adjusting bolt and locknut into release lever and turn until it stops against locknut. (1 Roll clutch spline release shaft forward until throw-out bearingis against pressure plate. (Must be held in this position for next step, to over come throw-out bearing return spring tension (fig. 2-60.1). (8) Reposition release lever on release shaft 80 adjusting bolt contact area is as close as possible to adjusting tang. (Make sure throw-out bearing is against clutch plate when installing release lever). (® Reinstall nut and screw on release lever and tighten. (Torque to 70 to 90 Ibe-ft). (10) Turn bolt in or out until required two inch free play is achieved. Tighten locknut. (11) Lower inspection cover to clutch hoysing should be installed and secured with six bolts and lockwashers. d, Major Adjustment Clutch Assembly Spacer Removal. NOTE Spacer removal is required if clutch ‘clips after linkage adjustment and free play ‘adjustment has been made. CAUTION DONOT ADJUST PRESSURE PLATE IN VEHICLE. (@) Remove six bolts and lockwashers from clutch housing, lower inspection cover; remove cover. @ Working through inspection hole, loosen 12 bolts securing pressure plate to flywheel two full turns, rotating flywheel as necessary.(@ After all 12 bolts are loose, remove each bolt ‘and lockwasher and pull out spacer. Reinstall bolt and lockwasher finger tight, and proceed tonext bolt, rotating flywheel as necessary (fig. 2-60.1). (@) Tighten all 12 bolts 25 to 28 Ibe-ft torque. (© Check linkage and adjust free play. NOTE If spacers have been removed at previous adjustment, it will be necessary to replace two clutch disks, ¢, Removal (fig. 2-63). (2) Remove self-locking hex nut (1, fig. 2-63) and hexshead screw (2) securing clutch pedal stem assembly (8) with pad (4) to clutch pedal lever (5) and pull stem assembly out of lever. @) Unhook pedal return spring (6) and remove. (8) Remove self-locking hex nut (7) and hex-head bolt 8) securing pedal lever and return spring elip (9) to pedal lever shaft and remove pedal lever (6). (4) Remove two cotter pins (10) and (11) and clevis pin (12) and (18) securing clutch control clevis (14) to pedal shaft lever (15) and release ever (16) and remove clevis. (©) Remove selflocking hex nut (17) and hex- head screw (18) securing pedal shaft lever (15) to shaft (19) and remove lever. © Pull pedal lever shaft (19), and two bushing type bearings (20) and (21), at each end of shaft out of bracket. (1) Remove self-locking hex nut (22) and hex- head screw (23) securing adjusting lever to clutch tHrowout shaft and remove adjusting lever (24). Slide off release lever (16). Remove hex-head bolt (25) and locknut (26) from release lever. @ Remove two self-locking hex nuts (27 and 28) and two hex-head screws (29 and 30) securing the pedal bracket with bearing assembly (31) on engine mounting bracket and remove bracket with bearing assembly. . Installation (fig. 2-63). |) Position bracket with bearing assembly (81, fig. 2-63) on engine mounting bracket and secure with one each hex-head screw (80), self-locking nut (28) in upper hole, and hex-head screw (29) and self-locking hex nut (27) in lower hole. (2) Screw hex locknut (26) on hex-head adjusting bolt (25) and screw bolt into release lever (16). (8) Stide clutch release lever (16) on throwout shaft and position release adjusting lever (24) on shaft engaging boss on adjusting lever in cutout in release lever (16). Secure with hex-head screw (28) ‘and self-locking hex nut (22). (4) Install pedal lever shaft (19) and two bushing type bearings (20) and (21) in bracket with lubrica- tion fitting facing toward outside of vehicle. (® Position pedal shaft lever (15) on end of shaft (19) opposite lubrication fitting and secure with hex-hesd screw (18) and self-locking hex nut (17). © Position clutch control clevis (14) to pedal shaft lever (15) and secure with clevis pin (12) and cotter pin (10). Position other end of clutch control levis to release lever (16) and secure with clevis pin (18) and cotter pin (11). (7D) Position clutch pedal lever (6) and return spring clip (9) on pedal shaft (19) and secure with hex-head bolt (8) and self-locking hex nut (7). ® Hook pedal return spring (6) into spring clips. (®) Insert pedal stem assembly (8) with pad assembly (4) through hole in cab floor and into end of pedal lever (6) and secure with hex-head screw (2) and self-locking hex nut (1). (10) Adjust pedal stem assembly (3) and clutch release lever a above. Page 2-62. Delete figure 2-59. Page 2-68. Delete figure 2-60. Add figure 2-60.1 as follows:Page £-64, Delete figure 261. Page 2-75, paragraph 2-62a(8). Change (fig. 2-65) to (ig. 2-66). Page 2-88, Figure 2-87. Change call out 9, “Bolt” to “Locknut”. Page 2-116, Paragraph 2-118is superseded as follows: 2-118. Alternator ig. 2126) a. Removal. (2) Disconnect battery ground eable from nega- tive () poat of battery. ® Disconnect electrical connector from alter- nator. @ Remove bolt securing belt adjusting arm and remove drive belts. (4) Remove two mounting bolts and washers securing alternator to mounting base. Remove alternator assembly. b. Installation. @) Position alternator on mounting base and install two mounting bolts. Do not tighten bolts. @) Install bolt in belt adjustment arm. Do not tighten bolt. @) Install two V-belts over pulley. (@ Use a suitable bar and pivot alternator to 0.25 DIA - 2 HOLES: PART A = INSULATOR MATERIAL: POLYVINYL CHLOMDE bel PART C= BUSHING (MATERIAL: BAASS (PRESSED FIT) 1 DIA + .010 0.275 DA adjust belts. Tighten adjustment arm bolt and the two mounting bolts. (©) Check belt adjustment (para 2-972). () Connect electrical connector to alternator. (1 Connect battery ground cable to negative () post of battery. Page 2-118, Paragraph 2121.1 is added as follows: 2-121.1. Battery Cables and Terminal Block Modification @. General, M128A1C and M123E2 positive (+) battery post loosens or breaks due to multiple terminal connections. The problem can be corrected by fabricating and installing a terminal block on the vehicle frame to which the multiple cables are ttached. at b, Fabrication. (1) Fabricate a mounting block insulator (Part A), a mounting block (Part B), and a brass bushing (Part ©) as shown on figure 2:128.1. @ Fabricate a60 inch length of 40 size electrical cable with terminals comparable to the battery to starter motor cable. 8) Lengthen the 12 volt (12 gage wire) cold start, lead approximately 4 inches. (@) Materials required are listed in table 2-5. DIA- .010 chy aa bei} a als PART B= MOUNTING mock MATEMAL: POLYVINYL CHLORIDE NOTE: ALL DIMENSIONS SHOWN "ARE IN INCHES, TaoT06es ‘Figure £-188.1, Fabrication of terminal block.Polyvinyl Chloride 6 x 2-12 x 1 inch Brass Tubing 88 in, ID x 1 in, OD x Lin.le (Cable, Electrical, 40 size @0 in. reed) ‘Terminal, Cable, 40 ize @ rea'd) Wire, Electrical, 12 gage (in, rid) Screw, Cap: U4 -20 x 8-12 i. Ig eared Washer, Flat: 14 in. dia. 2 reid) Nut, Hexagon: 1M - 20 thd size 2 carey) Screw, Cap: 98-16 x 212 in. Ig Gea req'd) Washer, Flat: 98 in. dia. 2 rid ‘Nut, Hexagon: 26 - 16 thd size 2 carer) ¢. Installation (fig. 2-128.2 and 2-128). (1) Press the fabricated bushing into the fabri- cated block. @ Disconnect all battery ground (.) terminal connections. (8) Remove battery to ground cable from vehicle frame. Retain for later installation between the positive (+) battery post and the fabricated terminal block. (@ Disconnect all the cables from the battery Positive (+) post. (©) Remove and discard the positive (+) cable bracket and clamp from the vehicle frame. (@ Assemble and install fabricated insulator board and terminal mounting block, with bushing installed, to vehicle frame using the two rear (vertical) holes previously used to mount the cable bracket. Insert the two 2) V4 x 3-1/2 inch screws through the mounting block, insulator board and vehicle frame. Sécure with flatwashers and hex nut. (@ Lengthen cold start lead approximately four (@)inches which is sufficient to permit battery box to slide outward to limit for future battery servicing. ®) Reinstall cable (removed in (3) above) between the battery positive (+) terminal clamp and the frame mounting block. (®) Attach the five (6) positive (+) cables to the terminal block with 98 x 2/2 inch screw. Secure with flatwashers and hex nut. (10) Attach the fabricated cable(b(1) above) and the ground cables directly to the vehicle frame with an 38 x 212 inch long screw. Secure with a flatwasher and hex nut.fn] TO STARTER (P08) AATTERY KIT, RAH, SIDE ‘TO ALTERNATOR (POS) Figure £1982. Modified battery cable schematic. INSULATOR a, i2) 1/4 x 2-1/2 SCREW ahetat wasner 2) HEX NUTS Figure 2.1284. Battery cable connection and terminal block. TanI0Ne6 4 styPage 2-122, paragraph 2-124b(1) (a). Change (fig. 2207) to (fig. 2-133). Page 2-147, paragraph 2-1634(6), line 4. Change “retainer cup (8)” to, “retainer cap (8)”. Page 2-151, Paragraph 2-168.1 is added as follows: 2-168.1. Brake Pedal and Control Linkage (fig. 2-163.1) 4. Removal. () Brake pedal. (a) Remove cotter pin and headed pin secur- ing pedal to idler shaft linkage. (6) Remove cotter pin and headless pin securing pedal to brake pedal bracket and remove jal. @ Idler lever. (a) Remove cotter pin and clevis pin securing brake control rod to idler lever. (0) Remove cotter pin and clevis pin securing pedal linkage to idler lever. (c) Remove cotter pin and pivot shaft securing idler lever to mounting bracket and remove idler. (® Brake pedal to idler shaft linkage. (a) Remove cotter pin and headed pin secur- ing linkage to brake pedal. (0) Remove cotter pin and clevis pin securing linkage to idler shaft and brake pedal. (@ Brake control rod linkage. (a) Remove cotter pin and clevis pin securing brake valve control rod to brake idler lever. (b) Remove cotter pin and clevis pin securing control rod to center hole of brake valve arm and remove linkage. (©) Brake application valve lever. (a) Remove cotter pin and clevis pin securing control rod to center hole of brake valve lever. () Remove cotter pin and pivot pin securing brake valve lever to mounting bracket and remove lever. b, Installation. () Brake application valve lever. () Aline holes and install pivot pin and cotter securing brake valve lever to mounting bracket. (2) Aline holes and install clevis pin and cotter pin securing control rod to center hole of brake valve lever. @ Brake control rod linkage. (a) Position brake control rod over brake valve arm with clevis over center hole. (6) Secure with clevis pin and cotter pin. (©) Secure opposite end of control rod to the brake pedal idler shaft with clevis pin and cotter pin. (8) Brake pedal to idler shaft linkage. (a) Aline holes and install headed pin and cotter pin securing linkage to brake pedal. (&) Aline holes and install clevis pin ana cotter pin securing linkage to idler shaft, (@) Idler lever. (a) Aline holes and install pivot shaft and cotter pin securing idler lever to mounting bracket. (&) Aline holes and install clevis pin and cotter pin securing pedal linkage to idler lever. (©) Aline holes and install clevis pin and cotter pin securing brake control rod to idler lever. © Brake pedal, (a) Aline holes and install headless pin securing pedal to brake pedal bracket. (®) Aline holes and install headed pin and cotter pin securing pedal to idler shaft linkage. CAUTION After removalinstallation/adjustment of any of the brake linkage or components: 1 Assure that all parts and linkage move through the required range (full release to full apply) without binding or interference. 2. Assure that the brake application valveis against the stop in the released position. 8. Assure that full brake application occurs within the range of brake pedal travel. 4. Assure that all cotter pins and locking nuts are properly installed and secure. 5. Assure that linkage rods have sufficient threading into clevis (should be more than rod diameter) to safely hold during opera- tion, 6 Adjustment. @) Brake pedal. Vertical positioning of pedal, if required. (a) Loosen locknut securing lower clevis of pedal to-idler-shaft linkage. (0) Remove cotter pin and clevis pin from idler r. “(¢) Tam dlevis clockwise to lower pedal or counterclockwise to raise pedal to the required ‘position. (d) Aline clevis with idler lever hole, install levis pin and cotter pin. (e) Tighten locknut securing clevis to rod. ® Brake valve application lever. Lever must be in full release position with lower end oflever against adjustable stop screw in application valve mounting bracket. (@) Brake control rod Kinkage. (a) Remove, if installed, and loosen clevis lock nuts. () Major adjustment: Turn each clevis (both ends) an equivalent number of times (clockwise to shorten linkage; counterclockwise to lengthen.) (c) Minor adjustment: Turn one end clevis one or two threads (clockwise to shorten; coun-terclockwise to lengthen.) (A) Install brake control rod linkage. (e) Tighten clevis lock nuts securely. LEVER MOUNTING ‘BRACKET PEDAL Figure £-168.1. Brake pedal and control linkage. 13Page 2-154, paragraph 2-172a(7). Delete subpara- graph (3). Add subparagraph (e) as follows: () Inatallation. Position new gasket on com- pressor with two bolts, preformed packings and copper washers. Page 2-161, paragraph 2%1798(4). Change (para 2-176b) to (para 2-175c). Page 2-168, paragraph 2-185c(1), line 2. Change the word “top” to read, “bottom”, Page 2-177, paragraph 2-198a(8). Change (1, fig. 2-204) to (1, fig. 2-201), Page £-179, paragraph 2-200a(1). Change, “Refer to paragraph 2-87,” to, “Refer to paragraphs 2-87 and 2940”, Paragraph 2-200a(2). Change “Refer to paragraph 287d,” to, “Refer to paragraphs 2-87d and 2-94d.” Page 2-181, paragraph 2-208, Change, “Disassembly (fig. 2-210),” to, “Disassembly (fig. 2-208)” Page 2-183. Paragraph 2-211b is superseded as follows: }. Shock Absorbers. Shock absorbers will be serviced if they function properly. When they malfunction, remove shock absorbers and related parts, No replacement is authorized. Page 2-185. Delete paragraphs 2-213 and 2214. Page 2-187, Add para 2-220.1 as follows: 2-220.1. Cab Doors: a. Removal, () Remove retaining pin and disconnect door stop. (2 Remove eight screws from door hinge and remove door. , Installation. (2) Position door and aline holes. Secure door hinge with eight screws. @ Aline holes and reinstall retaining pin in door stop. Page 2-194, Add paragraph 2-220d as follows: @. Cable Repair. Repair by installing hook and swivel as shown in figure 2-225.1. Page 2-197, paragraph 2-230 (1). Change (para 2-228a) to (para 2-238). Page 2-205. Change paragraph “2-214, Windshield Wiper Assembly” to read, “2-244. Windshield Wiper Assembly”. “ srer@) wonove ov seine s0@ s0@ APPLY NEW IUNLAY STRANDS ad [CUT HEMP CORE “A ICLOSE AS POSSIBLE TO SEIZING. APPROX. 3/4 s@ UNLAy STeANDS se My CLOSE STRANDS | “a AND SUP Nore: sueeve stetve ON END Yo Cance ENO MUST HE ‘APPROX. 1-1/2 INCHES s10@® BEND ENDS (OF STRANDS. INWARDLY NOTE: ALL DIMENSIONS SHOWN ARE IN INCHES ster) INSERT PLUG. AND DRIVE TO. SOLID SEAT AND. ICLOSE STRANDS OVER- PLUG sree section STRANDS CAN be SEEN IN, INSPECTION HOLE IF PROPERLY s10@® ATTACH SOCKET TO SLEEVE TIGHTEN SECURELY AFTER TIGHTENING. Ono E3256 ‘Figure 2885.1. Cable connector attachment, Page 3-16, paragraph 3-29) (4) is superseded as follows: (4) Remove Rheostat — M123A1C, M123E2. Page B-7. Delete Functional Group 1604 and all entries pertaining to this group from the MAC.By Order of the Secretary of the Army: FRED C. WEYAND General, United States Army Chief of Stay Official: VERNE L. BOWERS Major General, United States Army The Adjutant General Distribution: ‘To be distributed in accordance with DA Form 12-88, Organizational maintenance Requirements for Trucks, Cargo 10 Ton, M125, Tractor, M123, M128A1C, M128C, M1282.Changes in force: C5 and C8 a No.6 ‘TM 9-2320-206-20 C8 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, DC, 19 November 1976 anizational Maintenance Manual TRUCK, TRA M1236 (2320-00-294- M1231 OR, 10-TON, 6x6, M123 (2320-00-395-1875) M123A1C ¢ 9-61 CARGO 10-TON, 6x6, M125 226-6081) AND TRUCK, 19-7340) Current as of 9 July 1976 ‘TM 9-2320-206-20, 22 October 1971, is changed as follows: Page 1-1, paragraph 1-3, line 6 Change “ATTN: AMSTA.” to “ATTN: DRSTA..” Pages 2-8 and 2-19. Section V. Troubleshooting The Vehicle, is superseded as follows: 2-13, Scope ‘This section contains troubleshooting or malfunction information and tests for locating and correcting most of the troubles which may develop in these 10-ton trucks. Each malfunction or trouble symptom for an individual component, unit, or system is followed by a list of tests or inspections necessary for you to determine probable causes and suggested corrective actions for you to remedy the malfunction. 2-14. Procedures This manual cannot list all possible malfunctions that may occur or all tests or inspections, and corrective actions. If a malfunction is not listed (except when malfunction and cause are obvious), or is not corrected by listed corrective actions, you should notify higher level maintenance. Tables 2-1 through 2-4 list the common malfunctions that you may find during the operation or maintenance of these 10-ton trucks or their components. You should perform the tests/inspections and corrective actions in the order listed. Table 21. Troubleshooting Gasoline Engine - M128, Mi2sC, M125 MALFUNCTION ‘TEST OR INSPECTION ‘CORRECTIVE ACTION GASOLINE ENGINE — M123, M123C, M125 WARNING ‘When disconnecting or connecting vehicle battery cables, the ground cable(s) must be disconnected first and connected last. Non-compliance could result in personal injury and vehicle damage. 1 ENGINE FAILS TO CRANK WHEN STARTER BUTTON IS DEPRESSED. Step 1. Check electrolyte specific gravity (para 2-22). Replace defective battery (para 2-120). Step 2 Check for bare or broken wires and loose or corroded connections. Test battery voltage (ara 2-22), Repair or replace defective cables and clean and tighten connections (see warning para 227), Step 3 Check for defective starter if starter will not crank (para 2-27). Replace defective starter (para 2-107). 2 NO SPARK (BATTERY-GENERATOR INDICATOR SHOWS LOW OR NO READING). Step 1. Check to see if ignition switch is on. Tum on ignition switch. Step 2 Check for defective ignition switch (para 2-34). Replace defective ignition switch (para 2-105).Table 2-1, Troubleshooting Gasoline Engine - M188, M128C, M125 ~ Continued MALFUNCTION, ‘TEST OR INSPECTION CORRECTIVE ACTION e GASOLINE ENGINE — Mi MI2IC, MIBs — (Continaed) Step3. Check fordefeetive ignition coil (para 2-34d(8)), or defective distributor (para 2-S4c andd). Replace defective ignition coil (para 2-102i,) andlor replace defective distributor (para 2-102). Step4. (hee continuity of iret No, 12 from ignition switch to coil, and from coil to distributor (Gig. 2-152). Ifcurrent shows from switch to coil, but not from coil to distributor, replace coil (para, 21022). Step 5. Inspect distributor breaker points, Replace if burned or pitted (para 2-102), Adjust point gap (para 2-102) & NO SPARK (BATTERY-GENERATOR INDICATOR READS NORMAL). Step 1. Check for defective distributor capacitor (para 2-34d (6)). ‘Replace capacitor (para 2-102). ‘Step 2 Check for loose or corroded electrical connections (see warning para 2-27). Clean and tighten all electrical connections from starter to distributor. 4. STARTER INOPERATIVE. ‘Step 1 Check for broken battery cables and loose or corroded terminal clamps and electrical connections at battery, ground, and starter. Replace broken cables and clean and tighten electrical connections (see warning para 2-27). Step 2 Check for defective starter magnetic switch (para 2-276). Replace defective switch (para 2-108). Step 3. Check linkage from starter pedal to upper clevis of starter. Adjust linkage as required to assure full engagement of starter shaft. Test adjustment by depressing starter to energize switch. Step 4. Check for defective starter motor (para 2-28). Replace defective starter (para 2-107). 6. NOISY STARTER. Step 1. Check for loose starter mounting. Tighten starter mounting nuts (para 2-107) and socket head screw. Step2. Ifstill noisy after tightening mounting nuts, problem is probably due to internal defects such as defective drive assembly, worn commutator or bushings, or dry bearings. Replace starter (para 2-107). 6. STARTER SLUGGISH: WILL NOT CRANK AT FULL SPEED. Step 1 Check battery electrolyte level and specific gravity (para 2-120). Recharge or replace battery as necessary (para 2-120). Step 2 Check for dirty or loose battery terminal connections. Clean and tighten terminal connections. Step 3. If starter is still sluggish, problem is probably due to internal defects such as sticking brushes, or commutator or armature rubbing field coils. Replace starter (para 2-107). 7. ENGINE CRANKS BUT FAILS TO START. Step L Check fuel level in tank. Fill fuel tank. Step 2 Engine flooding might be indicated by odor of gasoline fumes. Push choke in, open throttle and crank engine to remove excessive fuel. Step 3. Refer to TEST OR INSPECTION FOR MALFUNCTION 2 and 3 above for spark. Refer to CORRECTIVE ACTION FOR MALFUNCTION 2 and 3 above. ‘Step 4. Check carburetor for proper mounting and adjustment (para 2-69). Remount carburetor and properly adjust (para 2-69). Replace carburetor if necessary (para 2-69). Step 5. Remove air cleaner-to-carburetor air inlet elbow at carburetor and inspect choke valve for proper operation. Adjust choke controls (para 2-67).Table £1. Troubleshooting Gasoline Engine ~ M128, M12sC, M125 — Continued ‘MALFUNCTION ‘TEST OR INSPECTION @ ‘CORRECTIVE ACTION GASOLINE ENGINE — M128, M1230, M125 — Continued & ENGINE DOES NOT ATTAIN MAXIMUM RPMs. Step 1. Refer to TEST OR INSPECTION FOR MALFUNCTION 2 and 3 above for spark. Refer to CORRECTIVE ACTION FOR MALFUNCTION 2 and 8 above. Step2. Check engine oil level and check lubrication log to determine whether proper grade of oil has been used. If wrong grade of oil was used, drain cylinder block and refill with proper grade. If proper grade was used, add oil to correct level. ‘Step 8, Check temperature gage for normal operating range (106°— 1809. If temperature rises rapidly to 212°, stop engine and determine cause of overheating. Refer to malfunction 16 below. ‘Step 4 Check valve clearance (para 2-53). Adjust valves if necessary (para 2-58). ‘Step 6. Remove cylinder head cover (para 2-68) and check for sticking valves. Apply penetrating oil to valve stems. If valves still stick, notify supporting maintenance personnel. Step 6. Test compression (para 2-548). Notify supporting maintenance personnel if faulty piston rings, leaking cylinder heed gaskets, or sticking valves (refer to step 5), are indicated (para 2-54). ‘Step’. Check for collapsed mutfler and collapsed or clogged tail pipe which could increase back pressure. Remove obstruction from tail pipe or replace muffler and/or tail pipe. ‘Step & Check carburetor for proper mounting and operation. e Remount carburetor and properly adjust (para 2-69). Replace carburetor ifnecessary (para 249), Step 9. Check for clogged fuel pump filter plates. Clean filter plates (para 2:70c). Step 10. Check for defective fuel pump. Refer to MALFUNCTION 9, TEST OR INSPECTION Steps 2 and 3. Replace defective fuel pump (para 2-70). Step 11. Check carburetor linkage (para 2-67). Adjust linkage as necessary (para 2-67). Step 12. Check for clogged or dirty air cleaners. Remove and service air cleaners (para 2-66). Step 18. Check ignition timing (para 2-101). Adjust timing (para 2-101). 9% FUEL DOES NOT REACH CARBURETOR. Step 1. Check fuel gage with ignition switch on. Make physical check of fuel level in tanks to be sure fuel gage is operative. ‘Add fuel to tanks if necessary. Step2 Disconnect fuel line from inlet side of carburetor. If fuel does not flow freely with ignition switch on and fuel pump switch properly positioned to tank being tested, check fuel pump. Refer to step 8 below. Step 8 Disconnect outlet fuel line from fuel pump on tank and install pressure gage on outlet side of pump, Turn ignition and fuel pump switches on. Fuel pump pressure should be between 375 and 55 pai. Replace fuel pump (para 2-70) if pressure is less than 3.5 pei. Step 4 Disconnect fuel tank vent line and check for clogging. Clean or replace fuel tank vent line (para 2-47), Step 5. Cheek for clogged or dirty fuel pump filter plates. Geean filter plates (para 2-70).Table 2-1, Troubleshooting Gasoline Engine - M128, Mi28C, M125 ~ Continued MALFUNCTION ‘TEST OR INSPECTION CORRECTIVE ACTION @ GASOLINE ENGINE — M123, M1230, M125 — Continued Step 6 Disconnect fuel line between fuel tank and the check valve and check for clogging. Clean or replace fuel line (para 2-47). 10. LOW FUEL PRESSURE. Step 1. Inspect fuel pump outlet lines at top of fuel tank and lines through to carburetor for leaks. Stop leaks or replace lines (para 2-47). Step 2 Check for defective fuel pump. Refer to malfunction 9, steps 2 and 3. Replace fuel pump (para 2-70) if pressure is less than 3.5 psi. Step 8 Check for clogged fuel lines or filters. Refer to malfunction 9, steps 4, 5 and 6. Clean or replace as necessary. 11, FUEL DOES NOT REACH CYLINDERS. ‘Remove a spark plug. While engine is being cranked, check for strong fuel odor. If strong odor is not present, carburetor jets are probably clogged. Replace carburetor (para 2-69). Notify supporting maintenance personnel. 12, EXCESSIVE FUEL CONSUMPTION. ‘Step 1. Inspect all fuel system components for leaks. ‘Tighten or replace leaking connections. Replace leaking lines. Step 2 Check for clogged air cleaners. ‘Remove and service air cleaners (para 2-66) Step 3. Recheck fuel consumption rate. If still excessive, replace carburetor (para 2-69). 18, ENGINE MISFIRES AT IDLE SPEEDS. ‘Step 1. Check choke control adjustment (para 267). @ Adjust if necessary (para 2-67). ‘Step 2 Check carburetor idle mixture and idle speed adjustments (para 2-69). ‘Adjust (para 269). Step 3. Check for burned or corroded spark plug electrodes and check plug gap (para 2-104). Clean plug if corroded; replace if burned; adjust gap (para 2-104). ‘Step 4. Cheek for defective distributor (para 2-84c and d), and burned or pitted points, and cheek point gap (para 2-102c). Adjust point gap or replace points and capacitor (para 2-102). Replace distributor if necessary (para 2-102a and b). Step 5. Use engine oil to check for vacuum leaks at throttle shaft, carburetor flange and intake manifolds. ‘Tighten mounting nuts. If leak continues, replace gaskets. ‘Step 6. Check valve clearance (para 2-68). Make proper clearance adjustment (para 2-53). ‘Step 7. Make engine vacuum and compression tests (para 2-54) to check for leaky head gasket or defective or sticky valves. ‘Tighten cylinder head stud nuts to specified torque (para 2-5éc). Replace head gasket if necessary. With cylinder head cover off, apply penetrating oil to valve stems. If sticky valves cannot be freed, orf valves are defective or valve springs broken, notify supporting maintenance personnel. 44, ENGINE MISFIRES AT HIGH SPEEDS. ‘Step 1. Check valve clearance (para 2-53). Make proper adjustment. ‘Step 2 Cheek for leaking cylinder head gasket. a ana mmsanamemmmcmnaa Gl necessary. Step 3. Check for defective fuel pump (refer to malfunction 9, step 3). Replace fuel pump (para 2-70) if defective.Table £-1. Troubleshooting Gasoline Engine ~ M188, Mi28C, M125 ~ Continued MALFUNCTION 'TEST OR INSPECTION ® CORRBCTIVE ACTION “GASOLINE ENGINE — Mi93, Mi290, Mi25 — Continoed Step 4. Check points and plugs for corrosion, pitting and proper gaps. Clean, adjust gap, or replace plugs (para 2-104). Adjust gap or replace points (para 2-102). Step 5. Check for defective ignition coil (para 2-34d(8)). Replace defective coil (para 2-102). Step 6 Check spark plug cables and coil cable for breaks and corroded contacts. Replace cables if necessary. 15, ENGINE IDLES TOO FAST. Step 1. Check carburetor idling speed and idling mixture adjustments (pare 2-69). Adjust (para 269). Step 2 Check carburetor choke control and throttle control adjustments (para 2-67). Adjust (para 267). Step 3. Use engine oil to check for leak at intake manifold gasket. Tighten mounting nuts. If leak continues replace gasket. 16, ENGINE OVERHEATS. Step 1. Check Cooling System (see malfunction 29). Refer to malfunction 29. Step 2 Check carburetor idling mixture adjustment (para 2-69). Adjust idling mixture. Step 3. Check for leaks at manifold and carburetor gaskets. Tighten mounting nuts. If leak continues replace gaskets. Step 4. Cheek ignition timing (para 2-101). Adjust timing if necessary (para 2-101), ® Step 6. Check oil level and grade. Refer to malfunction 8, step 2 1, ENGINE FALTERS. Step 1. Make vacuum and compression tests (para 2-64) to check for struck, worn, or defective piston rings. Notify supporting maintenance personnel. Step 2 Replace carburetor. If engine still falters, notify supporting maintenance personnel. 18, ENGINE BACKFIRES. ‘Step 1. Check spark plug cables to insure that they are connected to the proper plug and distributor terminals (para 2-103). Make proper connections for firing order sequence (1-8-7-3.6-5-4-2). Step2 Check distributor cap and coil for cracks or carbonized spots indicating current leakage. Inspect all carbon tips in cap. Replace cap or coil if cracks or carbonization is noted (para 2-102), Step 8. Check ignition system timing (para 2-101). Correct timing (para 2-101). 19, EXCESSIVE OIL CONSUMPTION. ‘Step L Inspect engine, engine components, and ground under engine for oil leaks. ‘Tighten leaking connections and repair or replace broken lines, or notify supporting maintenance personnel. Step 2 Check for engine overheating. Refer to malfunction 16. Step 3. Check ventilation regulator and strainer for clogging (para 2-61). 2 Service regulator and strainer (para 2-61). Step 4 Test compression on all cylinders (para 2-54). If difference of 10 pei between cylinders is noted, notify supporting maintenance Personnel.Table 21. Troubleshooting Gasoline Engine - M128, M12sC, M185 ~ Continued ‘MALFUNCTION ‘TEST OR INSPECTION CORRECTIVE ACTION GASOLINE ENGINE — M123, M128C, M125 — Continued @ 20, LOW ENGINE OIL PRESSURE INDICATED BY OIL PRESSURE GAGE. ‘Step 1. Check engine oil level and viscosity. Refer to malfunction 8, step 2 Step 2. Test oil pressure gage (para 2-32). Replace defective gage (para 2-154). Step 3. Test oil pressure sending unit (para 2-33). Replace defective sending unit (para 2-158). Step 4. Ifabove steps do not correct gage reading, a defective engine oil pump, or loose, worn or damaged engine bearings are indicated. Notify supporting maintenance personnel. 21, EXCESSIVE NOISE WITH ENGINE IDLING, ON INCREASED ACCELERATION, OR UNDER LOAD — INSUFFICIENT LUBRICATION INDICATED. Notify supporting maintenance personnel. GENERATOR SYSTEM — M123, M123C, M125 WARNING When disconnecting or connecting vehicle battery eables, the ground cable(s) must be disconnected first and connected last. Noncompliance could result in personal injury and vehicle damage. 2. BATTERY-GENERATOR INDICATOR SHOWS LOW CHARGE. Step 1. Cheek electrolyte le Add water to eae if level is low. Step 2 Cheek electrolyte specific gravity (para 2-22), Replace defective battery. Step 8. Check for loose or corroded connections at battery terminals and generator voltage regulator. Clean and tighten connections. Step 4. Test generating system (paras 2-23, 2-24, and 2-25). Replace generator voltage regulator if required (para 2-116). Polarize generator (para 2-116c). Notify supporting maintenance personnel. 23, NOISY GENERATOR. Step 1. Check for loose generator mounting bolts and loose drive pulley. ‘Tighten mounting bolts and drive pulley (para 2-116). Adjust drive belts (para 2-00). Step2. Ifnoise continues, indication is a worn commutator, sticky brushes, or armature rubbing on field coils. Replace generator (para 2-115). Polarize generator (para 2-115c). Notify supporting maintenance personnel. 24, GENERATOR DOES NOT CHARGE. Step 1. Check for broken or loose drive belts. Replace or adjust drive belts (para 2-90). ‘Step 2 Test generating system (paras 2-23, 2-24, and 2-25). Replace generator voltage regulator if required (para 2-116). Polarize generator (para 2-115c). Notify supporting maintenance personnel. Replace generator if required (para 2-115). Polarize generator. Notify supporting maintenance personnel. 25. GENERATOR OUTPUT EXCESSIVE (BATTERY-GENERATOR INDICATOR ALMOST ON EX- TREME RIGHT OF METER SCALE). Test generating system (paras 2-23, 2-24 and 2-25). Follow corrective actions in step 2, malfunction 24. 26. GENERATOR OUTPUT LOW OR UNSTEADY (BATTERY-GENERATOR INDICATOR FLUC- TUATES BETWEEN LOW AND MEDIUM CHARGE WITH ENGINE OPERATING). Step 1. Check for loose drive belts. ‘Adjust belts (para 2-90). q Step 2. Check circuits No. 8 and No. 4 for continuity (fig. 2-150). Tighten connections in battery-togenerator and generator voltage regulator circuits.Table 4-1. Troubleshooting Gasoline Engine - Mies, M1esC, M125 ~ Continued aaron —— e ee eee Step 3. Test generating system (paras 2-23, 2-24 and 2-25). Replace generator voltage regulator if required (para 2-116). Polarize generator (para 2-116c). Notify supporting maintenance personnel. Table £2. Troubleshooting Diesel Engine — MISsA1C, MItSE2 MALFUNCTION “TEST OR INSPECTION ‘CORRECTIVE ACTION DIESEL ENGINE — Mi22A1C, Mi23E2 1 ENGINE FAILS TO CRANK WHEN STARTER SWITCH IS DEPRESSED. ‘Step 1. Check for loose or corroded battery cables and terminals. Clean and tighten battery terminal connections. Step 2 Check electrolyte level in battery and check specific gravity (para 2-120). ‘Add water if necessary. Replace defective battery (para 2-120). Step 3. Test starter circuit (para 2-28). If defective, replace starter switch (para 2-112), master switch (para 2-113), starter solenoid (para 2-111), andior starter (para 2-110). ‘Step 4. If no defects are found in the starter circuit, hydrostatic lock or mechanical seizure within the engine are indicated. Notify supporting maintenance personnel. 2, ENGINE CRANKS BUT FAILS TO START (ADEQUATE FUEL IN TANK. Step1. Ifengine starters cranking too slow, defective battery or starting system is indicated. Perform corrective actions for Steps 1, 2 and 3, MALFUNCTION 1. Step 2 Check for dirty fuel filter(s). Service (para 2-75). Step 3. If engine still does not start, a defective fuel pump or fuel injector is indicated. ‘Notify supporting maintenance personnel. & ENGINE STARTING MOTOR OPERATES BUT DOES NOT ENGAGE FLYWHEEL RING GEAR. .- + + Damaged starter pinion or drive assembly, or damaged flywheel ring gear indicated. Replace starter (para 2-110) and starter solenoid (para 2-111). If starter still does not ‘engage, notify supporting maintenance personnel. 4 ENGINE MANIFOLD HEATER FAILS TO OPERATE PROPERLY (COLD WEATHER STARTING). Step 1. Turn on glow plug switch. If indicator does not light, replace switch. Step 2. If indicator light works, test glow plug (para 2-36). Replace defective glow plug (para 2-77). ‘Step3. Operate primer pump control. If pressure gage does not register 80 to 100 psi check pump control linkage. Repair linkage. Replace manifold heater if necessary. 5 ENGINE STARTS BUT MISFIRES OR DOES NOT RUN SMOOTHLY. EXHAUST MAY CONTAIN CONSIDERABLE AMOUNT OF BLUISH-WHITE SMOKE. ‘Step 1 Check fuel filters for dirt or water. Service (para 2-75). Step 2 Check air filter indicator. Service (para 2-73). Step 3. If malfunction still occurs, one of the following is indicated: Defective or restricted fuel 0 injector fuel pump out of adjustment; leaking cylinder head gasket; defective or sticking valves. ‘Notify supporting maintenance personnel.Table 2-2, Troubleshooting Diesel Engine - MI2SA1C, M12sE® ~ Continued MALFUNCTION ‘TEST OR INSPECTION CORRECTIVE ACTION é DIESEL ENGINE — MI23A1C, M123E2— Continued 6, ENGINE DOES NOT DEVELOP FULL POWER. EXHAUST MAY EMIT PUFFS OF SMOKE OR CONSIDERABLE HEAVY BLACK SMOKE. Step 1. Check air filter indicator. Service (para 2-73). Step 2. Check for restricted or defective exhaust system. Clean or replace exhaust system as required (paras 2-82, 2-83 and 2-85). Step 3. If malfunction still occurs, one of the following is indicated: Defective or improperly adjusted fuel pump; defective or restricted fuel injector; broken or badly worn piston rings; defective or sticking valves. Notify supporting maintenance personnel. 7. ENGINE OVERHEATS AS INDICATED BY COOLANT TEMPERATURE GAGE. ‘Step 1. Check for broken or loose fan belts. Replace if necessary. Adjust tension (para 2-97). Step 2 Cheek oil level and viscosity. ‘Add oil to proper level. If wrong viscosity ofl was previously used, drain and refill with correct oil. Step 3. Test coolant temperature gage (para 2-32). Replace gage if necessary (para 2-153). Step 4. Test temperature gage sending unit (para 2-33). Replace sending unit if necessary (para 2-168). Step 5, Test thermostat (para 2-89). Replace thermostat if necessary (para 2-89). Step 6 Inspect radiator and cooling system (para 2-87). Repair (para 2-875). Replace if necessary (para 2-87). Step 7. If malfunction still occurs, improper or late cylinder combustion is indicated. Notify supporting maintenance personnel. & ENGINE OIL PRESSURE LOW AS INDICATED BY OIL PRESSURE GAGE. Step 1. Check oil level and viscosity. ‘Add oil to proper level. If wrong viscosity oil was previously used, drain and refill with correct oil. Step 2. Test oil pressure gage (para 2-32). Replace gage if necessary (para 2-154). Step 3. Test oil pressure guge sending unit (para 2-33). Replace sending unit if necessary (para 2-158). Step4. Ifmalfunction still occurs, defective oil pump, or loose, worn or damaged engine bearings are indicated. Notify supporting maintenance personnel. 9. ENGINE OIL COMSUMPTION EXCESSIVE. Step 1. Check for proper oil viscosity. If wrong viscosity oil was used, drain and refill with correct oil. Step 2 Check for leaking oil pan or gasket. If leaking, notify supporting maintenance personnel. Step 3. If oil consumption remains excessive, badly worn valve guides or worn or damaged piston rings are indicated. Notify supporting maintenance personnel. 10, ENGINE WILL NOT SHUT OFF (REMAINS AT IDLE). Defective fuel shutoff solenoid indicated. Notify supporting maintenance personnel.Table £3. Troubleshooting the Vehicle ~All Models MALFUNCTION ‘TEST OR INSPECTION ‘CORRECTIVE ACTION CLUTCH 1 CLUTCH SLIPS. ‘Step 1. Check for insufficient free pedal travel (para 2-50). Make minor adjustment (para 2-50). If free travel not restored, make major adjustment (para 2-50). Step2 Ifmalfunction still occurs, worn disk facings or intermediate plate, grease or oil on disk, or weak compression springs are indicated. Notify supporting maintenance personnel. 2 CLUTCH DRAGS (GEARS CLASH ON INITIAL ENGAGEMENT, OR VEHICLE “CREEPS” WITH CLUTCH PEDAL DEPRESSED TO FLOOR). ‘Step 1. Check for excess free pedal travel (para 2-50). Adjust pedal linkage (para 2-50). Step 2 If malfunction still occurs, warped or cracked intermediate plate, intermediate plate tight on driving lugs, or warped flywheel are indicated. Notify supporting maintenance personnel. & CLUTCH CHATTERS. Step 1. Inspect for loose or defective clutch mounting bolts, insulators, or brackets. Inspect propeller shafts, universal joints and bearings for improper or loose connections, ‘Tighten or replace hardware as required. Step 2 If malfunetion still occurs, grease or oil in disk facings, warped pressure plate or intermediate plate, or weak compression springs are indicated. . Notify supporting maintenance personnel. COOLING SYSTEM WARNING Before checking or draining radiator, turn radiator filler cap to the left until stop is reached. Cap is then in vented position to allow pressure to escape. Noncompliance could result in serious burns. 4 ENGINE OVERHEATS — TEMPERATURE RISES OVER 200°F. ‘Step 1. Check coolant level. ‘Add water or anti-freeze to proper level. Step 2. Check for leak or collapsed hoses (paras 2-88 and 2-94). Tighten or replace hoses (paras 2-88 and 2-94). Step 3. Inspect radiator (paras 2-87 and 2-94). Replace defective radiator (paras 2-87 and 2-94). ‘Step 4. Check for obstructions preventing free air flow through radiator. Remove bugs, leaves and accumulated dirt from radiator, using high pressure air or water. CAUTION Do not use steam. Step 6. Check fan belt tension. Adjust belts (paras 2-90 and 2-97). Step 6. Remove and test thermostat (paras 2-89 and 2-96). Replace defective thermostat (paras 2-89 and 2-96). Step 7. If malfunction still occurs, defective water pump, sludge or scale in cylinder block, or plugged water jacket are indicated. 0 Drain and clean cooling system (paras 287 and 2-94), Reverse flush radiator and neutralize system (TM 750-254). Replace water pump if necessary (paras 2-92 and 2-99), Make sure all drain cocks and plugs are closed before refilling.Table 2-8. Troubleshooting the Vehicle - All Models - Continued MALFUNCTION ag ‘TEST OR INSPECTION CORRECTIVE ACTION Sa STAT ¢ 5. OVERCOOLING (INABILITY TO ATTAIN PROPER ENGINE OPERATING TEMPERATURE AFTER SUITABLE WARMUP PERIOD). Step 1. Test thermostat (paras 2:89) and 2-96). Replace defective thermostat (paras 2-89 and 2.96). Step 2 Cheek for defective temperature gage (para 2-32n). Replace defective gage (para 2-153). EXHAUST SYSTEM 6 EXHAUST ODORS OR EXPOSURE SYMPTOMS (SEE WARNING PAGE). Step 1. Check for defective or restricted muffler or exhaust pipe. Clean or replace muffler or exhaust pipe (paras 2-82 through 2-85). Step 2 Check for loose or defective manifold and exhaust pipe flange clamps. Tighten or replace flange clamps as required. Step 3 Check for defective exhaust manifold gaskets. Replace gaskets (paras 2-48 and 2-62). BATTERIES 7. BATTERIES DISCHARGED OR LOW. ‘Step 1. Check electrolyte level. Fill to proper level (para 2-120). Step 2 Test battery (para 2-22). Recharge battery. Replace if defective (para 2-120). Step 8. Check battery terminal connections Clean terminals and cable connectors and tighten. Step 4. Check generator/alternator drive belt tension (paras 2-90 and 2-97). Adjust belt tension. Replace generator/alternator if required (paras 2-90 and 2-97). & BATTERIES OVERHEATED. Check generator/alternator voltage output (paras 2-24 snd 2-26). Replace generator/alternator if voltage output is too high (paras 2-115.and 2-118). TRANSMISSION — TRANSFER 9, EXCESSIVE NOISE. Step 1 Check lubricant level in transmission and transfer. ‘Add as required per L09-2820-206-12. Step 2 Check universal joints for worn needle bearings (para 2-163). Replace worn needle bearings. Step 3. Check propeller shaft for alinement and check flanges for loose mounting bolts. ‘Tighten mounting bolts (para 2-162). Step 4. If noise still occurs, worn, broken or loose shaft gears or bearings are indicated. ‘Notify supporting maintenance personnel. 10. SLIPPING OUT OF GEAR. Excessively worn gears or bent shifting fork indicated. Notify supporting maintenance personnel. 11, HARD SHIFTING (GEARS CLASH ON ENGAGEMENT). Step 1. Pay attention to shifting technique. ‘This unit must be double-clutched to synchronize gears. Step 2 Refer to malfunction 2, CLUTCH. Refer to corrective actions for malfunction 2. 12, LUBRICANT LEAKS. Step 1. Check for loose drain plugs. Tighten plugs. Step 2 Check for leaks at gaskets and seals or damaged housings. Notify supporting maintenance personnel. Step 3. Check for overfilling. Drain to level of filler plug. 10MALFUNCTION Table £8. Troubleshooting the Vehicle All Models - Continued ‘TEST OR INSPECTION ‘CORRECTIVE ACTION PROPELLER SHAFTS 18, EXCESSIVE NOISE OR VIBRATION. Step 1. Step 2 Step 3. Step 4 Step 5. ‘Step 6. Check propeller shaft universal and slip joints for lack of lubricant. Lubricate according to LO 9-2820-206-12. Check for worn universal joint parts. Replace worn parts (para 2-163). Remove propeller-shaft (para 2-162) and check condition of slip joint splines. Replace worn alip joints (para 2-168). Cheek for loose drive flange bolts. ‘Tighten flange bolts attaching drive flange to propeller shaft and transmission. Check for spring propeller shaft. Replace propeller shaft (para 2-162). Check that slip joint yokes are in plane. ‘Remove slip joint yoke and reinstall in plane with yoke on other end of shaft (para 2-162), FRONT AND REAR AXLES 14 DIFFICULT TO TURN STEERING WHEEL. Step 1. Step 2 ‘Step & Step 4 ‘Check hydraulic power steering unit and pump, Refer to malfunction 34, steering system. Cheek for low tire pressure. Inflate to correct pressure (para 2-191). ‘Check lubricant in steering knuckles, kingpins, tie rods and drag link ends. Lubricate in accordance with LO 9-2320-206-12 ‘Jack up front axle to clear wheels off ground. Disconnect drag link at steering lever left end assembly (para 2-194). Turn wheels from side to side. If binding, lubricate knuckle. If binding persists, notify supporting maintenance personnel for replacement of front axle and assembly. 15. HARD STEERING, WANDERING. ‘Step 1. Step 2 Step 8. Step4. Check tire inflation for equal pressure. Inflate properly (para 2-191). ‘Measure from front spring rear eye to a fixed point on axle. Compare with like ‘measurement on opposite side. If they do not agree, inspect for broken front spring main leaf or center bolt. Check for loose or broken spring U-bolts. Replace defective parts (para 2-212), Check toe-in (para 2-196). Adjust toe-in (para 2-196). If malfunction still occurs, front wheel bearings out of adjustment or insufficient caster are indi Notify supporting maintenance personnel. 16. CONTINUOUS NOISE FROM AXLE AREA. Step 1. Step 2. Step. Step 4. Step 5. Check for improperly inflated or damaged tires. If noise is caused by tires, noise will disappear when vehicle is driven over soft terrain. Inflat tires properly (para 2-191). Check wheel bearing lubrication. Lubricate in accordance with LO 9-2320-206-12. If noise seems to come from front axle area after lubrication, front wheel bearings are probably out of adjustment or defective. Notify supporting maintenance personnel. Check rear wheel bearings for wear and adjustment (para 2-190). ‘Adjust bearings. Replace worn parts as necessary (para 2-190). Coasting hum may indicate defective rear axle. Notify supporting maintenance personnel. "Table 2-8. Troubleshooting the Vehicle - All Models - Continued MALFUNCTION ‘TEST OR INSPECTION ‘CORRECTIVE ACTION FRONT AND REAR AXLES — (Continued) 17, EXCESSIVE BACKLASH IN REAR AXLE DRIVE FLANGE. Step 1. Check for loose axle flange nuts. Torque nuts to 160 lb-ft. Step 2 Ring gear and pinion excessive wear or misadjustment indicated. Notify supporting maintenance personnel. 18 BINDING IN FRONT AXLE SHAFT, RIGHT AND LEFT END ASSEMBLIES. ‘Check for excessively worn parts. Notify supporting maintenance personnel. HANDBRAKES 19, HANDBRAKE DOES NOT HOLD PARKED VEHICLE. Step 1. Check for loose brake linkage (para 2-166). Adjust linkage (para 2-168). Step 2 Inspect brake linings for grease on surface or excessive wear (para 2-166). Replace brakeshoe if required (para 2-166). 20, BRAKE DRAGS AND OVERHEATS, Step 1. Check handbrake lever for full release. Release fully. Step 2 Check handbrake adjustment (para 2-166). Adjust turn cap on top of brake lever (para 2-166). Step 8. Inspect handbrake drum for distortion (para 2-165). Replace defective brakedrum (para 2-165). Step 4. Check for weak or broken brakeshoe retractor spring. Replace defective spring (para 2-166). SERVICE BRAKES 21, INSUFFICIENT BRAKES. Step 1. Check brake adjustment, ‘Adjust (para 2-169) or replace brakeshoe. Step 2 Check air pressure gage for 80 psi. If low air pressure, build up by operating engine at fast idle speed. Step 3. Test brake application valve (para 2-175). Replace valve if required (para 2-176). 22, BRAKES APPLY TOO SLOWLY OR DO NOT APPLY. Step 1. Check air pressure gage for 80 psi. If low air pressure, buildup by operating engine at fast idle speed. ‘Step 2. Check for worn brakeshoe linings. Replace brakeshoe (para 2-169). Step 3. Check for broken or leaky brake chamber or brake cylinder. Replace chamber (para 2-184) and/or brake cylinder (para 2-185). Step 4 Inspect brake lines and hoses for damage or restrictions. Replace as necessary (paras 2-183 and 2-186). Step 5. Test brake application valve (para 2-176a). Replace valve if required (para 2-175). Step 6. Test quick release valve (para 2-1762) Replace valve if required (para 2-176) 23. BRAKES RELEASE TOO SLOWLY OR DO NOT RELEASE. Step 1. Drain air reservoir and inspect brake air lines for damage or restrictions, Remove and clean air lines (paras 2-183 and 2-186). Replace or repair as necessary. ‘Step 2 Check for binding actuating cam. Lubricate cam. Notify supporting maintenance personnel if lubrication does not eliminate binding. Step 3. Check for brakeshoe binding on anchor pin. Clean anchor pin and lubricate. 2 ¢Table 28. Troubleshooting the Vehicle — All Models - Continued ‘MALFUNCTION ‘TEST OR INSPECTION CORRECTIVE ACTION SERVICE BRAKES — (Continued) Step 4. Test brake application valve (para 2-175). Replace valve if required (para 2-175). Step 5. Test quick release valve (para 2-176a). Replace valve if required (para 2-176). 24 BRAKES GRAB. ‘Step L Check for grease or dirt on brake lining for looee lining. Replace brakeshoe (para 2-169). Step 2 Check for binding brake linkage. Lubricate anchor pins and actuating cam. Step 8 Check for loose or broken front spring U-bolts. ‘Tighten or replace U-bolts (para 2-212). 25, ONE BRAKE GRABS. Step L Check brake adjustment. Adjust brakes (para 2-169). Step 2 Check for weak or broken brakeshoe retractor spring. Replace spring (para 2-169). Step & Check for binding at brakeshoe anchor pin and actuating cam. Lubricate anchor pin and actuating cam. If lubrication does not eliminate binding at actuating cam, notify supporting maintenance personnel. Step 4. Inspect rear wheel bearings (para 2-190). ‘Adjust and lubricate or replace if necessary (para 2-190). Step 5. Check for restricted brakelines. Replace as necessary (para 2-186). Step6. Ifmalfunction still occurs, defective front wheel bearings, or out of adjustment indicated. Notify supporting maintenance personnel. ‘26, UNEVEN BRAKES. Step L Check brake adjustment, Adjust brakes (para 2-1692). Step 2 Check for sufficient lubrication. Lubricate according to LO 9-2320-206-12. Step 8 Check for worn brake lining, or grease or dirt on lining. Replace brakeshoe if necessary (para 2-169). Step 4. Check for weak or broken brakeshoe retractor spring. Replace defective spring (para 2-169). Step 5. Test air chamber for operation and leakage (para 2-184a). Replace defective air chamber (para 2-184). Step 6. Check for out-of-round brake drum. Replace drum (para 2-189). 27. NOISY BRAKES. Step 1. Check for defective brakeshoe or bent anchor pin. Replace defective brakeshoe or anchor pin (para 2-168). Step 2 Check for scored or damaged brakedrum. Replace brakedrum (para 2-189). Step & Check for defective actuating cam. If defective, notify supporting maintenance personnel. 28, TRAILER BRAKES INOPERATIVE. Step 1. Test hand control valve (para 2-178a). Replace if necessary (para 2-178). Step 2 Check for disconnected or leaking intervehicular brake hose. ‘Connect, repair, or replace hose (para 2-183). AIR PRESSURE WILL NOT RISE TO NORMAL, OR RISES SLOWLY. ‘Step 1. Check for leaks in air ines or fittings. Tighten fittings or replace lines or fittings as required (para 2-186). 3Table £8. Troubleshooting the Vehicle - All Models ~ Continued MALFUNCTION ‘TEST OR INSPECTION ‘CORRECTIVE ACTION SERVICE BRAKES — (Continued) Step2. Check for clogged or defective compressor discharge tube (para 2-172a orb). Replace tube (para 2-1722 or). Step 3. Inspect compressor drive belts and check freeplay (para 2-90). Adjust belts, Replace if necessary (para 2-90). Step4. Perform operating and leakage tests on air compressor (para 2-172). Replace compressor if defective (para 2-172). ‘Step 5. Inspect air compressor strainer (para 2-172). Clean strainer (para 2-172). Step 6 Perform éompressor governor tests (para 2-178). Replace defective governor (para 2-173). Step7. Test brake application valve (para 2-176). Replace defective application valve (para 2-170). 30, EXCESSIVE AIR PRESSURE. ‘Step. Check for open tire inflation valve (fig. 2-182). ‘Turn valve operating handle to normal position. Step 2. Perform leakage test to determine if compressor unloading mechanism is defective (air-cooled compressor) (para 2-172). Replace defective compressor (para 2-172). Step3. Check for excessive unloader valve clearance (water-cooled compressor) (para 2-172). ‘Adjust unloader valve clearance (para 2-172). Step4. Test compressor governor (para 2-178). Replace defective governor (para 2-178). Step5. Check for restriction in air tube from compressor to governor. ‘Replace tube if necessary (para 2-172). WHEELS AND TIRES 81, EXCESSIVE OR UNEVENTIRE WEAR. Step1. Cheek tire inflation. Inflate to proper pressure (para 2-191). Step2. Check toe-in (para 2-196). Adjust toe-in (para 2-195). Step3. Check brake adjustment. Adjust brakes (para 2-169). ‘Step 4. Check for excessively worn torque rod ball ends, Replace defective torque rod (para 2-216). Step 5, If malfunction still occurs, one of the following is indicated: Tire and wheel assembly out of balance; sprung frame; front and rear wheels do not track; excessive motion between sidemembers due to loose rivets or bolta; front wheel bearings damaged or worn. ‘Notify supporting maintenance personnel. 82, WHEEL POUNDING. ‘Step1. Check forbent wheel. Replace wheel (para 2-188). Step2. Check for defective rear hub bearings. Replace defective bearings (para 2-190). Step3. If pounding continues, damaged front wheel bearings or wheel and tire assembly out of balance is indicated. Notify supporting maintenance personnel. 38. SHIMMY. Step1. Check front tire inflation. Inflate to proper pressure (para 2-191). ‘Step2 Check for bent wheel or rim, ‘Replace wheel (para 2-188). “Table 2-3. Troubleshooting the Vohicle - All Modols — Continued MALFUNCTION ‘TEST OR INSPECTION = ® = Step 8 Check for worn tie rod ends. Replace defective tie rod end (para 2-196). Step 4. Check for air leak at hydraulic steering pump quick disconnect fittings. ‘Tighten or replace fittings. Step5. Ifshimmy continues, tire and wheel assembly out of balance, or worn, loose, or damaged front wheel bearings are indicated. Notify supporting maintenance personnel. STEERING SYSTEM 34. STEERING WHEEL DIFFICULT TO TURN. Step 1. Check oil level in power steering reservoir. Raise to proper level according to LO 9-2820-206-12, ‘Step2 Check for air leak at hydraulic steering pump quick disconnect fittings. ‘Tighten or replace fittings. ‘Step. Check for misalined steering column. ‘Loosen steering column clamp at instrument panel. Aline column and tighten clamp. ‘Step 4. Jack up front axle to clear wheels off ground. Disconnect drag link at steering lever left and assembly (para 2-194) Turn wheels from side to side. If binding, lubricate knuckle. If binding persists, notify supporting maintenance personnel for replacement of front axle end assembly. Step 5. If malfunction still occurs, tight steering gear, or damaged bearings, cam or lever are indicated. Notify supporting maintenance personnel. D 35. INABILITY TO MAINTAIN STRAIGHT COURSE (WANDERING OR WEAVING). Step1. Check oil level in power steering reservoir. Raise to proper level according to LO 9.2820-206-12. ‘Step 2. Check for loose or improperly adjusted steering gear drag links. ‘Adjust (para 2-194). Step 3. If malfunction still occurs, a tight or worn steering gear is indicated. Notify supporting maintenance personnel. 36. SLOPPY OR SPONGY STEERING. Bleed hydraulic steering system to eliminate air. If malfunction remains, defective universal joint on steering power unit is indicated. Notify supporting maintenance personnel. 87. INABILITY TO MAKE TIGHT TURNS. Step 1. Test differential brake control valve (para 2-179). Replace defective valve (para 2-179). Step2 Check for restricted differential brake lines. ‘Remove lines and clean or replace. 88, STEERING SYSTEM OIL LEAKS. Step 1. Check for broken lines and loose or defective fittings. ‘Tighten connections. Replace defective parts (para 2-47)., Step 2 Ifleaks continue, defective oil seal in housing, or loose cover or gasket are indicated. Notify supporting maintenance personnel. DRAWBAR AND PINTLE— M125 89, DRAWBAR OR PINTLE TOO LOOSE IN HOUSING OR STUCK IN HOUSING Remove drawbar or pintle and inspect for excessive wear or damage (para 2-208). Replace defective parts and properly install (para 2-208). FRONT SUSPENSION 40. “BOBBING” AFTER CROSSING CHUCK HOLES OR RAILROAD TRACKS. Inspeet springs for broken leaves. Replace defective springs (para 2-212). 6Table 28. Troubleshooting the Vehicle - Alt Modele ~ Contirved ‘MALFUNCTION ‘TEST OR INSPECTION CORRECTIVE ACTION FRONT SUSPENSION — (Continued) 41, INSUFFICIENT FLEXIBILITY. Check for frozen spring shackles. Free shackle and lubricate according to LO 9-2320-206-12. Replace pivot pins that cannot be freed (para 2-212). 42. EXCESSIVE NOISE. Step L Use pry bar to test for excessive wear of spring pins and shackle bolts. Replace if necessary (para 2-212). Step2. Check for broken spring leaf. Replace broken spring (para 2-212). WINCH 43, WINCH DOES NOT OPERATE. Step 1. Check for broken drive chain. Replace drive chain (para 2-231). Step 2. Check for broken shear pin. Replace shear pin (para 2-228). Step3. If malfunction still occurs, indication is that the drum clutch is not engaging. Notify supporting maintenance personnel. 44 WINCH DOESNOTHOLD LOAD. ‘Cheek for slipping winch brake. Adjust winch brake (para 2-235 or 2-236) or replace brake assembly (paras 2-235 and 2-236). 45, EXCESSIVE HEAT AT WINCH BRAKE CASE. Check winch brake adjustment. Adjust winch brake (paras 2-236 or 2-236). 48, NOISY OPERATION. Lubricate winch according to LO 9-2820-206-12. If noise continues, internal damage or wear is indicated. Notify supporting maintenance personnel. Page 2-19. Paragraph 2-16 is superseded as follows: 2-15. General This section contains detailed troubleshooting in- formation for locating and correcting malfunction in 16 the electrical system. Refer to table 2-4. Individual and combined vehicle electrical circuits are covered, using authorized test equipment referenced in table 28.1 and paragraph 2-17. Page 2-19. Add table 2-3.1 as follows: (Table 88.1. General Instructions for Use of Multimeters (sheet 1 of 18). ‘A. INTRODUCTION. IN AUTOMOTIVE TROUBLESHOOTING, THE SIMPSON 160, THE TS-325B U, AND ‘THE AN. URM-105 WILL DO THE SAME JOB. THEREFORE, YOUR AUTOMOTIVE SHOP SETS MAY CONTAIN ANY ONE OF THESE MULTIMETERS. ANY OF THESE THREE MULTIMETERS CAN BE USED TO TROUBLESHOOT THE ELECTRICAL SYSTEM SIMPSON 160 TS-352B/U NOTE: THE SIMPSON 160 IS ONLY AVAILABLE IN NEW SHOP SETS AS A SUBSTITUTE aes FOR THE TS-322B,'U or AN.'URM-105, TA037613 7Table 28.1. General Inatructions for Use of Multimeters (sheet 2 of 12). B. USING THE OHMS SCALE. THE OHMS SCALE IS USED TO MAKE TESTS FOR CONTINUITY, SHORTS, AND RESISTANCE. THE MULTIMETER MUST BE SET UP AND “ZEROED” BEFORE MAKING THESE TESTS. DO THE FOLLOWING STEPS THAT MATCH THE MULTIMETER YOU HAVE: 1, AN/URM.105, SET SELECTOR SWITCH TO X1 NOW ZERO THE METER. TOUCH THE 2 PROBES OHMS POSITION. TOGETHER x19 on w 100 SJ) Fa hi \Yaion 108 ext 019 SHUNT -- NEEDLE IS OVER “0” ON THE TOP SCALE. WHILE TURNING OHMS ADJ KNOB UNTIL... NOTE: IF NEEDLE WILL NOT “ZERO”, REPLACE THE BATTERIES. IF THE NEEDLE STILL WILL NOT “ZERO” AFTER REPLACING ( THE BATTERIES, TURN THE METER IN FOR REPAIR. TAO37614Table £8.1. General Instructions for Use of Multimeters (sheet 8 of 12) USING THE OHMS SCALE - 2, Ts352 B/y @. RANGE SWITCH ON “RX1"" —s &. BLACK LEAD (=) INTO a THE “OHMS -DCEAC™ JACK. ¢. RED LEAD (-+) GOES IN THE UPPER LEFT "OHMS" JACK 4, FUNCTION SWITCH ON “OHMS” onms ¢. NOW “ZERO” THE METER BY TURNING THE “‘OHMS ZERO ADJ" KNOB WHILE TOUCHING THE PROBES TOGETHER. OHMS ZERO ADJ f, NEEDLE SHOULD MOVE TO “0” ON TOP SCALE. NOTE: IF NEEDLE WILL NOT “‘ZERO™, REPLACE THE BATTERIES. IF THE NEEDLE STILL WILL NOT “ZERO” AFTER REPLACING THE BATTERIES, TURN THE METER IN FOR REPAIR. TA037615Tabie 23.1. General Instructions for Use of Multimeter (sheet 4 of 18). B. USING THE OHMS SCALE - Continued. 3, SIMPSON 160 . SET SELECTOR SWITCH ON “RX1", b. PUT BLACK PROBE IN “‘COM<” JACK. ¢. PUT RED PROBE IN “-b"" JACK. d. NOW "ZERO" THE METER. WHILE TOUCHING THE PROBES TOGETHER, TURN “:A\" KNOB UNTIL NEEDLE IS OVER THE “0 ON THE TOP SCALE. TOUCH THE 2 PROBES TOGETHER SELECTOR SWITCH ON RX1 2? aps knoe NOTE: IF THE NEEDLE WILL NOT “ZERO” , REPLACE THE BATTERIES. IF THE NEEDLE STILL WILL NOT “ZERO” AFTER REPLACING THE BATTERIES, TURN THE METER IN FOR REPAIR. ‘TA037616 (Table #-.1. General Instruetions for Use of Multimeters (sheet Sof 18). D C. CONTINUITY TESTS. CONTINUITY TESTS ARE MADE TO CHECK FOR BREAKS IN A CIRCUIT (GUCH AS THE SWITCH, LIGHT BULB, OR ELECTRICAL CABLE ILLUSTRATED). TO MAKE A CONTINUITY CHECK, DO THE FOLLOWING STEPS: 1, SET UP AND “ZERO” THE MULTIMETER (See poragraph 8.1) CAUTION FAILURE TO DO THE FOLLOWING STEP CAN DAMAGE THE MULTIMETER. 2. DISCONNECT THE CIRCUIT BEING TESTED. TO BE SAFE, DISCONNECT THE BATTERY GROUND STRAP. 3. CONNECT THE METER PROBES TO BOTH TERMINALS OF THE CIRCUIT BEING TESTED. (THE TS-352 BU iS ILLUSTRATED BELOW, BUT THE PROBES ARE CONNECTED TO THE CIRCUIT THE SAME WAY WITH ALL THREE MULTIMETERS). TESTING BULB BLACK LEAD 4, LOOK AT THE METER NEEDLE. ©. IF THE NEEDLE SWINGS TO THE FAR RIGHT OVER THE “0' ON THE TOP SCALE (ON ALL THREE MULTIMETERS), THE CIRCUIT HAS CONTINUITY b, IF THE NEEDLE DOESN'T MOVE, THE CIRCUIT IS OPEN (BROKEN). ¢, IF THE NEEDLE JUMPS OR FLICKERS, THERE IS A LOOSE CONNECTION IN THE CIRCUIT BEING-TESTED. TA037617Table 8.1. General Instructions for Use of Multimeters (sheet 6 of 18). D. TESTING FOR SHORTS. A SHORT (OR SHORT CIRCUIT) OCCURS WHEN TWO CIRCUITS THAT ( SHOULD NOT BE CONNECTED HAVE METAL TO METAL CONTACT WITH EACH OTHER. ‘A SHORT ALSO CCCURS WHEN A CIRCUIT THAT SHOULD NOT TOUCH GROUND HAS METAL TO METAL CONTACT WITH GROUND. TO CHECK FOR SHORTS, DO THE FOLLOWING STEPS: 1, SET UP AND "ZERO" THE MULTIMETER (SEE PARAGRAPH B 1). CAUTION FAILURE TO DO THE FOLLOWING STEP. (CAN DAMAGE THE MULTIMETER. 2. DISCONNECT THE CIRCUIT BEING TESTED. TO BE SAFE, DISCONNECT THE BATTERY GROUND STRAP. 3, WITH ALL THREE MULTIMETERS, CONNECT ONE PROBE TO ONE CIRCUIT AND THE OTHER PROBE TO THE OTHER CIRCUIT OR GROUND (IF CHECKING FOf TO GROUND), THE EXAMPLE BELOW SHOWS A CHECK TO SEE IF WIRE SHORTED TO WIRE “‘B" IN THE WIRING HARNESS. (GENERATOR-TO— REGULATOR CABLE 4, LOOK AT THE NEEDLE. o, IF THE NEEDLE SWINGS TO THE FAR RIGHT OVER THE ‘‘0" ON THE TOP SCALE (ON ALL THREE MULTIMETERS), THE CIRCUITS ARE SHORTED. b. IF THE NEEDLE DOESN'T MOVE, THE CIRCUITS ARE NOT SHORTED, c. IF NEEDLE JUMPS OR FLICKERS, THE CIRCUITS ARE OCCASIONALLY SHORTED. vs aoa7eioTable 2.1. General Instructions for Use of Multimeters (sheet 7 of 18). E. TESTING RESISTANCE. TO MEASURE RESISTANCE IN A CIRCUIT DO THE FOLLOWING STEPS. 1, SET UP AND “*ZERO” THE MULTIMETER (SEE PARAGRAPH C.1). CAUTION FAILURE TO DO THE FOLLOWING STEP (CAN DAMAGE THE MULTIMETER 2, DISCONNECT THE CIRCUIT BEING TESTED. TO BE SAFE, DISCONNECT THE BATTERY GROUND STRAP. 3. IF THE TEST IN THIS MANUAL CALLS FOR AN “OHMS RANGE” DIFFERENT THAN “RX” OR “*X1"* SET THE SELECTOR SWITCH TO THAT RANGE (LIKE “RX10" OR X10"), NOTE: “ZERO” THE METER WHENEVER YOU CHANGE RANGES, 4, WITH ALL THREE MULTIMETERS, CONNECT THE PROBES ACROSS THE CIRCUIT OR ITEM TO BE MEASURED. THE EXAMPLE BELOW SHOWS MEASURING THE RESISTANCE.OF A TEMPERATURE yo» SENDING UNIT. ‘ . = TEMPERATURE ious y SENDING UNIT ecnat) 76 (SAMPLE TEST) 5, READ THE METER. IF THE METER SWITCH IS ON THE “*RX1" OR ‘*X1"" RANGE, THE READING IS TAKEN DIRECTLY FROM THE TOP SCALE. IF THE METER SWITCH IS ON A DIFFERENT RANGE, MULTIPLY THE READING ON THE SCALE ACCORDING TO THE TABLE BELOW, OHMS SWITCH SETTING X1 OR RX1 READ NUMBER ON SCALE X10 OR RX10_ MULTIPLY READING BY 10 X100 OR RX100 MULTIPLY READING BY 100 XIK OR RXIK_> = MULTIPLY READING BY 1000 X10K OR RX10K MULTIPLY READING BY 10,000 (REMEMBER: K=1000) You Do! TA037619Table £-8.1. General Instructions for Use of Multimeters (sheet 8 of 18). E, TESTING RESISTANCE - Continued). FOR EXAMPLE, THE METERS BELOW SHOW THE FOLLOWING READINGS: OHMS SWITCH SETTING! READING X1 OR RX1 4 OHMS X10 OR RX10 40 OHMS X1000R RX100 400 OHMS F, USING THE DC VOLTS SCAL! THE ELECTRICAL SYSTE! BEFORE USING THE MULTIMETER TO MEASURE DC VOLTAGE, DO THE 4 FOLLOWING STEPS THAT MATCH THE MULTIMETER YOU HAVE: HE DC VOLTS SCALE IS USED TO MEASURE ALL VOLTAGES IN 1. AN/URM-105 SET METER SWITCH TO DC VOLTS RANGE GIVEN IN TM, (TO MEASURE 24 VOLTS DC, SET SWITCH ON ‘100 DC VOLTS" RANGE.) BLACK LEAD t ea TA037621Table 8.8.1. General Instructions for Use of Multimeters (sheet 9 of 18). D F. USING THE DC VOLTS SCALE - Continue 2, TS.354 B/y , SET FUNCTION SWITCH TO DIRECT @® (RANGE SWITCH CAN BE AT ANY POSITION.) b. PUT BLACK LEAD IN “DC/+AC/OHMS” JACK. @ METER MEASURI c. TO MEASURE 24 VOLTS DC, PLUG RED LEAD INTO “5OV"" JACK ON LEFT SIDE OF = (IF MEASURING LESS THAN 10 VOLTS DC, USE “10V"" JACK. IF IG LESS THAN 2.5 VOLTS DC, USE “*2.5V"JACK.) 3. SIMPSON 160 ‘a. CONNECT BLACK LEAD TO “‘COM—"" JACK. b. CONNECT RED LEAD TO “+"" JACK ¢, TO MEASURE 24 VOLTS DC, SET SELECTOR SWITCH TO “V/DC 50" POSITION. (IF MEASURING LESS THAN 10 VOLTS DC, SET SELECTOR SWITCH TO “*V/DC 10" POSITION. IF MEASURING LESS THAN 2.5 VOLTS DC, SET SELECTOR SWITCH TO “V/DC 2.5" POSITION. d. SET POLARITY REVERSING SWITCH TO THE “DC POSITION. POLARITY REVERSING| SWITCH D BLACK “e LEAD 14037620Table 23.1. General Instructions for Use of Multimeters (sheet 10 of 2). G. MEASURING DC VOLTAGE. TO MEASURE DC VOLTS, DO THE FOLLOWING STEPS: 1, SET UP MULTIMETER (SEE PARAGRAPH F). NOTE: IF YOU ARE NOT SURE OF THE VOLTAGE TO BE MEASURED ON THE VEHICLE, ALWAYS START ON THE HIGHEST RANGE SHOWN IN PARAGRAPH F. THIS WILL PROTECT THE METER. 2. WITH ALL THREE MULTIMETERS, CONNECT THE RED PROBE TO THE POSITIVE (+) SIDE OF THE CIRCUIT AND THE BLACK PROBE TO THE NEGATIVE (—) SIDE. THE EXAMPLE BELOW SHOWS 24 VOLTS DC BEING MEASURED ACROSS THE BATTERIES. OC VOLTS 100 POSITIVE LEAD REO A037622Table 8.1. General Instructions for Use of Multimeters (sheet 11 of 2). > G, MEASURING DC VOLTAGE ined, 3. READ THE METER. (THE EXAMPLES BELOW SHOW HOW TO READ ALL THREE MULTIMETERS.) If THE NEEDLE TRIES TO MOVE OFF SCALE TO THE LEFT. REVERSE THE PROBES ON THE CIRCUIT. ‘0. SIMPSON 160 READ THE “DC VOLTS” SCALE FOR THE RANGE THE SELECTOR SWITCH IS SET AT. ‘SWITCH SETTING vocso 0. vocio v0C25 0 (AND DIVIDE BY 10) THUS THE METER ILLUSTRATED IS SHOWING THE FOLLOWING READINGS. SWITCH ) setting READING VDC S0 20 VOLTS DC VDC 10 4 VOLTS DC V.DC2.5 1 VOLY DC READ THE “DC” VOLTS SCALE FOR THE RANGE THE RED LEAD IS PLUGGED IN AT. SOV 0.5 (AND MULTIPLY BY 10) lov 0 2.5 d TA037623Table 8.1. General Instruetions for Use of Multimeter (sheet 18 of 18). G, MEASURING DC VOLTAGE - Continued. THUS THE METER ILLUSTRATED |S SHOWING THE FOLLOWING READINGS: 20 VOLTS DC 4 VOLTS DC 1 VOLT DC © AN/URM.105 READ THE UPPER, BLACK, STRAIGHT-LINED PORTION OF THE “‘AC and OC VOLTS” \ SCALE FOR THE RANGE THE SELECTOR SWITCH IS SET AT. SWITCH SETTING 1000 DC VOLTS -10 (AND MULTIPLY BY 100) 100 DC VOLTS 1-10 (AND MULTIPLY BY 10) 10 DC VOLTS -10 1 DC VOLT 1-10 (AND DIVIDE BY 10) SWITCH SETTING READING 100 DC VOLTS 20 VOLTS DC 10 DC VOLTS 2 VOLTS DC 1 DC VOLT .2VOLTS DC TA037624L LIGHTING SYSTEM — ALL MODELS LIGHTS DO NOT LIGHT. Step 1. Check for broken or burned out lamp. ‘Replace defective lamp (para 2-128). Step2 Use a jumper wire across light switch contacts. If lamp lights, switch is defective. Replace switch (para 2-181). Steps. Refer to lighting creuit diagram and locate breakin cable, pair cable. FREQUENT LAMP FAILURES. HIGH BATTERY-GENERATOR INDICATOR READING Step 1. Check for loose or corroded battery and lamp ground connections. Clean and tighten. Step2 Ifmalfunction still occurs, indication is that generator-regulator/alternator-regulator is out of adjustment. Replace voltage regulator (para 136 and generar (para 116 or elternator para 2118). INSUFFICIENT LIGHT — LOW BATTERY-GENERATOR INDICATOR READING ‘Step 1. Check for loose or corroded lamp and battery terminal and ground connections. Clean and tighten connections. ‘Step2. Check battery electrolyte level and specific gravity (para 2-120). Raise electrolyte to proper level. Charge battery. Replace if necessary. RADIO INTERFERENCE SUPPRESSION — M123, M123C, M125 INTERFERENCE WHILE VEHICLE IS IN MOTION WITH ENGINE OPERATING. Check for loose or corroded cable connections in vehicle wiring and for frayed cable insulation or bonding. Clean and tighten connections. Repair or replace defective wiring, INTERFERENCE ONLY WHEN ENGINE IS RUNNING. ‘Accelerate engine and turn ignition switch off with engine at high speed. If noise continues after sch ehut of cause isin the generator rte. supporting maintenance personnel (para 2-898). . VARIABLE PITCH WHINING ‘NOISE WHICH VARIES WITH ENGINE RPM. Step 1. Check regulator ground cable and its mounting bolts to determine if connections are free from dirt, paint, or other foreign material that could impair conductivity. Check for tightness. Clean and tighten connections. Step2 Check for loose or frayed fan belts. Tighten or replace belts as necessary (para 2-00). Step 8. If noise still occurs, a defective generator-regulator capacitor is indicated (refer to para 2-89) Replace generator and/or notify supporting maintenance personnel. VARIABLE CLICKING NOISE WHICH VARIES WITH ENGINE RPM. Step 1 Accelerate engine and turn ignition switch off with engine at high speed. If noise stops immediately, cause isin the ignition system. Perform checks in steps 2 through 6 below. Step2 Check spark plug and point gaps. Step3. Check spark plug cables. Replace defective cables (para 2-103). Step 4. With engine running, disconnect cables from plugs ene at a time. If noise is reduced or eliminated, cause is the spark plug. Replace plug (para 2-104). Step 5. Check fuel pumps and electrical connections for tightness, Tighten.S Table £4, Troubleshooting ~ Electrical System ~ Continued MALFUNCTION ‘TEST OR INSPECTION ‘CORRECTIVE ACTION INSTRUMENTS, GAGES AND SENDING UNITS — ALL MODELS 8 SPEEDOMETER OR TACHOMETER NOISY OR FLUCTUATING. Check flexible shaft for binding or kinks. Replace flexible shaft (para 2247). 9, WATER TEMPERATURE GAGE INOPERATIVE. Step 1. Test temperature gage sending unit (para 2-83) Replace defective sending unit (para 2-168) Step2. Test temperature gage (para 2-32). Replace defective temperature gage (para 2-163). Step 8. Check circuit for broken wire (fig 2-86). Replace broken wire. 10. FUEL LEVEL GAGE INOPERATIVE. Step L Test fuel gage sending unit (para 233). Replace defective sending unit (para 2-168). Step2 Test fuel gage (para 2-32). Replace defective fuel gage (para 2-152). Step. Check circuit for broken wire (fig. 2-36). Replace broken wire. 11, AIR PRESSURE GAGE INOPERATIVE. Step 1. Run engine to build up pressure to 100 pei. If gage does not register immediate buildup replace gage (para 2-150). Step2 Close air reservoir drain cocks. Start engine and test for air leaks (pars 2-174). Replace leaking drain cocks (para 2-174). 12 OIL PRESSURE GAGE INOPERATIVE. Step1. Test oil pressure gage sending unit (para 2-83). \ Replace defective sending unit (para 2-168). Step2, Test oil pressure gage (para 2-32). Replace defective oil pressure gage (para 2-154). Step 8. Check circuit for broken wire (fig. 2-96). Replace broken wire. 18. HORN INOPERATIVE. Step1. Check air pressure gage for proper operating pressure. Start engine and build up pressure. Step?. Check circuit No. 25 for continuity to horn button (figs. 2-152 and 2-168). Replace defective horn switch (para 2-184). Step 3. If malfunction still occurs, defective horn solenoid is indicated, ‘Notify supporting maintenance personnel. Page 2-42. Add figure 2-36.1. Page £-5b, paragraph 2-48a(1)(¢). Delete “or mineral spirits paint thinner.” Page 2-55, paragraph 2-440(2)(a). Delete “or mineral spirits paint thinner.” Page 2-56, add the following before paragraph 2-450(1): CAUTION Ifoil cooler element is not properly installed in the oil cooler housing a leale may develop or the element may be damaged and re- quire replacement. ‘Add subparagraph 2-48f as follows: ( fServicing Figure 2-36.1. Transmission temperature indicator circuit. (1) Remove oil cooler element at least quarterly@ and clean with dry cleaning solvent to remove dirt, sludge, and other foreign particles. ‘@ Dry carefully with compressed air. Page 2-57, paragraph 2-46b(1)(a). Delete “or mineral spirits paint thinner.” Page 2-58, paragraph 2-47d(2). Delete “or mineral spirits.” Page 2-67, paragraph 2-51a(1)(g). Delete “or mineral spirits paint thinner.” Page 2-74, paragraph 2-59a(2)(a). Delete “or mineral spirits paint thinner.” Page 2-82, paragraph 2-69. Delete “or mineral spirits paint thinner.” Page 284, paragraph 2-108). Delete “or mineral spirits paint thinner.” Page 2-92, paragraph 288. Delete the “Warning”. Page 2-98. Add figure 2-92. a0 1 Bracket, complete 9 Screw, cap, shield (®) 2Pipe,complete, vertical (10 lamp, crossover pipe exhaust 11 Pipe, crossover sCamp@® 12 Screw, cap 6) 4 Shield 18 Pipe, complete, exhaust 5 Spring (60) MGaskee 6 Washer, clamp(6) 15 Screw, cap 6) ‘TNut a 16 Clamp, vertical exhaust pipe 1) ‘8 Washer, shield (2 1 Screw, cap) >» Figure2.02.1, Vertical echaust system ~MISSAIC, MI23E2. Page 2-101, paragraph 2-94, in the NOTE. Change “TM 9-2858" to “TM 760-254.” Page 2-104, paragraph 2-98. Add the following after subparagraph (1): CAUTION Make sure fan hub is not cocked on shaft. ‘Tighten shaft nut securely. Failure to do s0 ‘can cause nut to loosen under belt tension and vibration. Damage may result. Page 2-118, paragraph 2-110a(8). Change “Disconnect starter positive cable from post on end of starter (fig. 2-122)” to read “Disconnect starter positive cable from post on solenoid (fig. 2-122)” Paragraph 2-1106(1). Delete “mineral spirits paint thinner or.” Paragraph 2-110c(2). Change “Connect starter positive cable to post on end of starter” to read “Connect starter positive cable to post on solenoid.” Page 2-114, on figure 2-122, change “BATTERY POSITIVE THERMINAL” to read: “BATTERY NEGATIVE TERMINAL.” Page 2-127, paragragh 2-137a. Add subparagraph (3) as follows: (8) If receptacle spacer was used to avoid spare tire interference, it is not necessary to remove spacer from eab. Remove four capscrews, washers, and lockwashers securing receptacle to receptacle spacer and remove receptacle. Paragraph 2-137. Add subparagraph (3) as follows: (8) If receptacle spacer (P/N 11641173 or 11659873) is being added, position spacer on cab and secure with four eapscrews and lockwashers. Apply sealing compound Type II, Spec MIL-S-45180 to joint. Insert receptacle and secure with four capscrews, ‘washers and lockwashers. Connect electrical leads. Page 2-1hs, paragraph 2-153, Add the following: Install transmission temperature indicator on fabri- cated mount to secure to dash panel. Assure that indicator case is properly grounded. Connect compo- nents as shown in figure 2-36.1. Page 2-146, paragraph 2-168. Add subpara- graph (3) as follows: (8) Transmission temperature transmitter. In- stall transmitter in drain plug hole at bottom of transfer case using 9/4-inch hole to U2-inch size pipe bushing. Connect components as shown in figure 238.1. Page 2-148, paragraph 2-163c(1). Delete “or mineral spirits paint thinner.” Page 2-156, paragraph 2-172a(7) (c)1. Delete “or mineral spirits paint thinner.” Page 2-165, paragraph 2-183a(8) (a). Delete “or mineral spirits paint thinner.” Page 2-168, paragraph 2-185c(1). Change “top” to “bottom.” Page 2-170, paragraph 2-190b(2) (c) and (d). Delete a“or mineral spirits paint thinner.” spirits paint thinner.” Page 2-181, paragraph 2-208¢(1). Delete “or mineral Page 2-201. Figure 2-235 (AT 84748) is superseded by spirits paint thinner.” figure 2-235 (TA035461). Page 2-195, paragraph 2-2306(1). Delete “or mineralPage 2-202, Figure 2-236 (AT34749) is superseded by D O} Sy) KM . } WINCH CONTROL} vase | ie 5; / TENSIONER| VALVE! ‘ tH —___ douse; = cneck-vALvel figure 2-236 (TA035462). » ? Ta03s462 Figure 2286. Winch controle M128, Mi28C, MI2SA1C, MI28E2, Page 8-4. Paragraph 38a(4). Delete “or mineral Page 3-9. Paragraph 3-150(8). Delete “or mineral spirits paint thinner.” Pages B-1 and B-2, Paragraph B-3 is superseded as follows: 8-3, Explanation of Columns ‘The purpose and use of the columns and symbols are explained as follows: @. Column 1, Group Number. This column lists group numbers, the purpose of which is to identifycomponents, assemblies, sub-assemblies, and mod- ules, with the next higher assembly. 5. Column 2, ComponentiAssembly. This column contains the noun names of components, assemblies, sub-assemblies, and modules for which maintenance is authorized. ¢. Column $, Maintenance Functions. This column lista the functions to be performed on the item listed in column 2. @. Column 4, Maintenance Category. This column specifies, by the listing of “work time” figure in the appropriate subcolumn(s), the lowest level of maintenance authorized to perform the function listed in column 8. This figure represents the active time required to perform that maintenance function at the indicated category of maintenance. If the number or complexity of the tasks within the listed maintenance function vary at different maintenance categories, appropriate “work time” figures will be shown for each category. The number of man-hours specified by the “work time” figure represents the average time required to restore an item (assembly, sub-assembly, component, module, end item or system) to a serviceable condition under typical field | operating conditions. This time includes preparation time, troubleshooting time, and quality assurance/ quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the mainte- nance allocation chart. ¢. Column 5, Tools and Equipment. This column specifies by code, those common tool sets (not individual tools) and special tools, test, and support equipment required to perform the designated fanetion. Pages B-£ through B-8, section II is superseded as follows:ono o102 103 0104 o10s 0106 o102 0103 0104 o10s ‘Section Il. MAINTENANCE ALLOCATION CHART TRUCK TRACTOR, 10-TON, 6x6 and Truck Cargo, 10-TON, 6x6 o Component asembiy Maintenance Category “ Tose and ENGINE (DIESEL) Engine Assembly Insulators, Engine Mounting ‘Block, Engine Head, Cylinder ‘Sleeve, Cylinder (Crankshaft and Bearings Damper, Vibration Pulley, Drive Flywheel Auembly Platons and Connecting Rods Bearings, Connecting Rods Gears, Timing Valves, Springs, and Guides Camshaft fl Pump, Main and Scavenger ‘Valve, Presmre Regulator iter, Ol Cooler, Olt Breather Valve, Crankase Lines and Connections Pan, Oi! Manifolds ENGINE (GASOLINE) Engine Assembly Ingalators, Engine Mounting Block, Engine Head, Cylinder Stoove, Cylinder (Crankshaft and Bearings Damper, Vibration Pulley Flywheel Anembly Patong, Connecting Rods, Gears, Timing Valves, Springs and Guides0106 0108 02 0200 0202 03 0301 0302 0304 0306 0308 0309 O31 0312 sot ENGINE (GASOLINE) ll Pump Auembly Filter Oi! Breather Valve, Crankcase Lines and Connections Pan, O11 Manifolds CLUTCH Housing, Clutch Beating, Clutch Plot Disk, Driven, Clutch Plat, Pressure Beating, Release, Cutch ‘Contrdls and Linkage, Clutch Yoke, Cluteh Shaft, Release Pedal Clutch FUEL SYSTEM Injector, Fuel (Diesel) Carburetor (Gasoline) Pump, Fuel (Dies) ‘Pump, Fuel (Gasoline) (Gleaner, Att (Dry, Diesel) ‘Gleaner, Air (Of, Gesotine) Tank, Fuel Lines and Fittings, Fuel Governor, Engine Speed Filter, Fuel [Glow Piug (Diese) Resistors (DiexeD) Pump, Primer Controls, Choke and Tarottle (Gesoline) Controls, Throttle (Diesel) Controls and Linkage, ‘Accelerator ‘EXHAUST SYSTEM Muffers and Pipes ‘COOLING SYSTEM Radiator0610 0611 ‘COOLING SYSTEM (Continued) Shroud, Radiator Point Set Cap, Distributor Capacitor Rotor Col, Ignition Spark Plugs Cable, St, Spark Plug Breaker, Circuit Buzzer, Warning, Low Switch, Brake Warning Slave Receptacle Tum Signals Lamps and Lamp Units Lights Light, Flood Sending Units0613 0615 0700 o701 0708 0900 10 1000 1002 1004 u 1100 not 1102 EC ‘SYSTEM (Continued) Battery, Box and Supports, Battery Cables, Batery Connector Receptacle, ‘Trailer ‘Wiring Harnesses Radio Suppression ‘TRANSMISSION AND TRANSFER ‘Transmission and Transfer Screen, Oil Strainer Breather Vent Phugs, Drain Line, Oil Pump Return ‘Transmission Shafts, ‘Bearings, Seals and Gears Pump, Of Shaft, Power Take-off Cover, Dust, Gear Shift Levers Cover, Transfer Top Cover, Transmission Top (Shift Shaft Carrer) PROPELLER SHAFT Shaft, Propeller Joint, Universal FRONT AXLE, ‘Axle Anembly Breather Vents Differential, Front, with (Carrier ‘Arm, Steering Kauckle, Steering End, Drive, Front Axle Shaft, Axle REAR AXLE ‘Axle Auembly1201 1202 1206 1208 1209 mn 3 Bu 1313 REAR AXLE (Continued) lange, Drive BRAKES Brake, Hand Drum, Handbrake Shoe, Handbrake Lever Assembly Brake, Service Shoe, Brake, Service Spring, Brake Shoe Return (Front Wheel) Spring, Brake Shoe Return (Rear Wheel) Pedal and Linkage ‘Adjuster, Slack, Brake Lines and Fittings, Air ‘Ait Chamber, Brake Cylinder, Brake Reservoir, Air Valves, Ait System Valve, Tractor Protection Valves, Tie Inflation ‘Compressor, Air (Gasoline) (Compressor, Air (Dies!) Governor, Compressor Bett Lines, Connectors, and Couplings, Trailer Brake Valve, Hand Control WHEELS, HUBS, AND DRUMS Hub Assembly Bearings and Seals Drum, Brake, Service Wheel and Tire Awembly Tires Tubes 02 02 os| 40 As 20 18 29 20Compnnent ase Maintenance Categry* recnne exvipment “4 STEERING 1401 Link, Dag Drive, Steering Angle End, Tie Rod (Two) Tie Rod Assembly Wheel, Stering 1407 | Steering Gear Assembly 1410 Pump, Hydraulic Steering wit Lines and Fitts Hydraulic 1412 | Cylinder, Power ais Valve, Control, Steering 1s FRAME AND BRACKETS sor Frame Bumper Brush Guard, Radiator 1503 Pintle Shackle, Lifting 1504 Spare Tire Carrier 1506 | Fifth Wheel 16 ‘SPRINGS 1601 Spring, Front Spring, Rear Beating, Trunnion 160s Torque Rod 8 BODY, CAB AND HOOD 1801 Hood Guards, Splash ab Doors 1802 Board, Running Fender Windshield Assembly 1806 | Seat ‘Seat Cushion 1808 | Stowage Racks, Boxes. Strape 1810 | Rody, Cargo 20 WINCHES 2001 Winches Band, Brake2201 2202 2210 ‘WINCHES (Continued) Cable, Winch Valve, Cable Tensloner Joint, Universal, Drive Shaft Shaft, Drive, Propeller BODY CHASSIS AND ACCESSORY ITEMS Bows (M125) Cover, Body (M125) Cover, Cab Top. ‘Arm and Blade, Windshield Wiper Motor, Windshield Wiper Mirror, Rear View Plate, Vehicle Data GAGES, (NON-ELECTRICAL), ‘MEASURING DEVICES Speedometer ‘The subcolumns are as follows: (C- operator/crew (© - organizational F — direct support 1H — general support D— depot aBy Order of the Secretary of the Army: BERNARD W. ROGERS General, United States Army Offici Chief of Staff PAULT. SMITH Major General, United States Army The Adjutant General Distribution: ‘To be distributed in accordance with DA Form 12-38, Organizational TM requirements for 10-ton Truck ‘Tractor, 6x6, M123, M123A1C, M123C, M128E2 and 10-ton Cargo Truck, 6x6, M125, «*TM 9-2320-206-20 ‘TECHNICAL MANUAL \ HEADQUARTERS DEPARTMENT OF THE ARMY a ‘No. 9-2820.206-20 WASHINGTON, D.C. 22 October 1971 ORGANIZATIONAL MAINTENANCE MANUAL FOR TRUCK TRACTOR, 10-TON, 6x6 M123 (2320-395-1875) M123C (2320-294-9552) M123A1C (2320-226-6081) M123E2 (2320-879-6177) AND TRUCK CARGO, 10-TON, 6x6 M125 (2320-219-7340) CHAPTER 1. INTRODUCTION ‘Section I. General eT TL, Description and data 16 CHAPTER? ORGANIZATIONAL MAINTENANCE INSTRUCTIONS. Section I. Service upon receipt of materiel a 24 TL. Repair parts, special tools, and equipment 24 24 HL Lubrication instructions at 23 IV. Preventive maintenance checks and services 29 23 V. Troubleshooting the vehicle 2g 23 ‘VL ‘Troubleshooting the electrical system 25 219 VIL. Radio interference suppression — M128, M129C, M125 231 VIII. Engine maintenance in vehicle — Diesel M128A1C, M123E2 240 TX. Engine maintenance in vehicle — Gasoline M128, M123C, M125 282 X. Fuel aystem — gasoline M122, M123, M125 285 XI. Fuel system and induction system — MI23A1C, M123E2 27 XIL, Exhaust system 281 XII. Cooling system — M128, M1290, M125 286 XIV. Cooling system — Mi2SA1C, M123E1 2.98 XV. Ignition system — M123, M1290, M125, 2.100 XVL_ Starting system — M123, M129C, M125 2.106 XVIL Starting system — M123A1C, MI23E2 2.109 XVIII. Generating gystem — M123, M129C, M125 2a XIX. Alternator system — MI23A1C, MI23E2 aur XX. Electrical system 2119 XXL. Special lichting — M128A1C, M1232. 2138 ‘XI Wiring eireuits and harnesses... eat ‘The monuel supersedes TM 9-2320-208-20, 1 April 1966, including ail changes.XXII XXIV, XXV. XXVL XXVIL XXVIII, XXIX XXX, XXXL XXXIL XXXILL XXXIV, XXXV. XXXVI CHAPTER 8. Section I. IL m1. Vy, APPENDIX A. B Section I 0. INDEX Instrument cluster, gages, buzzer, and sending units Axles Brakes Compressed air aystem ‘Wheels, drums, and hubs Steering aystem Frame and brackets Front spring suspension Rear spring suspension Cab components, Cargo body, components—MI25 Winches and components Body chassis and accesory items Gages (non-electrical) measuring devices SPECIAL PURPOSE KITS Personnel hot water heater kit — M123, M128C, and M125 Gasoline heater kit — M123, M129C, M125 ‘Winterization heater kit — Artic Zone — MI23A1C and M123E2, Electric brake REFERENCES MAINTENANCE ALLOCATION CHART Introduction Maintenance Alloeation Chart, 219 2189 a1 35 a8 38 2181 2190SERSRERER BE EEDEEEEEEEEEBEEEEDRSESBSEREREEE LIST OF ILLUSTRATIONS ‘Special Tools and Equipment... Electrical Test Equipment Test Meter Lands Low Voltage Circult Testers. Electrical Test Equipment Adapter Sets ‘Schematic Layout of Low Voltage Cireult Testers Battery System Battery Voltage Test Load Bank Voltage Test Combined Basar Vlg Tat Battery Indicator Battery Indleator Cireuit Generator System Wiring Generator Adapter Connecting Points. Generator Output Test Hook-up Regulator Adaptar Connecting Points Regulator Voltage Control Test Hook-up. Regulator Current Control Test Hook-up. Generator Regulator Line Switch Cutout Test Hook-up. Alternator Output Voltage Test Startar Draw Check at Battery — M128, M129C, M125 Magnetic Switch Test Hook-up — M123, M129C, M126. Starter Current Draw Test—M123, M129C, M125, Starter Current Draw at Battery—MI23A1C, MIZSE2. Starter Current Draw at Starter — MI28AIC, MI2SE2 Frame to Battery — Cable Ground Loss Check — M123, M123C, M125. Battery Connector Cable Check — M123, M128C, M125 Battery-to-Magmeti Starter Switch Cable Chock — M123, M129C, M125. Startar Magnetic Switch-to-Starter Connector Check — M123, Mi28C, M125 ‘Starter Switch Test — M128, M129C, M125 ‘Frame-to-Battory-Cable Ground Loes Test — MIZSAIC, M123E2 Interconneeting Ground Cable Test — M123A1C, M129E2 Battery Connector Cable Test — MI2SAIC, M1232 Interconnecting Battery Cable Test — MI23A1C, M123E2 ‘Battery-to-Magnetic Starter Switch Cable Test — MI2BAIC, M123E2 {Intereonnecting Battery-to- Magnetic Starter Switch Cable Test — MI23A1C, M123E2 {Instrument Cireuit Diagram Instrument Testing Diagram, Agnition Cireuit Diagram — Mi Ignition Cireuit Check Distributor test, Cap Removed Lighting Clreult Diagram — M128A1C, MI23E2. Light Switch Positions Glow Plug Schematie — MI23A1C, M1232. Distributor with cover Removed Radiator Drain Cock, Outlet Hose and Bonding Strap Engine Compartment — MI28A1C, M123E Front Support, Mounts, and Vibration Damper — MIZ8AIC, M123EZ Adjusting End Motion at Powerplant Rear Mount Full-Flow Oil Filter it Filter — Partially Exploded View By-Pass Oil Filter Related Parts M290, M125 By-Pasa Filters. Oil Cooler ‘Crankease Breather Valve Lines and Fittings Engine Compartment — Right Front View - M123A1C, Mi23E2 Exhaust Manifold Engine Priming Hand Driven Pump Checking Pree Pedal Travel ‘Cluteh and Clutch Linkage ‘Clutch Housing Lower Inspection Cover ‘Checking Release Bearing Clearance SREES7 225 225 226 & 281 g 22 228 298 22 22 £28 EEELELLELLESEES ESSE ELE EE 251BEEEEER £ 20, 2m. 222. 28, 21, 25, 216, 2m. 278 279, g zal. SELEREEE 290, 291 292, SESEEEE 2-100, 2101. 2102, 2.108. 2.104 2.105 2106, 2107. 2108, 2100, 210, 2a. 2a. zag, 2M. 2415, 216, 2, 218, 2419, 2.120, 22. zie, 2123, 2124, LIST OF ILLUSTRATIONS—Continued Tie Clutch Pedal Lever and Linkage — Exploded view ‘Transmission and Transfer Oil Magnetic Plugs, and Breather Dust Boots Engine Compartment — Left Front View — M123, M123C, M125 Adjusting Valve Clearance Cylinder Designation and Firing Order Engine Compression Test Engine Front Support, Mounts and Vibration Damper (Cylinder Head Stud Nut Tightening Sequence. (Cylinder Block Covers ‘Removing Crankshaft Pull Replacing Oil Filter Element Removing or Installing Ventilation Regulator and Strainer Disconnect Points on Right Side of Engine Intake and Exhaust Manifold Stud Nut Tightening Sequence. Engine Compartment from the Rear — M128, M128C, M125 Removing or Installing Air Cleaner Reservoir Choke and Throttle Control Arrangement Carburetor Adjustment Points Carburetor Disconnect Points Engine Speed Governor and Slave Unit, Removingor installing Fuel Pump Fuel Tank — M123, M1230, M125 Engine Compartment — Front Vie ‘Accelerator Linkage and Controls. ‘Triple Stage Fuel Filter Glow Plug Diesel Engine Starting Aids Fuel Tank - M123A1C, M123E2 Exhaust System Arrangement ‘Vertical Tailpipe — MI28A1C, M123E2 Bumper and Brosh Guard Disconnect Pints iator Viewed from Rear — M123, M1230, M125 Radiator and Related Parts Cooling Systm — Exploded View — M128, M128C, M125, ‘Adjusting Fan Drive Belts Adjusting Generator Compressor Drive Belts Fan Drive Belt Arrangement. ‘Water Pump — Exploded View ‘Crossover Water Tube Drain Cock Radiator Water Inlet Fitting and Support Rod Cooling Systm — MI28A1C. M123E2. ‘Water Pump and Thermostat Housing — MI23AIC. M1231. Fan and Drive Belts ‘Water Pump, Drive Belts and Related Parts Fan Hub. Water Pump — MI23A1C, M123E2 ‘Timing Pointer and Timing Marks Correct Timing Using Distributor Clamp Wrench Diatributor Disconnect Points ‘Setting Distributor Breaker Point Gap Checking Breaker Lever Spring Tension Replacing lznition Coil Removing or Installing lznition Switeh—M123, M128C, Mi25 Starter Cireuit — M123, M128C, M125, ‘Starter Cable Disconnect Points Removinyor Installing Starter — M123, M1280, M125 ‘Magnetie Switch Disconnect Points Starter Circuit — MI23AIC, M1232 Starter — MI23A1C, MI23E2 ‘Starter Solenoid Generator — Regulator MI2BAIC, M123E2 MIZSAIC, Mi23E2. EEDSCE SSCS SESE EESSESERREREERESS 2106 2101 2a0T 2108 2108 2109 2109 2 21N 2g 2Ne ue aang, 21M 2a 25 a»ember 125, 126, 21m. 2128, 2129, 2130. 231. 2192. 2138. 2134, 235, 2136, 2st. 2138, 2139, 2140, 2a. 21a. 2143, 2a 214s, 2146, 2a, 2148, 2149, 2150, 2A. 282, Diss ee ss. Diss, bist, Piss Biss, Pie Bil. bee Dies Pie iss. ise ier Diss Die0, bin pin, bie 2s, bine bits. 216, zim Dim, pine, Pio, 281 2182, 2-183. 2184. 2185. 2.186. LIST OF ILLUSTRATIONS—Continued Tie Generator Alternator Batteries — M123, M1230, M125, Batteries — M123A1C, MI29E2 Headlight and Blackout Driving Light Headlight Adjustment Removing or Installing Headlight Sealed Beam Unit, Removing or Installing Blackout Sealed Beam Unit, Removing or installing Blackout Driving Light stalling Blackout Marker Lamp Receptacle and Combination Stop, Turn, and Taillight Instrument Cluster ‘Air Horn — MI23A1C, M123B2. Horn Switeh Wiring Direetional Signal Light Switeh Slave Receptacle ‘Composite Light — Exploded View Marker Light — Exploded View ‘Turn Signal Light — Exploded View ‘Taillight = Exploded View ‘Taillight and Reflector Warning! irectional Signal Control and Warning Light Tomgle Switch ‘Signal Control Flasher Wiring Diagram — Special Lighting Wiring Cireuit Dingram—M128, M123C, M125, ‘Wiring Cireuit Diagram — M123A1C, M123E2 Harness Diagram — M123, M123C. M125 Harness Diagram — MI23A1C, M1232 Pressure Gage Sending Unit Removing or Installing Fuel Tank Sending Unit. Front Propeller Shaft ‘Removingon Installing Rear Propeller Shaft Interasle Propeller Shaft Propeller Shaft and Universal Joint — Exploded View Installing Journal Seal Using Replacer Removing or Installing Slip Joint Handbrake Drum — Exploded View Handbrake Assembly Handbrake Linkage — Exploded View ‘Adjusting Service Brakeshoes Removing or Installing Brakeshoe Retractor Spring. ‘Service Brakeshoe Disconnect Points ‘Adjusting Unloader Valve Clearance Water-Cooled Air Compressor. Water-Cooled Air Compressor Strainer Air-Cooled Air Compressor i-Colled Air Compressor Strainer-Exploded View ‘Air Compressor Governor . Brake Application Valve Quick Release Valve Double Check Valve Hand Control Valve Hand Control Valve Position Differential Brake Control Valve ‘Tractor Protection Valve — M12BA1C, MI23E2. ‘Two-Way Control Valve—MIZ3A1C, M123E2, Tire Inflation Valve ‘Sectional Views of Hose Assemblies Hose Assembly—Exploded View ‘Connector Nut and Sleeve Positioned on Hose. Removing Protector Cover From Gasket. 2a16 2at 2118 2118 2n9 2120 2120 22 2 2B 22 2125 par 2izt 2azt 21m 2129 2130 2181 2a Base 2133 2134 2134 2135, 2st 2139 21a 243 25 26 2a 2a 28 214g 219 219 2150 2151 282 2.158 2158 2154 + 2185 2.155 2156 251 2158 2158 2160 2.160 2161 2162 2162 2163 2163 2164 2164 2165, 2165, 2166 2166emer 2243, 22M, < LIST OF ILLUSTRATIONS—Continued Te Installing Gasket into Bottom of Recess in Connector Body Placing Hose in Connector Body Installing Hose Coupling Gasket Brake Chamber-Front Brake Cylinder-Rear ‘Wheel Installation with Correct Nut Removing or Installing Rear Wheel! Assembly Lubricating Rear Wheel Hub and Bearing (Sheet 1 of 2) Lubricating Rear Wheel Hub and Bearing (Sheet 2 of 2) Removing Steering Wheel Drag Link Assembly — Exploded View Checking Toe-In with Gaye ‘Tie-Rod Assembly — Right Side Power Steering Pump MI23A1C, MI23E2 Flow Control Valve Power Steering Pump and Mounting Bracket Exploded View Power Steering Filter Power Steering Reservoir Assembly: — MI23A1C, M123E2 Davit Locked in Travel Position — M125, Removing or Installing Fifth Whee! Front Bumper Disconnect Points—M125 Pintle, Drawbar and Yoke Block Assembly — M125 Pintle Assembly — Exploded View. ‘Towing Pintle Stowed for Travel — M125 Front Spring, Front Axle-to-Spring Attaching Parts — Exploded View Prying Torque Rod Free of Carrier Lux ‘Rear Torque Rod-Disconnected Windahield and Windshield Wiper Assembly Cab Sear Cargo Body ‘Spare Tire Carrier and Davit Disconnect Points — M125 Liquid Container Stowage Rack — M125— Exploded View Dual Winch — M123, MI23E2 ‘Single Winch M128C, MI23A1C Front Single Winch — M125 Checking Cable Tensioner Adjustment Front Mounted Winch Drum Shaft and Upper Pillow Block Upper Chain Adjustment — Dual Winch Lower Chain Pillow Block — Dual Winch ‘Winch Drive Shaft and Universal Joint—Exploded View ‘Winch Brake with Cover Removed — M123, MI2SC, MI23A1C, M125 ‘Winch Brake with Cover Removed — MI23E2 ‘Winch Brake Adjustment Procedure — M123E2 ‘Single Winch Unit Assembly — M123C, MI23A1C ‘Winch Controls — M123, C1230, MI28A1C, M123E2 M125 with Bumper Removed (Cab Cover — Lashed in Place Installing Cab Cover — Side Bead (Cab Cover and Top Frame Installing Cab Cover — Front Bead Rear View Mirror ‘Tachometer Cable Disconnect Points ‘Tachometer Drive — MI23A1C, M123E2 Hot Water Personnel Heater Wiring Diagram 2166 2166 2a6t 261 2.168 2.169 2168 2a 2am 2au 2am 215 21 2A 27 27 21% 2179 2.180 2aBt 2B 2Be 282 2.188 21M 21a 2186 2186 2187 2.188 2.189 2.190 2191 291 2192 2192 2193 2.193 2194 2194 2.195, 2.196 2.196 2.198 2.198 2.19 2199 2.199 2201 2203 2.206 2am 22m at SELRETES LIST OF ILLUSTRATIONS—Continued Inlet and Outlet Water Hose Connections Inlet and Outlet Air Hose Connections. Diverter Assembly Control Bracket and Air Defroster Cable Installation Exhaust Diverter Assembly Igniter Fuel Pump and Filter Primer Pump and Control Cables Right and Left Side Hood Covers and Winterfront Radiator—Covers-tnstalled Personnel Heater Assy — MI23A1C, M123E2 Heater Fuel Pump — MI23A1C, M123E2 Heater Exhaust Tube — MI23A1C, M123E2 Heater Controls — M123A1C, M123E2 ‘Winterization Kit Wiring Schematic — M128A1C, M123E2 Personne! Heater Control Box — MI23A1C, M123E2 Coolant Heater and Circulating Pump — M123A1C. M123E2 Heater Coolant Lines — M123A1C, M1232 ‘Coolant Heater Exhaust Tube and Coolant Hose — M123A1C, M123B2 Batteries Installed Winterization Kit — MI2SAIC, M123E2 Controller Installed Rheostat Installed on Flange — M123, M1230, M125 Rheostat Installed on Steering Column — MI2SAIC, M123E2 SESELELL ELE T vitMember LIST OF TABLES AND CHARTS TABLES ee Special Tools, Test and Support Equipment Preventive Maintenance Checks and Services Spark Plug Cables Instrument Panel Circuits CHARTS: ‘Troubleshooting — Gasoline Engine — M123, M123C, M125 ‘Troubleshooting — Diesel Engine — MI23A1C, M123E2 ‘Troubleshooting — Vehicle ‘Troubleshooting — Electrical SystemCHAPTER 1 INTRODUCTION 0 Section |. GENERAL 1-1, Scope ‘@ This manual contains instructions for organi- zational maintenance of the 10-ton, 6x6 truck tractor M123 and M123C (dual and single winch, gasoline engine vehicles), M123A1C, M123E2 (dual and single winch, diesel engine vehicle) and the 10-ton, 6x6 cargo truck M125 (single front mounted winch, gas- oline engine vehicle), This Tanual also contains a description of major units and their functions in relationship to other components of the materiel. b, Appendix A contains a list of current references, including supply manuals, forms, technical manuals, and other available publications applicable to the ‘M123 series truck tractor and M125 cargo truck. ¢. Appendix B contains the maintenance allocation chart which lists the maintenance responsibi allocated to each echelon of maintenance. 1-2. Maintenance Forms and Records Maintenance forms, records, and reports which are to be used by maintenance personnel at all mainte- nance levels are listed in and prescribed by TM 38-750, 1-3. Reporting of Equipment Publication Improvements Report of errors, omissions, and recommendations for improving this publication by the individual user is encouraged. Reports should be submitted on DA Form 2028, Recommended Changes to Publications, and forwarded direct to Commanding General, U.S. Army Tank-Automotive Command, ATTN: AMSTA- ‘MAP, 28251 Van Dyke, Warren, MI. 48090. 1-4, Destruction of Army Materiel to Prevent Enemy Use For procedures on destruction of Army materiel to prevent enemy use, refer to TM 750-244-3, 1-5, Administrative Storage Refer to TM 740-90-1 for vehicle storage procedures. ‘Section Il. DESCRIPTION AND DATA -6. Description A general description of the truck tractor, 10-ton, 6x6, M123, M123C, M123A1C, M123E2, and truck cargo, 10-ton, 6x6, M125 and information pertaining to the identification plates are contained in TM 9-2820-206-10, A more detailed description of specific components and assemblies is contained in the applicable section (s) of this manual. CAUTION ‘These vehicles exceed the dimension limita- b. Tabulated Data Piston displacement ldling speed . . . Governed speed: No load . . : > ‘Crankshaft rotation (viewed from front) | . cubic inches. Firing order Valve clearance (hot) (running) - ‘Valve clearance (hot) (running) - tions permitted under AR 700-105, Advance planning will be required in the selection of routes because of bridge capacities and un- derpass and road clearances involved. 1-7. Identification and Tabulated Data a, Identification. Refer to the Operator’s Manual (TM 9-2820-206-10) for identification plates and additional data. M123, M123C, M125 MI23AIC, MI23E2 LeRoi Co. ‘Cummins Co. THe ‘v8-300 valvedivhead 300 va 785 450 rpm 650 rpm 2,150 rpm. 3,000-3,300 rpm clockwise clockwise 18736542 15486372 intake-0.013 intake-0.015 exhaust-0.015 exhaust 0.028Tabulated Data—Continued Cylinder block ventilation regulator location Water Water Capaci Recommended torque speci Make Model . Type Release bearing clearance, adjustment Freepedal, ‘drain number drain location ot Cooling systems Oil pressure Water temperature Manifold vacuum, at idle Manifold vacuum, at recommended toad Compresion presure at cranking speed: (approx 200 rpm. ations: Cylinder head stud nuts oF screws. Manifold stud nuts PIII Spark plugs 6.0.2 er (2)Cluteh, vel (3) Fuel System. Air cleaners: Fuel pump: Radiator: Water Distibutr an igution co Spark 12 Make... Mode! number (4) Cooling System. ‘Operating pressure .. Make .. : Number of biades | Drive Shroud pump: Make... Mounting... « Location (5) Ignition System. Rotation Breaker point pressure Breaker point opening Voltage lugs: She .. Gap ‘M123, M123C, M125 water cooled ‘on cylinder block cover 3 fone on each side of cylinder block and ‘one at bottom of ofr 20 ats 66 ats 25 psi at $00 rpm 50-60 psi at 2.000 rpm 160° to 180° F, 18 to 22 in, mercury 3.10 6 in. mercury 130 to 140 psi 90 wet 60 Ibe 30 Weft Mack cLso dual, dry-disk U8 to 3/16 in. two used Donaldson Co. DN E1006 Zenit 2-29D-14RZ Zenith Mechanovae 2-B732-2 two used Carter POIs 4 pal Hayes s triple V-belts attached to radiator LeRoi ‘centrifugal impeller er integral with engine front of crankcase clockwise 19 to 23 oe ooi6in. 2A volts 1mm 0.030 in. MI23A1C, M123B2 water cooled left cylinder head cover 4 ‘one on each side of cylinder block, one at bottom of radiator, pipe (some models) 32 qts 49 ats 5.25 pi at 650 pm 3045 pai at 2.600 rpm 165° to 195° F. 175 to 185 Ist 30 to 35 Ibeft Mack cL-s0 dual, dry-disk 18 in. Din, fone used Donaldson Co. Cummins fone used Cummins SOCR1S70 12 pal Cummins 6 tiple V-belts attached to radiator Cummins centrifugal impeller single V-belt integral with engine rightfront engine‘Tabulated Data—Continued (6) Starting System. Starter: Voltage 62. e ee Solenoid: Ordnance number ‘Voltage (1) Generating System. Generator: ‘Voltage Amperage Generator Regulator: (8) Alternator System. ‘Alternator: Output Current . Output Voltage | (9) Electricat Sytem. Voltage rating. Number of batteries used Plates (for each cell). “Ampere hour capacity (at 20 hour rate) Specific gravity: ally charged (at 80 (10) Axles. Front axle: Make caer Type : Ratio | Rear axle: Make. Type - Ratio . cece (It) Propeller Shafts. Front propeller shat Location : Sip joint tocaion Rear propeller shaft: Location Slip joint location Interaxle propeller shat: Location... Sip joint location (12) Brakes. Service brakes: Make Type - Number. Actuation Sizefront Lining. 22222 ‘attachment M123, M123C, M125 24 volts 24 volts 2s vibrating 24 volts 25 amperes 24 volts 2 2B 100 1275 to 1290 Mack triple reduction 9.019:1 Mack fulk floating double reduction 9.02:1 transmission to front axle at transmission end to forward from forward-rear axle to reartear axle at forward rear axle Mack internal. expanding, dual shoe 6 1% x6 I%x6 moulded, % in, thick bolted cast iron Bendix-Westinghouse Bendix-Westinghouse Wagner ‘MI23AIC, M123E2 24 volts 1119848, 24 volts (60 amperes 24 volts DC 24 volts 4 2 100 1275 to 1290 Mack triple reduction 1o.Ant Mack fullfoating double reduction tots transmission to front axle a transmission end transmission to forward rear axle at transmission end from forward-eat axle to rearrear axle at forward rear axle Mack internal, expanding dual shoe’ 6 1% x 6 IM% x6 moulded, % in, thick bolted cast iron Bendix-Westinghouse Bendix- Westinghouse WagnerTabulated Data—Continued ‘M123,M123C,M125_- M123A1C, M123B2 Hand brake: Make . Bendix-Products Bendix Products Type 22 internal expanding internal expanding Lining atachment 22222 tveted riveted (13) Compressed Air System. Air compresor: Make sess BendixWestinghouse Cummins Dive 2222 Tl batt er (14) Wheels and Tires. Whee: ee eee eee eee eee eee eee + disk disk Ties: Sie ++ 1400 x 24 14.00 x 24 Py. wae’) 20 Front | 2) single singe Rea. St dua dua Type 1 nondirectional, mud and nondirectional, mud and ‘now ‘mow (15) Steering System. Type ne hydeaue Ratio 2222211 I 209311 Steering whee! diameter 2040, Hydraulic pum belt dren Mack presed channel heattreated chrome ‘mangancse steel ‘ oe ( 36 in. (17) Suspensions. Front suspension: Spring type - 0000 + multiaf semiliptic———multiat semicipie ‘Arrangement - aeeeeeeee 25 longitudinal Aongituinal ‘Attachment reanfited eye, font- ——_reafined eye, front shackle shackle Shock absorber: Type - double-acting osilating- —doubleactng oxcilating- Attachment. bolted on frame, linked to bolted on frame, linked to ate se Rear suspension: Spring type - mulieaf somiliptic ———_multileaf semietliptic ‘Arrangement | Tongitudinal, with upper longitudinal, with upper torque rods torque rods Attachment rubber insulators at ends, rubber insulators at ends ‘xllating journal on oilating journal on trunnion tube at center trunnion tube at center (18) Body components-M125. Inside width . . .- Outside width Overall width Height—(Noor to underside of bow) ‘Overall inside length. Load space=(back from tre cartier). ‘Tailgate and front panct Side panels... eee ad q (19) Winches. Winch and components: Dual-M123, Dual-M123E2 hake PCC Garwood Garwood 14‘Tabulated Data—Continued Diameter... 2.4 ++ Winch capacity (Ibs ea) Worm reduction. : Diameter of drum (in... Cable: Diameter... 2-4... Winch capacity (Lbs ca) Worm reduction... .. Diameter of drum (in). « Make 5 Model. 2222 2DIDT1 Cable: Diameter... ees Winch capacity (Ibs ea) - Worm reduction... 2. Diameter of drum (in ¢. Torque Specification. The following are standard torque wrench requirements. Special requirements are used for critical attachment or alinement of vehicle component parts and are listed in their ap- propriate paragraphs throughout the manual. When not specified, bolts, screws, and nuts are to be tightened in accordance with standard requirements. M123,M123C, M125 -M123A1C, M123E2 143000902 43000902 power takeoff Power takeoff ain, Xin, 45.000 45,000 90:1 90:1 7 7 Single-M123C Single-M123A1¢ Garwood Garwood 1430003697 430003697 power takeoff power takeofT ain, ain, 45,000 45,000 sot 90:1 7 7 Front-M125 Garwood 3007680 power takeoff in. 45.000 as 7 ‘Standard Torgue Wrench Requirements [es a rests, é me a me Ee 4 ° 3 20 8 site w s 6 ” ae 2 s 16 u m6 50 10 “ 20 n 18 0 B 20 one no 1s 2 18 sis 150 2» u 8 oa 265 3s 10 16 118 420 ° “ 1 640 % 8 “ 200 100 7 2 1000 120 2 2 1200 150 ‘ n 1p 1500 200 ‘ n 15CHAPTER 2 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section I. SERVICE UPON RECEIPT OF MATERIEL 2-1. General 4, Perform a “run-in” of at least 50 miles on all new or reconditioned vehicles and a sufficient num- ber of miles on used vehicles to completely check their operation, according to procedures in Chapter 2of TM 9-2320-206-10. }. Whenever practicable, the vehicle driver will assist organizational maintenance personnel in the performance of these services. 2-2. Inspecting and Servicing the Equipment a. General Proceduren. (1) If any exterior surfaces are coated with rust- preventive compound, remove it with dry-cleaning solvent or mineral spirits paint thinner. (2) Read Processing and Deprocessing Record for Shipment, Storage and Spare Engines tag (DD Form 1397) and follow all precautions checked there- on. This tag should be in the driver's compartment attached to the steering wheel, shifting levers, or ignition switeh. (3) On processed materiel, when engine has been stored for over 30 days, service engine (gasoline powered M123, M123C, M125 only) as follows: (a) Remove spark plugs from each eylinder. (b) Atomize spray two ounces of lubricating oil, OE 10, into each eylinder through the spark plug opening. (c) After an interval of 15 minutes, rotate engine using the starter (ignition switch off) for approximately 80 seconds. (@) Reinstall spark plugs. NOTE If the vehicle has been driven to the using organization, most or all of the foregoing procedures should have been performed. (4) Follow the general procedures. paragraph 2-11 of Section IV, Preventive Maintenance Services. . Specific Procedures. (1) Tighten cylinder head bolts before starting engine. Refer to paragraph 2-56c for proper torque rating and proper tightening sequence. (2) Lubricate points illustrated in Lubrieation Order regardless of interval, excluding gear cases and engine. Check processing tag (a. (2) above) for gear case and engine oil. Provided the tag states that oil is suitable for 500 miles of operation and is of the proper viscosity for local climatic operation, check the level but do not change the oil. (3) Schedule “S” service on DA Form 2403, Pre- ventive Maintenance Roster, and arrange for oil change at 500 miles. 2-3. Correction of Deficiencies 4. Deficiencies disclosed during preliminary in- spection and servicing, or during “break-in” period, will be corrected by organizational maintenance or supporting maintenance personnel. . Serious deficiencies, which appear to involve unsatisfactory design or materiel, will be reported on DA Form 2407, Maintenance Request. The using organization will submit the completed form to the Commanding General, U. 8. Army Tank-Automotive Command, ATTN: AMSTA-M, Warren, MI. 48090. Section Il. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT 2-4, Tools and Equipment Standard and commonly-used tools and equipment having general application to this materiel are authorized for issue by the Table of Allowances (TA) and the Tables of Organization and Equipment (TOE). 2.5, Special Tools and Equipment ‘The Special Tools and Equipment tabulated in Table ‘21 are required to perform the organizational mail tenance operations described in this technical manual. References and illustrations indicating the use of these tools are listed in the table. aFata YY 4 AT 34513 Fipure 2-1. Special tools and Equipment.Table 2-1 Special Tools, Text and Support Equipment he oy Raernce ve " Fee Pan We WRENCH: socket siz03e3o136 | 2411 21016. Distibator mounting sew 7 51203479387 | 2119 2107 Starter mounting screw. ‘4 SOCKET: socket wrench $120473-7739 | 2-196 218s. Inner and outer whee! nut 2 WRENCH: tubular 51204737741 Oil filter tube. 3 REPLACER: oll sal 51205699787 | 2.160 2.1634. ‘Transmission to front rear axle ‘ ‘universal joint oil seal. REPLACER: oil seal 51205699788 | 2.160 21634. ‘Transmission to front axle or front | $ rear axle to rear, rear axle universal joint ol seal WRENCH: spanner 51206258997 | 2197 2.1908. Rear wheel bearing adjustment, 1 2-6. Maintenance Repair Parts Repair parts and equipment are listed and illustrated in the Repair Parts and Special Tool List, TM 9-2320- 206-20P, covering organizational maintenance for this equipment. Section Ill. LUBRICATION INSTRUCTIONS 2-7. General Any special lubricating instructions required for a specific mechanism or part are covered in the perti- nent section in this chapter. 2-8. Lubrication Order ‘The Lubrication Order (LO 9-2320-206-12) prescribes cleaning and lubrication procedures relative to locations, intervals, and the proper materials for the vehicle. Whenever necessary, the operator will assist organizational maintenance personnel in lubrication of the vehicle. Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES. 2-9. General Preventive maintenance is the systematic care, spection, and service of equipment to maintain it in a serviceable condition, and to detect faults and failures before extensive and time-consuming re- pairs or replacements are required. The Army system of maintenance prescribe two types of preventive maintenance services; these services are briefly described in paragraphs a. and b. below. Also, refer to TM 38-750 for complete information pertaining to preventive maintenance forms and records. @. Operator or Crew. The Operator's Manual (TM ‘9-2820-206-10), prescribes preventive maintenance services performed by the vehicle operator or crew each day the vehicle is operated. b. Organizational Maintenance. This section con- tains procedures and instructions necessary to per- form semi-annual “S” services. These second echelon services are performed by organizational mainte- nance personnel, with the assistance of the vehicle operator or crew, every six months or 6.000 miles, whichever occurs first. On-vehicle equipment is given, preventive maintenance concurrently with the ve- hiele. 2-10. Recording Repairs The equipment record system provides for recording repairs required and accomplished on specific items of equipment. This will inelude, but is not limited to, adjusting, cleaning, replacing, and straightening. Deficiencies and shortcomings not corrected by op- erator, or those discovered during periodic in- speetions, will be corrected insofar as possible by organizational maintenance personnel. These repairs will be indicated on DA Form 2404 and recorded on the organizational maintenance record of the equip- ment log. 2-11. General Procedures @ Automatic Application. All of the general pro- cedures given in the Operator's Manual (TM 9-2320- 206-10) will be followed. Organizational mechanics must be #0 thoroughly trained in these procedures that they apply them automatically at all times in the performance of their dutie b. Cleanliness. Cleanliness is essential in all component assembly operations. Dirt and dust even in minute quantities are abrasive. Parts must be cleaned as specified and kept clean. Wrap or cover 23parts and components when assembly procedures are not immediately completed. ©. Preformed Packings. Lubricate all preformed packings and their associated grooves with hydraulic fluid, MIL-H-5606. d. Metallic Parts. Lubricate all metallic parts with lubricant utilized in the component during op- eration (refer to LO 9-2320-242-12). e. Locking Procedures. Installation of cotter pins and lockwire shall be accomplished as specified in MS 33540. Ff Torque Values. Critical torque values are spec- ified, bolts, screws, and nuts are to be tightened in accordance with standard torque values. 9. Hydraulic and Fuel Components. All hydraulic and fuel components must be kept thoroughly clean at all times. Plug all open ports until the component is installed in the vehicle. h. Oil Seals. When replacing lip-type seals, place spring-loaded side toward oil. Coat housing contact surface with a non-hardening sealer to prevent leaks. Lightly coat lips of seals with grease (GAA). i. Pressing Operations. All pressing operations should be accomplished using a suitable press and adapters unless otherwise specified J. Plates. Nameplates, caution plates, and instrue- tion plates made of steel rust very rapidly. When they are found to be in a rusty condition, they should be thoroughly cleaned and heavily coated with an application of lacquer. ‘k. Services. Organizational maintenance services are defined by, and restricted to the following general procedures unless approval has been given by supporting maintenance. (1) Adjustments, Make all necessary adjustments in accordance with instructions contained in their pertinent section of this technical manual or technical bulletins. 24 (2) Cleaning. Clean the unit as outlined in Op- erator’s Manual (TM 9-2320-206-10) to remove old lubricant, dirt, and other foreign material. (3) Special lubrication. This applies to lubrica- tion operations that are the result of a logistic 4 operation (i.e. deep-water fording). (4) Services. This usually consists of performing operations, such as replenishing battery water, drain- ing and refilling units with oil, and changing or cleaning the oil filter, air cleaner, or cartridges. (5) Tightening Operations. All tightening oper- ations should be performed with sufficient wrench torque to tighten the unit according to good mechan- ical practice. Use a torque-indieating wrench where specified. Do not over tighten, as this may strip threads or cause distortion. Tightening will always be understood, to include the correct installation of lockwasher, locknuts, lock wire, or new cotter pins, to secure the tightened nut. (6) Modification work order application. Enter all required modification work orders (MWO) appli- cable to the equipment on forms as prescribed in ‘TM 38-750. 1. Special Conditions, When conditions make it difficult to perform the complete preventive-main- tenance procedures at one time, they can sometimes be handled in sections. Plan to complete all oper- ations within the week, if possible. All available time at halts and in bivouac areas must be utilized, if necessary, to assure that maintenance operations are completed. 2-12. Specific Procedures Specific procedures for performance of the semiannual “S” services on vehicles are given in Table 2-2. To perform the services in the most timely, economical manner, follow the number sequence shown in Table 22, 4Table 2-2. Preventive Maintenance Checks and Services Ormateiona MalatnaneeCatry Monthy Seeder quartets) e —— 12 Sa Seca ee Siac eae a ee ac a eee peer oe a So Sa eeo Foo ihateos 4 Drawber and yoke block -M125 ICheck for condition. s Chasis inspect for damaged, cracked or broken frame and crossmembers. ‘6 Brakes inspect sir hoses, fittings, chamber and cylinder linkage for looseness. Check for possible lock ‘up or aippage. Adjust brakes. Close reservoir air valves. 7 Fuel tanks and filters Drain water and sediment, Para 2-71, 2-79, 8 Shock sbeorbers Inspect for leakage and possible damage to linkage. ‘Check fui level. 9 Front and rear springs Inspect condition of leaf rebound clips, and possible damage to springs. Check for possible loose Udo 10 Battery Inspect cases for cracks and leaks. Inspect cables, ‘terminals, posts, holddown frames, and water level. Clean and repair a8 required. Paint metal parts as required. Front bumper Inspect for looseness or damage. Radiator Inspect radiator core, shell, hoses, cap and gaskets. Notice if radiator cores are clogged with foreign matte or if fins ae bent. Radiator must be filled to height of level cock on filler neck. If required, drain radiator and cylinder block, flush and refi cooling system. Test coolant with a hhydrometer to determine if cooling system contains sufficient antifreeze. Add 25 required. Tighten radiator mounting, and hose clamps as required. Check valve spring of cap for tension. 3 Steering controls Check for looxe or worn tie rod and drag link. Inspect front tires for wear due to improper alinement. Examine steering column for aline- ‘ment. Check oil level in reservoir and add oil if necessary. “ Hydraulic pump (steering) Inspect for seepage or leaks at housing and pressure ‘hoses. Check oil level (reservoir) Fill to screen iflow. as Power train Inspect propeller shafts and U-joints for service- ability. Tighten flange bolts 45 to 50 Ib-t torque. 6 Cylinder block (Check oll level. Check ol iters for leaks and lines | Para 2-43, 2-44, 2-59 for possible breaks. If necessary, change oil and | 2461. LO 9-2320-206- replace oil filters. Inspect cylinder block ventilator | 12. sepalator for operation; clean strainers for cylinder block. ” Water pump, fan, pulleys, and all dive belts (Check for leaks. Inspect pulleys and fan for aline- | Para 2.90, 2.91, 2.92 ‘ment, and belts for proper tension. 2.97, 9:98, 2-99. 18 ‘Carburetor M123, M123C, M125 Inspect throttle linkage, noting if shafts and Para’2-69. Linkage operate freely and are not worn exces- sively. Observe if choke valve opens fully when control is released and if throttle valve opens fully when the accelerator i fully depressed.eee] 19 2 2 2B 2s 6 n * 26 Table 2-2, Preventive Maintenance Checks and Sericen—Continued ae Creaiationa Masten Tema tobe ‘napecte ‘Accelerator and throttle controle M123A1C ‘M123E2 Ait compressor Electrical components (engine)-M123, M123C, M125 Electrical components (engine)- M123AIC, ‘M123E2 ‘Cab and body Safety devices Winches, power take-off Fifth wheelM123, M123C,M123AIC, M123E2 Starter ‘Air pressure cut-off point Instrument panel ‘lena Seba lr gurtr) Inspect accelerator, noticing if shafts and linkage ‘operate freely and are not worn excessively. ‘Observe that accelerator opens fully when depressed. Inspect throttle linkage, noticing ifeable binds or does not open accelerator [Examine to see that itis in operational condition, ‘properly alined, and secured. Check air filter. Inspect generator, starter, and distributor for tightness and general condition. Check wiring for loose connections or worn insulation. Inspect alternator and starter for tightness and ‘reneral condition. Inspect wiring for loose ‘connections or worn insulation. Inspect doors, hardware, glass, soft-top frames, ‘curtains and fasteners, seats, windshield frame and glass. Check mountings and springs. Operate doors, windshield, hood hinges and fasteners. Make a general inspection of cargo body including fenders, running boards, brush guards, tile, stakes and center bows, tarpaulin and ‘curtains, Examine condition of paint and ‘check markings, legibility of caution and ‘identification plates. If cab mounting bolts require tightening, loosen steering column clamp. Tighten cab bolts and steering ‘column clamp. [Sound horn (if tactical situation permits). Test ‘windshield wipers for proper operation. Check mirrors for damage or looseness. Check all lights. Inspect for condition of prop shafts, Uoint, drive chains, pillow blocks, shearpins, and cable. Test ‘operation of winch. Adjust winch safety brakes, if necessary. Tighten assembly and mounting bolts. Check plunger lock and coupler lock. Inspect tralet air ‘hose and connectors. Check condition of elec- trical trailer plugs and cable. ‘START ENGINE Observe that the starter engages smoothly without ‘unusual noise and turns engine with normal cranking speed. Use electrical troubleshooting instructions for diagnosis of maifunction. Start ‘and warm up engine. Observe if engine starts easily and if action of throttle is satisfactory. Note if idling speed is 450 ‘rpm at normal (gasoline) or 650 1pm at normal (Giesel) Listen for any unusual noises at idle and higher spegds. Engine operating temperatures 160°F to 180°F (gasoline) or 165°F to 195°F (ese. |Governor cut-out pressure is 95 to 120 pal. With ‘engine running, slowly reduce ai pressure by ‘depressing and releasing brake treadle and note pressure on gage at which compressor resumes ‘pumping. This is the governor cut-in pressure and should be 90 pal Inspect for leaks. Stop engine and) notice if there is appreciable drop on air pressure ‘ge within one minute. Check low sir pressure buzzer. Observe all instruments for normal readings. Notice Af the oll gage registers doquate oll pressure. Para reterenee Para 2-74. Para 2-171, Para 2-102, 2-107, as. [para 2-110, 2-118. Para 2-229, 2-230, 7M %2320-206-10, para 2-205. Para 2-107, 2-110, Para2-173. Check controls for normal operation. Note senerator/lterator output on battery indicator ‘immediately after stating engine, before regulator ‘has reduced the charging rate of generator] alternator. 43h 2 3 ” 3” a a “a | Table 2-2. Preventive Maintenance Checks and Servicer—Continued Maatnane Cat Trmeto be Inspect ‘Steering Intake and exhaust maifolds ‘Vatve mechanism Exhaust pipes and mufflers mutch Speedometer and tachometer Performance ‘Transmision-transfer ‘Unusual noises Brakes (service and hand) Vehicle assemblies. Running gear Lubrication Mathy Schedule rear) Procedare Parareterence Hrurn che stering wheel through its entire rang and note any bind: When rk sin motion check for wandet, shimmy, Side pul, or excessive fice pay. inspect for condition. Look for signs of leakage at |Para 2462. the manifold gasket, napect vate cover for leaks. vas are nony, [Para 253,284 adjust lcneck mountings for tightness. Listen for encensive [Para 22,285. noises and inspect for exhaust leaks Joneck fee travel Pedal shoul have two inches free [Par 2-50. tewvel. Not if ston of pedal return springs satisfactory, depres clutch. Not if engages smoothly of cattery, grabs, oF sip. Listen for unusil noise which may indicate a defective release bearing ROAD TEST observe tha these instruments function satisfactorily Para 2-247, 2248, 24s, CAUTION Engine speed must not exceed 2750 rpm (M123, MI23C, M125) or 3300 ‘pm (M123AIC, M123E2) at any time. When operating vehicle, notice iit has normal power nd acoceration in each geat of range, i there in A lack of power, engine misfire, or excessive exhaust moke is noted. Check troubleshooting {instructions for diagnosis of malfunction, Listen {or any unusial noses when engine is under load. lcneck lever action. Shit tensmision and transfer [TM 9-2520-206-10 {nto all speds. Observe any unusual stiffness of the shift eer, tendency to lp oat of gear, noe ‘or excetsive vibration. Make similar observations ‘ith front dive contro lever cob and body attachments. Check fr exces nose that may indicate looseness. Ab observe Similar conditions on whess and powertrain which could als bea ick of nbietion. Note braking effect. Foe for side pull, noie or [Para 2-164. chatter Make evra stops noting font sir chambers and rea ylindrs are operating property and if there is any evidence of locking of wheels, Obsere if handbrake hold. Stop on fan incline and apply brakes to ee that they hold the vehicle, When towing semitraeror equipment with electrically operated brakes, apply these Drakes alone and observe if they operate satsactoriy. AFTER ROAD TEST mediately afer rod test, check brake drums, ‘hub, axle housings. An overheated wheel hub ‘and brake drum indicates an improperly adjusted, Aefectine or ry wheel bearing or dragging bake. ‘there has been a brake deficiency indicted in 2168. previous steps or during the rod tes, teardown Wil be extended only to accomplish noraary repair. Adjust brakes if required. Latricate vehicle in sccordance with bxcation |L0 9232020612 order. FINAL ROAD CHECK Perform final road test to ensure that operational deficiencies have been conrcted. Pay particular Attention to thowe items which hee just been repaired of adjusted, Correct any reeaining deficiencies that show up on this tect un. 27Section V. TROUBLESHOOTING THE VEHICLE 2-13. General This section contains troubleshooting information and tests for locating and correcting some of the troubles which may develop in the vehicle. Refer to Charts 2-1, 2-2, and 2-3. Each symptom of trouble iven for an individual unit or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to remedy the malfunction. 2-14, Procedures a. This manual cannot cover all possible troubles and deficiencies that may occur under the many conditions of operation. If a specific trouble, test, and remedy are not covered herein, proceed to isolate the system in which the trouble occurs and then locate the defective component. Do not neglect use of any test instruments such as voltmeter, ammeter. test lamp, hydrometer, and pressure and vacuum gages that are available. Standard automotive theories and principles of operation apply in trouble- shooting the vehicle. Question vehicle operator to obtain maximum number of observed symptoms. The greater the number of symptoms of troubles that can be evaluated, the easier will be the isolation of the defect. +. Good operational trouble analysis depends upon sound and systematic investigation to determine the primary cause of malfunction. The tests and remedies provided herein are governed by the scope of the organizational level of maintenance.Chart 2.1, Proubleshooting-Gasoline Engine-M128. M12SC, M125 mainecton Probale canes ‘Carectve atin GASOLINE ENGINE-M123, MI23C, M125 WARNING: 1 Engine fails to erank when starter ‘button is depressed. indicator pointer shows low ‘or no reading). 3. No. spark. (Battery generator indicator reads norma). 4. Starter inoperative. 5. Noisy Starter. 6. Starter sluggish: will not attain full crank speed. 7. Engine cranks but fails to start. eee pape 8 Defective batteries, wiring, connectors, or starting system. Seizure of starter or engine Ignition switch off. Defective ignition witch. Defective ignition coil or distributor Distributor breaker points not opening or faulty Defective distributor capacitor. Defective distributor rotor or cap. Loose electrical connections. Loose, corroded, or broken battery ables Defective magnetic switch Defective starter switch. Defective starter motor. Loose starter mounting. Defective drive assembly. Worn commutator or bushings. Defective bearing duc to lack of lubrication. Discharged or defective batteries. Dirty or loose terminals. Sticking brushes, commutator or armature rubbing field coils. Fuel tanks empty. Engine flooded. No spark Carburetor improperly mounted or inoperative. Carburetor choke inoperative, ‘ert Trobbaoatin the tri Stem Section VI ‘When disconnecting or connecting vehicle battery ‘ables, the ground cable(s) must be disconnected first and connected last. Non-compliance could result in personal injury and vehicle damage. ‘Check electrolyte specific gravity. Replace defective batteries (para 2-120), Replace starter (para 2-107). ‘Turn ignition switch on. Replace switch if required (para 2-108). ‘Check continuity of circuit No. 12 from ignition switch to coil, and from coil to distributor (fig. 2-152). Ifcurrent shows from switch to coil, Bt not from coll to distributor, replace coil (para 2-102). 4. Inspect breaker points. If bumed or pitted, replace (para 2-102). Adjust point ‘opening (para 2-102c). 1 Replace capacitor (para 2-102). Replace rotor. Check cap for cracks (para 2.102e). pers @ (Clean and tighten all electrical connections at battery, ground and starter. Replace cable if broken, orif terminal clamp is excessively corroded. Replace defective switch if required (para 2-108). (Check linkage from starter pedal to upper levis of starter. Adjust linkage a3 required to assure full engagement of starter shaft. Depress starter pedal to energize switch for testing purpose. Test defective switch. ® Tighten starter mounting nuts (2) (para 2-107) and socket head screw. Replace starter (para 2-107). Replace starter (para 2-107). Replace starter (para 2-107). (Check electrolyte level and specific gravity. Recharge or replace batteries as necessary (para 2120). (Clean and tighten terminal connections. Replace starter (para 2-107). Sane il tanks, Push choke in, open throttle and crank engine to remove excessive fuel, Refer to items 2 and 3. (Check carburetor mounting, and correct a ‘necessary. Adjust carburetor for proper ‘operation (para 2-69). Replace carburetor (par 249). Remove sir cleaner-to-carburetor air inlet ‘elbow at carburetor. Inspect choke valve for proper operation and adjust choke controls (para 2-67). 8 AP 28Chart 21, Tronbleshooting-Gesoline Ewgine-M123. M12sC, M125—Continued snow Frobaecawee T Goren con GASOLINE ENGINE MID, Setanpeimine "|b tticator copper sade oft, | bisa sh cone e sia nope pa ofa «Ean ove, netteien tn ae 4. gree ssiment 4. Cnc ec and if ee du ‘oan 59) Steg aes. Remove yer ead corpus 253, an Sor reewcingad rene eas Weare ruc ot testy opertng mar tees nal £, Fmty ampresion recone gan 256 Leet auetocmersar | £ Gener pe mtr pan 245) ot pe ‘Sinncd mateo arse Cabernet eared ot | A. Refer totem 76 oe. ee «coger «Chan tes e270 ‘j. Faulty fuel pump. j- Refer to item 9%. 1, Gitte be mpropery ssa, | Chek ink nd ads nessa gu 267). 1 Clg sit canes 1 Remon and sisi caesar 240, te Bear ont ine rm hing gee 2100, o.Fuatdetsotracheubueter, | o Lec eee GO teller gion sich on ae ipa check a arin nsw fof pee open. 2. Fuel pump inoperative bine le om it ie of ection ig 80 ael aos et ow fel nie thon sl pump twieh opty pone otk eg thd ce fel pump eter «Lowe pump ps. picanec one hele bo pepe ‘te pean Stuy Tum gin oe el pone ston Ped peoe pene aid be Seteen 35 md pa un paves pony gut 27) Clog uel nk nt ine wheel and can ek ene ‘oun Coed ul nso te, 4 Repore esanckan (pan 20), Cen inline eter ol at td che ae (para 2-47). 10. Low fuel pressure. @ Air leaks at fuel lines or fuel pump. @ Inspect fuel pump outlet lines at top of fuel tunes tough we cere fr Istage: Cones rags eps Senet 2. efecive pump 1 efron 9. sow. 2 Gener ers © eterte tm 3 toe 11, Fuel does not reach cylinders, 4 Carburetor jets clogged. @ Replace carburetor (para 2-69). Notify spare uta enone 12 Bee utconmmption, | Fatieats. intra halgcm n rat Tien alcomatn feo me Bek 1. Chg i cae 1. Remora isi ees (ue 246, Wotror caged carton pat 2 Repicecanerie enh) 13, Engine misfires at idle speeds, 4 Carburetor idle setting incorrect. 4, Adjust choke control and linkage (para 2-69). 4 Chet impperypottence 4 Ad cot onl and tg: 28 ¢. Spark plug gaps improperly set. ¢ Adjust spark plug gap (para 2-104), & ear pee oar Meco eat. Unio cc forks ot ote ‘hart xr fing diet mnie. f. Improper valve clearance. f. Adjust valve clearance (para 2-53). 2:10 ¢«Chart £-1. Troubleshooting-Gasoline Ewgine-Mi2s, M128C. M125—Continued 13, Engine miafizes at idle speeds. ‘Continued 14, Engine misfres at high speeds, 15. Engine idles too fast. 16. Engine overheats, 17. Engine falters, 18, Engine backfires, 19, Excessive oll consumption. 20, Engine oll pressure low as indi- cated by oll pressure gage. nh OS PAD ee ps oP GASOLINE ENGINEM123, 'M123C, M125-Continued Leaky cylinder head gasket. \. Defective or sticky valves, Broken valve springs. Improper valve adjustment. Leaking cylinder head gasket. Defective fuel pump. Spark plug gaps improperly set. Distributor breaker opening improperly set. Defective ignition col. Defective ignition wiring. Improper carburetor idle adjustment. Improper carburetor linkage adjustment. Intake manifold gaskets leaking. Low coolant in system, 3. Lean air-fuel mixture. Late ignition timing. Insufficient or improper grade of oil. Piston rings stuck, wor, or improperly fitted. >. Clogged or worn carburetor parts. Crossed spark plug cables 3. Cracked coll or distributor cap. ut of time, Oil leaks, Engine overheating. (Clogged cylinder block ventilation regulator ‘and strainer. Poor compression. [Excessive low speed driving in too high gear range. Inadequate engine oll supply; low oll evel. Defective oil pressure gage. PAD SRR eS Corecivecton Tighten cylinder head stud nuts to specified torque (para 2-56c). Replace gasket if necessary. ‘Check engine vacuum (para 2-54). Erratic vacuum gage readings at constant engine speed, indicate defective valves operation, [Notify supporting maintenance personnel if gage reading is erratic. [Notify supporting maintenance personnel. (Check and adjust valve clearances (para 2-53). Refer to item 13g. Refer to item 9. ‘Adjust (para 2-104), ‘Check breaker point opening and adjust if necessary (para 2-102). Inspect cables and connections. Test coll and replace if necessary (para 2-102) ‘Check spark plug and coll cables for continuity. Replace if necessary (para 2-103 and 2-104). ‘Adjust carburetor idle misture (para 2-69) and adjust throttle adjusting screws (para 249). Adjust (para 2467). Inspect gaskets for leakage. Replace if necessary (para 262). Refer to cooling system (para 2-86) ‘Adjust carburetor (para 26). Inspect engine {for leaks at manifold and carburetor gaskets. (Check ignition timing and adjust as necessary (para 2-101). Refer to item 86. [Notify supporting maintenance personnel. Replace carburetor (para 2-69). Notify sup- porting maintenance personne! if engine stil falters ‘Check cables for proper firing order sequence 18-73-6542). Inspect distributor cap and coil for cracks or cearbonized spots, indicating current leakage. Inspect all carbon tips in cap. Replace cap ‘or col if any cracks or carbonization is noted (para 2-102c). ‘Check ignition system timing (para 2-101). Inspect engine, engine components, and sground under engine for oll eaks Tighten leaking connections and repair or replace ‘broken lines or notify supporting main- tenance personnel. Refer to item 204. ‘Check ventilation regulator and strainer. ‘Service as indicated in (para 2461). ‘Test compression on all cylinders (para 2-54). If difference of 10 psi between cylinders i noted, notify supporting ‘maintenance personnel. Vehicle must be operated in proper gear ratio {for desired speed according to road. conditions. (Check engine oil for proper level and proper viscosity; replenish oll Replace gage (pars 2-154). 241Chart 2.1. Troubleshooting-Gasoline Brgine-Mi28, M12SC, M125—Continued —|— ainecton Probenie causes Corective ation GENERATOR SYSTEMM123, M123C, M125 20, Engine oi pressure ow as indi- | ¢ Defective oil pressure sending unit. ‘& Replace sending unit (para 2-158). cated by oll pressure gage. 4d, Defective engine oll pump. 4. Notify supporting maintenance. “Continued Loose, worn or damaged engine bearings. | ¢. Notify supporting maintenance... £ Improper oil viscosity. £. Drain and refill with oll of proper viscosity. 21. Excessive noise on increased Insufficient lubrication Notify supporting maintenance personnel. acceleration. 22. Excessive noise with engine idling. | Insufficient lubrication. [Notify supporting maintenance personnel, 23, Excessive noise under load. [Notify supporting maintenance personnel. WARNING When disconnecting or connecting vehicle battery cables, the ground cable(s) must be disconnected first and connected last. Non-compliance could result in personal injury or vehicle damage. 24. Battery-generator indicator shows | ‘a. Faulty batteries. Refer to item 1a above. Tow charge. 25. Noisy generator. rator does not charge. 27. Generator output excessive. (Battery generator indicator almost on extreme right of rmeter scale). 28, Generator output low or unsteady. (Battery generator indicator fluctuates between low and ‘medium charge with engine operating.) WARNING Before checking oF dr turn radiator filler c ‘until stop is reached. Cap is then vented position to allow pressure to.scape. Non-compliance could result in serious burns. 29, Engine overheats, temperature ‘ses over 200°F. 1, Electrolyte level low in batteries & Loose connection in gencrator-regulator or battery eieuit 4. Gonerator-regulator out of adjustment. 1. Loose generator mounting. 1. Generator dirve pulley loose on shaft. Worn commutator, sticky brushes, of armature rubbing on field coil. Broken of loose drive belts ‘5, Faulty voltage regulator. & Faulty generator. Faulty voltage regulator. +. Faulty generator. 1 Loos drive belt. 'b, Looe connections in battery-togencrator ‘or voltage regulator circuit. Faulty voltage regulator. COOLING SYSTEM- All Models 1 Lack of coolant, Rete Trobe the til atm, fection 212 a Replace ger *D. Replace generator (para se ‘Add water to correct level. Check battery- ‘generator indicator for high reading. & Clean and tighten battery terminal connections In circuit (fig. 2-130). *d, Replace generator-regulator if required (para 2-116). Polarze generator. Notify support- ing maintenance personnel. {@ Tighten generator mounting bolts and adjust drive belts (para 2-90), Tighten pulley (para 2-115). Replace generator (para 2-115). Polarize generator. Notify supporting maintenance personnel. Replace or adjust drive belts (para 290), Replace gencrator-egulator i required (para 2-116), Polarze generator. Notify supporting maintenance personnel. se *e. Replace generator if required (para 2-115). Polatize generator. Notify supporting maintenance personnel. erator-regulator if required (para 2-116). Polarize generator. Notify supporting ‘maintenance personnel. 115). Polarize generator. Notify supporting maintenance personnel. Tighten drive bolts (para 290). (Check cireuit Nox. B and 4 for continuity and tightness (ig. 2-152). e. Replace gencrator-repulator if required (para 2-116), Polarize generator. Notify supporting ‘maintenance personnel. 44 Replenish water in radiator, Add antifreeze if nccessary. A (Chart 2-1. Troubleshooting-Gasoline Engine-Mi88, M128C, M125—Continued 29, Engine overheats temperature |. ies over 200°F,-Continued a _— 30. Overcootin. (Inability to attain engine operating temperature after suitable warmup period). WARNING Fxxhaust gases are dangerous. ‘Troubleshoot exhaust systems in well ventilated area to pre- clude injury to personnel 31. Defective exhaust system. a Prova cause ‘COOLING SYSTEM~All Models-Continued ‘Coolant leaks. Faulty water pump. Leaky radiator core. (Clogged radiator. 1. Obstruction preventing free air low through radiator. Inlet or outlet hose collapsed. ‘Shudge in cylinder block. Plugged water jacket. Seale in eylinder block, Improper draining at service. Defective thermostat. Inaccurate temperature gage. Defective or restricted muffler or exhaust pipe Loose or defective manifold and exhaust pipe flange clamps. Defective exhaust manifold gaskets. aD oF Inspect cooling system for leaks. Tighten or replace hote as necessary. Replace pump (para 2-92). Replace radiator (para 2-87 and 2-94). Notify supporting maintenance personnel. ‘Adjust belts (para 2:90 and 2.97). Remove and test thermostat (para 2-89 and 2.96); replace if necessary. (Clean and flush radiator (para 2-87 and 2-94), Remove bugs, eaves, and accumulated dirt {from radiator, using high pressure ar or ‘CAUTION DO NOT USE STEAM. (Check condition of hoses and replace if necessary, Drain, Mush, and refil cylinder block. Drain system (para 2-87 and 2-94). Disconnect radiator hose and reverse flush the raidator. Refer to TM 9-2858, (Clean and neutralize system. Refer to TM 9.2858. Be sure all drain cocks ae closed after cnengementsorvehice “ereps"| b, Warped ox catced intermediate plate. |, Nolly sopporting maintenance personel Siitehtch peda depresed” | ¢. Intermediate plat tight on driving gs. |e! Notify porting maintenance personnel to oon. & Warped tywneel. Notify mpporting maintenance personel. 3. Clutch “chatter” 4 Loot, broken, or defective clutch mounting | @ Inmect transmission attaching bot, propeller ‘oly, insulators, or brackets shafts, univeral joints and bearing for improper or loose connections. Tighten atrequired, 2, Grease or oll on disk facings Notify sipporting maintenance pertonnel Prewure pat or intermedicte plate warped. | © Not sopprting maintenance pertonnel | Weak compression springs 44. Not sipporting maintenance perionnel 4. Excessive noite. ‘5. Slipping out of gear. 6. Hard shifting: gears cash on cemgagement. 7. Loss of lubricant. 8. Excessive lubricant, ‘TRANSMISSION-TRANSFER 2. Insufficient iubrication. '. Gears or bearings broken, worn, or loose on shafts, Propeller shaft misalined or out of balance. Excessively worn gears. Gears do not fully engage. ‘Bent shifting fork. Poor shifting technique. apes Dragging clutch. Loose drain plugs. Damaged gaskets, seals or housings. Overfilled. ‘Reet Trobethoatn the letiel 8tem Seton VI 1& Check level and if required, ad sbricant according to lubrication order (LO 9- 2320-206-12).. b, Notify supporting maintenance personnel. Check universal joints for worn needle bear- ings (para 2-163). Replace if necessary. ‘Check propeller shaft for alinement and check flanges for loose mounting bolts [Notify supporting maintenance personnel. [Notify supporting maintenance personnel. ‘Notify supporting maintenance personnel. ‘This unit must be double-lutched to sychronize gears. Refer to item 2. Tighten drain plugs Notify supporting maintenance personnel. ‘Check lubricant level and drain to level of filer plug. BO eR eee 215Chart 2-8. Troublethooting-Vehicle—Continued 9, Excessive noise of vibration 10, Difficult to tur steering wheel. 11, Hard steering; wandering. 12. Continous axle noise. 13, Excessive backlash in rear axle ‘rive Mange. 14, Excessive of uneven tire wea 1S. Binding in front axle shatfs, ight and loft end assemblies. 16, Does not hold parked vehicle 216 PROPELLER SHAFTS 2. Lack of lubrication. ‘5. Worn universal joint parts. ¢. Wor slip joints. 4. Loose drive Mange bolts € Shaft sprung from contact with obstruction F. Yokes notin plane. FRONT AND REAR AXLES 2. Hydraulic power steering unit inoperative. , Tires underinfated. ¢. Lack of lubrication. 4 Bind in steering knuckles. €. Alt leak on suction sie of hydraulic steering pump. 1 Axle shifted, > Tires unequally inflated. Front whee! bearings out of adjustment. Insufficient caster. Insufficient torn. Wheel bearings in need of lubrication. pean Front wheel bearings out of adjustments. Rear whee! bearings out of adjustment. pe 5 Tires improperly inflated or damaged. €. Defective rear axle assembly causing coasting hum. ‘Axle flange nuts loose. Ring gear and pinion out of adjustment or ‘worn excessively. Improper wheel alinement. Improper brake adjustment. Improper tre inflation. ‘Torque rod ball ends excessively worn, Excessively worn parts, BRAKE SYSTEM~ HANDBRAKES Loose brake linkage. . Brake lining worn. Grease on lining. oe Zanes 6 (LO 9-2320-206-12). Replace worn parts (para 2-163). Remove propeller shaft (para 2-162). Check condition of slip joint splines and replace slip joint if necessary (para 2-163). Tighten flange bolts attaching drive Mange to propeller shaft and transmission. Replace propeller shaft (para 2-162). Remove slip joint yoke and reinstall in plane with yoke on other end of shaft (para 2-162). Refer to item 32, Chart 23. ‘Check tre pressure and inflate as specified (para 2-190). ‘Check lubricant in steering knuckles. Grease kingpins, tie rods, and drag link ends according to LO 9-2320-206-12, Jack up front axle to clear wheels off ground. Disconnect drag lnk at steering lever left end assembly (para 2-194b,). Turn wheels from side to side. If binding, disconnect one end of tie rod from steering lever. If binding persists and lubrication does not free knuckle, notify supporting maintenance personnel {or replacement of front axle end assembly. Refer to item 32b., Chart 2-3). eee: na ins Toate ot erro pecbrcrer lee ocean, Peete earracestece ener e ‘Check tire inflation and inflate properly. See eect emt fast mre ees nce ie rena Pee foe se coe err en Sencar ieeomr eee Tighten nuts to a torque of 160 Ib-ft. Notify supporting maintenance personnel. ‘Adjust toe-in (para 2-195). ‘Adjust brakes (para 2-169). Inflate tires evenly (para 2-191). Replace torque rod (para 2-216). (tify supporting maintenance personnel. ‘Adjust linkage (para 2-166). Replace brakeshoe (para 2-166). Replace brakeshoe (para 2-166).Chart 2.3. Troubleshooting-Vehicle—Continued ‘Gorestve ation De nr nt one — 19. Brakes apply too slowly. 20. Brakes release t00 slowly or do not release. 21. Brakes do not apply. 22, Brakes grab. 23. One brake grabs. 24, Nolsy brakes. 2S. Uneven brakes. paan BRAKE SYSTEM HANDBRAKES-Continued Vehicle operated with brake ps . Handbrake improperly adjusted. fkedrum out-ofround, 1. Weak brakeshoe retractor spring, ‘SERVICE BRAKES Brake linings worn Low air pressure (below 80 psi). Defective application valve. Low air pressure. Broken or leaky brake chamber or brake cylinder. Restriction in brake lines of hoses. 1. Worn brakeshoe linings. Application valve defective. ‘Quick release valve inoperative Restricted ait lines. Brake actuating cam binding. ¢ Brakeshoe binding on anchor pin. 4d. Defective application valve. Pe PAD SE PR PSRR ON AA Quick release valve inoperative. [No air pressure in brake system, ». Restricted of broken tubing oF air lines. Grease or grit on brake lining. Brake linkage binding. Front spring U-bolts loose or broken. 1. Loose lining on brakeshoe. Improper brake adjustment. ‘Weak or broken brakeshoe retractor spring. ‘Actuating cam binding. 1. Brakeshoe binding on anchor pin. ‘Wheel bearings (front) defective or out of adjustment Rear wheel bearings defective or out of adjustment. Restricted brake line. Defective brakeshoe assembly. Scored or damaged brakedrum. Bent brakeshoes, anchor pins, or act Improper brake adjustment. Insufficient lubrication, ‘Worn brake lining. Grease on lining, Brakeshoe retractor spring weak or broken. Air chamber spring broken. Be Ra yRRPeA > PRS ‘Check hand brake lever for full release position p. Adjust turn cap on top of brake lever (para 2-166). Replace drum (para 2-165). 1. Replace spring (para 2-166). ‘Adjust (para 2-169) or replace brake shoe (para 2-168). Build up air pressure by operating engine at {ast ile speed. ‘Test valve. Replace if required (para 2-175). ‘Build up pressure above 80 psi by operating ‘engine at fast idle speed. Replace chamber and/or cylinders (para 2-184 and 2-185). ‘est lines and hoses. Replace as necessary (para 2-183 and 2-186). 1. Replace brakeshoe (para 2-168). Test valve. Replace if required (para 2-175). ‘Test vale, Replace if required (para 2-176). Drain air reservoir. Remove and clean brake air lines. Replace or repair as necessary (para 2-183 and 2-186), Lubricate cam. Notify supporting maintenance ‘personnel if lubrication does not eliminate binding. (Clean anchor pin and lubricate. Test valve for proper operation. Replace if required (para 2175). ‘Test valve. Replace if required (para 2-176). Build up air pressure above 80 psi by operating engine a fat idle. Inspect airlines, tighten all connections or replace lines as necessary (para 2-183 and 2-186). Replace brake shoe (para 2-169). Lubricate anchor pins and actuating cam. Tighten or replace U-bolts (para 2-169). Replace brakeshoe (para 2-168). ‘Adjust service brakeshoe (para 2-169). Replace spring (para 2-169). Lubricate cam. Notify supporting maintenance ‘personnel if lubrication does not eliminate binding. Lubricate anchor pin. [Notify supporting maintenance personnel. Inspect bearings, adjust and lubricate of replace if necessary (para 2-190b.). Locate and replace line (para 2-186). Replace brakeshoe (para 2-169). Replace drum (pare 2-189). Notify supporting maintenance personnel ‘Adjust brakes (para 2-169a.). Lubricate according to lubrication order (LO 9-2320-206-12). Replace brakeshoe (para 2-169). 1. Replace brakeshoe (para 2-168). Replace spring (para 2-169). Replace chamber (para 2-184. 247Chart 2. Troubleshooting. /ehicle—Continued ‘Gorestive aston 25, Uneven brakes.~Continued 26.7 2 brakes inoperative. 21. Air pressure will not rise to ‘normal or rises slowly. 28, Excessive alr pressure 29, Excessive tire wear. 30. Wheel pounding. 31. Shimmy. 32. Steering whee! difficult to turn. 33. Inability to maintain straight course (wandering or weaving) | 34. Steering system oil leaks. TRAPS RAD SRSA SSR eRaS DADS = ary AD 3. Hose connections leaking or disconnected. Defective compressor governor. 1. Front wheel bearings damaged or worn. BRAKE SYSTEM HANDBRAKES-Continued (Chamber diaphragm leaking. Brakedrum out-of-round. Hand control valve faulty. Leak in air ines of fittings Clogged compressor discharge line. Loose compressor drive belts Defective compresso Leak at application valve Restricted filter. ‘Air supply vale open ‘Compressor unloading mechanism defec- tive (air cooled compressor). Excessive unloading vale clearance take. Sprung frame. Front and rear wheels do not track. Excessive motion between sidemembers due to loose rivets or bolts. ‘Wheel and tire assembly out of balance. Front hub bearings damaged. Rear hub bearings damages. Wheel and tire assembly out of balance. ‘Wheel bent. Front tires improperly inflates Bent wheel or rim. ‘Wor, loose, or damaged front wheel bearings} ‘Wom tie-rod ends. ‘Tire and wheel assembly out of balance. ‘i leak on suction side of hydraulic steering ‘pump. ‘STEERING SYSTEM Power steering system inoperative. Air leak on suction side of hydraulic steering pum Tight steering gear. Damaged bearings, cam or lever. Steering column misalined. Steering knuckles, right or lft end assembly. bind. Steering gear tight. Steering gear worn. Steering gear drag link ends loos, or improperly adjusted. Steering hydraulic system inoperative. Defective oil seal in housing Loose cover or gasket Broken or loos oil lines. DAD SAAS erry 7 Ee AAD RAPPARAR PPP rary ar PSP Replace chamber (para 2-184). Replace drum (para 2-189). ‘Test vale for proper operation and replace it necessary (para 2-178). Check hose connections and proceed asin item 27. 2. Locate and tighten all loose fittings or replace lines as necessary (para 2-186). Replace line (para 2-172a and b). ‘Adjust belts (para 2-90). Replace compressor (para 2-172). (On vehicles equipped with water-cooled com- pressor, replace governor (para 2-173); Otherwise replace compressor (para 2.1728). ‘Test valve, Replace if necessary (para 2-175). Clean Close valve. 3. Replace compressor (para 2.1728). = Adjust valve clearance (para 2-1722). Replace compressor governor (para 2-173). Replace line (para 2-172). Notify supporting maintenance personnel. Notify supporting maintenance personnel. Notify supporting maintenance personnel. 1. Notify supporting maintenance personne! Replace wheel (para 2-188). Notify supporting maintenance personnel Replace bearings (para 2-1906). Replace wheel (para 2-188). Replace wheel (para 2-183). Inflate tres property (para 2.191). Replace wheel (para 2-188). Notify supporting maintenance peronnel Replace ievod end (para 2-195). Notify supporting maintenance personne. ‘Check quick disconnect fittings at pump. ‘Check oil kvel in power steering reservoir. ‘Check quick-disconnect fitting to pump. Notify supporting maintenance personnel 1. Notify supporting maintenance personnel. Loosen steering column clamp at instrument panel. Aline column and tighten clamy Jack up front axle. Refer to item 10d. Chart 23). Notify supporting maintenance personnel. Notify supporting maintenance personnel. Inspect and adjust drag link end (para 2-194). ‘Check steering hydraulic system fluid level. Notify supporting maintenance personnel. Notify supporting maintenance personnel. Notify supporting maintenance personnel. ‘Tighten connections. Replace if stil leaking (para 2.47).Chart 2. Tronbleshooting-Vehicle—Continued D se masentsenr = a 37. Drawbar of pintle loom in housing. 38. Drawbar or pintle stuck in housing. 39, Winch does not operate. 40. Winch does not hold load. 41. Excessive heat at winch brake case. 42. Noisy operation. 43. “Bobbing” after crosing chuck hols o rlroad tracks. d 44. Insufficient Nexibiity. 4S. Excentve noise. FRONT SUSPENSION SYSTEM Continued Air in hydrautic ine, D. Universal joint on steering power unit defective. ‘4 Differential brake control valve inoperative. », Differential brake lines restricted. DRAWBAR AND PINTLE-M125 Broken spring. Bent pintle shank, or drawbar mounting holes ‘out-ofround. WINCH ‘& Broken drive chain. . Shear pin failure. Drum clutch not engaged. Brake slipping. Brake incomecty adjusted, ‘& Lack of lubrication. Wom or damaged intemal pats. FRONT SUSPENSION SYSTEM ‘4. Defective shock absorber. ‘. Insufficient fuid in shock absorbers €. Shock absorbers inoperative. 44. Broken spring leaves. Frozen spring shackles. 4 Wom spring pins or shackle bolts. . Wom or broken shock absorber links, Spring leaf failure at spring eye. 4. Spring leaf failure at center section of, ‘pring. 2. Bleed steering hydraulic system. >. Notify supporting maintenance personnel Test vale for proper operation (para 2-179). 'b, Remove and clean lines. Notify supporting maintenance personnel. Replace drawbar or pintle (para 2-208). @ Replace drive chain (para 2-231). 1b. Replace shear pin (para 2-228). Notify supporting maintenance personnel. ‘Adjust brake (para 2-235 and 2-236). or replace brake atsembly (para 2-2360). ‘Adjust brakes (para 2-235, 2-236). Lubricate winch. Refer to LO 9-2320-206-12. Replace winch, -P ® Operate shock absorber manually. If it works ‘easily, its considered defective and needs to-be replaced (para 2-213). 'b. Replace shock absorbers (para 2-213). ‘ Disconnect shock absorber links and test action. If little of no resistance is felt, replace shock absorbers (para 2-213). 4. Inspect springs for broken leaves. If required replace spring (para 2-212). Free shackle and lubricate according to LO 9-2320- 206-12. Replace pin that cannot be freed (para 2-212). Use pry bar to test wear of pins or bolts. Replace if necessary (para 2-212). 1, Inspect links for wear, damage of looseness. Replace shock absorber if necessary (para 2-214), Replace spring (para 2-212). Torque U-bolts (para 2-212) ‘4. Replace spring (para 2-212). Tighten U-bolts {0 tonyue recommended (para 2-212). Section Vi. TROUBLESHOOTING THE ELECTRICAL SYSTEM 2-15. Gener: ‘This section contains detailed troubleshooting in- formation for locating and correcting malfunctions in the electrical system. Refer to Chart 2-4. Electri cal cireuits that will be covered in this section are listed in paragraph 2-16. Individual and combined vehicle electrical cireuits are covered, using authoriz~ ed test equipment referenced in paragraph 2-17. 2-16. System Circuits ay «Ay Batters 2a (2) Generator/ Alternator 2oa22s ) Starter 2298 (4) Monitor Gages and Sending Units 282/288 vei Prrnraph (6) ignition (4123, M123C, M125) 2a (6) Lighting, 235 (1)Glow Plug—MI23A1C, Mi23E2 236 2-17. Test Equipment Test procedures covered in this section are based on the use of the Low Voltage Circuit Tester (fig. 2-3) and Wheeled Vehicle Adapter Set or Adapter Set. Test procedures may also be performed on the vehicle using any suitable voltmeter, ammeter, or ohmmeter having the required electrical range. 2192-18. Types of Low Voltage Circuit are mounted in a metal case, which also provides Testers stowage space for the meter leads and accessories (fig. 2-2) with which all the necessary tests can be Figure 2-3 illustrates the two types of Low Voltage made. Other test sets which consist of these elements Cireuit Testers (LVCT) in general use. The LVCT _(volt meter, ammeter, te.) as separate units; the tests consists of a voltmeter, an ammeter, a fixed re- described can be performed equally well using meters sistance, load bank, and field rheostat unit: They and load banks separately. EXTERNAL SHUNT AMMETER LEADS POSITIVE (RED) NEGATIVE (BLACK) NEGATIVE (BLACK) POSITIVE (RED) ikosat NEGATIVE QUACK) POSITVE (ED) ete J VOLTMETER LEADS AT 3uS14 Figure de, Blectrical text equipment text meter leads, Figure 22. Low mltage cirent teater,Chart 24. Troubleshooting-Blectrical System 0 1. Lights do not light. 2. Frequent lamp failures High battery generator indicator wading, 3. Insufficient light. Low battery: ‘generator indicator reading. 4. Interference while vehicle sin ‘motion with engine operating. S. Interference only when engine is running. 6. Variable pitch whining noise ‘which varies with engine rpm, 7. Variable clicking noise which varies with engine tpm. 8. Speedometer or tachometer noisy oF fluctuating. 9. Water temperature gage inoperative 10. Fuel level gage inoperative. 11. Air pressure gage inoperative. Probate cones LIGHTING SYSTEM~ All models Broken or burned out lamp. Defective light switch, Broken light cable. Generator segulator/alternator-egulator ‘out of adjustment. Poor battery ground connection Poor lamp or battery ground connections. Loose lamp terminals connections. Discharged batteries. RADIO INTERFERENCE SUPRESSION M123, M123C, M125 ‘Loos cables, bonding, of connections: frayed insulation in vehicle wiring. Generator system. LLoowe of dirty regulator connections. Defective gencratorregulator capacitor. LLoote or frayed fan and drive belts Defective gencrator-regulator capacitor. Ignition system. {Improper spark plug gop. Improper distributor point adjustment. Defective spark plug cables. Defective spark plugs. PROP Fuel pumps. INSTRUMENTS, GAGES AND. SENDING UNITS- All models Binding or kinked Mexible shaft. ‘Temperature sending unit faulty. Gage fauty. Broken wi Fuel tank sending unit faulty Gage faulty. Broken wire Compressed air reservoir supply low. RO RRA SP ‘Ai reservoir drain cocks open. —T Replace lamp (para 2-123). 9. Use a jumper wire across switch contacts. I¢lamp lights, replace switch (para 2-131). Refer to lighting circuit diagram, Locate ‘break and repair cable a necessary (fig. 241), Replace regulator (para 2-116). Replace alternator (para 2-118). ‘Clean and tighten battery and lamp ground connections. ‘Clean and tighten battery and lamp ground connections. Locate and tighten loose terminal connections. ‘Check electrolyte level and specific gravity (para 2-120). Charge of replace batteries (para 2-120). Inspect all wiring and replace if defective. Clean ‘and tighten all connsetions. ‘Accelerate engine and tum ignition switch off with engine at high speed. If noise continues after switch is shut off, cause isin the generator system (para 2-39). 4 Check regulator ground cable and its mounting, bolts to determine if connections are free from dirt, pant, or other foreign material that could impair conductivity. Check for tightness. Check generator system. Notify supporting ‘maintenance personnel. Tighten or replace belts as necessary ( 2:90). Replace generator (para 2-39). Notify support- ing maintenance personnel. ‘Accelerate engine and turn ignition switch Off with engine at high speed. If noise stops immediately cause isin the ignition system. ‘Adjust gap (para 2-102). c. Adjust points (para 2-102). Replace cables (para 2-103). With engine running disconnect cables from plugs one ata time. If noise is reduced ‘or climinated, cause isthe spark plug. Replace plug (para 2-104). ‘Check fuel pumps and electrical connections for tighteness. 8 PROF Replace Nexible shaft (para 2-155). Replace sending unit (para 2-158). Replace gage (para 2-153). Check circuit. Replace wire. Replace sending unit (para 2-158). Replace gage (para 2-152). Check circuit. Replace wire Run engine to build up pressure to 100 psi. If gage does not register immediate buildup replace gage (para 2-155). (Close drain cocks (para 2-174). BAe ROSE 221Chart 24. Tronbleshooting-Blectrcal Sytem —Continved “Continued 12. Oil pressure gage inoperative. 4. Engine not running. ‘Sending unit faulty, Gage faulty D 13. Horn inoperative @ Low or no air pressure. 6. 6 Defective solenoid. 2-19. Adapter Sets At present, there are two adapter sets in use. They are interchangeable, differing only in design. Both adapter sets are used for external connections in the ignition system and four for the charging system. The other set consists of five pieces; three for the ignition system and two for the charging system (fig. 2-4). NOTE There are two models of the Low Voltage Circuit Tester shown (fig. 2-3). Throughout. this section one model is designated meter Aand the other meter B. 2-20. Tester Functions and Use CAUTION Do not test for over 100 amperes without using shunt (step b. below), as meter can be damaged. a. Voltmeter. The two voltmeter terminals are mounted below (meter A) or beside (meter B) the voltmeter (fig. 2-5). There is one terminal marked Positive (+) and one marked negative (—). The proper meter range is selected by placing the selector switch in the proper voltage range. For example, if the high- est reading were expected to be less than one volt, the 1-volt range would be used. To read the battery voltage of a 12-volt battery, use the 20-volt range, ete. 222 INSTRUMENTS. GAGES AND ‘SENDING UNITS- All models Fectrieal circuit broken in horn system, 5 ‘Start engine. Gage should slowly indicate 60 to 80 psi presaure | Replace sending unit (para 2-188), eR (para 2-154). Check air pressure gage. ‘h. Check vireuit No. 25 for continuity to hom button figs. 2-152 and 2-153). Replace ‘hom switeh if necessary (para 2-134). Notify supporting maintenance personnel. b. Ammeter. The ammeter is mounted on upper left-hand side of case (fig. 2-5) and like the voltmeter, has terminals for connecting the leads. There is a common or plus terminal and three negative termi- nals, which are marked 10, 50, and 100 amperes, re- spectively. In addition, an external shunt may be used on this meter to read ampere values up to 500 amperes by using the terminals provided for the ‘small leads on the shunt. Note that the meter’s zero is one-third of the way up the scale. This permits reading current flow in either direction in a circuit without changing meter leads. The large leads on the shunt are connected to the component being tested. ‘The small leads are connected to the meter. The meter is then connected in series with the cireuit being tested. Note that the terminals are marked ex- ternal shunt. ¢. Resistance Unit. The two terminals marked \4-ohm resistor or fixed resistor on the instrument panel provide fixed resistance for testing units in the charging circuit. The resistance unit is designated for either 6- or 12-volt svstems. Connecting test leads between the two terminals provides 4-ohm resis- tance. The ammeter test leads are used when utilizing this resistance unit; but this unit is not in any way connected to either the voltmeter or ammeter. d. Field Rheostat Unit. The two field rheostat terminals on the instrument panel provide a connec- tion for a rheostat (or changeable resistance) located under the instrument panel. This unit is used to as sist in charging system checks. (FLEXIBLE GENERATOR FLEXIBLE REGULATOR ADAPTER ‘ADAPTER \ \ GENERATOR ‘ADAPTER > DIsTRIBUTOR ADAPTER } vi REGULATOR SPAR GNITION ‘ADAPTER PWG SDAPTER ADAPTER AT 34516 Figure 24, Blectrical text equipment adapter sets. e. Load Bank. This unit differs on different testers. Meter A (fig. 2-5) has six terminals marked 6-volt, 5-100 A; 12-volt, 5-100 A; 12-volt. 5-50 A: 24-volt, 80-100 A; 24-volt, 10-80 A; and 24-volt, 5-10 A, and a common terminal. These terminals are used on cir- cuits with readings within limits mentioned. The third terminal from the top is used for both 12 volts and 24 volts. The common terminal is located in the upper left of panel next to ammeter face. A load bank knob is used to control the load, and a switch is pro- vided to connect or disconnect the load from the sys- tem being checked. Meter B has four terminals mai ed 6, 12, and 24 volts, with the common terminal on the left. Current flow is controlled by adjusting the coarse and fine control knobs. 2-21. General Instructions WARNING Remove rings, watches, ete., prior to per- forming any electrical troubleshooting to prevent accidental short circuits and/or electric shock. a. Prior to performing any test with meters, ob- serve the following instructions. (1) Be sure of test being made. To assure correct testing, sequence listed in individual tests must be followed. (2) Always select a meter range higher than the expected reading. (3) Ammeters are always inserted in the current- carrying line in series. Breaking an ammeter con- neetion will open the line. (4) Voltmeters are always inserted across a load, in parallel. Breaking voltmeter connections discon- nect the voltmeter. (5) Always barely touch the positive lead to its post to see if meter movement is in right direction before firmly attaching to post. ®. The proper hook-up of the LVCT is very im- portant in order to afford protection to the meters ‘as well as to obtain accurate readings. 2-23KXKKKKKXKKKK YY ARR aN WRK RA XNAXYNNN RAK° 2-22. Batteries WARNING Do not permit a “hot” wire to touch metal parts of the vehicle at any time. Testing by striking a hot wire against a ground (flash testing) will ereate an arc that can cause per- sonal injury and destroy the connector on the lead. Vehicle batteries should be tested prior to performing any electrical checks in the vehicle. The M123, M123C, and M125 vehicles have two 12-volt batteries connected in series furnishing 24 volts to the elec- trical system. The M123A1C, M122E2 vehicles have four 12-volt batteries connected in series furnishing 24 volts to the electrical system. The M123A1C, MI23E2 vehicles have four 12-volt batteries con- nected in series-parallel furnishing 24 volts to the electrical system. Both electrical systems use a negative (—) ground and a positive (+) power feed to the electrical components. Turn on ignition switch/ master switch and observe battery indicator in ac- cordance with figure 2-6, «a. Battery Test. (1) Specific gravity. Using a battery hydrometer, check each battery cell. Water should not be added prior to this test. Vehicle battery specific gravity readings should be at least 1225 on each cell. Vari tion of more than 25 gravity points per cell (temper- ature corrected) indicates a battery fault. If this oc- curs, replace battery. Check batteries for damaged case, terminals, or cell cover plates. Check for hold- down-to-cable short circuit. Check battery hold- downs to determine if they are tight enough to hold battery rigid, but not too tight to damage battery case. If any of these conditions exist, corrections will be required. (2) Battery voltage test (fig. 2-7). Using a volt- meter (50-volt scale), check each battery for tight cable connections and voltage charge status. Indivi- dual battery voltage must not be less than 11 volts or ‘more than 13 volts. b. Individual Battery Check Using Load Bank (fig. 28). (1) Connect one end of negative ammeter lead to 100-amp ammeter terminal of tester (fig. 2-5), and the other end to negative terminal of the same battery to which positive lead is connected. (2) Connect one end of positive ammeter lead to 12-volt, 50- to 100-amp load bank terminal of tester (fig. 2-5), and the other end to positive terminal of one of the batteries. (3) Connect one end of negative voltmeter lead to negative terminal of tester (fig. 2-5), and the other end to same negative terminal of battery to which negative ammeter lead is connected. sartery CONNECTING CABLE TATTERY AT REST: READINGS HERE INDICATE A DEAD BATTERY, COULD BE LUNDERCHARGING ‘OR A SHORT IN ELECTRICAL SYSTEM. IF NEEDLE REMAINS HERE, BATTERY 15 WORN OUT OR DEFECTIVE. READINGS HERE SHOW BATTERY WAS RECENTLY CHARGED AT HIGH RATE (OVERCHARGED) Fiqwre 2-6, Battery syxtem, VOLIMETER POSITIVE - 50. VOLT SCALE VOLIMETER POSITIVE - 20. VOLT SCALE VOUTMETER NEGATIVE AT 34519 Fire 2.7. Battery voltage text. (4) Connect one end of the voltmeter positive lead to the voltmeter positive terminal of the tester (fig. 2-5), terminal of the battery to which the posi- tive ammeter lead is connected. (5) Turn voltage selector switch to 20-volt scale. (6) Place load bank switch to ON position and install a load of 80 to 90 amperes by turning load bank knob clockwise, Read voltmeter. (7) Battery voltage under load should not drop below nine volts. (8)For all remaining batteries repeat step b. (9) Turn load bank knob counterclockwise to stop position. Place load switch and voltmeter selec- 2-25lev} POSITIVE - 12 VOLT ~ ea 100 AMP AMMETER NEGATIVE ‘LEAD 100 AMP. VOLTMETER NEGATIVE LEAD (20 - VOLT SCALE) A 34520 Figure 2. Load bank voltage text izv| J BATTERY GROUND. NEGATIVE TERMINAL ‘VOLTMETER NEGATIVE LEAD (50 VOLT SCALE h2v| BATTERY GROUND . NEGATIVE TERMINAL _ VOLTMETER NEGATIVE LEAD (50 VOLT SCALE) sane AT 34521 Figure 2.9, Combined battery woltage tet. tor switch to OFF position. Disconnect all leads from battery and then disconnect all leads from tester. ¢. Combined Battery Voltage Test. To check com- bined battery voltage, connect voltmeter in accord- ance with figure 2-9, and take readings shown. NOTE Connect voltmeter as shown in figure 2-9, across both sets of batteries on the M123A1C and M123E2 vehicles. CAUTION Do not crank over 30 seconds. Battery volt- age must not be less than 18 volts. (1) Open circuit voltage 24 to 26 volts. (2) Leave ignition/master switch OFF. Leave test leads on. Crank engine with vehicle starter. (3) If batteries will not meet the above criteria, replace or charge batteries (para 2-120). 2-23. Generating System—M123, M123C, M125 Troubleshooting of the generating system includes checking of the generator, generator regulator, and cables. To test generator circuit, four components on the vehicle must be checked in the following se- quence to assure troublefree operation and @ mini- mum of meter connections. a. Prior to starting engine, check generator fan belts for proper adjustment. Generator belts must be adjusted in accordance with paragraph 2-97 to assure maximum output of the generator. Loose belts can give low voltage readings. low amperage readings, and can cause belt squeal. 6. Turn ignition switch ON, observe battery gen- erator indicator (fig. 2-10); this indicator should be in the yellow seale or on the edge of the green. Indi- ator should never be in the red scale when ignition switch is in the ON position. c. Start engine and observe action of battery indi- eator. When engine is operated at approximately 1,000 to 1,200 rpm, battery indicator should move toward the green scale or to the right side of meter (fig. 2-10). d. If meter does not operate as prescribed, the fol- lowing troubleshooting procedure should be per- formed. (1) Turn ignition switch OFF. (2) Disconnect wire at battery indicator and connect it to the positive lead of voltmeter. With the negative lead of the voltmeter grounded, and the ignition switch ON, voltmeter should indicate bat- tery voltage. (3) Start and run engine at 1,000 to 1,200 rpm. Voltmeter should inidieate generator voltage of 27.5, 1028.5 volts. (4) If voltmeter does not indicate generator volt- age as specified, check generating system and ad- just, replace, or repair components as necessary. Battery indicator wiring is shown in figure 2-11. (5) If voltmeter indicates generator voltage as specified and battery indicator does not conform to test in a. through d. above, replace battery indicator (para 2-151). 2-24. Generator Testing—M123, M123C, M125 WARNING Prior to placing adapter in the generating system, the vehicle ground cable (negative battery cable) must be disconnected to avoid possible equipment damage and personal injury. To assure that proper operational checks are made, two adapters (figs. 2-13 and 2-15) will be required and the following procedures must be followed. For generator wiring see figure 2-12. a. Disconnect the generator to regulator cable at the generator and insert adapter, figure 2-13. 4ENGINE RUNNING. ‘AT NORMAL SPEED FOR SEVERAL MINUTES, AND. POINTER RESTS HERE, MEANS artery 15 NOT CHARGING. CHECK VOLTAGE REGULATOR. IF ‘OK, CHECK GENERATOR, INDICATE THAT BATTERY 15 NEARLY WORN, ENGINE RUNNING AT MAXIMUM. CHARGING SPEED LONG ENOUGH TO CHARGE BATTERY, WITH ALL ELECTRICAL UNITS TURNED ON, POINTER SHOULD STAY IN GREEN SECTION. IF NOT, VOLTAGE REGULATOR 15 SET TOO LOW, OR BATTERY 15, WORN OUT. ‘wit ALL ELECTRICAL UNITS OFF, RUN ENGINE TO MAXIMUM CHARGING RATE, If VOLTAGE REGULATOR IS PROPERLY SET, POINTER WILL FALL IN TOP HALF OF |=) GREEN SECTION. ‘OVERCHARGE SECTION (MALADUSTED On DEFECTIVE VOLTAGE, REGULATOR. Figure 2.10, Battery indicator. VOLTMETER POSITIVE LEAD 50 VOLT SCALE IGNITION Ff SWITCH GENERATOR REGULATOR VOUIMETER NEGATIVE LEAD 50 VOLT SCALE + ar 94523 Figure 11, Battery indicator circuit ©. Disconnect the battery to regulator cable at the vehicle regulator and insert adapter, figure 2-15. ¢. Check all connecting links to make sure they are closed and not touching any metal on the vehicle. . Check all connecting cables for proper connec- tions and assure that they are clear of metal objects on the vehicle, ¢. Conneet battery ground cable. F Open both links on generator-mounted adapter and, with lead connected to 24-volt positive (+) ‘source, just touch “No. 1” field lead of the generator. This will assure that the generator has correct polarity. g. Connect ammeter negative (—) lead to meter side (fig. 2-5), 50-amp seale, and connect other end to vehicle generator ground or battery ground, figure 2-14. ‘h. Connect ammeter positive (+) lead to load bank le of ammeter, 24 volts, 10 to 80 amps, and con- nect other end to armature lead of the generator, figure 2-14, i Connect negative (—) lead to negative (—) side of meter (fig. 2-5), and other end to vehicle frame or battery ground. 4. Connect positive (+) lead of voltmeter (fig. 2-5) to positive (+) side of meter connecting and other end to armature side of generator, figure 2-14. k. Select 50-volt seale (fig. 2-5). 4 Connect one lead of variable resistance to generator armature and the other lead to generator field, figures 2-13 and 2-14. F Deergtion Batteries Slave receptacle Battery-generatorindiator in awitel ator Generator-regulator om Coot Dace Battery to regulator “A” terminal © Battery mound 14 Ignition switch to batery indieator Houlator hunt) to creat breakers Bale tery to slave receptacle (+) 8 SverSeopade obetcs () 9 Battery internnecting cable 8 __Radioreceptace to battery (ground) Noe A name hen on rein cwrpod rnt rt sb abed re. ‘Figure 2-12, Generator System wiring. BBESESase FP ounce 2a7(GENERATOR GROUND] POINT (NEGATIVE) METER LEADS. REGULATOR SIDE [ARM CONNECTING] ARMATURE SIDE] FIELD LEAD} GENERATOR SIDE Ii AT 34525 Figure 2-18. Generator adapter connecting points. m, With meters connected as in figure 2-14, and variable resistor and load switch in the OFF posi- tion, start engine and set to run at high idle (1,000 to 1,200rpm). n. With load switch in the OFF position, move variable field rheostat and observe voltmeter. When 30 volts is shown on meter, stop turning field rheo- stat. o. If no voltage is registered, check to see that connections are correct. If correct, replace generator. p. With load bank knob in the counterclockwise position, turn load switch on. Observe ammeter and slowly apply about 5-amp load by turning load knob clockwise. As load is increased, voltage will drop. CAUTION Do not exceed 30 volts and 30 amps as dam age to generator could result. q. With engine running 1,000 to 1,200 rpm, turn field control knob and maintain 30-volt output. Then turn load control knob. Load should not exceed 30 amps. As current increases in this test, voltage will drop. Field control knob must be turned to maintain proper voltage. Then turn load control knob to increase current. rr If 80 volts and 30 amps cannot be maintained, check belts for proper adjustment (para 2-90). Loose belts can slip when load is applied giving low read- ings. 8. If all checks are made and generator output requirements of 30 volts and 30 amps at 1.200 engine rpm cannot be reached, replace generator 228 24 = VOLT AMMETER LOAD] BANK POSITIVE LEAD 30 = VOLT LEAD| TO GROUND! "AMMETER 50 - AMP LEAD| t Lid Figure 2-15. Generator output text hook-up. 2-25, Regulator Testing—M123, M123C, M125 Prior to making the following regulator tests, the generator must be completely tested as in para- graph 2-24. The same adapters used in generator testing are required to test regulator. Radio ground strap must be connected to assure grounding of regulator. a, Voltage Control Test (fig. 2-16). (1) Select 50-volt scale and turn load bank switch OFF; load bank control knob must be in the full counterclockwise position. (2) With engine stopped, connect meter to adapt- ers in figures 2-15 and 2-16. Check to assure that cables are properly connected and not touching vehi- cle metal. (3) With all adapter links closed, start engine and observe voltmeter reading. This should be 27.5 to 29 volts with engine running at 1,000 to 1,200 rpm. (4) Open adapter link on regulator and check voltage on open circuit. engine at 1,000 to 1,200 rpm, voltage should be 27.5 to 29 volts. (5) If voltmeter shows less than 27.5 volts, check wiring between generator and regulator for broken wire (fig. 2-12). (6) If wiring is not defective and regulator voltage is under 27.5 or exceeds 29 volts, replace regulator, paragraph 2-116. b. Current Control Test. (1) If the regulated voltage is 27.5 to 29 volts as in voltage control test, then with engine idling, connect ammeter and voltmeter as in figure 2-17. CAUTION Link must be open for the following test. (Figure 218, Regulator adapter connecting pointn. VOLTMETER. NEGATIVE LEAD VEH, FRAME —— = _ VEHICLE FRAME GENERATOR (2) Turn load switch ON; watch ammeter and voltmeter. If voltage drops and current shows on meter, turn control knob until voltage reads at least 23 volts and low current is shown on meter. CAUTION Do not allow voltmeter to go below 22 volts while making this test. (8) Run engine at 1,000 or 1,200 rpm. Turn con- trol knob until ammeter reads 24 to 27 amps. Volt- meter should start dropping at that point and am- meter should remain at 24 to 27 amps. (4) If ammeter exceeds 27 amps or reads below 23 ampe, replace regulator (para 2-116). (5) If regulator meets the requirements in volt age control and current control tests, 27.5 to 29 volts and 28 to 27 amps, it is regulating correctly. Cutout switch must still be checked. ¢. Line Switch, Cutout. (1) Connect voltmeter, ammeter, and variable theostat as shown in figure 2-18. Turn field rheostat fully counterclockwise. (2) With field link on generator adapter open and link on regulator adapter open, accelerate engine to 1,000 to 1,200 rpm and observe ammeter and volt- meter. Reading should be below 10 volts and no cur- rent reading. GEN. REG. ADAPTER LINK (OPEN AFTER ENGINE STARTS, ‘ADAPTER REGULATOR Figure 2.16, Regulator voltage control text hook-p, 229AMMETER VOLTMETER NEGATIVE NEGATIVE (50- 50 - AMP RANGE VOLT SCALE) VEHICLE FRAME GENERATOR REGULATOR ‘ADAPTER OPEN ‘AFTER ENGINE STARTS REGULATOR LOAD BANK POSITIVE 10 TO 80 AMPS - 24 VOLTS; VOLTMETER POSITIVE AT 34529 igure 2.17, Regulator current control teat hook-up. (8) Turn field rheostat clockwise until ammeter shows a low charge rate of one to five amps. Thi indicates line switch is closed. Observe voltmeter. This should be reading 22 to 25 volts. Line switch must close below regulated voltage (27.5 to 29 volts). (4) With engine still at 1,000 to 1,200 rpm, turn field rheostat counterclockwise and observe amme- ter. Meter should move to the discharge side to ap- proximately 10 to 12 amps, then to zero. This indi- cates line switch is open. (5) If regulator will not meet the above test spec- ifieations, replace regulator (para 2-116). 2-26. Alternator Output Voltage Test— M123A1C, M123E2 (fig. 2-19) Check the alternator output voltage using the low voltage circuit tester (LVCT) as follows: 2:30 . Prior to starting engine, check alternator drive belts for proper adjustment. Belts must be adjusted in accordance with paragraph 2-97 to assure mi mum output of the alternator. b. Turn master switch ON, observe battery indica- tor. The indicator should be in the yellow scale or ‘on the edge of the green. Indicator should never indi- cate in the red portion of the scale. ¢, Start engine and observe the battery indicator. When the engine is operated at approximately 650 rpm, the battery indicator should move toward the green portion of the scale., FIELD LINK OPEN. JGENERATOR FIELD VARIABLE RHEOSTAT ADAPTER GENERATOR FIELD Anwaeten RHEOSTAT NEGATIVE ‘LEAD VOUTMETER AND AMMETER POSITIVE LEAD ~ 50 AMP GENERATOR REGULATOR ‘ADAPTER LINK OPEN. [AFTER ENGINE STARTS VOLTMETER NEG. LEAD 50-VOLT SEL AT 34530, Figure -18. Generator regulator line switch cutout text hook-up. d. If the indieator does not operate as prescribed, Proceed to step e. e. Remove the protective cap covering the electri- cal terminals on the alternator (fig. 2-19). f. Connect positive (+) voltmeter lead (fig. 2-5) to Positive (+) side of the LVCT voltmeter. Connect the other end of the lead to the positive (+) terminal on the alternator. g. Connect negative (—) voltmeter lead (fig. 2-5) to negative (—) side of the LVCT voltmeter. Connect the other end of the lead to the negative (—) termi- nal on the alternator. ‘A. Turn the voltmeter selector switch to the 50-volt seale (fig. 2-5). i Start engine and run at 1,000 rpm. The voltmeter should indicate 27.8 to 28.5 volts. 3. If voltmeter does not indicate 27.8 to replace alternator (para 2-118). 2-27. Testing Starter Circuit—M123, M123C, M125 WARNING Prior to checking starter cables for tight connections, ground cable must be removed from vehicle batteries. This is required to eliminate shorting of tools and jewelry on vehicle frame, causing vehicle damage and endangering personnel. Figure2.19, Alternator output voltage test. Prior to making electrical checks on the starter, bat- tery condition and electrical connections must be checked to assure that proper voltage and current are available. ‘The starter circuit consists of a magnetic switch, starter switch, and starter motor. To test complete starter circuit for current draw and funetioning of components, the following checks should be made at the battery: @. Starter Draw Check at Battery (fig. 2-20). (1) Disconnect ground eable from battery post of grounded battery. (2) Connect the light positive external shunt lead to positive external shunt terminal of the tester, and connect the light negative external shunt terminal of the tester. 231EXTERNAL 500 = AMP: POSITIVE LEAD EXTERNAL 500 - AMP NEGATIVE] LEAD! VOLTMETER NEGATIVE LEAD - 50 VOLT AMMETER NEGATIVE LEAD BATTERY POSITIVE TERMINAL IVOLTMETER POSITIVE AMMETER POSITIVE LEAD. VEHICLE FRAME AT 34532 Figure 2-20, Starter draw check at battery — M123, M12SC, M125. (3) Connect the heavy positive external shunt lead to ground cable, as in figure 2-20. (4) Connect heavy negative external shunt to negative post of the grounded battery and connect negative lead of voltmeter to selector on 50-volt scale. (5) Connect positive voltmeter lead to battery plug terminal. (6) Close starter motor switch (with ignition ‘switch in OFF position) and read ammeter. (7) Starter motor current should not exceed 150 amps, maximum. (8) Voltage should read not less than 18 volts. (9) If starter circuit conforms to the above tests, remove test leads and connect ground cable to nega- tive post of grounded battery. (10) If starter circuit does not meet the above requirements, check circuit using the following se- quence. 6, Testing Starter Magnetic Switch. (1) Set voltmeter on 50-volt scale. Connect nega tive (black) lead, to vehicle battery ground or frame. Connect positive (red) lead to battery side of magnetic ‘switch (fig. 2-21). Meter should read battery voltage of 23 to 26 volts. (2) Move positive (+) red lead to small contact connected by jumper, figure 2-21. Meter should read 232 battery voltage. (3) Move positive (+) red lead of voltmeter to small terminal on starter side of magnetic switch, figure 2-21. Meter should read battery voltage. (A)If battery voltage is not obtained at this point, disconnect wire from magnetic switch running to starter switch; meter should read battery voltage. If no voltage is obtained, replace starter magnetic switeh (para 2-108). This test indicates coil is defec- tive. (5) If battery reading is present, move red posi- tive (+) lead to large ternfinal of switch on the starter side, figure 2-21. Depress starter switch lever. Starter magnetic switch should close and meter should read battery voltage. (6) If magnetic switch does not close, use jumper wire and ground small starter switch terminal to frame. Switch should close and meter should indicate battery voltage. If magnetic switch closes with this check, starter switch circuit is defective. (7) If magnetic switch will not close during this check, replace switch (para 2-108). ¢. Starter Current Draw Test. Starter current draw test is made at the starter to assure that required voltage and current are reaching starter and are not, through the connecting components. (o d (1) Connect voltmeter leads and 500 ammeter shunt leads to tester. (2) Place voltage selector to the 50-volt position and connect negative lead of voltmeter to battery or frame ground, figure 2-22, (3) Disconnect starter cable at starter and con- neet large positive external shunt lead to eable, fig- ure 2-22. (4) Connect large negative external shunt lead and voltmeter positive lead to starter cable post on starter, figure 2-22. (5) Close starter switch and observe readings; voltage 18 to 24 volts and current 150. amps. (6) If starter circuit closes and voltage and am- Perage are correct, starter circuit and connections are functioning correctly. (7) If starter voltage is present but starter will not erank, check cables for line drop. (8) If current draw is too high, replace starter (para 2-107), as this indicates internal malfunctions. The same is true if voltage is present, but.no current is shown on meter. 2-28. Starter Circuit Testing—M123A1C, M123E2 WARNING Prior to checking starter cables for tight con- nections, the battery to chassis ground cable must be removed from vehicle batteries. This is required to eliminate shorting of tools and jewelry on vehicle frame, causing vehicle damage and endangering personnel. STARTER CABLE ‘AMMETER (POSITIVE) STARTER TERMINAL 1500 - AMP EXTERNAL VOLTMETER (POSITIVE) ‘SHUNT 50 - VOLT SCALE /AMMETER (NEGATIVE) EXTERNAL SHUNT ‘VEHICLE FRAME VOLTMETER NEGATIVE, LEAD 50 - VOLT SCALE AT 3833 Flawre 2-21. Mognetic nwitch test hook-up — Miss, Mi23C. M125. = ‘youimeren rosirve (a0 eVOLt SCALE) VEvNCLE FRAME VOLIMETER (NEGATIVE) (30 = VOLT SCALE) STARTER CABLE STARTER SWITCH Te JUMPER WIRE Jcircutt 14 VOLTMETER| Positive (50 - VOLT SCALE) BATTERY CABLE CIRCUIT 8! ay 34534 Figure 2.22, Starter current drau test — Mi2s, M123C, M125. Prior to making electrical checks on the starter, bat- tery condition and electrical connections must be checked to assure that proper voltage and current are available. The starter circuit consists of a starter, magnetic switch, and starter switch. The magnetic switch is mounted on the starter housing. To test complete starter circuit for current draw and funetioning of components, the following checks should be made at the battery. @. Starter Draw Check at Battery (fig. 2-23). (1) Disconnect ground cable from battery post of grounded battery. (2) Connect the light positive external shunt lead to positive external shunt terminal of the tester. and connect the light negative external shunt termi- nal of the tester. (3) Connect the heavy positive external shunt lead to ground cable, as in figure 2-23. (4) Connect heavy negative external shunt to negative post of the grounded battery, and correct negative lead of voltmeter to selector on 50-volt scale. (5) Connect positive voltmeter lead to battery plug terminal. (6) Press the starter motor switch (with master ‘switch in OFF position) and read ammeter. (7) Starter motor current should not exceed 150 amps, maximum. (8) Voltage should read not less than 18 volts. (9) If starter circuit conforms to the above tests, remove test leads and connect ground cable to nega- tive post of grounded battery. 6. Starter Current Draw Test. Starter current draw test is made at the starter to assure that re- quired voltage and current are reaching starter and are not lost through the connecting components. 233MAGNETIC SWITCH STARTER nme EXTERNAL, ‘500 AMP NEG. LEAD exrehnat 300 Ae 105. EAD \ourmerer NG, Lead So out anweree Neo. Ad ota VEMCLE FRAME XTERNAL SHUNT z Figure 2.23, Starter current drave at battery — MI23AIC. MI23E2. MAGNETIC swiTcH STARTER TERMINAL VOLTMETER (POS. 50 VOLT SCALE 'AMMETER (NEG. ) EXTERNAL SHUNT STARTER CABLE AMMETER (POS) ‘500 AMP EXTERNAL SHUNT H H 4 H H H f H ‘VEHICLE FRAME Figure 2.24, Starter current draw at starter — MI2SA1C, MI23BY,(1) Connect voltmeter leads and 500-amp ex- ternal shunt leads to tester. (2) Turn voltage selector to the 50-volt position and connect negative lead to voltmeter to battery or frame ground, as in figure 2-24. (8) Disconnect starter battery cable at starter and connect large positive external shunt lead to cable as in figure 2-24. (4) Connect large negative external shunt lead and voltmeter positive lead to starter eable post on starter, as in figure 2-24. (5) Press starter switch (master switch off) and observe readings; voltage 24 to 18 volts and current 150 amps. (6) If starter circuit voltage and current are correct, starter circuit and connections are function- ing correctly. (7) If starter voltage is present but starter will not crank, check eables for line drop. (8) If current draw is too high, replace starter (para 2-110), as this indicates internal malfunctions. The same is true if voltage is present, but no current is shown on meter. 2-29. Electrical Power Loss Tests— M123, M123C, M125, ‘These tests are made to assure that required voltage and current are reaching the components and are not logt through connecting cables and switches. a. Frame-to-Battery-Cable Ground Loss Test (fig. 2-25). (1) Connect voltmeter leads to tester. Select 50- volt scale. (2) Connect positive voltmeter lead to vehicle frame (fig. 2-25). (3) Connect negative voltmeter lead to negative post of grounded battery. (4) Close starter motor switch (with ignition ‘switch in OFF position) and read voltmeter. (5) If voltage reading is below 20 volts, change selector switch to 20-volt position and repeat proce- dure (4) above. (6) If voltage reading is below ten volts, change selector switch to 10-volt position and repeat proce- dure (4) above. (7) If voltage reading is below one volt, change selector switch to 1-volt position and repeat proce- dure (4) above. (8) Maximum allowable voltage loss is 0.1 volt. (9) Place voltmeter selector switch in OFF posi tion and remove voltmeter leads from frame and battery post. . Battery Connector Cable Test (fig. 2-26). (1) Turn selector switch to 50-volt position on tester. VOLTMETER POSITIVE LEAD ar 597 Fianre 2.25, Frame to battery — cable ground loa check — Mi2s, MI2iC, Mizs. (2) Connect the positive voltmeter lead to posi- tive post of the grounded battery. (3) Connect the negative voltmeter lead to un- grounded battery negative post. (A) Close starter switch (with ignition in OFF position) and read voltmeter. (5) If voltage is less than 20 volts, place selector switch in 20-volt position and repeat procedure (4) above. (6) If voltage reading is less than ten volts, place selector switch in 10-volt position. Repeat proce- dures (4) above. (7) If reading is less than one volt, place selector switch in I-volt position and repeat procedure (4) above. (8) The maximum allowable voltage loss is 0.2 volt. (9) Turn voltage selector switch to OFF position after check is completed, and remove test leads from battery cable. ¢. Battery to Magnetic Starter Switch or Starter Solenoid Cable Check (fig. 2-27). (1) Place voltage selector switch to the 50-volt position. (2) Conneet the positive voltmeter lead to posi- tive post of the ungrounded battery (3) Connect the negative voltmeter lead to starter magnetic switch terminal. (4) Close starter switch (with ignition switch in OFF position) and read voltmeter. (8) If voltage reading is less than 20 volts, change selector switch to 20-volt position and repeat proce- dure (4) above. (6) If reading is less than 10 volts, change to 10-volt position and repeat procedure (4) above. (7) If reading is less than one volt, change to 1- volt position. Repeat procedure and read voltmeter. 238UNGROUNDED BATTERY VOLTMETER NEGATIVE LEAD VEHICLE BATTERY |CONNECTOR BATTERY VOLTMETER POSITIVE LEAD ASS Figure 2.26. Battery connector eable check — M123, MI29C, Mi. (8) Maximum allowable voltage loss is 0.2 volt. (9) After check is completed, turn voltage selector switch to OFF position and remove voltmeter leads from battery to magnetic starter switch cable. d. Starter Magnetic Switch-to-Starter Connector Check (fig. 2-28). (1) Place voltage selector switch to the 50-volt position. (2) Connect positive voltmeter lead to the term- inal at the magnetic switch starter connector side. (3) Connect negative voltmeter lead to the term- inal of the connector on starter motor housing. (4) Close starter switch (with the ignition switch on OFF position) and read voltmeter. (5) If voltage reading is less than 20 volts, change selector switch to 20-volt position and repeat proce- dure (4) above. (6) If reading is less than ten volts, change selec- tor switch to 10-volt position and repeat procedure (A)above, VOUTMETER NEGATIVE LEAD MAGNETIC STARTER SWITCH VOLTMETER POSITIVE LEAD ATES Figure 2.27, Battery to magnetic starter switch cable cheek — M23, MISC, M125, 2:36 (7) If reading is less than one volt, change selector switch to L-volt position and repeat procedure (4) above. (8)Maximum allowable voltage loss is 0.2 volt. (9) Turn voltage selector switch to OFF and re- move test leads. é 2-30. Starter Switch Test—M123, M123C, M125 (Fig. 2-29) a. Starter switch is located on top of the starter and is used to ground the starter magnetic switch -and complete the starter circuit. b. To check starter switch connect negative lead to ground of vehicle (fig. 2-29). Turn voltage selector switch to the 50-volt position. ¢. Connect positive lead of voltmeter to magnetic side of starter switch. Meter should read battery voltage. If meter reads battery voltage, circuit to switch is complete. d. Remove positive lead and reconnect to other side of starter switch. Meter should read no voltage. e. Reconnect positive lead to magnetic side of starter switch and negative lead to ground side of switch. Meter should read battery voltage. F Close starter switch with ignition switch OFF. Meter should read no voltage. 19. Remove test leads. 2-31. Electrical Power Loss Tests— M123A1C, M123E2 ‘These tests are made to assure that required voltage and current are reaching the components and are not lost through connecting cables and switches. MAGNETIC SWITCH STARTER TERMINAL VOLTMETER POSITIVE VOLTMETER LEAD NEGATIVE LEAD TTB roresot tae eather»a. Frame to Battery Cable Ground Loss Test. (1) Connect voltmeter leads to tester. Select 50-volt scale. (2) Connect positive voltmeter lead to vehicle frame (fig. 2-30. (8) Connect negative voltmeter lead to negative ost of grounded running board battery. (4) Press starter switch (with master switch in OFF position) and read voltmeter. (5) If voltage reading is below 20 volts, change selector switch to 20-volt position and repeat proce- dure (4) above. (6) If voltage reading is below ten volts, change selector switch to 10-volt position and repeat proce- dure (4) above. (7) If voltage reading is below one volt, change selector switch to I-volt position and repeat proce- dure (4) above. (8) Maximum allowable voltage loss is 0.1 volt. (9) Return to 50-volt seale on the tester. (10) Reconnect the negative voltmeter lead (step 3) to the negative post of the battery under the righthand seat (fig. 2-31). Repeat steps (4) through 8). (11) Place voltmeter selector switch to the OFF position and remove voltmeter tester leads from frame and battery post. , Battery Connector Cable Test (fig. 2-82). (1) Turn voltage selector switch to 50-volt posi- tion. (2) Connect one end of the positive voltmeter lead to positive terminal of tester and the other end to positive post of the grounded running board bat- tery. POSITIVE LEAD VOLTMETER STARTER MAGNETIC SWITCH. NEGATIVE LEAD \VOUTMETER 50 ~ SEL A 3asa1 Figure 229, Starter awiteh test — M188, M12SC. M125. (3) Connect one end of the negative voltmeter lead to negative terminal of tester and the other end to ungrounded running board battery negative Post. (4) Press starter switch (with master switch in OFF position) and read voltmeter. (5) If voltage is less than 20 volts, place selector switch in 20-volt position and repeat procedure (4) above. (6) If voltage reading is less than ten volts, place selector switch in 10-volt position. Repeat procedure (4) above. (7) If reading is less than one volt, place selector pried in 10-volt position and repeat procedure (4) above.34542 AT 34543 a N Figure 2.81, Interconnecting ground cable teat — Figure £.$0, Frame to battery — cable rownd loss test — ‘MISSA1C, MISSES. ‘MISSA1C, MissB2. 238(8) The maximum allowable voltage loss is 0.2 volt. (9)Return to 50-volt scale on the tester. (10) Disconnect the test Jead from the running board batteries. (11) Connect the tester positive voltmeter lead to the positive post of the grounded battery under the seat (fig. 2-33). (12) Connect the tester negative voltmeter lead to the negative post of the ungrounded battery under the seat, (fig. 2-33). (18) Repeat steps (4) through (8). (14) Turn voltage selector switch to the OFF posi- tion and remove test leads. Cee ¢. Battery to Magnetic Starter Switch Cable Check (fig. 2-84), (1) Turn voltage selector switch to the 50-volt position. (2) Connect the positive voltmeter lead to posi- tive post of the ungrounded running board battery. (8) Connect the negative voltmeter lead to mag- netic starter switch terminal. (4) Press starter switch (with master switch in OFF position) and read voltmeter. (5) If voltage reading is less than 20 volts, change selector switch to 20-volt position and repeat proce- dure (4) above. (6) If reading is less than ten volts, change to 10-volt position and repeat procedure (4) above. AT 34546 Figure £.$2, Battery connector cable test — MI2SA1C. MIS3E¥. 2.39VOLTMETER POS, LEAD + Qtisseexssssssssesssssssesssssd a em AT 34545, Figure 2.88. interconnecting battery cable tert — ‘MISSAIC, MIRSER. (7) If reading is less than one volt, change to 1- volt position. Repeat procedure and read voltmeter. (8)Maximum allowable voltage loss is 0.2 volt. (9) Turn voltage selector switch to the 50-volt position. (10) Reconnect the positive voltmeter lead (step (2) above) to the positive post on the ungrounded battery under the seat, fig. 2-35). (11) Repeat steps (4) through (8). (12) Turn voltage selector switch to the OFF posi- tion and remove test leads. 2-32. Monitoring Circuits (Fuel, Oli and Temperature Gage) Testing (fig. 2-86). 4. Check vehicle battery voltage. Charge or replace A battery if voltage is not as prescribed in paragraph 222, 6. Check battery cables and terminals for good condition. Repair or replace battery cables and terminals, as required. Be sure that they are properly secured. ¢. With ignition/master switch turned OFF, dis- connect wire No.7 lead from back of gage being tested (fig. 2-36). d. With voltage selector on the 50-volt scale, con- neet negative lead of voltmeter to vehicle ground and Positive lead to wire No. 27 from the ignition/master switch. ¢. With ignition/master switch turned ON (fig: 2-96), voltmeter should indicate battery voltage.VOLTMETER NEG. LEAD. VOLTMETER POS. LEAD Figure 2.84, Battery-to-magnetic starter switch — cable test — ‘MISSAIC, Mi2sBe, VOLTMETER POS, LEAD CI 4 p TIA 4 4 Figure 2.85, interconnecting battery-to-magnetic starter switch — cable tent — MI28A1C, M123B2. AT 34546, AT 34547 241NOTE If fower than the battery voltage, or zero voltage reading is indicated, check circuit for loss or broken connections. Repair as re- quired. Uowak erasers switch Low air pressure buzzer Gil pressure sender ‘Temperature sender Oil pressure gage Airgage ‘Temperature gage Battery-generator indicator (M123, M1230, M125) lage Foe an sender uit Battery generator indicator (M123A1C, MI23E2) Cotte Crier “ Regulator to battery-generator indicator sou Ipition switch to eatramenta a it Fuel sender unit to ease a erature sender oat to rage B i preaure sender unit o ane Bo enktion switch tolow are pressure % sor a q OzErmszaumbom> 5 “ ‘switch and buzzer Master awitch to battery-generator “ Indicator (MIzaAIC- MASSES) Aitaunber shown of devin rrnpndterdaune cit nme tabbed wire. Figure 2.36, Instrument cireuit diagram. f. Remove voltmeter’s negative (—) lead from vehi- cle ground and contact case of gage (fig. 2-37); volt- meter should indicate battery voltage. NOTE ‘This check is important. If case of gage is not properly grounded, gage will not operate. g. Turn ignition/master switch OFF. h. Disconnect voltmeter positive (+) lead from ignition/master switch-to-gage wire and connect wire to gage. i Disconnect wire from gage to sending unit of gage. j. Connect suitable jumper wire to sending unit side of gage. 242 k. Connect one lead of field rheostat to jumper wire from gage, and other field rheostat wire to vehicle ground (fig. 2-37). | L Turn ignition/master switch ON. m. Turn field control knob and watch gage. of pressure or fuel gage should go from zero to ful scale if operating correctly. Using a 13-to 15-ohm resistance, gage should read “scale. NOTE This check will not test temperature gage, as this is a high resistance gage. n, To check temperature gage, ground one end of | jumper wire from gage to vehicle ground. Tempera- ture gage should read zero when grounded, and high | temperature when jumper is not grounded (fig. 2-37). o. Turn ignition/ master switch OFF. p. Remove jumper wire from gage end and con- neet wire from sending unit to gage. 4. Disconnect wire from sending unit to gage at sending unit (fig. 2-37). 7, Turn ignition/master switch ON. 8. Make same checks as in e. and n. above. If gage does not conform to readings outlined, repair or replace wire from gage to sending unit. t, Turn ignition/ master switch OFF. Connect wire from gage to sending unit. NOTE Electrical gages indicate an approximate q reading; for accurate readings, the use of master gages connected to the circuit being tested is recommended. 2-33. Sending Units CAUTION Do not connect ohmmeter to ignition cir- cuit and turn ignition/master switch ON as ‘ohmmeter will be damaged. To test function of sending units, an ohmmeter with 0 to 7,000-ohm range is recommended. The following procedure applies to any sending unit being tested: a. Disconnect wire from gage-to-sending unit at sending unit. 6. Connect positive lead of ohmmeter to sending unit and negative lead of ohmmeter to vehicle ground (fig. 230). (1) Temperature gage sending unit. (a) If ohmmeter indicates a zero reading when engine is cold, replace sending unit. (b) Start engine. Ohmmeter will indicate a lower reading as engine is warming up. (c) Stop engine. Ohmmeter will indicate a high « reading as engine is cooling. (d) Replace sending unit as indicated in (b) and (c) above. if readings are not(2) Oil pressure gage sending unit. (a) The ohmmeter should indicate 0 to 1-ohm reading with engine stopped; if ohmmeter does not indicate this reading, or exceeds 1 ohm, replace send- ing unit. (b) Start engine. Ohmmeter should indicate higher reading (10 to 40 ohms); if higher reading is not indicated, replace sending unit. (8) Fuel gage sending unit. (a) Check ground between fuel tank and vehicle with an ohmmeter. Zero reading should be obtained. If the fuel tank is not grounded to the vehicle, the sending unit will not operate. (6) The ohmmeter should indicate a reading between 0 and 40 ohms, depending on the amount of fuel in the tank. If the ohmmeter indicates a read- ing higher than 40 ohms, replace the sending unit. (c) The ohmmeter should indicate a higher reading as fuel tank is filled and a lower reading a8 the fuel is withdrawn. If the sending unit does not conform to this test, replace sending unit. (d) To test inaccessible sending units and electrical wire from gage to sending unit, omit proce- dure in (b) and (c) above, and proceed as follows: 1. Disconnect wire from gage to sending unit at gage. 2. Connect positive lead of ohmmeter to wire from sending unit and ohmmeter negative lead to vehicle ground. 3. Follow procedures outlined in c. (1) through c.(3) above for sending unit being tested. (e) Defective sending units will be replaced as prescribed in pertinent technical manuals. 2-34. Ignition Circuit Test—M123, M123C, M125 (fig. 2-38) Prior to making ignition circuit checks, voltage check must be made on starter circuit to determine if 18- volts are present when cranking engine. a. Primary Circuit Test. (1) Disconnect primary wire at distributor and insert primary ignition adapter. Unscrew plug from the top of distributor and insert distributor adapter. figure 2-39. (2) Place voltage selector in the 50-volt position and ground the negative lead. (3) Connect positive ( +) lead to primary adapt turn on ignition switch checks to determine if igni tion switch is functioning. (4) If no voltage is present with ignition switch ‘on, check generator regulator to see that it is properly connected. If regulator is unplugged at the battery side, no voltage will be present at the distributor. (5) If voltage regulator is plugged in, remove meter leads and check power to the ignition switeh. b. Ignition Switch Test. (1) Remove battery ground cable. (2) Disconnect ignition switch feed wire (No. 11). Connect positive voltmeter lead to wire from ignition switch, figure 2-38, (3) Place voltage selector in the 50-volt position and ground the negative lead. (4) Replace ground cable on battery. Meter should read battery voltage. (5) If voltage is present, remove ground cable and connect No. 11 wire to switch, (6) If voltage is not present, disconnect battery side of generator regulator. (1) Connect voltmeter lead to the A pin of the disconnected plug on the harness. (8) With battery ground strap connected and negative lead of meter connected to ground, battery voltage should show on meter. (9) If voltage is present, connect a small jumper from pin “A” on the harness to pin C. If voltage is still present, replace regulator (para 2-116). If no voltage is present, check wiring for breaks or shorts and repair as required (para 2-148), ¢, Distributor Testa, Cap On (fig. 2-38). (1) With voltage selector on the 50-volt scale, ground meter to side of distributor. (2) Connect positive lead to distributor adapter (fig. 2-39), (8) Turn on ignition switch. (4) Observe voltmeter. Voltmeter should read low voltage or battery voltage, depending on distributor point position. (5) If points are open, voltmeter should read battery voltage. (6) If points are closed, voltmeter should be on zero or have a maximum 0.3 volt. (1) If voltmeter reads battery voltage, but will not drop when points close, points are defective. Re- move and replace points or distributor. (8) If voltmeter not read battery voltage when points are open, distributor components are defective. Remove and replace distributor or check in accordance with the following procedure. 4. Distributor Test, Cap Removed (fig. 2-40). (1) Remove distributor cap with ignition iteh off. (2) Ground negative lead of meter to case selec- tor in 50-volt position.IeniTion/master C8 SW OFF = ‘A, NORMAL CIRCUIT = IGNITION/MASTER SW ON IGNITION/MASTER, SW ON = ¢. Test oo > + IGNITION/masTeR CB GAGE BAT SW ON b. TEST wt St FIELD RES IGNITION/MASTER WON €, TEST IGNITION/MASTER SWON, = F. TEST IGNITION/MASTER CB SW OFF G. Test AT 34549 Pianre 2.37, Instrument texting diagram, 244AT 34850 moom> F TOGEN REGULATOR Cowie ten me Gar (Chet Drip Coil and distributor pou ea eee 2 —-14_—_—_Agnition awiteh to ctreuit breaker Ignition awiteh 3B M4 Fuel pump control feed re foel pamy ‘uel pump switch to fuel pump left Bleetri fuel pump TR —-14_—_—uel pumpswiteh tofuel pump right, Dash receptacle terminals J and H 79 14 Pueltank ground Figure 238, Ignition cirnit diagram — M123, M12SC, M125.* POSITIVE VOLTMETER LEAD fa 50 VOLT SCALE DISTRIBUTOR Ui | Avarrer i ; PRIMARY DISTRIBUTOR ‘ADAPTER NEGATIVE VOLIMETER f {LEAD - CASE PP rosmmve VOUTMETER LEAD- RESISTOR * FEED-THROUGH ‘CAPACITOR POSITIVE VOLTMETER LEAD, POINT SIDE OF COIL POSITIVE VOLTMETER LEAD - RESISTOR SIDE OF COIL Figure 2-40, Distributor text, cap removed. (8) Use short jumper lead and connect across points. (4) Turn on ignition switeh. (5) Connect positive lead of meter to top of re- sistor. Voltage reading should be 24 volts. If not, primary circuit or feed-through capacitor is defective. (6) Connect positive lead of meter to resistor side of coil. Voltage should be 5 to 8 volts. If not, resistor is defective or jumper on points is not grounded. (7) Remove points and insert insulating material between points, or assure that they are fully open. (8) Connect positive lead of meter to point side of coil. Voltage should read battery voltage. If no voltage is shown, coil on condenser is defective or points are grounded. 246 2-35, Light Circult Test 4a. Description. The electrical wiring of this vehicle is of waterproof construction. Where multiple con- nectors are necessary, they are the screw-type. by preformed packing on a sealed composition cont neetor. Also, the cables in the high voltage system of ‘the engine (M123, M123C. M125) are shielded to avoid radio interference (para 2-317). The electrical circuits are numbered in accordance’ with the ordnance sys- tem and can be identified from the diagram shown in figure 2-41. To establish continuity of any circuit. check with suitable test equipment, using the tech- nique described in this gui . Test Procedures. All lights described in this see- tion are 24-volt operated and have a 24-volt negative ground. The following procedures should be used to test the light circuit. (1) Place headlight switch (fig. 2-42) in desired position indicating light to be checked. (2) Visually check light for proper operation. (3) Actuate dimmer switch for headlight opera- tion and again visually check for proper operation. (4)If one headlight will not operate but the oth units will, problem is not in the light switch or cuit breakers. Replace lamp unit if defective. Check for loose or corroded ground connection. Clean and tighten if necessary. Determine voltage at light socket to ground. Check light harness for open cir- cuit. Replace as required. 4d (5) If all of the light units are inoperative, prob- lem could be in the circuit breakers or light switch. Also, check to see that the battery cables are tight- ened securely. Replace circuit breakers or light switch and tighten battery cables as required. ¢. Directional Turn Signal. NOTE Headlight switch must be in ON position. (1) If all lights are inoperative, check cireuit breaker (fig. 2-41). (2) If only one light (either front or rear) is in- operative, check bulb socket for corrosion, replace lamp or check wiring. (8) If lights illuminate but do not flash, replace flasher (fig. 2-41). 2-36. Testing Glow Plug—M123A1C, M123E2 (fig. 2-43). To test operation of glow plug, turn cold start switch to ON. After 20 seconds, stroke the hand prime pump three times. Feel if intake manifold is warm. If there is no heat present, check wiring. If wiring check is satisfactory, remove pipe plug from air intake mani- fold near glow plug and check for flame while helper performs cold weather starting procedure described above. If no flame is observed, close glow plug manualswitch 15-seconds and observe glow plug through pipe plug hole, The glow plug should be white hot; if not, connect glow plug to a 6-volt battery and check : current draw which should be 30- to 23-amperes (minimum). If glow plug is all right, check manual switch and resistor. Pilot light will burn out if re- sistor is burned out. Section Vil. RADIO INTERFERENCE SUPPRESSION — M123, M123C, M125 2-37. General Methods Used to Attain Proper Suppression Essentially, suppression is attained by providing a low resistance path to ground for the stray currents. The methods used include shielding the ignition and high-frequency wires, grounding the frame with bonding straps, and using capacitors and resistors, 2-38. Interference Suppression Components Radio interference suppression is accomplished in the electrical subassemblies of this vehicle by use of shielding, feed-through-type capacitors, teeth-type lockwashers, suppressed spark plugs, and braided bond straps. 247248 ml e L D K A F 8 J lc H N DZNESTaRneUS Gs0) DNMHCEBFJALK 6 Figure 241. Lighting cirenit diagram — MI24A1C, M123B2OFF. POSITION Free RESTRICTED MOvemeNt | MOVEMENT aestRicTeD Free MOVEMENT \y“ ye MOVEMENT Main switch . HEADLIGHTS 5 with storicHt // one ‘OR seRvice baive ONLY ws! et Key to gue 241: vers unockep quot MAIN SWITCH tw Desetgtion ast gyyJ } 4 0. marker, parking light and directional A ne rker, parking light and directi signal x“ / c Panel lights, 7 5 eh ea E PARKING. LOCKING F auxitiaey re Swe § Semen s1oruictt ox y SeRvice ORIVE faraesd k ONY t x Piper 242. Light auitch pst Stoplieht switch re 2.42 Light witch pnitons. P Felttoaneior — semi 8 onal sya control Tar smal distribution box s BO. sopleht ' Ficedlamp t Floodlamp switch om 10 6 B Cygne switch to dimmer eee u Bimmer switch toheadlights high beam and indicator & itch to headlights lower beam 6 ch to BO. driving ht 2 th to B.O. marker lights aso a a & a {ight steno instrument sits s {ijt switch toatoptiht switch 2 ‘Trailer receptacle fo ground a1 Headlight ground 6 ‘Turmsimal distribution box to riht front and right rear sina its pr ‘Turmaignal distribution bor to ett front and eft rear sia lhe py Blackout clesrance It Prt {et seth to parking lights Sts ‘Greut breaker to floodiamp switch and switch to fleodlamp 249‘COLD WEATHER STARTING PANEL SWITCH 12v BATTERY RIGHT HAND, RUNNING OARD = AT 34855 Figure 2.48. Glow plug schematic — M128A1C, M1235.2.39. Replacement of Suppression Components 4@ Ignition and Starting System Radio Interference QD scroresion (1) General. The high tension harness assem- blies and the cable to each spark plug are individually shielded utilizing molded rubber-covered, woven, metallic hose shielding terminated at all joints with appropriate threaded fittings. Each spark plug is integrally shielded and suppressed with 10,000 ohm built-in resistor-suppressor. The ignition coil is likewise integrally shielded and suppressed. The primary connection at the distributor terminal is equipped with a feed through eapacitor (condenser). (2) Maintenance. (a) Distributor capacitor (condenser) (fig. 2-44). To replace distributor capacitor, disconnect primary cable at distributor. Remove eight screws and lock- washers from distributor cover and remove cover and gasket. Discard gasket. Remove four screws and lockwashers holding primary lead in receptacle to side of distributor and remove receptacle and gasket. Discard gasket. Disconnect capacitor cable or primary cable from resistor terminal, and pull out capacitor. Install new distributor capacitor. Connect capacitor cable at resistor terminal. Install new gasket. Use the four screws and lockwashers rs install recepticle. Install new distributor cover gasket. Reseat distributor cover and tighten by using eight screws and lockwashers. Connect primary cable at distributor. (b) Spark plug cables, Replace spark plug cables if rubber or metallic shielding is damaged in any way (para 2-103). istRBUTOR| Figure 2-44, Distributor with cover removed. (e) Starter capacitor. Remove commutator end cover from starter by raising clips from groove in starter housing and slide off cover. Disconnect capacitor cable from terminal on brush holder, re- move capacitor-mounting screw, and remove capaci- tor. Position new capacitor and install mounting serew. Connect cable to brush holder terminal through groove in starter frame. Install commutator end cover. b. Generator System Radio Interference Sup- pression, (1) General. The generator mounting bracket is bonded to the engine with plate toothed lockwashers. ‘The generator itself is bonded to its mounting brack- et in similar manner, and is integrally shielded and suppressed. The armature and field lead from the generator to the regulator is inclosed in rubber-cov- ered flexible metallic hose and terminated at each end utilizing appropriate threaded fittings. The generator regulator is integrally shielded and sup- pressed and its mounting is bonded to the firewall of the vehicle with plated teeth-type lockwashers. (2) Maintenance. (a) Generator capacitor. Since generator capac- itor replacement requires generator disassembly: the capacitor will not be removed while generator is mounted on vehicle. Notify supporting mainte- nance personnel. (6) Generator-regulator capacitor. Generator- regulator capacitor replacement requires regulator disassembly; therefore, the capacitor will not be re- moved while regulator is mounted on vehicle. Notify supporting maintenance personnel. ¢. Radio Interference Suppression Bonding. (1) General. Bond straps are used to unite all parts and thereby form a shield about the entire powerplant. (2) Description and Data. The following is a list of locations of the bonding straps surrounding the powerplant. fa) The upper brush guard support brackets are bonded to each fender by a tinned copper braid bond strap and plated teeth-type lockwashers. (6) The radiator is bonded to the engine sup- port brackets on each side by a tinned copper braid bond strap and plated teeth-type lockwashers (fig. 2-45). (c) The engine cylinder head is bonded to the firewall in similar manner. (d) The transmission is bonded to the frame sidemember by a tinned copper braid bond strap and plated teeth-type lockwashers. 281‘and bonding ntrap. Figure 2.45, Radiator drain evek, outlet hone, ¢ Section Vill. ENGINE MAINTENANCE IN VEHICLE—DIESEL— M123A1C AND M123E2 2-40. Description (fig. 2-46) The vehicle is powered by an 8-cylinder Cummins, V-type, 4-cyele, liquid cooled, compression ignition diesel engine. The engine has overhead valves. The radiator, engine, clutch, and transmission are con- sidered as one unit (the powerplant). The fan end of the engine will be referred to as the front. The fly- wheel end will be referred to as the rear. The terms “left” and “right” as used with reference to the en- gine, are as viewed from the rear or flywheel end, 2.52 looking toward the front or fan end. 2-41. Engine Mounts a. Removal. (1) Front mount (fig. 2-47). (a) Remove four self-locking nuts securing each end of mounting bracket to frame sidemember. (b) Jack up engine at lower pan using a block of wood to distribute weight. (c) Remove two bolts and self-locking nuts securing insulators to bracket and remove insulators.Figure 2.47. Front support, mounts, and vibration damper — ‘MIR3AIC, MI2SB2. (2)Rear mount. fa) Remove two nuts, lockwashers, lower insulators, and bolts from each of the two mounting brackets, (b) Jack up transmission and lift out upper insulators. b. Installation. (1)Front mount. (a) Jack up engine and position upper insulators between bottom flange of engine gear case cover and mounting bracket and install two bolts. Install lower insulator over bolts and secure with self-lock- ing nuts. (b) Position engine front mounting supports on left and right mounting brackets and secure with eight bolts and self-locking nuts. (2)Rear mount (fig. (a) Jack up transmission and insert two rub- ber insulators between rear mounting bracket on transmission assembly and bracket on frame side- member, with bevel side of insulator up. (b) Insert driftpin in adjacent holes of bracket 253and aline bracket so a mounting bolt can be inserted. c) Install bolt through insulator (bevel side down) and secure through lower insulator with self- locking nut. (a) Repeat this procedure on opposite mount- ing. The remaining mounting bolts and insulators may now be installed without further alinement. fe) Check adjusting bolts by inserting a 0.015 feeler gage between transmission mounting bracket and head of adjusting bolt at each end of left rear powerplant support bracket (fig. 2-48), Adjust bolts until a slight drag is felt on feeler gage when re- moved, Tighten locknut. 2-42. Crankshaft Pulley and Vibration Damper (fig. 2-47). a. Removal. (1) Remove seven capscrews and lockwashers securing accessory drive pulley and damper to crankshaft. (2) Remove outer pulley (accessory drive), (3) Use @ soft hammer to loosen and remove damper. (4) Remove inner pulley (water pump) drive from crankshaft, Installation, (1) Position water pump drive to crankshaft flange. (2) Position vibration damper and aline capscrew holes. (3) Position accessory drive pulley (drives idler pulley and fan) to vibration damper. (4) Install lockwashers and capscrews. (5) Tighten bolts alternately 190 to 200 Ib-ft. 2-43. Full-flow Oil Filter (fig. 2-49). a. Filter Element. (1) Removal. fa) Drain oil filter. (b) Remove four filter flange capscrew. (c) Remove oil filter body and filter. (d) Discard filter element and gasket. (e) Clean filter body with dry-cleaning solvent or mineral spirits paint thinner. (2) Installation, (a) Insert new filter element. (b) Install filter body and gasket with four lockwashers and capscrews. Do not over tighten. Fill engine with oil (LO 9-2320-206-12). (c) Start engine and check for leaks. Stop en- gine and cheek oil level in cylinder block. (d) Add oil until the level reads FULL on the dipstick. 254 Figure 248, Adjusting end motion at powerplant rear mount b, Filter Body Bracket. (1) Removal. a) Disconnect inlet and discharge lines from filter body. (b) Remove three capscrews and self-locking nuts which secure the filter bracket to the frame bracket. (2) Installation. (a) Position the filter body bracket and secure with three capscrews and self-locking nuts. (b) Connect inlet and discharge lines to filter body. (c) Start engine and run until operating temp- erature is reached. Check filter body and lines for tightness and leaks, (a) Stop engine and check cylinder block oil level. Add oil as necessary. FILTER BRACKET Paure 2.49, Full flow ol filter.2-44, By-Pass Oll Filter CAUTION Re sure there are no leaks around filter covers and oil line connections. a. Filter Element. (1) Removal. (a) Remove drain plugs and drain (fig. 2-52) Remove end filter cover retai ‘capscrews, covers, and gaskets (discard gaskets) (fig. 2-50). (0) Lift out the replaceable filter elements and discard. (2) Installation. (a) Clean inside of filter bodies with dry-clean- ing solvent or mineral spirits paint thinner, and in- stall new filter elements. (0) Install drain plugs. (c) Install filter body covers with new gaskets and tighten filter cover retaining capscrews. Fill engine with oil (LO 9-2320-206-12). Start engine and run until operating temperature is reached. (a) Stop engine and check oil level in cylinder block. Add oil until the level reads FULL on the dip- stick. b, Filter Bracket fig. 2-51) (1) Removal. > (a) Disconnect inlet and discharge lines secur- i filter bodies. (b) Remove five bolts and self-locking nuts which secure the filter bracket on frame. Discard gasket. (2) Installation. (a) Place new gasket on oil filter mounting bracket. (b) Position and secure mounting bracket with five bolts and self-locking nuts. (c) Connect inlet and discharge lines at filter and quick disconnect points. (d) Start engine and run until operating tem- erature is reached. Check filter assembly for tight- ness and leaks. Stop engine and check eylinder block oil level. (e) Add oil as necessary. 2-45. Oli Cooler (fig. 2-53) @. Removal, (1) Remove capserews, lockwashers and flat washers securing oil cooler covers and oil cooler element to cylinder block. (2) Remove oil cooler cover and oil cooler from Ainder block. (3) Separate cover and oil cooler. Discard all gaskets and lockplates. 6. Testing. (1) Plug oil outlet and attach 700/100 psi air line tooil outlet. (2) Immerse unit in water and apply air pres- sure. The slightest leak will be indicated by the ap- pearance of air bubbles. (3) Assemble front and rear heads to cooler. (4) Plug either inlet or outlet connection and check for leaks at described in steps (1) and (2) above. ~~ GASKET, COVER f}- FILTER ELEMENT [kK FILTER BODY GASKET igure 250. Oil filter — partially exploded view.INLET LINE DISCHARGE LINES INLET LINE On FILTER. FILTER BRACKET FRAME BRACKET seur- LOCKING AT 34563 Figure 251. By- pass ol filter related parts. Figure 252, By-poss filters «. Installation. (1) Position engine oil cooler element with new gasket to left side of left eylinder block (fig. 2-58). Hold in place by installing flat washers, lockwash- ers, and capscrews in two holes that go through ele- ment only. (2) Tighten all capserews alternately to 30 to 50 lb-ft torque. 2-46. Crankcase Breather Valve . Removal (1) Loosen hose clamps securing crankcase vent line at fording breather manifold (mounted on fire- wall) and at crankease breather valve. Remove breather line. (2) Disconnect flex control cable at tee between crankcase breather body and breather line (fig. 2-54):COVER, Figure 258. Oil cnoler. (3) Remove two capscrews and lockwashers secur- ing breather line to breather body (fig. 2-54). Re- move breather line, (4) Remove three capscrews, lockwashers, and flat washers securing breather valve adapter to body and remove cover, gasket, screen and baffle from breather body (fig. 2-54, . Cleaning and Inspection. WARNING Particles blown by compressed air are haz- ardous. Make certain the air stream is direct- from user and any other persons in the area. (1) Cleaning. fa) Submerge parts in dry-cleaning solvent or mineral spirits paint thinner to remove all foreign material. (b) Remove sludge and gum deposits using a stiff brush. CONTROL, carve CRANK CASK BREATHER 80Dy Figure 2-54. Crankease breather valve. (c) Blow out all castings and taped holes with compressed air. (2) Inspection. (a) Inspect adapter and cover for cracks, nicks, burrs, and raised metal. (b) Check pipe plugs and threaded inserts for damaged or stripped threads. fc) Check mating flanges for warpage. Installation. (1) Position baffle, sereen, and gasket in breather body. (2) Place adapter with cover on breather body and secure with three capscrews, lockwashers, and flat washers (fig. 2-54). (3) Position breather line to breather body. Sec- ure with two capscrews and lockwashers (fig. 2-54). (4) Connect flex control cable to control bracket on tee between breather body and breather line (fig. 2-54). NOTE Be sure control cable is completely depressed on instrument panel and pressurization valve is fully open when connecting flex con- trol cable. (5) Connect crankcase vent line at fording breath- er manifold (mounted on firewall) and at crankcase breather valve and secure with hose clamps. 2-47. Lines and Fittings a, Removal. NOTE Before removing line, mark or tag line to insure proper installation. (1) Hold connector with one wrench and unscrew nut with another wrench. (2) Disconnect and remove line is same manner at both ends. NOTE ‘Avoid bending or kinking lines. (3) Cap or cover all exposed lines and open ports to prevent entrance of foreign material. (4) Remove line clips and line. Inspection, (1) Inspect lines for kinks, fractures, tube wall separation, and damaged ends. (2) Inspect fittings, hex nuts, and sleeves for damaged threads or fractures (3) Replace all worn, damaged, or otherwise unserviceable parts. c. Fabrication (1) Lines. (a) Cut tubing to exact size. Make sure ends of tube are square. () Debur inside and outside tubing wall. (c) Bend tubing to conform to shape of defective line. 257(2) Fittings — Compression Type. fa) Position hex nut on tubing with threaded end toward tube end (fiz. 2-58). (b) Position tight fitting sleeve on tubing, with head toward nut (fig. 255). {c) Install tube in connector. fd) Aline tubing to bottom on connector shoulder and turn nut finger tight (fig. 2-55). fe) Place connector in vise and turn nut slowly with wrench while turning tube by hand until sleeve grips tube and tube can no longer be revolved by hand. (f) Turn nut one and one-half additional turns after sleeve grips tube. (3) Fittings — Flare Type. (a) Install hex nut on tubing with threaded end toward tube end, CONNECTOR SLEEVE way ASSEMBLE NUT AND SLEEVE TO TUBE INSERT TUBE IN CONNECTOR TIGHTEN FINGER TIGHT SHOULDER NuT CUTTING EDGE AT 34567 TIGHTEN WITH WRENCH Figure 2-55, Lines and fittings. 2.58 (b) Flare tubing end with a flaring tool. NOTE Make sure flare is even all around. (c) Insert flared end into recessed part of hex nut to insure that a good seat is provided. ¢ d. Installation. CAUTION Do not over tighten nuts as damage to fit- tings may oceur. (1) Remove protective caps or covers from line. (2) Clean line thoroughly using dry-cleaning solvent or mineral spirits (3) Dry with compressed air. NOTE If dry compressed air is not available, place line on clean surface and air dry for a mini- mum of five minutes. (4) Remove caps or covers from component con- nectors and wipe connectors with a clean lint-free cloth, dampened with solvent or mineral spirits. (5) Lubricate threads with hydraulie fluid. (6) Aline tube ends in connectors and turn nut finger tight. (7) Hold connector with one wrench and tighten nut with another wrench until nut is seated. 2-48. Manifolds , Removal. (1) Intake (fig. 2-56). d (a) Drain radiator (para 2-87). (b) Remove five bolts. lockwashers, and two locknuts securing air inlet housing and radiator sup- ort rod to intake manifold (c) Loosen hose clamp and remove air inlet housing from air cleaner. (a) Remove alternator assembly (para 2-118). {e) Loosen hose clamp and disconnect air com- pressor intake hose from air intake crossover as- sembly. (f) Disconnect air restriction indicator hose from intake crossover assembly. (g) Disconnect bolts and lockwashers securing support clamps for water temperature senser and alternator wires to right intake manifold. (h) Disconnect water line between air com- pressor and engine water pump. () Loosen bolts securing power steering mounting assembly to cylinder head. Remove bolt securing power steering pump mounting assembly and right intake manifold assembly. G) Remove remaining 15 bolts securing right and left intake manifold assemblies to cylinder head Remove intake manifold assembly and discard gas- kets, (2) Exhaust (fig. 2-57).(a) Remove band clamp joining exhaust man- ifold and exhaust pipe. (b) Unlock lockplates. (c) Remove eight bolts and lockplates securing exhaust manifold to cylinder head. fd) Remove exhaust manifold and diseard gasket. ©. Cleaning and Inspection. Wipe clean and inspect for cracks and distortions. ¢. Installation. (1) Intake. (a) Position air intake manifold assembly to cylinder heads using new gaskets and secure with 15 bolts. Tighten to 30 to 35 Ib-ft in 15 Ib-ft increments (fig. 2-56). (6) Install bolt securing power steering pump mounting assembly and right intake manifold as- sembly. (c) Tighten power steering pump mounting assembly bolts. fd) Reconnect water line between air com- pressor and engine water pump. fe) Install bolts and lockwashers securing support clamps for water temperature sender and ‘AIR COMPRESSOR INTAKE HOSE {AIR RESTRICTION. INDICATOR HOSE alternator wires to right intake manifold. (f Reconnect air restrietion indicator hose to intake crossover assembly. (g) Reconnect air compressor intake hose to air intake crossover assembly. Tighten hose clamp. (h) Install alternator (para 2-118). (i) Position air inlet housing to air cleaner and secure with hose clamp. ) Position opposite end of air inlet housing and radiator support rod to intake manifold and secure with five bolts, washers, and two locknuts. (k) Fill radiator (para 2-87). (2) Exhaust, fa) Position new gasket and exhaust mani- fold to cylinder head. NOTE Make sure the gasket has the word OUT to the outside. (b) Install new lockplates. Tighten bolts to 30 to 35 Ib-ft in 15 Ib-ft increments (fig. 2-57). (c) Secure lockplates. (d) Position exhaust pipe to exhaust manifold and secure with band clamps. WATER TEMPERATURE SENDING UNIT igure 2.56, Bagme compartment — right front new — MI28A1C, MI2SB2, 259Se RIGHT EXHAUST MANIFOLD. =s igure 2.57, Exhaust manifold, 2-49. Primer Pump (fig. 2-58) a. Removal. (1) Disconnect two fuel lines connected to primer pump. 2-60 (2) Remove hex nut securing primer pump to mounting bracket. (3)Remove primer pump. , Installation, (1) Position primer pump in mounting bracket and secure with hex nut. (2)Conneet the two fuel lines to primer pump. 2-50. Clutch Controls and Linkage a. Adjustment. (1) Free-pedal travel check (fig. 2-59). (a) Hook a rule over pedal pad. (6) Select an inch mark on rule and place a chalk mark on rule and seat cushion opposite. (c) Depress pedal until meeting resistance other than that caused by return spring. (d) Place second mark on rule opposite original mark on seat cushion. fe) Distance between the marks on rule is equal to free-pedal travel. NOTE Free-pedal travel should be two inches; if free-pedal travel is less than one inch, an adjustment in the control linkage or re- moval of spacers as required is necessary.7 e ADAPTER ) Y me DIVERTER [4 \ 1 — CONTROL r 4q 2-61(2) Minor adjuatment (fig. 2-60). fa) Loosen locknut and turn adjusting screw “PRE PEDAL TRAVEL POSITION out to increase or in to decrease and achieve desired two-inch travel. fo) Tighten locknut without further move- ment of adjusting screw. (3) Major adjustment. If free-pedal travel can- not be restored by minor adjustment, proceed with following: (a) Remove six bolts and lockwashers securing lower inspection cover to clutch housing. Remove cover and discard gasket (fig. 2-61). Figure 259, Checking free pedal travel, 2462Figure 260, Clutch and clutch linkage. AT 572 243ar 34573 Figure 21. Clutch housing lnwer inspection cover. 264 (b) Loosen adjusting screw locknut and un- serew adjusting screw until only very end of serew is remaining in adjusting lever (fig. 2-60). (c) Loosen locknut on release lever (fig. 2-60). (d) Use a 1/8-inch metal bar as a gage and in- sert it between thrust washer and release bearing (fig. 2-62). (e) Reposition release lever on release shaft so adjusting screw contact area is as close as possible (fig. 2-60). (f) Tighten locknut on release lever and tighten to 70 to 90 Ib-ft torque. (g) Turn in adjusting serew, until contact is made with adjusting lever, then tighten locknut (fig. 2-60), (h) Remove the 1/8-inch bar between thrust washer and release bearing (fig. 2-62). (i) Check free-pedal travel (1) above and repeat procedures for minor adjustment (2) above, if neces- sary. G) Install new gasket and position lower in- spection cover to clutch housing and secure with six bolts and lockwashers (fig. 2-61). (4) Spacer removal. Spacer removal described below may be needed to obtain necessary 1/8-inch clutch measurement. (a) Remove six bolts and lockwashers from clutch housing lower inspection cover (fig. 2-62). (6) Remove cover and discard gasket.LOCKING RELEASE ADJUSTING SCREW Figure 282. Checking releane bearing clearance, (c) Working through inspection hole, loosen 12 bolts, securing backplate to flywheel, two full turns. rotating flywheel as necessary. (d) After all 12 bolts are loose, remove each bolt and lockwasher and pull out spacer. Reinstall bolt and lockwasher fingertight, and proceed to next bolt (fig. 2-60), rotating flywheel as necessary. NOTE If spacers have been removed at previous adjustment, it will be necessary to replace the two clutch disks. (5) Tighten all 12 bolts 25 to 28 lb-ft torque. 6. Removal (fig. 2-63). (1) Remove self-locking hex nut (1, fig. 2-63) and hex-head screw (2) securing clutch pedal stem assembly (3) with pad (4) to clutch pedal lever (5) and pull stem assembly out of lever. (2) Unhook pedal return spring (6) and remove. (8) Remove self-locking hex nut (7) and hex-head bolt (8) securing pedal lever and return spring clip (9) to pedal lever shaft and remove pedal lever (5). (4) Remove two cotter pins (10) and (11) and levis pin (12) and (13) securing clutch control clevis (14) to pedal shaft lever (15) and release lever (16) and remove clevis. (5) Remove self-locking hex nut (17) and hex- head screw (18) securing pedal shaft lever (15) to shaft (19) and remove lever. (6) Pull pedal lever shaft (19), and two bushing type bearings (20) and (21), at each end of shaft out of bracket. (7) Remove self-locking hex nut (22) and hex- head serew (28) securing adjusting lever to clutch throwout shaft and remove adjusting lever (24), Slide off release lever (16). Remove hex-head bolt (25) and locknut (26) from release lever. (8) Remove two self-locking hex nuts (27 and 28) and two hex-head serews (29 and 30) securing the pedal bracket with bearing assembly (31) on engine mounting bracket and remove bracket with bearing assembly. ¢. Installation (fig. 2-63). (1) Position bracket with bearing assembly (31, fig. 2-68) on engine mounting bracket and secure with one each hex-head screw (30), self-locking nut (28) in upper hole, and hex-head screw (29) and self-lock- ing hex nut (27) in lower hole. 265Hex nut 2 Hex-head screw '3Stem assembly 4Pad Pedal lever Return spring. ‘THex aut BHex-head bolt 9 Spring clip, 10Cotter pin 110 AT USS 21 hajuating ever haji Figure 2.63, Clutch pedal lever and linkage—exploded view. 266(2) Serew hex locknut (26) on hex-head adjusting bolt (25) and serew bolt into release lever (16). (8) Slide clutch release lever (16) on throwout shaft and position release adjusting lever (24) on shaft engaging boss on adjusting lever in cutout in release lever (16). Secure with hex-head screw (23) and self-locking hex nut (22). (4) Install pedal lever shaft (19) and two bushing type bearings (20) and (21) in bracket with lubri- cation fitting facing toward outside of vehicle. (5) Position pedal shaft lever (15) on end of shaft (19) opposite lubrication fitting and secure with hex- head screw (18) and self-locking hex nut (17). (6) Position clutch control clevis (14) to pedal shaft lever (16) and secure with clevis pin (12) and cotter pin (10). Position other end of clutch control levis to release lever (16) and secure with clevis pin (18) and eotter pin (11). (1) Position clutch pedal lever (5) and return spring clip (9) on pedal shaft (19) and secure with hex-head bolt (8) and self-locking hex nut (7). (8) Hook pedal return spring (6) into spring clipe. (9) Insert pedal stem assembly (8) with pad as- sembly (4) through hole in cab floor and into end of pedal lever (5) and secure with hex-head screw (2) and self-locking hex nut (1). (10) Adjust pedal stem assembly (8) and clutch release lever a. above. fa) Have vehicle on level ground and st oner- ating temperature. (®) Drain oil from transmission and transfer by removing the drain plugs from bottom of trans- fer section and bottom of transmission. fc) Also remove upper magnetic plug and gasket located on upper right side of transmission section just behind the transmission front mounting bracket (fig. 2-64) and lower magnetic plug with sasket located on transfer case (fig. 2-64). (d) Wipe all metallic collections from magnets. Wipe out upper magnetic plug oil gallery. (@) Disconnect oil pump return line at tube fitting nut on oil strainer flange. (7) Remove three screws and lockwashers se- curing strainer to transfer case and remove oil strainer and gasket. (g) Clean strainer in dry-cleaning solvent or mineral spirits paint thinner. (2) Fitting. a) Position new gasket and insert strainer into transfer case. Secure with three screws and lock- washers and install magnetic and drain plugs (fig. 264), (b) Connect oil pump return line, (c) Fill transmission and transfer until lever in 1/2-inch below filler hole.BREATHER VALVES GASKET 5 TRANSMISSION FRONT MOUNTING BRACKET GASKET LOWER O1L [UPPER OIL MAGNETIC PLUG = MAGNETIC PLUG GASKET COIL STRAINER FLANGE STRAINER AT 34576 Figure 2-5, Transmianion and tranafer oil magnetic plas and breather. ©. Breather (fig. 2-64). (1) Transmission breather. NOTE Cab floor tunnel must be removed for access to transmission breather. (a) Removal. Unscrew breather from mount: ing located on top of the transmission housing be- hind the shifter cover. (b) Installation. Replace by screwing breather (a) Removal. Unscrew breather from mount- ing located on the rear cover above the handbrake drum. (b) Installation. Replace by screwing breather back into position. ¢. Dust Boots (fig. 2-65). (1) Removal, (a) Place control levers in neutral position. (b) Remove screws securing boot assembly over control levers and remove each boot. . (2)Installation. fa) Place control levers in neutral position. (b) Slide boot assembly over control levers. (c) Secure boot to tunnel with self-tapping screws. (Figure 2-65. Dust boots, d Section IX. ENGINE MAINTENANCE IN VEHICLE-GASOLINE-M123, M123C, M125, 2-52. Description (Fig. 2-66). The vehicle is powered by an 8-cylinder, V-type, 4- eyele, liquid-cooled gasoline engine with overhead valves. The radiator, engine, clutch, and trans- mission are considered as one unit (the powerplant). ‘The fan end of the engine will be referred to as the front. The flywheel end will be referred to as the rear. The terms “left” and “right” as used with ref- erence to the engine, are as viewed from the rear of flywheel end, looking toward the front or fan end. Cylinders are numbered starting from the left front, and reading from left to right. Viewing the engit from the front, the crankshaft rotates clockwise. 2-53. Valve Clearance Adjustment 4. General. Two sequences are described: (1) A method of establishing initial valve clear- ‘ance after all adjustments have been disturbed, as when replacing a cylinder head or gaske (2) A clearance check after the engine has been normalized. (1/2 hour of idle running when cold, or 16 minutes idle running after coming off the road.) This is known as hot idle clearance. ». Initial Clearance (1) Proceed to first cylinder on left bank and turn crankshaft until timing pointer is alined with timing mark on crankshaft pulley (fig. 2-110) and both valves of No. 1 cylinder are closed (push rods in bottom position). (2) Adjust intake valves by using 0.016 feeler age to check clearance between rocker arm and end of valve stem. If clearance is correct, a slight drag will be felt when removing gage. If clearance is in- correct, loosen adjusting screw locknut and turn adjusting screw until a slight drag is felt on the feeler gage (fig. 2-67), Without further movement of serew, tighten locknut. Check clearance with feeler mage. (8) Repeat above procedures on exhaust valves, using 0.020 feeler gage. (4) Proceed to last cylinder on right bank and turn crankshaft 90 degrees at which time intake and exhaust valves of No. 8 cylinder will be closed. Ad- just valves in same manner as described in (2) and (3) above. 2-69‘CARBURETOR AIR INTAKE HOSE ASSEMBLY ‘COMPRESSOR GOVERNOR GENERATOR CABLE WATER: ‘OUTLET. HOSE ASSEMBLY connor AS? A DISCHARGE LINE vn CYLINDER Figure 2-66. Engine compartment-left front view—MI23, MI2SC, M128, (5) Continue through firing order (fig. 2-68) of engine, adjusting both valves for each cylinder as described in (2) and (3) above. Crankshaft must be rotated 90 degrees for each cylinder. ¢. Hot Idle Clearance. (1) Remove cylinder head covers (fig. 2-66). Stop engine when normal operating temperature is reach- ed. Disconnect cylinder head breather line at eyl- inder head cover. Remove four nuts and washers securing cover to cylinder head and remove cover. Perform this operation on both banks of cylinders and start engine. (2) Check cylinder head stud nut torque at 90 Ibeft. 2.70 (3) Check and adjust valve clearance. With the engine idling (450 rpm), and temperature normaliz- ed, check intake valve clearance using 0.013 feeler gage, and exhaust valve clearances using 0.015 feeler gage. Proceed as in b. (2) and b(3) above. (4) Install eylinder head covers. Install new gas- kets if necessary, then position cylinder head cover securing with four hex nuts and washers. Connect breather line to cover and wipe all oil from base inder head cover. Start engine and check for oil leaks at cover, especially at high engine speeds. Tighten cover attaching nuts to correct leaks. If leaks continue, remove cover, and inspect mating edge for rough spots or breaks. Replace cover if necessary.Figure 267. Adjusting valve clearance. EXHINT_INTEXHEXHINT INT EXH FIRING ORDER 1-8-7-3-6-5-4-2 Figure 2-64, Cylinder desiguation and firing order. 2-54. Vacuum and Compression Tests a, Vacuum Test. (1) Remove pipe plug in intake manifold (fig. 2-75) and install vacuum gage. (2) Start engine and run at idling speed (450 rpm). NOTE With engine running at idling speed, vacuum gage should read between 17 and 21 inches of mercury. If gage reads consistently below 17 inches of mercury, faulty piston rings, retarded ignition, or manifold leak is in- dicated. If gage falls back from the ori- > ginal reading, sticking valves are indicated. If gage valve fluctuates, sticking valves, or manifold air leak is indicated. (3) Slowly accelerate engine. If reading on gage is steady, return to idling speed. NOTE ‘An unsteady reading indicates sticking valves, weak valve springs, leaking cylinder head gaskets, or faulty ignition. (4) Depress and quickly release accelerator treadle. The gage should fall to zero as engine is ac- celerated and rise to between 24 and 26 inches of mercury as throttle closes. An appreciably lower reading indicates faulty piston rings. . Compression Test (fig. 2-69). (1) Run engine until normal operating temper- ature is reached. Stop engine. (2) Disconnect spark plug cables and remove all spark plugs. (3) Pull the throttle hand control lever out from panel to maximum position, and push choke control lever to panel. (4) Install compression gage in spark plug hole of No. 1 cylinder. (5) Turn engine over five revolutions with starter. The gage should read from 130 to 140 psi on the compression stroke. Minimum allowable com- pression 100 psi. (6) Perform this test on each cylinder. The gage reading should not vary more than ten psi between ers. NOTE Low readings indicate warped or sticking valves, faulty piston rings, or leaking cy- linder head gasket. (7) Pour two tablespoons of engine oil into each cylinder at which a low gage reading was noted, and again perform the compression test. If compression is increased faulty piston rings are indicated. No,in- crease in gage reading indicates sticking valves or leaking cylinder head gaskets. (8) Install the eight spark plugs in the cylinder heads and connect cables. 2-55. Engine Mounts a. Removal, (1) Front mount (fig. 2-70). (a) Remove four self-locking nuts securing mounting bracket to frame sidemember. (b) Jack up engine at lower pan using a block of wood to distribute weight. (c) Remove two bolts and self-locking nuts securing insulators to bracket and remove in- sulators. (2)Rear mount. (a) Remove two nuts, lockwashers, lower insu- ators, and bolts from each of the two mounting brackets. 271Figure 269, Engine compression tet (b) Jack up transmission and lift out upper insulators. 6. Installation (1) Front mount. (a) Jack up engine and position upper insulators between bottom flange of engine gear case cover and mounting bracket and install two bolts. Install lower insulator over bolts and secure with self-locking nuts. UPPER INSULATOR, INSULATOR Ar 34582 Figure 270, Engine front aupport, mounts, and vibration damper 272 (b) Position engine front mounting supports on left and right mounting brackets and secure eight bolts and self-locking nuts. (2) Rear mount. (a) Jack up transmission and insert two rubber insulators between rear mounting bracket on trans- mission assembly and bracket on frame sidemember with bevel side of insulator up. () Insert driftpin in adjacent holes of bracket and aline bracket so a mounting bolt can be inserted. (c) Install bolt through insulator (bevel side down) and secure through lower insulator with self- locking nut. fd) Repeat this procedure on opposite mount- ing. The remaining mounting bolts and insulators may now be installed without further alinement. (e) Check adjusting bolts by inserting a 0.015 feeler gage between transmission mounting bracket and head of adjusting bolt at each end of left rear powerplant support bracket (fig. 2-48). Adjust bolts until a slight drag is felt on feeler gaye when removed. Tighten locknut. 2-56. Cylinder Head and Cylinder Head Gaskets a Removal. (1) Remove intake and exhaust manifolds (par 2-62), (2) Disconnect four spark plug cables from plugs. Remove bolt and lockwashers securing harness sui port from head. Move harness and cable to top of engine. Remove four spark plugs. (3) Remove eylinder head cover (para 2-53) and lift off four eylinder head cover spacing sleeves from each rocker arm bracket stud. (4) Remove four hex nuts and washers securing rocker arm assembly to cylinder head assembly. (5) Lift off rocker arm assembly (fig. 2-71). (6) Disconnect oil line from cylinder block to eylinder head at rear of cylinder head. (7) Carefully lift out eight push rods. Remove remaining 13 hex nuts and washers which hold ¢ inder head assembly to cylinder block assembl and remove cylinder head. Remove two sleeve-type dowels, which are used to aline eylinder head to eylinder block, from lower front and rear studs. Remove and discard cylinder head gaskets. Scrape clean mating surfaces of block and cylinder heads toremove old gasket material. (8) Repeat above procedure at other bank of cylinders. b. Inspection. Inspect cylinder head for cracks and sand holes. Replace head if either is evident.. Installation (1) Install two cylinder head locating sleeve-type dowels on studs at each end of p.lSand 14, fig. 2-70. Y (2) Place new cylinder head gasket on cylinder lock being careful to aline gasket perfectly so as not to obstruct any oil or water passages. (3) Carefully position eylinder head on eylinder block, ing dowels as guides. Install 13 washers and hex nuts on all studs except those which support rocker arm assembly (studs 11, 4, 3, and 12, fig. 71). Tighten nuts fingertight. Conneet oil tubing at rear of cylinder head. NOTE Inspect push rods for cracks or defects and loose ends. Roll the push rods on a flat sur- face to check for bent rods. All bent or de- fective rods must be replaced. (4) Insert eight push rods in openings through evlinder head, making sure ball ends of rods rest in sockets of lifters. (5) Install rocker arm assembly on four long studs, securing each bracket with plain washer and hex nut tightened fingertight. (6) Use torque-indicating wrench to tighten all hex nuts securing cylinder head to cylinder block to 90 Ib-ft torque in tightening sequence shown in figure 2-71. Use the same procedure to install remain- ” eylinder head. (7) Install intake and exhaust manifolds (para 2-62). (8) Before engine can be started, an initial valve clearance adjustment (para 2-53) must be made. (9) Install spark plugs and new gaskets. (10) Position both harness brackets and secure each with bolt and lockwasher. Connect cables to spark plugs. (11) Fill cooling system (para 2-87). (12) Start engine and run until normal operating temperature is attained. With engine idling, check valve clearance (para 2-53) and install cylinder head covers (fig. 2-66). 2-57. Cylinder Block Covers a. Removal. (1) Remove intake and exhaust manifolds (para 2-62). (2) Remove 17 bolts (fig. 2-72) and copper washers securing cover assembly to cylinder block. (8) Lift cover assembly off and discard gasket. ©. Cleaning and Inspection. (1) Wipe clean and inspect front and rear halves, to be sure they are not bent, cracked, or broken. (2) Check condition of bolting surfaces and mounting bolt holes. (8) Replace cover if necessary. = rte \Y ise Figure 2-71. Cylinder head stud nut tightening nequenee.COVER, CRANKCASE, FRONT HALF ASSEMBLY COVER, CRANKCASE, REAR HALF Figure 2-72, Cylinder block covers. c. Installation. (1) Clean cylinder block gasket surfaces. (2) Install a new gasket. Position cylinder block cover on cylinder block and secure with 17 hex-head bolts and copper washers (fig. 2-72). 2-58. Vibration Damper and Crankshaft Pulley a. Removal. (1) Remove six bolts and lockwashers securing vibration damper to crankshaft pulley and remove vibration damper (fig. 2-70). (2) Remove serew, lockwasher, and flat washer securing crankshaft pulley to crankshaft (fig. 2-70). (3) Using suitable puller, remove crankshaft pulley (fig. 2-73). (4) Remove Woodruff key. b. Installation. (1) Insert Woodruff key in keyway in crankshaft and drive on crankshaft pulley with mounting holes for vibration damper facing out. (2) Secure pulley with screw. lockwasher, and flat washer. (3) Position vibration damper on crankshaft pulley and secure with six bolts and lockwashers. 2-59. Oil Filters CAUTION Be sure there are no leaks around filter covers and oil line connections. a, Filter Element (fig. 2-14). (1) Removal. (a) Remove drain plugs and drait (6) Remove end filter cover retaining capscrew. 274 Figure 2-73, Removing crankshaft pulley with puller. cover, and gasket (discard gasket). Lift out re- placeable filter elements and discard. (2) Installation. (a) Clegin inside of filter bodies with dry clean- ing solvent or mineral spirits paint thinner. Install new filter elements. Install drain plugs. (b) Install filter body covers with new gaskets and tighten filter cover retaining capscrew. Add oil until operating temperature is reached. (c) Stop engine and check oil level in crank- case. (d) Add oil as necessary. ©. Filter Body. (1)Removal. fa) Disconnect inlet and discharge lines se- curing filter bodies. fb) Remove five bolts and self-locking nuts securing filter bracket on frame. Discard gasket. (2) Installation, (a) Place new gasket on oil filter mounting bracket. (b) Position and secure mounting bracket with five bolts and self-locking nuts. (c) Connect inlet and discharge lines at filter quick disconnect points. Hand tighten should be suf- ficient. If wrench is used, hold mating end of quick disconnect with another wrench. (d) Start engine and run until operating tem- perature is reached. Check filter assembly for tightness and leaks. Stop engine and check erank- case oil level. Add oil as necessary. 2-60. Lines and Fittings Refer to paragraph 2-47.2-61. Ventilation Regulator and Strainer (fig, 2-75). a. Removal. (1) Disconnect ventilation regulator-to-intake 0 manifold tube at tee in inlet manifold. (2) Remove two serews and lockwashers securing ventilation regulator cover to cylinder block cover and remove regulator with cover, strainer, and gasket. Discard gasket. . Servicing. The ventilation regulator must be serviced quarterly or after 3,000 miles, whichever occurs first. (1) Submerge regulator and cover in dry-clean- ing solvent or mineral spirits paint thinner to re- move any foreign material. (2) Submerge and flush ventilation strainer in similar manner. Dip in engine oil and allow to drain. ¢. Installation. (1) Using new gasket, insert strainer in recess in rear half of eylinder block cover. (2) Position ventilator and cover in evlinder block cover and secure with two capscrews. (3) Connect tube to tee in intake manifold and tighten tube nut. 2-62. Manifolds a. Removal. (1) Drain cooling system by opening drain cock at bottom left of radiator (fig. 2-45), and two drain cocks on engine cylinder block (one on each side). NOTE If antifreeze solution is present in coolant, it can be collected and saved. (2) Loosen clamps on four hose connections on carburetor air intake hose assemblies (fig. 2-66). and slide hose toward center of pipes. Lift out both pipe assemblies. > Figure 2-74, Replacing oil filter element. * Figure 2.75. Removing or installing ventilation regulator and strainer. (3) Remove two bolts and lockwashers securing elbow flange of each outlet hose assembly (fig. 2-66) to exhaust manifolds. Loosen clamp on rubber hose section of each assembly, and lift out. Discard elbow flange-to-exhaust manifold gasket. (4) Disconnect flange fitting on compressor dis- charge tube (fig. 2-66) at air compressor, and remove bolt and lockwasher from clamp which secures this tube to intake manifold. (5) Disconnect compression fittings on air tube to compressor governor (fig. 2-66) at compressor and where it meets flexible section of line. (6) Remove ventilation regulator strainer tube from intake manifold by removing tubing nut. (1) Disconnect generator cable (fig. 2-66) con- nection at generator and remove bolt and lockwasher securing bracket at manifold elbow, and move cable to rear of engine compartment. (8) Disconnect cylinder block breather line st cylinder head cover (fig. 2-65) to avoid damage to line when removing manifolds. (9) Remove carburetor assembly (para 2-67). (10) Disconnect compressor coolant discharge tube, on vehicles so equipped, at intake manifold and at rear half of cylinder block top cover assembly. Remove line. (11) Remove three bolts and washers securing each exhaust pipe assembly (figs. 2-66 and 2-76) to exhaust manifold, and remove four bolts and lock- nuts securing each pipe to muffler. Pull exhaust pipe assembly away from manifold and discard gasket. 275‘GENERATOR CABLE ELBOW Figure 2-76, Disconnect pointn om right side of engine. (12) Remove clevis pin securing radiator stay rod (fig. 2-66) to intake manifold bracket and loosen nut on end of stay rod at radiator. Lift out stay rod. (13) Disconnect temperature gage wire connection (fig. 2-76) at right exhaust manifold. (14) Remove 12 hex nuts and washers (fig. 2-77) securing intake and exhaust manifolds to cylinder heads. Remove eight clamp washers interlocking intake and exhaust manifolds. Lift off both exhaust manifolds. (15) Remove four capscrews and washers securing intake manifold heat connection flanges to cylinder heads. Lift off intake manifold. Remove both mani- fold gaskets. 276 b. Cleaning and Inspection. Clean and inspect for cracks and warpage. ¢ Installation, (1) Install new manifold gasket on each cylinder head and position the intake manifold, heat tubes, and connections. The manifold is doweled to facil- itate attaching to cylinder head. (2) Position two exhaust manifolds and center ‘on end studs. Install eight manifold clamp washers ‘on studs which secure intake and exhaust manifolds. (8) Position manifolds by hand tightening 12 hex nuts and washers. Use a torque-indicating wrench and tighten hex nuts to 60 Ib-ft torque in tightening sequence shown in figure 2-77.RAH, EXHAUST MANIFOLD Pore 2-77, Intake and exhanst manifold wtud wut tightening sequence, (4) Secure both intake manifold heat connecting flanges to cylinder heads with two capscrews and lockwashers in each flange. (5) Connect temperature gage wire connection (fig. 2-76) right exhaust manifold. (6) Position radiator stay rod (fig. 2-66) and secure one end to intake manifold bracket with clevis pin. Insert rod into mounting bracket on top of radiator. Tighten nut. (7) Install new gasket on each exhaust manifold ‘and swing both exhaust pipes over respective exhaust manifold. Secure each exhaust pipe to exhaust manifold with three bolts and lockwashers. Secure each exhaust pipe to muffler with four bolts and self-locking nuts. (8) Connect crankcase breather line to intake manifold and rear half of cylinder block top cover assembly (fig. 2-66). (9) Connect compressor coolant discharge tube on vehicles so equipped (fig. 2-66) to left exhaust manifold and to rear of air compressor assembly. (10) Install carburetor (para 2-69). (11) Connect generator cable (fig. 2-66) at generator connection and also clamp in midportion of cable. (12) Connect air line to compressor governor (fig. 2-66), at compressor, and at flexible tube from compressor governor. (18) Connect compressor discharge line (fig. 2-66) to air compressor. Position line clamp and secure to intake manifold with bolt and lockwasher. (14) Place new gasket on each exhaust manifold and position two water outlet hose assemblies (fig. 2.66). Secure each assembly to its exhaust manifold with two bolts and lockwashers. Silide rubber hose section of each assembly into position at thermostat housing, and tighten clamps. (15) Position each carburetor air intake hose fig. 2-66) and slide rubber hose sections into n. Tighten eight clamps on pipes. (16) Close all drain cocks and fill cooling system. 2-63. Clutch Controls and Linkage Refer to paragraph 2-50. 2-64. Transmission Refer to paragraph 2-51. 207Section X. FUEL SYSTEM—GASOLINE—M123, M123C, M125. 2-65. General Both fuel tanks contain an electric fuel pump. Se- lection of fuel tank and pump is accomplished by the fuel pump selector switch on the instrument panel, and indication of fuel level in the tanks by the fuel gage switch. Switches are energized when the ignition switeh is turned on. Fuel is pumped from the tank selected direct to the carburetor. Air for combustion passes through dual air cleaners and is piped to the carburetor air intake. Control of engine maximum speed is by a mechanically-actuated vacuum-operated governor (fig. 2-83) the slave unit of which is integral with the carburetor throttle valve assembly. 2-66. Air Cleaners a. Removal. (1) Left air cleaner. (a) Raise hood and lock in place. (b) Unhook side panel and lay against fender (fig. 2-79). (c) Disconnect all breather lines at air cleaner body (fig. 2-78). (d) Loosen two clamps at end of cleaner to carburetor tube and slide tube free of air cleaner outlet (fig. 278). (e) Remove four cleaner support band clamp bolts and lockwashers, and lift out cleaner. (2) Right air cleaner. (a) Perform steps (a) through (d) above. (b) Remove engine oil level gage. (c) Remove nut from spark plug cable bracket bolted on cylinder head valve cover. (d) Move breather line and spark plug cable to rear to clear air cleaner. AIR CLEANER MOUNTING BRACKET Figure 2-14, Exgine compartment from the rear- M128, M12sC, M185. 278(e) Remove four air cleaner support band clamp bolts and lockwashers, and lift out air cleaner. 6. Cleaning. (1) Remove air cleaner a. above. 0 (2) Remove reservoir by loosening clamp screw. (3)Submerge cleaner body in dry-cleaning solvent or mineral spirits paints thinner and allow to remain 1/2-hour. (4) Reverse flush manually by lifting cleaner body out of dry-cleaning solvent or mineral spirits paint thinner, outlet fitting up. and allow to drain. (5) Repeat (4) above several times until visible area of mesh at bottom of body is clean. (6) Clean reservoir and fill to level mark with engine lubricating oil (OE) (LO 9-2320-206-12). (7) Position body on reservoir and tighten clamp serew. (8) Install c. Installation. ()) Left air cleaner. (a) Unscrew lower clamp bolt, remove reservoir (fig. 2-79), clean and fill with lubricating engine oil (LO 9-2320-206-12). (b)Install cleaner body on reservoir and tighten lower clamp bolt. (c) Lift cleaner into position and aline outlet with carburetor air tube. (d) Install two bolts and lockwashers in upper support band and tighten. Install two similar bolts and lockwashers in lower support band. (e) Slide carburetor air tube over cleaner out- let. position clamps, and tighten clamp screws. (A Connect all breather lines to air cleaner body. (2) Right oir cleaner. (a) Perform steps (a) through (f) above. (b) Install spark plug cable bracket on cylinder head and secure with nut removed in a. (2) above. (c) Install engine oil level gage. (d) Close side panel and secure. (e) Close and secure hood. 2-67. Carburetor Controls and Linkage @. Choke Control. (1) Adjustment. ir cleaner c. below. NOTE ‘The choke control is in proper adjustment when choke plate is in full-open position with the control knob against instrument panel and the choke plate can be fully closed by pulling knob away from panel. (a) Adjust choke by loosening setscrew on choke lever at carburetor. (b) Push control knob against instrument panel, and with choke plate in horizontal position, tighten swivel screw on choke. AT 24591 9 D emt ~ igure 279, Removing or installing air cleaner (2) Removal, (a) Loosen swivel screw in choke control lever and cable clamp serew and pull cable assembly free. (b) Remove nut (1. fig. 2-80) and lockwasher (2) on inside of instrument panel releasing control assembly (3) from panel. (c) Pull choke control cable assembly out through panel. (3) Installation. (a) Insert choke control assembly (3) through instrument panel and secure assembly to panel with hex nut (1) and lockwasher (2). (b) Position control so lettering on control knob is in horizontal position, and tighten nut. (c) Insert control assembly through dash panel grommet (4). (d) Thread cable through clamp, then insert wire into swivel on choke lever; tighten clamp serew. (e) Adjust control as outlined in step a. (1) above. , Treadle Assembly and Bracket. (1) Removal. fa) Remove self-locking nut (5, fig. 2-80) from control rod (6). (b) Remove cotter pin from pedal rod (7) at accelerator pedal (8). (c) Remove four bolts (9) and nuts from bracket. (10) and remove bracket assembly (10). (d) Remove bolts (11) from accelerator pedal bracket (12) and remove accelerator pedal assembly. (2) Installation. (a) Insert pedal rod (7) through hole in floor- board and position bracket (10) with mounting holes. (b) Secure bracket (10) with four mounting bolts (9) and nuts. (c) Install control rod (6) in idler lever (13) of bracket (10). 279(d) Secure control rod (6) with self-locking nut (5). (e) Aline accelerator pedal (8) with floorboard mounting hole: (A) Insert pedal rod (7) in accelerator pedal (8). (g) Install cotter pin in pedal rod (7). (h) Secure accelerator pedal (8) and bracket (12) with two mounting bolts (11) and nuts. ¢. Throttle Control. (1) Adjustment. (a) Throttle control assembly (14) is in proper adjustment when throttle control T-handle is against, instrument panel and carburetor throttle control lever is in idling position (para 2-69a.(1)). NOTE Pedal is adjusted to stop when throttle is fully open. Speed range is controlled by en- gine speed governor. (0) Adjust idling control by loosening serew in collar (15) on end of wire of cable assembly. (c) Check to see that control knob is against instrument panel, then slide collar (15) against link clip (16) and tighten screw. (d) To adjust full-open pedal stop. loosen self-locking nuts (17 and 18) and turn eapserew (19) as required, and lock in position. (2)Removal (a) Loosen screw in collar (15), which is on wire end of throttle control assembly (14), and slide off collar. (b) Loosen nut which holds control assembly cable clip to throttle clip mounting bracket (20) and pull control assembly out of clip. (c) Remove jamnut (21) and lockwasher (22) securing control assembly to instrument panel by reaching behind panel. (d) Remove control assembly. (3) Installation. (a) Insert throttle control through instrument panel. (b) Position control T-handle so lettering is vertical. (c) Secure assembly to panel with hex jamnut (21) and lockwasher (22). (d) Feed control assembly cable through grommet (23) in dash panel and insert clip at throttle clip mounting bracket (20). (e) Tighten nut which holds securing control assembly cable in position. (A) Insert wire protruding from control as- sembly through plate secured to throttle rod (24), and slide collar (15) on wire. (g) Adjust throttle as outlined in step ¢. (1) above and tighten the collar serew: assembly (14) ip to bracket 2-68. Lines and Fittings Refer to paragraph 2-47. 2-69. Carburetor 4 a, Adjustment NOTE After engine temperature is normalized (1/2-hour at idle speed, or ten minutes idling of an engine just off the road), lift hood and lock in place. Install vacuum gage (para, 2-54). (1) Adjust idling speed. (a) Adjust throttle stop adjustment screw until engine speed is 450 rpm. (b) Check control linkage for proper adjust- ment (para 2-67 a. (1) (2) Adjust idling mixture. (a) With engine idling at 450 rpm turn idle adjustment screw clockwise to make gas-air mixture richer, and counterclockwise to make mixture leaner (fig. 2-81). (6) Normal setting is from one-half to a full turn open. Turn idle adjustment screw clockwise or counterclockwise to obtain highest reading on vacuum gage. (c) If engine idles too fast after ajustment, adjust throttle stop adjustment serew until 450 rpm is obtained. é NOTE Regulation of idling speed does not affect function of carburetor at highest speeds. b. Removal. (1) Raise hood and lock in open position. (2) Disconnect air intake tubes at air cleaners and carburetor elbow by loosening hose clamp serews and sliding hose onto tubes (fig. 2-82). Remove tubes and hoses. (3) Disconnect fuel line at carburetor (fig. 2-82). (4) Loosen setserew in choke control lever and clamp screw on choke control casting. Remove choke control wire (fig. 2-81). (5) Disconnect throttle control rod from throttle lever by removing self-locking nut and ball stud from lever (fig. 2-81). (6) Disconnect air inlet elbow by removing four bolts and lockwashers (fig. 2-82). (7) Break seal on governor slave unit and remove hex plug on upper housing (fig. 2-83). Loosen socket- head setscrew exposed by plug removal. Remove control cable tube nut from speed control unit (fig. 2-83) and pull out tube and cable assembly. (8) Remove six carburetor mounting nuts and lockwashers and lift off carburetor (fig. 2-82). Dis- card gasket.LJamnut 2Lockwasher ‘3Choke control { Acelraor pedal ‘9 Bolt Lee 12 Bracket 13|idler lever 14 Throttle control assy 15 Collar 16 Chip YTNut 18 Self-locking nut 19.Capscrew 20Bracket 21 Jamnut 22 Lockwasher 23Grommet 24Rod Figure 280, Choke and throttle control arrangement. 2-81FUEL INLET GOVERNOR SLAVE UNIT Le ‘ADJUSTMENT SCREW THROTTLE STOP 5 ‘ADJUSTMENT SCREW THROTTLE Lever Figure 2.41, Carburetor adjuatment points, ©. Cleaning. NOTE Never use a wire or drill to clean out jets. Clean all metal parts thoroughly with dry-cleaning solvent or mineral spirits paint thinner. d. Installation. (1) Clean flange surface of manifold, making sure no particles of gasket remain, and position new gaskets on studs. (2) Position carburetor on studs and secure with six hex nuts and lockwashers. (8) Connect throttle control rod by installing ball stud in lever and secure with self-locking nut (fig. 281). (4) Thread choke contro! cable through cable clamp and engage wire in lower swivel making sure choke knob is against panel and choke plate is in full open position. Tighten swivel screw on choke 282 lever and screw on cable clamp serew (fig. 2-81), (5) Connect fuel inlet line, transferring elbow from removed carburetor. (6) Insert governor control cable into recess of collar. Use sockethead setscrew wrench to force collar into cable after hand tightening tube nut. Tighten setscrew and tube nut; then install hex plug and washer. Install seal on tube nut and plug. (7) Install air inlet elbow, using four bolts and lockwashers. (8) Install two air intake tube assemblies by Positioning hose ‘and tightening hose clamp screws. e. Testing. (1) Start engine. When engine temperature is normal, adjust idling air mixture (para 2-69a. (2)). (2) Check engine no-load speed to 2,750 rpm. over 2.750 rpm. notify supporting maintenance. (3) Close and secure hood.arse fi 283CONTROL CABLE 4 AND TUBE ‘SPEED GOVERNOR WITH ADAPTER Figure 2.13. Engine speed governor and slave unit. 2-70. Fuel Pumps a. Testing. Test fuel pump pressure, by connect- ing gage at outlet at tank, and with the tank at least, one-quarter full of fuel. A pressure gage, line, and adapter for connecting gage to fuel outlet fitting at fuel tank are required to perform the test. (1) With ignition switeh off, disconnect fuel line from outlet fitting at tank. Connect pressure gage to fitting. (2) Turn ignition switch ON and turn fuel pump switch to the tank being tested. Observe reading on pressure gage. For satisfactory operation, pres- sure reading should be between 8.75 and 5.5 psi. (3) If fuel pump pressure is below 3.75 psi, re- place pump (b. and d.) below. b. Removal (fig. 2-84). WARNING Before performing any fuel pump opera- tions, disconnect cable No. 77 when working on left tank or cable No. 78 when working on right fuel tank from electrical connector and wrap it with insulating tape to prevent the possibility of an electrical spark ig- niting fumes in the fuel tank. 284 cyMizs. (a) Remove winch tread plate over tank (para 2-241), (b) Drain fuel tank (para 2-71). fc) Remove fuel tank (para 2-71). (d) Remove 16 screws and lockwashers secur- ing fuel pump assembly to tank. (e) Lift fuel pump assembly out of fuel tank and discard gasket. (2) M125, Proceed as in (1) above. Omit item (a). ¢. Cleaning Filter Plates. Two filter plates, each attached by four screws and metal frame, are instal- led on each fuel pump hanger. To clean plates pro- ceed as follows: (1) Remove fuel pump assembly b. above. (2) Remove four screws which attach each filter plate frame to hanger. NOTE Plates should be marked so they ean be in- stalled in the original position with same side facing outward, (8) Remove frames and lift off filter plates. Wash thoroughly in dry-cleaning solvent or min: eral spirits paint thinner.ELECTRICAL CONNECTIONS Figure 2-45. Removing or installing fuel pump. (4) Position filter plates and retaining frames and secure each frame with four screws. (5) Install fuel pump in fuel tank d. below. 4. Installation. yrs. (a) Position new gasket on fuel pump opening jn fuel tank, and lower pump assembly into tank. (b) Secure pump to fuel tank with 16 screws and lockwashers. fc) Connect electrical cable, cable No. 77 for left tank and cable No. 78 for right tank. (d) Install fuel tank (para 2-71). (c) Install winch tread plate (para 2-241). (A Fill tank to proper level (para 2-65). (2) M125. Proceed as in (1) above. Omit item (e). 2-71. Fuel Tanks (Pig. 2-85). WARNING When draining tanks attach a ground wire from vehicle fuel tank to fuel receptacle to carry off static electri a. Removal, (1) Remove winch tread plate over tank (M123 only) (para 2-241). (2) Disconnect fuel gage sending unit cables cir- ‘cuit Nos. 28 and 29 (fig. 2-150). (3) Disconnect fuel pump cables circuit Nos. 77 and 78 (fig. 2-150). (4) Disconnect fuel tank ground eable circuit No. 79 (fig. 2-150) (5) Drain fuel tank. (a) Provide suitable clean containers and po- sition under each fuel tank at the drain plug. (6) Clean area around drain plugs and remove each drain plug by turning counterclockwise. (6) Disconnect fuel line from pump and vent line from top of tank. (7) Remove two self-locking nuts from bottom end of tank strap (T-bolts remain with straps). (8) Remove fuel tank. Installation. (1) Position fuel tank on mounting bracket. (2) Position holding straps and secure lower ends with two self-locking nuts. (3) Connect main fuel line to pump outlet and vent line to top of tank by securing tubing fittings. (4) Connect fuel tank ground cable circuit No. 19 (fig, 2-150) to left hand connector on fuel pump. Section XI, FUEL SYSTEM AND INDUCTION SYSTEM—M123A1C, M123E2 2-72. General ‘The fuel system used on the M123A1C, M123E2 die- sel engine is pressure-time, governor-controlled. The operation of the system is based on the principle that the volume of fuel flow is proportionate to the fuel pressure, the time allowed to flow, and the size of passage the fuel flows through. 2-73. Air Cleaner a. Removal. (1) Loosen hose lamp securing air cleaner inlet to hood side panel. (2) Loosen hose clamp at outlet end of air clean- er. (3) Remove two bolts securing air cleaner mount- ing straps to firewall. (4) Remove air cleaner assembly. 6. Cleaning. (1) Remove element at 1,000 miles and replace with a serviceable element. (2) Inspect element for evidence of damage. If damaged, discard element. (3) Wash with mild, non-sudsing detergent in cool or lukewarm water. Do not use gasoline or other solvents, (4) Soak element approximately five to ten min- utes and “slosh” and shelf dry at least three days. (5) After washing, carefully inspect for evidence 285a CoS. as, She ¢ 2 wr} TANK STRAP LPP ves ue VENT.LINE a a Oe FUEL TANK a LOK% SELF-LOCKING NUT AT 34597 Firure 2-85, Fuel tank—M128, MI28C, M125, ry of any holes, tears, or seal damage. If element is ser- viceable, return to stock. cc. Installation. (1) Position air cleaner in the installed position. Temporarily connect two mounting straps securing air cleaner to firewall. (2) Connect air cleaner outlet hose and secure clamp. (3) Install hood side panel and tighten air inlet hose clamps. (4) Tighten the two air cleaner mounting strap bolts. 2-74. Accelerator Linkage and Controls a. Throttle Control (fig. 2-87). (1) Adjustment. (a) The throttle control assembly (1, fig. 2-87) is in proper adjustment when throttle control T- handle is against instrument panel and engine is at idle speed. NOTE The accelerator pedal is adjusted to stop when accelerator is fully open. 286 (b) To adjust throttle control, loosen setscrew in collar (2) on end of wire of cable assembly. Check to see if control knob is against instrument panel. then slide collar (2) against throttle rod and tighten screw. (c) To adjust full-open pedal stop, loosen self- locking nuts (3), turn capscrew (4) as required, and lock in position. (2) Removal. (a) Loosen setserew in collar (2), on wire end of throttle control assembly (1), and slide off collar. (b) Loosen nut which holds control assembly cable clamp and pull control assembly out of clamp. fc) Remove nut (5) and lockwasher (6) securing control assembly to instrument panel by reaching behind panel. (d) Pull out control assembly. (3) Installation. (a) Insert throttle control assembly (1) through instrument panel. Position control T-handle so let- tering is verticle. fb) Secure assembly to panel with hex jamnut (5)and lockwasher (6). (c) Feed control assembly cable through grom: met (7) in dash panel and insert through cable clamp (8).AR RESTRICTION INDICATOR (CRANKCASE. PRESSURIZATION VALVE Piyure 2.48, Engine compartment—frot view—MI23A1C ‘MI3E2, (d) Tighten nut which holds clamp securing control assembly cable in position. fe) Insert wire protruding from control as- sembly through throttle rod, and slide collar (2) on wire, (9) Adjust throttle (a. (1) above). b. Treadle Assembly and Bracket. (1) Removal. fa) Remove winch accelerator control lock- nuts(9), (b) Disconnect accelerator rod joint (10) from fuel pump. (c) Loosen setscrew on throttle control collar (2), Remove cotter pin from accelerator rod (11) at treadle assembly (15). (a) Remove four bolts (12) and locknuts (13) securing bracket assembly (14) to floorboard, fe) Remove bracket assembly (14), @ Remove two bolts and locknuts securing treadle assembly (15) to floorboard. (g) Remove treadle assembly (15). 2:871 Throttle control 2Collar 3Nut 4 Bolt 5Jamnut ‘6 Lockwasher 7Grommet 8Clamp 9 Bolt 10Joint 11 Rod 12 Bolt 13 Locknut 14 Bracket assy 15 Treadle asey 16 Bolt Figure 287, Accelerator linkage and controlt—MI24A1C, MIZE, (2) Installation. a) Install two bolts (16) and locknuts securing treadle assembly (15) to floorboard. (b) Position bracket assembly (14) and install four bolts (12) and locknuts (13). (c) Install a new cotter pin in accelerator rod (11) at treadle assembly (15). (d) Connect accelerator rod joint (10) to injector pump lever. e) Install throttle control cable and tighten setserew on collar (2). (f) Adjust throttle (a. (1) above). (g) Install w inch throttle control locknuts (9). 2-75. Triple Stage Fuei Filter (Fig. 2-88) @. Strainer ist Stage. (1) Removal. (a) Close inlet valve. (b) Open drain cock at bottom side of housing and drain fuel. (c) Remove nut at bottom center of filter housing. (d) Remove and clean out housing. 4 (e) Inspect strainer and gasket, replace necessary.(2) Installation. (a) Close drain cock at bottom side of housing. (b) Refill filter housing with clean fuel. (c) Install housing. 9 (a) Open inlet valve. J Fitter Second and Third Stage. (1) Removal. (a) Close inlet valve (b) Open drain cocks at bottom of filter can, and drain fuel. (c) Remove bolt at top center of filter bracket. (d) Remove and clean can. (e) Remove dirty filter element. (2) Installation. (a) Install new filter element and gasket. (b) Close drain cocks at bottom of filter can. (c) Filan with clean fuel. (d) Install can and secure with bolt at top center of filter bracket. (e) Open valve at inlet to first stage filter. (Open inlet valve. 2-76. Fuel Shutoff Solenoid NOTE ‘Knob must be fully counterclockwise to per- mit normal solenoid operation. a Removal. (1) Disconnect electrical circuit number 54 (fig. 2-151) at solenoid valve. (2)Disconnect fuel inlet line. (3)Remove holddown screws. (4) Remove solenoid valve and discard preformed packing. b Installation. (1) Install preformed packing and solenoid valve. (2) Install holddown screws, (3) Connect fuel inlet line. (4) Connect electrical circuit number 54 (fig. 2- 151) at solenoid valve. 2-77. Glow Plug (Fig. 2-89) a. Removal. (1) Remove igniter wire from glow plug. (2) Unserew glow plug from air cleaner assembly connection. (3)Remove plain washer. b. Installation. (1) Install plain washer. (2) Serew glow plug into air cleaner assembly connection. (8) Connect igniter wire to glow plug. ” 2-78. Resistor renee 2-90) ‘CROSSOVER VALVE FUEL TANK) INLET VALVE AGE Fuee Fitters | Figure 2.4%. Triple stage fuel filter: (1) Disconnect resistor from harness assembly behind engine starting aid panel. (2) Remove nut, bolt, and clamp securing hand primer pump control to resistor bracket assembly. (8) Remove nut and bolt securing one end of resistor bracket to engine starting aid panel, and remove two screws securing other end of resistor bracket to firewall. (4) Drop resistor bracket assembly from under instrument panel. (5) Remove two nuts and bolts securing resistor to bracket assembly. 6. Installation. (1) Position resistor to bracket and secure with two nuts and bolts. (2) Place bracket assembly with resistor under instrument panel. Secure one end to firewall with two screws. Secure opposite end of engine starting aid panel with nut and bolt. WASHER AIR CLEANER ASSEMBLY CONNECTION Figure 2.49, Glave ply, 2-89HARNESS ASSEMBLY RESISTOR BRACKET GLOW PLUG SWITCH GLOW PLUG RELAY STARTING AID PANEL Figure 2-90, Dienel engine starting aids (8) Position clamp on hand primer pump and secure to resistor bracket assembly with nut and bolt. (4) Connect harness assembly to resistor. 2-79. Pressure Gage (Fig. 2-90) a. Removal. (1) Disconnect harness assembly from pressure gage behind engine starting aid panel. (2) Remove locknut and washer from behind pressure gage. (8) Remove three screws securing fuel pressure gage to starting aid panel. Remove pressure gage. , Installation. (1) Position fuel pressure gage into starting aid panel and secure with three screws. (2) Place washer and locknut on back of fuel pressure gage and tighten. (3) Connect harness assembly to fuel pressure age. 2-80. Fuel Tanks, Lines, and Fittings a. Fuel Tanks (fig. 2-91). 290 GLOW LUG HAND PRIMER INDICATOR PUMP ar 34602 WARNING ‘When draining tanks attach a ground wire from vehicle fuel tank to fuel receptacle to carry off static electricity. (1) Removal. (a) Remove winch tread plate over tank (para 2241), (b) Disconnect fuel gage sending unit cable (right tank only). (c)Drain fuel tank. 1. Clean area around each drain plug. 2, Provide suitable clean containers and posi- tion under each fuel tank at drain plug. 8. Remove each drain plug by turning coun- terclockwise. (d) Disconnect fuel tank vent line from top of tank. (e) Disconnect fuel line (bottom front of tank). Cap both connections. () Remove two self-locking nuts securing tank strap ends (T-bolts remain with straps). (9) Remove fuel tank. (2) Installation.d (a) Position fuel tank on mounting bracket. (b) Position holding straps and secure with two self-locking nuts. (©) Connect fuel line (bottom front of tank). (d) Connect fuel tank vent line to top of tank. (e) Connect fuel gage sending unit cable (right tank only). (A Install tread plates (para 2-241). (g) Fill tank to proper level. ©. Lines and Fittings. Refer to paragraph 2-47. Section Xl. EXHAUST SYSTEM 2-81. General a. M128, M128C, M125. Each bank of cylinders of this engine has a separate exhaust system, consisting. of an exhaust pipe, muffler, and tailpipe assembly. Esch exhaust pipe is flanged and secured by three mounting bolts to an exhaust manifold. The muffler is flanged both at front and rear and mounted to the exhaust pipe by four mounting bolts, and to the tail- pipe with three mounting bolts. The flanged joints are sealed with asbestos gaskets. b. MI2SAIC, M128E2. The exhaust system consists of two exhaust pipes and mufflers, one for each bank of cylinders of the engine, a crossover pipe, and vertical tailpipe assembly. Each exhaust pipe is flanged and secured with a band clamp to an exhaust, manifold. The muffler is flanged at both front and Tear and mounted to the exhaust pipe by four mount- ing bolts, and to the tailpipe with three mounting VENT LINE, FILLER CAP bolts. The flanged joints are sealed with asbestos gaskets. NOTE ‘The procedures for removal, and installation of components on left side of vehicles are the same as described on right side shown below. 2-82. Tailpipe a. Removal. (1) M128, M128C, M125 (fig. 2-92). (a) Remove three self-locking nuts (1, fig. 2-92) and bolts (2) securing tailpipe (3) to exhaust muffler (4) and discard gasket (5). (b) Remove bolt (6) and self-locking nut (7) securing tailpipe clamp (8) to tailpipe hanger (9) just forward of fuel tank. (c) Remove tailpipe (3). Daw LEFT FUEL TANK AT 34603, Figure 2.91. Fuel tank—MI28A1C, MI2SB8.(2) M128AIC, M128E8 (fig. 2-98). (a) Remove clamp securing crossover pipe to left hand muffler. Remove clamp securing crossover pipe to vertical tailpipe. Remove crossover pipe. (b) Remove three self-locking nuts and bolts securing vertical tailpipe to right hand muffler. Dis- card gasket. (c) Remove bolt and self-locking nut securing vertical tailpipe clamp to support brace located just below rear tread plate on frame sidemember. (d) Remove four serews, washers, springs, and self-locking m and two clamps securing vertical tailpipe and shield to vertical support bracket. Re- move vertical tailpipe shield and vertical tailpipe. . Cleaning and Inspection. Clean and inspect for cracks and excessive corrosion. Installation. (M128, M188C, M185 (fig. 2.98). (a) Position tailpipe (3, fig. 2-92) in tailpipe clamp (8) and secure with bolt (6) and self-locking nut (7). (®) Position new gasket (5) on exhaust muffler (4). (c) Secure tailpipe (3) to exhaust muffler (4) with three bolts (2) and self-locking nuts (1). (2) M12SAIC, M123E8 (fig. 2-98). (a) Position vertical tailpipe and shield to verti- cal support bracket, and attach two clamps, securing them with four screws, washers, springs, and self- locking nuts. (b) Position vertical tailpipe clamp to support brace located just below rear tread place, mounted on frame sidemember, and secure with bolt and self- locking nut. {c) Position new gasket on right hand exhaust muffler and secure vertical tailpipe to muffler with three bolts and self-locking nuts. (d) Position crossover pipe, securing one end to vertical tailpipe with muffler clamp and secure other end to left hand muffler with muffler clamp. 2-83. Muffler—All Models WARNING If vehicle is used to transport flammable or explosive material, install spark arrestor mufflers. NOTE If care is taken, either muffler can be re- moved and replaced without removing any other components in the system. Special care, however, must be taken when install- ing new gaskets. a. Removal (fig. 2-92). (1) To remove muffler (4, fig. 2-92), remove four bolts (10) and self-locking nuts (11) securing 292 muffler to exhaust pipe (12 or 13) and three bolts (2) and self-locking nuts (1) securing muffler to tail- pipe (3). (2) Disconnect the muffler clamp (14) by remov- ing bolt (15) and nut (16) securing it to frame bracket (a7) ink (18). (3) Remove muffler (4) and discard two gaskets (19 and 5). b. Cleaning and Inspection. Clean and inspect for cracks and excessive corrosion. ¢. Installation. (1) Position muffler (4) and secure with clamp (14) to frame bracket (17) and link (18) with bolt (15) and self-locking nut (16). (2) Carefully insert two new gaskets (19 and 5) between mating surfaces, and secure exhaust pipe (12 or 18) to muffler (4) with four bolts (10) and self-locking nuts (11). (8) Secure tailpipe (8) to muffler (4) with three bolts (2) and self-locking nuts (1). 2-84, Exhaust Pipe—M123, M123C, M125 «a. Removal (fig. 2-92). (1) Remove three bolts (20) and lockwashers (21) securing exhaust pipe (12) to exhaust manifold. (2) Remove four self-locking nuts (11) and bolts (10) securing exhaust pipe (12) to muffler (4). (8) Remove nut (22) and bolt (23) securing ex- haust pipe frame clamp (24) to mounting bracket (25), link (26) at rear step hanger. (4) Carefully maneuver exhaust pipe (12) through engine compartment. (5) Remove and discard gaskets (19 and 27) at exhaust manifold and muffler flange. b. Cleaning and Inspection. Clean and inspect for cracks and excessive corrosion. ¢. Installation (fig. 2-92). (1) Position exhaust pipe (12) up through engine compartment. (2) Position new gasket (19) between exhaust pipe (12) and muffler flanges. (8) Secure exhaust pipe (12) to muffler (4) with four bolts (10) and self-locking nuts (11). (4) Insert new gasket (27) between exhaust pipe and exhaust manifold and secure pipe to manifold with three bolts (20) and lockwashers (21). (5) Secure exhaust pipe frame clamp (24) to mounting bracket (25), link (26) at rear step hanger with bolt (23) and self-locking nut (22). 2-85. Exhaust Pipe—M123A1C, M123E2 a, Removal (fig. 2-92). (1) Remove band clamp (28) securing exhaust pipe (18) to exhaust manifold. (2) Remove four self-locking nuts (11) and ring ! (10) securing exhaust pipe to muffler (4).(8) Remove nut (22) and bolt (23) securing ex- haust pipe frame clamp (24) to mounting bracket (25), link (26) at rear step hanger. (4) Remove exhaust pipe (13) and discard gaskets (19 and 27). 6. Cleaning and Inspection. Clean and inspect for cracks and excessive corrosion. ¢. Installation. (1) Position exhaust pipe (13) between muffler ee ae Gunter ooted 4 oe eet ie etictae ites aie nee 1 Gasket hole (4) and exhaust manifold. (2) Secure exhaust pipe (13) to muffler with a new gasket (19), four bolts (10), and self-locking nuts an, (3) Secure exhaust pipe (13) to exhaust manifold with 24 band clamps (28). (A) Secure exhaust pipe frame clamp (24) to mounting bracket (25), link (26) at rear step hanger with bolt (23) and self-locking nut (22). nes Beaute ie 2 ee ieee, Fi FE mie ines Figure 2.92, Bheust system arrangement. 293Section XIll. COOLING SYSTEM—M123, M123C, M125. 2-86. General ‘The cooling system consists of the radiator, fan. water pump, thermostats, and connecting hoses. Coolant is drawn from the bottom outlet of the radia- tor and forced through the cylinder block around the cylinder sleeves by the water pump, then through water passages to the cylinder head and into the exhaust manifolds where it serves to cool the exhaust manifolds. 2-87. Radiator WARNING Before checking or draining radiator, turn radiator filler cap to left until stop is reach- te sHieu> | / 1 Figure 2.98, Vertical tailpipe — MI2SA1C, M1235. 2.04 ed. Cap is then in vented position to allow pressure to escape. Non-compliance could é result in serious burns. NOTE To efficiently clean cooling system of rust, seale, or sludge, use a cleaner followéd neutralizer. Refer to TM 9-2858. a. Removal. (1) Mis, M128C. (a) Loosen two bolts securing upper brush guard to mounting brackets (fig. 2-94), (0) Disengage brackets and remove two bolts and self-locking nuts securing upper brush guard to lower guard and remove (fig. 2-94). c) Remove bolt, flat washer, and lockwasher securing radiator shield support to both left and right headlight brackets, and remove shield support (fig. 2-94), (d) To drain system remove filler cap. (e) Open drain cock at bottom of radiator (fig. 2-45). () Open drain cocks on each side of engine cylinder block just above upper oil pan. (g) Loosen nut on end of support rod and lift ‘support rod free of bracket (fig. 2-95). (h) Remove bolt, nut, and lockwasher securing| each bond strap to engine front mounting support at lower left and right sides of radiator (fig. 2-45). (i) Remove bolt, nut, and lockwasher securing bonding strap at left and right sides from fender to side of radiator. GG) Loosen two clamps on outlet hose at lower right side of radiator, and pull hose away from radiator (fig. 2-45). fk) Remove four bolts and lockwashers secur- ing each thermostat housing to upper radiator tank. Discard gaskets (fig. 2-97). () Remove two hex-head capscrews and lock- r trunnion cap at left and right sides of radiator. Lift out eaps (fig. 2-96). (m) Tip radiator forward to allow shroud to clear fan and lift out of vehicle. (2) M125. (a) Loosen two bolts securing upper brush guard to upper mounting bracket. (0) Disengage brackets and remove two bolts and self-locking nuts securing brush guard to lower mounting brackets and lift upper brush guard from vehicle (fig. 2-94), (c) Proceed as in a. (1) above. . Inspection. (1) Make sure fins are parallel and that tubesUPPER RADIATOR Pigure 294, Bumper brush guard disconnect pointe, 2.95| # I THERMOSTAT BY-PASS HOUSING j Bg Sine THERMOSTAT) || | HOUSING Fy eres INTER-CONNECTING BY-PASS HOUSING. r THERMOSTAT BY-PASS Figure 2.95. Radiator viesced from rear — M123, MI23C, ML25, are not bent or broken. Straighten any bent tubes and misalined fins. (2) Check all soldered seams and attachments of filler neck, inlet, and outlet necks. Solder all loose connections. (3) Check security of all brackets, mounting trunnions, and filler cap chain. Replace any badly damaged parts. (4) Inspect outer shell and fan shroud for bends or breaks. Replace shroud if necessary (c. below). (5) Check for leaks. (a) Secure filler cap and close inlet or outlet neck, and end of overflow tube with suitable caps or stoppers. (b) Connect air hose to open inlet or outlet, sub- merge radiator in water and admit air. 2.96 CAUTION Keep air pressure under 8 psi. (c) Note leaks by air bubbles and mark them for repair. ¢. Shroud Replacement. (1) Remove shroud by breaking solder and re- moving 12 hexhead capscrews and lockwashers fastening shroud to radiator (fig. 2-96). (2) Install by positioning shroud on radiator, secure with 12 bolts and lockwashers and solder shroud to radiator. d. Installation. (M128, Mi2SC. fa) Position radiator so rubber bushings on mounting bosses on sides of radiator slip into trun- nion bracket and fan clears shroud (fig. 2-96). ne «FILLER CAP LOcKWASHER ‘CAPSCREW FAN SHROUD ‘CARSCREW Lockwasner Auster BUSHING. RADIATOR TRUNNION BRACKET MOUNTING 8055 aT 68 Figure 2.96, Radiator and related parts, (6) Push support rod into position and tighten nut on end of rod (fig 2-95). (c) Secure each trunnion cap to the trunnion bracket with two bolts and lockwashers (fig. 2-96). (d) Position new gadkets on upper radiator flanges securing each thermpstat housing to radiator with four bolts and lockwashers (fig. 2-95). fe) Connect each bonding strap from the engine front bolt with lockwasher and self-locking nut (fig. 2-45). (P Connect bonding straps from left and right fenders. Secure each with bolt, lockwasher, and self- locking nut. (g) Connect outlet hosé to outlet connection on lower right side of radiator and secure by tightening hose clamp (fig. 2-95). (h) Position support across radiator assembly and secure to headlight panel assembly with two bolts, lockwashers and flat washers (fig. 2-94). (@) Position upper brush guard and pull mount- ing brackets down into position. Secure each bracket to the guard with two bolts and self-locking nuts (fig. 2-94). @) Close radiator and cylinder block drain cocks. (k) Fill system to suit climatic conditions. 1 For operation above 32°F., partially fill with clean fresh water and add six ounces of rust in- hibitor. Fill with water to just below filler neck. 2. For operation below 32°F., fill system one-half full (33 qt.) of ethylene glycol antifreeze. Fill remainder with water to just below filler neck. Attach tag which denotes engine protection —32°F. (1) Install radiator cap. (2) M125. (a) Proceed as in (a) through (h) above. (6) Position upper brush guard into lower mounting brackets and pull upper mounting brackets down into position. fc) Secure each bracket by tightening to brush guard with two bolts and self-locking nuts (fig. 2-94). (d) Fill cooling system (4.(1) through (k) above). 2-88. Hoses (Fig. 2-99), a, Removal. (1) Loosen water hose clamps (1, fig. 2-97) (15), (17), and (19). (2) Disconnect and remove inlet (20), outlet (2), and bypass hoses (16) and (18). . Inspection. Inspect hoses for swelling, cracks, and deterioration. Replace if necessary. ¢. Installation. (1) Connect inlet (20), outlet (2), and bypass hoses (16) and (18). (2) Tighten hose clamps (1), (15), (17), and (19). 2-89. Thermostats NOTE The procedure given below is applicable to either the left or right thermostat. a. Removal. (1) Drain cooling system (para 2-87a(1Xd)). (2) Loosen clamps (1) on exhaust manifold water outlet hose assembly (2). Slide hose back toward ex- haust manifold. (3) Remove four bolts (5) and lockwashers (6) securing thermostat housing cover (7) to housing (a3). (4) Separate housing (13) and cover (7) and lift out thermostat (9). Diseard gasket (8). 6. Testing. If it is necessary to operate this type of system with either or both thermostats removed, a blind copper or brass plate, having 1/8-inch bleed hole, should be installed in the bypass circuit to in- sure circulation through the engine and radiator. Performance characteristics of thermostat can be checked by following (1) through (4) below. This test should be performed whenever system is drained and flushed. Before testing, examine the bellows for rupture or distortion. If the valve can be pulled or 2.971Clamp 2 Water outlet hose 3 Water outlet tube (left) 44 Water outlet tube (rizht) 5 Bolt SLockwasher ‘7 Thermostat housing cover BGasket 9 Thermostat 10Gasket Bolt 12 Lockwasher 13 Thermostat housing MGasket —<—_ psn 0 18 Radiator bypass hose 19Clamp. 20 Water inlet hose 21 Water pump inlet itis Gasket ° me 2B Capecrew 2B Leckwasher 2 Manifold outlet fting Gasket Figure 2-97. Cooting system — exploded view — Mies, M128C, M185. pushed off its seat with slight effort when the ther- mostat is cold, or does not seat properly, the unit may be considered defective. When troubleshoot- ing a coolant complaint, the thermostat should be tested without cleaning because sediment lodged between bellows convolutions changes its action. It may then be desirable to check it after cleaning. (1) Immerse thermostat and thermometer in water. 298 NOTE Season thermostat by operating thermostat for a period of 45 minutes at 200 degrees Fahrenheit. (2) Cool water to initial operating temperature of thermostat. (3) Compare thermostat operation with tem- perature indicated on thermometer. ¢(4) Discard thermostats not operating in correct range. ¢. Installation. (1) Position new gasket (8, fig. 2-97) on thermo- stat housing (13) and insert thermostat (9) with bellows to rear. (2) Aline cover (7) and housing (13) and secure with four bolts (5) and lockwashers (6). (8) Push hose (2) back into position and secure by tightening the two hose clamps (1). (4) Fill cooling system (para 287d.) 2-90. Drive Belts 4. Adjustment. NOTE Alll belts require the same amount of de flection or freeplay; 1/4 to 1/2-inch under a force of 20 pounds on the longest span. (1) Adjust fan pulley drive belts at idler pulley by reaching through access door on right front fender (fig. 2-98). (2) Loosen bolt located behind pulley wheel and bolt located on bracket. Move pulley assembly up to tighten fan belts and down to loosen belts. (3) To adjust generator-compressor belts, loosen bolt at top front of generator at bracket (fig. 2-99). (4) Move generator toward compressor to loosen belt or away from compressor to tighten b. Removal. igure 2s, Adjnating fa drive belt, R=? fd Sry COMPRESSOR DRIVE PULLEY| Figure 299, Adjusting generator comprennor drive belts NOTE Drive belts must be replaced in sets. (1) Loosen idler pulley and generator pulley belts (a, above). (2) Remove belt set from pulleys and slip over fan. ¢. Inspection. Inspect belts for fra ing. d. Installation. (1) Install new belt set by slipping belts over fan and positioning on pulleys, (2) Adjust belts (a. above). 2-91. Fan Assembly a. Removal. (1) Fan. (a) Remove belts (para 2-90b.). (6) Remove six bolts and lockwashers securing fan to fan hub pulley, and remove fan (fig. 2-100). (2) Fan hub assembly. fa) Remove fan ((1) above), fo) Remove fan hub assembly by working through the three elongated holes in web section of hub pulley (fig. 2-100), fc) Remove three bolts and lockwashers se- curing assembly to water pump cover and lift out entire assembly (fig. 2-100). (d) Remove self-locking nut securing fan hub support to end of shaft and remove support. (3) Idler Pulley. (a) Remove belts (para 2-906.) and weather- 2.99Figure 100, Fan drive belt arrangement. (b) Remove bolt securing idler pulley adjust ment and pivot two bolts securing idler pulley sup- port to engine and remove (fig. 2-98). (c) Remove jamnut and lockwasher securing support to shaft and remove support. +. Installation. (1) Fan, (a) Position fan and secure to fan hub pulley with six bolts and lockwashers. (6) Install belts (para 2-90d.). (2) Fan hub assembly. a) Install fan support on shaft and secure with self-locking nut. (o) Install fan hub assembly by working through the three elongated holes in web section of hub pulley (fig. 2-100). (c) Secure fan hub assembly to water pump cover with three bolts and lockwashers. (d) Install fan ((1) above). 2-100 (8) Idler pulley. (a) Install idler pulley support on end of shaft securing with lockwasher and jamnut (fig. 2-98). (0) Position assembly on engine and secure support to engine with two bolts, lockwashers, and one flat washer. (c) Install belts (para 2-90d.). 2-92. Water Pump a. Removal. (1) Drain cooling system (para 2-87a.(1Xd)). (2)Remove fan hub assembly (para 2-91a.(2)). (3) Remove water bypass connection by removing two bolts securing connection to water pump housing. (4) Remove eight nuts and lockwashers securing pump body cover to pump body. Remove cover and discard gasket (fig. 2-101). (5) Remove nut securing impeller to accessory driveshaft. , (6) Insert two capscrews into impeller and back off impeller. Remove Woodruff key. (7) Slide bellows type water pump shaft seal off accessory drive shaft and remove seal seat. Discard seal and seat. (8) Remove six bolts and lockwashers securing pump body to cylinder block. Remove and discard rasket (fig. 2-101). . Installation. (1) Using new gaskets at outlet connections, and sleeve to center housing bore on drive shaft, position water pump body on gear cover with accessory drive shaft passing through back of housing. (2) Secure water pump body with six bolts and lockwash (8) Slide seal seat on accessory drive shaft and bellows-type seal with rubber section against seat, and remove sleeve (fig. 2-101). (4) Insert a Woodruff key in keyway in accessory drive shaft and drive on water pump impeller with ribs facing out. (5) Using a new gasket, install water pump cover and secure with eight nuts and lockwashers. (6) Install new gasket and position bypass hose connection on water pump housing securing with two bolts. (7) Install fan-hub assembly (para 2-91b.(2)). (8) Fill cooling system (par 2-87d.(1)).Section XIV. COOLING SYSTEM—M123A1C, M123E2 D202 General The cooling system consists of the radiator, fan, water pump, thermostats, and connecting hoses. The coolant flows from the bottom of the radiator to the water pump. The water pump circulates the coolant through the engine cylinder block and cylinder heads where it serves as a heat absorbent. 2-94, Radiator WARNING Before checking or draining radiator, turn radiator filler cap to left until stop is reached. Cap is then in vented position to allow pres- sure to escape. Non-compliance could result in serious burns. NOTE To efficiently clean cooling system of rust, seale, or sludge, use a cleaner followed by a neutralizer. Refer to TM 9-2858. a. Removal. (1) Loosen two bolts securing upper brush guard to mounting brackets (fig. 2-94). (2) Disengage brackets and remove two bolts and self-locking nuts securing upper brush guard d tolower guard. (8) Remove bolt, flat washer, and lockwasher securing radiator shield support to left and right headlight bracket, and remove shield support (fig. 2-94). (4) To drain system, remove filler cap. (8) Open drain cock at bottom of radiator (fig. 2-45), (6) Open drain cocks on each side of engine eylinder block just above upper oil pan. (7) Open drain cock on crossover tube at rear of ‘engine above flywheel housing (fig. 2-102). (8) Open drain cock on air compressor. (9) Remove cotter and clevis pins and disconnect support rod (fig. 2-103). (10) Remove bolt, nut, and lockwasher securing each bond strap to engine front mounting support at lower left and right sides of radiator (fig. 2-45). (11) Remove bolt, nut, and lockwasher securing bonding strap at left and right sides from fender to side of radiator. (12) Loosen two clamps on outlet hose at lower right side of radiator, and pull hose away from radiator (fig. 2-45). (13) Loosen clamp on inlet hose at radiator inlet fitting and pull hose away (fig. 2-108). WATER PUMP BODY sour > Gasket | ~ LOCKWASHER BY-PASS} CONNECTION! IMPELLER GASKET Figure 2-101, Water pump — exploded view. 2-101Figure 2-102. Crossover water tube drain cock. (14) Remove two hex-head capscrews and lock- washers from each radiator trunnion cap at left and right sides of radiator and lift out both caps (fig. 2-96). (15) Tip radiator forward to allow shroud to clear fan and lift out of vehicle. 6, Inspection, Refer to paragraph 2-876, ¢. Shroud Replacement. Refer to paragraph 2-87c. d. Installation. (1) Position radiator so rubber bushings on ‘mounting bosses on sides of radiator slip into trun- nion bracket and fan clears shroud (fi (2) Position support rod and i and cotter pin (fig. 2-103). (8) Secure each trunnion cap to trunnion bracket with two hex-head eapscrews and lockwashers (fig. 296). (4) Position radiator hose on radiator inlet fit- ting, secure with hose clamp (fig. 2-108), (6) Connect each bonding strap to engine front bolt with lockwasher and self-locking nut (fig. 2-45). (6) Connect bonding straps to left and right fenders with bolt, lockwasher, and self-locking nut. (7) Connect outlet hose to outlet connection on lower right side of radiator and secure with hose clamp (fig. 2-45). (8) Position upper brush guard and pull mounting brackets down into position. Secure each bracket to the guard with two bolts and self-locking nuts (fig. 2-94). (9) To fill system close radiator, cylinder block, and crossover tube drain cocks. 2-102 PRESSURE, cAP SUPPORT ROD AND Figure 2.103, Radiator water inlet fitting and support rod. (10) Fill system to suit climatic conditions. 4 (a) For operation above 32° F., partially fill with clean fresh water and add six ounces of rust inhibitor. Fill remainder with water to just below filler neck. (b) For operation below 32° F., fill system one- half (24 qt) of ethylene glyco! antifreeze. Add water to just below filler neck. Attach tag which denotes engine protection -32° F. (11) Install radiator cap. (12) Close air vent cock on air compressor. 2-95. Hoses Refer to paragraph 2-88 and figures 2-104 and 105. 2-96. Thermostat a, Removal. (1) Drain cooling system (para 2-94a (4) through (ey. (2) Remove water outlet hose from thermostat housing cover (fig. 2-105). (3) Remove capserews and lockwashers securing cover to thermostat housing. Lift cover from housing. (4) Remove thermostat and gasket from housing; « discard gasket. 6. Testing. This test should be performed when- ever system is drained and flushed. Before testing,THERMOSTAT WATER INLET HOSE AT 34816 Figure 2-104, Cooling System — MI2SA11C, MI83B2. examine the bellows for rupture or distortion. If valve can be pulled or pushed off its seat with slight effort when thermostat is cold, or does not seat properly, the unit may be considered defective. When troubleshooting a coolant complaint, thermostat should be tested without cleaning because sediment lodged between bellows convolutions changes its action. It may then be desirable to check it after cleaning. For testing procedures, refer to paragraph 2-89b. (1) through (4). ¢. Installation. (1) Position thermostat in engine housing (bel- lows down). Install new gasket. (2) Position outlet connection to thermostat housing over thermostat. Be sure shoulder of thermostat is fitted in recess of outlet housing. (3) Install and tighten the two bolts. (4) Fill cooling system (para 2-944. (9)). 2-97. Drive Belts a. Adjustment. NOTE All belts require the same amount of deflec- tion or freeplay; % to %-inch under a force of 20 pounds on the longest span. (1) Adjust fan pulley drive belt by loosening alternator drive belt, ((4) below) and hydraulic power steering drive belt (6) below) (fig. 2-106). (2) Loosen nut securing fan pulley shaft to mount- ing bracket (fig. 2-108). ‘THERMOSTAT arte ourter | HOUSING COVER ‘ADJUSTABLE PULLEY. ‘AT 34617 Figure 2.105, Water pump and thermostat housing — ‘MIRSAIC, MI28B2, (8) Adjust belt tension by loosening or tighten- ing screws at top of hub mounting bracket (fig. 2- 108), Tighten nut securing fan pulley shaft. (4) Adjust alternator belt by loosening alternator adjustment bolt and mounting bolts (fig. 2-126). (5) Raise alternator to tighten, and lower to loosen. Tighten alternator adjustment bolt and mounting bolt. (6) Adjust power steering pump drive belt by loosening adjusting link capserew and pivot bolts. (1) Raise pump to tighten, and lower to loosen. Tighten adjusting link capscrew and pivot bolts. (8) Adjust water pump drive belt by removing three capscrews and lockwasher from face of adjust- able water pump pulley and turning outer half of water pump driven pulley. Turn clockwise to tighten and counterclockwise to loosen. (9) Replace capscrews and lockwashers. b. Removal. NOTE Drive belts must be replaced as complete sets. (1) Loosen fan pulley, alternator pulley, power steering pump pulley and water pump pulley belts (a, above) (fig. 2-107). (2) Remove belts from pulleys. 2-103BAT 34618 Figure 2-106, Fan and drive belts. ¢. Inspection. Inspect belts for fraying and weather- ing. d. Installation. (1) Install belts in matched sets where required. (2) Adjust belts (a. above). ALTERNATOR FAN BELT ADJUSTMENT SCREW ALTERNATOR PULLEY seur cei wel IN veut NP Figure 2.107. Water pump, drive belts and related parts. AT 34619 2-104 2-98. Fan and Fan Hub (Fig, 2-108). a. Removal. (1) Disconnect radiator support rod from radia- tor. Move support rod to one side. (2) Disconnect electrical leads on alternator. (8) Remove nut, bolt, and washer securing alter- nator adjustment arm. (4) Remove belt from alternator. (5) Loosen alternator mounting bolts and pivot alternator to one side. (6) Remove clamp securing radiator hose to manifold. Remove hose from manifold. (1) Disconnect hydraulic lines from power steer- ing pump. (8) Remove nut, bolt, and lockwasher securing power steering pump adjustment arm. (9)Remove belt from power steering pump. (10) Loosen power steering pump mounting bolts and pivot power steering pump to one side. (11) Reaching down between fan blade and radia- tor remove six bolts and lockwashers securing fan blade to fan hub, Remove fan blade. (12) Remove fan belt adjustment serew. (13) Remove self-locking nut and flat washer from end of fan hub shaft securing fan hub assem- bly to fan hub mounting bracket. (14) Remove fan belt from fan hub. (15) Pull fan hub assembly toward radiator. just enough to free shaft from mounting bracket. Lift fan hub assembly from engine, removing all belts from hub. 6. Installation. (1) Position fan hub assembly to fan hub mount- in bracket. Secure with self-locking nut and flat washer. (2)Install fan belts. (3) Install fan adjustment screw. (4) Install fan blade on end of shaft. Secure fan blade to fan hub with six bolts and lockwashers. (5) Place power steering pump in proper position, install fan belt, and secure adjustment arm with nut, bolt, and lockwasher. (6) Connect hydraulic lines to power steering, pump. (7) Position radiator hose to manifold. Secure with hose clamp. (8) Place alternator in proper position, install fan belt and secure adjustment arm with nut, bolt. and lockwasher. (9) Connect electrical leads to alternator. (10) Adjust belts (para 2-97a.). (11) Connect alternator support rod to radiator. «2-99. Water Pump and Pulley (Fig. 2-109). a. Removal. d (1) Water pump. (a) Drain cooling system (para 2-94a.(4)). (b) Loosen bypass hose clamp. (c) Disconneet air compressor water line from water pump housing (fig. 2-105). (a) Loosen water inlet hose clamp. fe) Remove drive belt (para 2-97). () Remove capscrews and lockwashers se- curing pump to cylinder block. (g) Remove pump and discard gasket. (2) Water pump pulley. (a) Remove drive belt (para 2-91). (b) Remove three capscrews and lockwashers from water pump adjustable pulley and unscrew outer half of pulley. Remove belt. b. Installation. (1) Water pump pulley. fa) Lubricate shaft outside diameter with multi-purpose industrial grease. (b) Support shaft on impeller end of shaft and Press on pulley fixed sheave until sheave hub is tight against bearing inner face. Attach adjustable sheave to complete pulley installation, fc) Install three capscrews and washers to secure pulley. (d) Install drive belt (para 2-97). (2) Water pump (fig. 2-105). (a) Position water pump under drive belt against block. (b) Position bypass and water inlet hoses over water pump connections. (c) Install new gasket, position water pump to engine. (d) Install eapscrews, lockwashers, and flat- washers and secure pump to cylinder block. (e) Tighten bypass and inlet hose clamps. (f) Connect air compressor water line. (g) Check water pump belt adjustment (para 2-97a.). (h) Fill cooling system (para 2-94d.(9). ADJUSTMENT ‘CREW sour ‘BRACKET SELF-LOCKING NUT AT 34820 Figure 2-108, Fan hub, 2105AIR COMPRESSOR WATER LINE CONNECTION CAPSCREW s WASHER PULLEY CONNECTION BY-PASS CONNECTION (en PULLEY k PUMP BODY INLET LOCKWASHER CAPSCREW At 34621 d Figure 2-108, Water pump — MI2SA1C, MI2SE2. Section XV. IGNITION SYSTEM—M123, M123C, M125 2-100. General ‘The ignition system (fig. 2-38) is composed of ignition switch, coil and distributor assembly, and spark plugs. ‘The ignition system produces and delivers high voltage current to spark plugs. 2-101. ignition Timing 4. General. The procedure for checking and cor- recting ignition timing for engines with a sealed ignition system requires special adapters which are part of the electrical connector tool kit. . Checking and Correcting Timing. (1) Timing is checked by alinement of 2 small pointers attached to timing gear cover, with timing mark (fig. 2-110) on crankshaft pulley. (2) Clean, adjust, or replace distributor points as necessary (para 2-102c.(1)). 2106 (3) Remove spark plug cable from No. 1 spark plug by unscrewing coupling nut and screw on spark plug testing adapter. (4) Attach spark plug cable to top of spark plug testing adapter. (5) Fasten clip of red lead from timing light to terminal on side of spark plug adapter. (6) Disconnect battery harness at generator- regulator and install regulator testing adapter. (1) Connect harness to adapter. Turn the voltage selector switch of the timing light to 24-volts, (8) Connect red gloved lead to either terminal on adapter and black gloved lead to suitable ground. (9) Apply chalk to 4 degree BTC mark (fig. 2 110) on crankshaft pulley to permit easy observa tion. (0) With engine running at idling speed aso rpm), direct beam of light down at timing pointerFigure 2110. Timing pointer and timing marks. (fig. 2-110) on timing gear cover. If timing mark is alined with pointer when viewed with timing light, timing is correct. (11) To correct timing, loosen bolt in clamp using socket wrench (7, fig. 2-1), holding distributor to crankcase (fig. 2-111) and rotate distributor as re- quired. NOTE Turning distributor body clockwise will re- tard spark, and counterclockwise will ad- vance spark. (12) Tighten distributor clamp bolt when timing is adjusted properly. (18) Disconnect timing light and remove timing testing adapters from spark plug and regulator. (14) Connect No. 1 spark plug cable, Connect battery harness to generator-regulator. 2-102. Distributor and Ignition Coil Assembly a. Removal. (1) Disconnect primary cable and spark plug cables from distributor (fig. 2-112). (2) Disconnect vent line from fitting on side of distributor. (3) Note radial position of No. 1 spark plug cable terminal in distributor housing at this point. (4) Remove eight screws and lockwashers and remove distributor cover with cap. (5) Turn engine over (b.(3) below) until top dead center mark on crankshaft pulley is alined with ignition timing pointer (fig. 2-110), engine is in firing position for No. 1 cylinder, and rotor segment is pointing to scribe mark on distributor housing. (6) Remove distributor clamp nut and lockwasher (fig. 2-111), and remove distributor clamp. (7) Lift distributor assembly out of cylinder block. NOTE As distributor is being removed, the rotor turns counterclockwise a few degrees as gears disengage; mark this second position of rotor on distributor housing. . Installation. (1) If engine has-not been turned over since re- moval of distributor, remove distributor cover and turn rotor so segment points to second scribe mark on distributor housing. If distributor assembly is new, No. 1 firing position of rotor can be determined by mark scribed on old distributor housing at time of removal. (2) As distributor is lowered into position and gears engage, rotor will turn back (clockwise) and should point toward first scribe mark on distributor housing indicating No. 1 firing position. It may be necessary to insert the assembly several times to find the correct position to bring rotor to No. 1 firing position. Figure 2-111. Correct timing using distributor clamp wrench. 2107Figure 2-112, Distributor dinconnect pointe, (3) If engine has been turned over since removal of distributor assembly, locate top dead center mark on crankshaft pulley and aline with pointer in timing gear cover. Do not turn ignition switch on. Deter- mine whether engine is in firing position for No. 1 cylinder, by removing valve cover and noting position of valves. If both valve tappets for No. 1 eylinder are free, indicating valves are closed, this will indicate firing position for No. 1 evlinder. If not, turn engine over in small increments with starter for one com- plete revolution and install distributor ((2) above). Install eylinder head cover (para 2-56e.). (4) Position distributor clamp on cylinder block cover and install hex nut and lockwasher (fig. 2-111). Tighten nut with special wrench (7, fig. 2-1). (5) Check and adjust point opening (c.(1) below). (6) Install distributor cover and connect spark plug cables to cover. NOTE Make sure spark plug cables are connected to provide correct firing order as marked on distributor cover. ¢. Distributor. (1) Set breaker point gap. (a) Remove distributor cover (a.(4) above). (b) Pull rotor from center shaft. (c) Clean breaker contacts, using contact point dresser. 2-108 (a) If contacts are badly pitted or burned re- place breaker lever, contact, and support ((3) below). (c) Turn engine over in small increments, by closing starting switch momentarily, and note posi tion of cam when engine stops. Continue process until breakerlever rubbing block comes to rest on high point of cam (maximum opening). ( Check gap with 0.016-inch feeler gage (fig. 2-113). If gap requires adjustment, loosen contact, lockscrew at rear end of contact and support and turn adjusting screw to obtain correct gap. (g) Tighten contact lockscrew. (h) Replace rotor on center shaft. (2) Diatributor cap. (a) Removal, 1, Remove distributor cover (a.(4) above). 2, Remove five screws holding distributor cap in cover and lift out cap (fig. 2-118). (b) Installation 1. Position distributor cap in distributor cover and fasten with five screws. 2, Install distributor cover and fasten with eight screws and lockwashers. (3) Distributor points (fig. 2-114). (a) Removal. 1. Disconnect two cables from contact and support. pivot pin. 3. Remove lockserew securing contact and support to breaker plate, and remove contact and support. (b) Installation. 2. Lift movable point breaker lever from ‘ JADJUSTING SCREW. Figure 2-118, Setting distributor breaker point gop.1. Put one drop of engine oil (OE/HDO) on pivot pin and place movable point distributor lever on pin. NOTE Breaker lever spring must be on inner side of contact and support lug. 2. Position the two lead terminals on con- ‘tact and support and install terminal screw and nut. 3. Press down lever spring 80 notch makes good contact with terminal screw and tighten nut. (4) Distributor capacitor (fig. 2-114). fa) Removal. 1. Disconnect distributor capacitor lead from connection on contact and support. 2, Remove capacitor mounting screw and lockwasher. () Installation, 1. Position distributor capacitor and install serew and lockwasher. 2, Conneet eapacitor lead to connection on ‘contact and support. , Ignition Coil (fig. 2-118). (1) Removal, (a) Disconnect three leads from ignition coil. () Remove two screws and lockwashers se- curing holddown bracket to housing and lift out bracket. (c) Lift out ignition coil and discard gasket. d (2) Installation, fa) Place new gasket on coil against shoulder and install coil in housing. NOTE Coil must be positioned so positive (+) ter- minal is near resistor. (>) Install holddown bracket and secure with two serews and lockwashers. CONTACT AND, DISTRIBUTOR SUPPORT CAPACITOR con BREAKER LEVER CAPACITOR ‘SPRING. RESISTOR LEAD IGNITION com Figure 2114. Checking breaker lever spring tension. AT 34626 Figure 2.115, Replacing ignition coil. (c) Connect resistor lead and coil capacitor lead to positive ( +) terminal on ignition coil. (@) Connect lead from contact support to ignition coil negative (—) terminal. €. Resistor (fig. 2-114). (1) Removal. (a) Disconnect primary lead to resistor and resistor lead to positive (+) terminal on ignition coil. fb) Remove screws and lockwasher securing resistor to housing and lift out. (2) Installation. fa) Position resistor securing with serew and lockwasher. (b) Connect resistor lead positive (+) terminal on ignition coil (c) Connect primary lead to resistor. F. Coil Capacitor (fig. 2-114). (1) Removal, (a) Disconnect coil capacitor lead from positive (+) terminal on ignition coil. (b) Remove coil capacitor clamp screw and lockwasher and lift out coil capacitor. (2) Installation. (a) Position coil capacitor on housing with holddown clamp, and secure with serew and lock- washer. fb) Connect coil capacitor lead to positive (+) terminal on ignition coil. 2-103. Spark Plug Cables 4. General. Because of location of distributor in reference to spark plugs. each spark plug cable is of a different length and must be assembled in 2109Proper sequence in distributor to insure proper fir- ing order. Refer to Tables 2-3 for cable lengths. Table 2-3 Spark Plug Cablex Clem. Lenath ich 1 8 2 33 3 6 4 6 7 8 . Removal (1) Unserew nuts from spark plugs and slide nuts back on spark plug cables. Carefully pull cables off spark plugs. (2) Remove two bolts, nuts, and lockwashers from cable support located at rear of left air cleaner mounting bracket. Remove both halves of support from bracket. (3) Remove cable clamp secured to compressor rear cover. (4) Remove two bolts, nuts, and lockwashers from cable support secured to top of right engine valve cover. Remove both halves of support from bracket (5) Unscrew nuts from cables at distributor cover, slide nuts back on cables, and carefully pull cables out of distributor. Remove cables from en- gine (fig, 2-112). ¢. Installation. (1) Aline cables for cylinders Nos. 2, 4, 6, and 8. Carefully push terminals into distributor in proper sequence as marked on distributor cover. (2) Secure cables into cable support placing cable No. 8 at the bottom groove, Nos. 2, 6, and 4 cables in top groove. (3) Secure cable support to bracket on engine valve cover with two bolts, lockwashers, and nuts. (4) Aline cables with proper spark plugs and carefully push connectors into spark plug shielding wells. (5) Tighten adapter nuts fingertight, then tighten an additional one-half turn with proper wrench. (6) Aline cables for cylinders Nos. 1, 3, 5, and 7 and secure cables as above, placing cable No. 7 in bottom groove, Nos. 5, 3, and 1 cables in top groove of cable support mounted on left air cleaner mount- ing bracket. (7) Aline cables into cable support mounted on left side of engine between Nos. 1 and 3 spark plugs. with cable No. 7 in bottom groove, No. 5 cable next, and No. 3 cable in top groove. Secure support as 2-110 above. No. 1 cable is installed directly in No. 1 spark plug. (8) Aline cables with their respective spark plugs and carefully push connectors on the spark plu shielding wells. Tighten adapter nuts foseregne @ then tighten an additional one-half turn with proper wrench. 2-104. Spark Plugs a. Removal. (1) Unscrew nuts from spark plugs and slide nuts back on spark plug cables. (2) Carefully pull spark plug eables out of spark plugs. (3) Use spark plug wrench on box wrench to re- move spark plugs. (4) Discard gaskets if spark plugs are to be re- placed. b. Cleaning and Inspection. (1) Use standard spark plug cleaning equip- ‘ment to clean spark plugs. (2) Make sure ceramic terminal sleeve and springs are in good condition, free of dirt, grease. and moisture condensation. (3) Cheek spark plug electrodes. If burned, re- place spark plug. ¢. Adjustment. Use round feeler gage to check proper gap between electrodes. Adjust gap to 0.030- inch by bending side electrode only. 4 d. Installation. (1) Place gasket on spark plug and start plug into cylinder head. (2) Tighten spark plug to 30 Ib-ft torque, using torque-indicating wrench and adapter. NOTE Handle with clean, dry hands. (3) To avoid damaging the sleeves, carefully push terminals straight into shielding barrel well (4) Install adapter nut on shielding barrel finger- tight. (5) Tighten nuts an additional one-half turn with proper wrench. 2-105. Ignition Switch (fig. 2-116). a. Removal. (1) Disconnect battery ground cable from bat- tery negative (—) terminal post before removal of ignition switch. (2) Remove screw from center of switch lever and remove lever. (3) Remove hex nut and lockwasher holding switch to instrument panel, and remove switel from rear. (4) Disconnect four cable connections. 6. Installation.NOTE Three terminal cables from switch are numbered with circuit marker sleeves. e. (1) Connect cable connectors as shown in Table (2) Position ignition switch in instrument panel securing with hex nut on front of panel. (3) Install switch lever and secure with fillister head screw. (4) Connect battery ground cable to battery negative (—) terminal post. Table 2, Instrument Panel Circuits = rout oer 1 Battery a 2 ‘Temperaturegage & a Oil pressure gage A Fuel ease e a Ignition coil eI , Figure 2.116, Removing or installing ignition seitch — M123, M1230, Mi2s, Section XVI. STARTING SYSTEM — M123, M123C, Mi25 2-106. General ‘The starting system is composed of the starter, mag- netic switch, batteries, and connecting cables. 2-107. Starter a. Removal (1) Disconnect battery ground eable at battery, and tape disconnected terminal. (2) Disconnect two cables at starter switch ter- minals cireuit No. 14 (fig. 2-117). (3) Diseonnect magnetic switch eable (fig. 2-118) at starter circuit No. 82(fig. 2-117). (4) Remove cotter pin from upper starter con- trol linkage clevis pin and disconnect linkage clevis from bellcrank (fig. 2-119). (5) Remove two nuts and lockwashers securing starter to flywheel housing (fig. 2-119). (6) Remove upper inside mounting serew, using Yiinch hexagon wrench extension (4, fig. 2-1) in com- Dee with open end wrench (fig. 2-119). (1) Pall starter straight away from flywheel housing to remove, Discard gasket. é = AT 34629 Figure 2-117, Starter cirewit — MI8S, M128C, M185. PottyFigure 2-118 Starter cable disconnect pointe. 6. Cleaning and Inspection. (1) Clean with mineral spirits paint thinner or dry cleaning solvent and dry with compressed air. (2) Inspect for cracks, burned insulation, cor- rosion, and secureness of mountings. ¢. Installation. (1) Position new gasket on starter and seat against flywheel housing. Secure with two nuts and lockwashers (fig. 2-119). (2) Install hexagon recessed head serew and secure using ¥4-inch hexagon wrench extension open end wrench combination as shown in figure 2-119. (8) Connect magnetic starting switch cable (fig. 2-118) cireuit No. 82 fig. 2-117) to starter terminal. (4) Connect two cables circuit No. 14 (fig. 2-117) tostarter switch terminals. (5) Remove tape from battery cable terminal ‘and install ground cable on battery. (6) Connect upper starter control linkage clevis to bellerank. Install clevis pin and secure with cotter pin (fig. 2-119), 2-108. Magnetic Switch a, Removal. (1) Disconnect battery ground cable at battery, and tape disconnected terminal. (2) Disconnect battery to magnetic switch cable (fig. 2-120) circuit No. 81 (fig. 2-117). (8) Remove starter switch cable circuit No. 14 (fig. 2-117) and magnetic switch to starter cable cir- cuit No. 82 (fig. 2-117) from switch terminals (fig. 2-120). (4) Remove four capscrews and self-locking nuts (fig. 2-120) holding switch to frame sidemember. 2412 LOCKING NUT at =) Figure 2.119, Removing or installing starter — M123, M123C. M125, 6. Installation. (1) Position magnetic switch over installation holes in frame sidemember. Install four capscrews and self-locking nuts (fig. 2-120). Tighten nuts. (2) Attach starter switch cable circuit No. 14 (fig. 2-117) and starter cable circuit No. 82 (fig. 2-117) to bottom switch terminal (fig. 2-120). (8) Connect battery cable circuit No. 81 (fig. ¢ 117) to top switch terminal. (4) Remove tape from battery cable terminal and install ground cable on battery. MAGNETIC SWITCH TO STARTER CONNECTION jl Figure 2.120, Magnetic nwitch disconnect pointsSection XVII. STARTING SYSTEM — M123A1C, M123E2 2-109. General The starting system is composed of the starter, starter solenoid, starter switch, master switch, bat- teries, and connecting cables. 2-110. Starter a, Removal (fig. 2-122). (1) Disconnect battery ground cable at battery. ‘Tape disconnected terminal. (2) Disconnect starter switch cable at starter solenoid circuit No. 214 (fig. 2-121). (3) Disconnect starter positive cable from post on end of starter (fig. 2-122). (4) Remove three bolts securing starter to fly- wheel housing (fig. 2-122). 6. Cleaning and Inspection. (1) Clean with mineral spirits paint thinner or dry cleaning solvent and dry with compressed air. (2) Inspect for cracks, burned insulation, cor- rosion, and secureness of mountings. c. Installation, (1) Position starter in flywheel housing and secure with three bolts (fig. 2-122), (2) Connect starter positive cable to post on end of starter. Do not overtighten nut (fig. 2-122). (3) Connect starter switch cable to the solenoid circuit No. 214 (fig. 2-121). 2-111. Starter Solenoid (Fig, 2-123), a, Removal, (1) Disconnect battery ground cable from battery and tape connections. (2)Remove starter (para 2-110). (3) Remove large plug from lever housing. (4) Remove hex nut securing solenoid plunger to shift lever. Re INDICATOR I ame) =o} — = ; STARTER SWITCH TOGGLE SWITCH 570, S71 To. circuit BREAKER SwiTcH ~ 7 Figure 2-121. Starter cireuit — M12SA1C, M1232, 2113MOUNTING Positive pours TERMINAL Figure 2-122, Starter — M128A1C. MI8SE2, Pus. LEVER HOUSING. STARTER HOUSING Ar 34635 Figure 2.128, Starter solenoid. (5) Remove electrical terminal from starter sole- noid, (6) Remove hex nut and lockwasher securing ‘solenoid to ground strap. (7) Remove four assembled washer screws se- curing solenoid to starter housing. 2414 , Installation. (1) Position solenoid assembly on starter hous- ing, securing with four assembled washer screws. (2) Install hex nut and lockwasher securing sole. noid to ground strap. (3) Install hex nut and retainer on solenc plunger and shift lever. (4) Install electrical terminal on starter solenoid. (8) Install large plug on lever housing. (6) Install starter (para 2-110), (Install battery ground cable. 2-112, Starter Switch @. Removal. (1) Disconnect battery ground cable from bat- tery and tape connection. (2) Disconnect three electrical connectors ci- cuit Nos. 214 and 14 (fig. 2-121) under instrument panel. (3) Remove rubber grommet covering starter switch. (4) Remove hex nut securing switch to instru- ment panel. . Installation. (1) Position switch in instrument panel and se- cure with hex nut. (2) Install rubber grommet over switch. (8) Connect three numbered electrical connec- tors circuit Nos. 214 and 14 (fig. 2-121) under ins ment panel. (4) Connect battery ground cable to battery. 2-113. Master Switch a. Removal. (1) Disconnect battery ground cable from bat- tery and tape connection. (2)Remove screw securing switch to knob. (3) Remove hex nut securing switch to instru- ment panel. (4) Remove switch from mounting hole to allow disconnection of electrical connectors. (5) Disconnect six electrical connectors cireuit No.s 27, 567, 85, 54, 568, and 11 (fig. 2-121) from switch. , Installation. (1) Connect six electrical connectors circuit Nos. 21, 567, 85, 54, 568, and 11 (fig. 2-121) to switch. (2) Position switch in instrument panel mount- ing hole. (8) Install switch identification plate and secure with flat washer and hex nut. (4) Position knob on switch and rotate switch fully counterclockwise. (5) Aline knob on switch to OFF position. knob with screw. (6)Connect battery ground cable to battery.Section X 2-114. General The generating system consists of the generator, ‘generator-regulator, and battery-generator indicator. 2-115. Generator and Generator Pulley @. Removal. (1) Generator. (a) Remove connector nut on generator-to- regulator harness at generator output elbow, and slide nut back on harness (fig. 2-76). (b) Carefully remove cables from generator and remove gasket. (c) Loosen two generator mounting bolts and nuts (fig. 2-125). (d) Remove generator adjusting arm serew and pivot generator toward engine as far as possible (fig. 2-125). (e) Remove drive belts from generator pulley. @ Remove generator mounting nuts, spacers, and bolts and lift generator from engine. (2) Generator pulley. (a) Remove self-locking nut and washer from tapered drive shaft. () Install a standard S-legged puller over pulley body. Tighten puller to shaft end and rap P= sharply to disengage pulley from shaft. (c) Remove and lift key from keyway on shaft. . Installation. (1) Generator pulley. (a) Position key in key way on shaft. fb) Aline pulley keyway with key and slip pulley over shaft and key. (c) Tap pulley into position and secure with self-locking nut and washer. (2) Generator. (a) Mount generator on mounting lugs and in- stall bolt, two spacers, and self-locking nut in mount ing hole at each end of generator. ‘NOTE Do not tighten nuts. (0) Position drive belts over generator pulley. (c) Install generator adjusting arm on gen- erator securing with adjusting screw and lockwasher. (4) Adjust drive belts (para 2-90a.). (e) Tighten mounting nuts and bolts. @ Install gasket and connect. generator-to- regulator harness to generator output elbow. Tighten connector nut. . Polarization. CAUTION Do not start engine until generator has been polarized. GENERATING SYSTEM — M123, M123C, M125 (1) Disconnect wiring harness from connector at generator. (2) Using a jumper wire with suitable prods, momentarily connect field terminal “B” at generator receptacle to positive (+) terminal on battery. NOTE This connection allows a momentary surge of battery current to flow through generator field windings, which automatically gives generator the correct polarity with respect to batteries. (8) Connect wiring harness at generator and tighten connector nut. 2-116. Voltage-Regulator (Pig. 2-124). a. Removal. (1) Disconnect battery-ground cable at battery. (2) Remove connedtor nut of generator-to-regu- lator harness and carefully pull harness from regu- lator. (8) Disconnect battery harness in like manner at regulator. (4) Remove four bolts, nuts, and lockwashers securing regulator to mounting. bracket. Remove regulator. . Installation. (1) Position generator regulator on mounting bracket so harness connectors are facing down. Se- cure to bracket with four bolts, lockwashers, and nuts. (2) Connect battery harness to four-contact con- nector of regulator by tightening connector nut. GENERATOR TO BY REGULATOR HARNESS Figwre 2.126, Generator-regulator 241sADJUSTING GENERATOR eat scRt PULLEY (GENERATO} MOUNTING BOLTS Figure 2-125. Generator (3) Connect generator-to-regulator harness to three-contact connector in like manner. (4) Connect battery-ground cable to negative (—) post of battery. CAUTION ‘Do not start engine until generator has been polarized. (5) Polarize generator (para 2-115a), Section XIX. ALTERNATOR SYSTEM — M123A1C, M123E2 2-117. General The alternator is a waterproof, sealed unit driven by ‘8 set of two matched V-belts from the fan pulley of the engine. The voltage regulator is an integral part within the alternator. 2-118. Alternator (Fig. 2-126). a. Removal, (1) Disconnect electrical connector from alter- nator. (2) Remove bolt securing belt adjustment arm and remove drive belts. (3) Remove two mounting bolts and washers securing alternator to mounting base. Remove alternator assembly. . Installation, (1) Position alternator on mounting base and in- stall two mounting bolts. Do not tighten bolts. (2) Install bolt in belt adjustment arm. Do not tighten bolt. 4 (3) Install two V-belts over pulley. (4) Use a suitable bar and pivot alternator to ad- | just belts. Tighten adjustment arm bolt and two mounting bolts. (5) Check belt adjustment (para 2-972.) (6)Connect electrical connector to alternator. Section XX. ELECTRICAL SYSTEM 2-119. General Two 12-volt, lead-acid type batteries, connected in series, supply electrical current for all lights, switches and directional indicators for the M123, ‘M123, and M125 series vehicles. The M123A1C and MI23E2 vehicles use four 12-volt batteries con- nected in series, parallel. 2-120. Batteries and Cables a. Specific Gravity Test. (1) Cheek specific gravity of each cell with a hydrometer. (2) Reading of at least 1275 (at 80°F.) in each cell indicates battery is fully charged. 2-116 (3) Readings in cells of any one battery must not vary more than 25 gravity points between one an- other. (4) If readings vary more than 25 gravity points or are lower than 1225, replace batteries (c. below). CAUTION Do not overfill batteries as it will result in subsequent overflow of electrolyte through the gas eseape vent in the cell caps. ©. Servicing. The water in the electrolyte will evaporate at high temperatures or at high charging rate. Inspect the electrolyte level and add distilled clean water, if necessary, to bring electrolyte Tov to three-eighths inch above separators.eect] peconvecr| Figure 2126, Alternator. c. Removal, WARNING When work on vehicle requires disconnect- ing or connecting vehicle battery cables, ground cable(s) must be disconnected first and connected last. Failure to follow this Procedure can cause serious burns to per- sonnel and damage to vehicle batteries. Re- ‘move ground cable from terminal clamp on M123A1C and M123E2 vehicles. Do not re- move clamp from running board battery as underseat battery would still be grounded. (1) Running board batteries. (a) Open battery box door (fig. 2-127). Loosen wing nuts on battery box clamps and unhook clamps from box. (6) Pull box forward to step and disconnect ground cables. On M123A1C and M123E2, discon- nect cireuits Nos. 7 and 50 (fig. 2-128). On M123, M123C, and M125 disconnect circuits Nos. 7, 50, and 73 (fig, 2-150). fc) Disconnect starter and battery positive (+) cables. On M123A1C and M123E2 disconnect cireuits Nos. 6, 10, 49, 68, 503 and 569 (fig. 2-128), On M123, M123C, and M125 disconnect circuits Nos. 4. 48, 49, and 81 (fig. 2-150). (d) Remove battery interconnecting cable cir- cuit No. 68 by loosening terminal nut on one battery. fe) Remove battery holddown frame by re- moving five nuts on holddown bolts. Lift off frame. (A Lift out battery by lifting handles at each end of battery. (2) Underseat batteries — M123A1C, M123E2 (fig, 2-128), fa) Remove companion seat. (b) Disconnect four battery box cover latches and remove cover. (c) Disconnect battery cable circuits Nos. 7 (ground), 68 from running board batteries, and No. 68 underseat battery interconnecting cable. (d) Remove four hex nuts securing battery retaining frame to battery box. (e) Lift batteries from battery box. d. Cleaning. NOTE The top of batteries must be kept clean. (1) Tighten vent plugs and clean batteries with a brush dipped in alkaline solution such as ammonia or bicarbonate of soda, and water solution. (2) After foaming stops, flush top of battery with clean water. (3) Clean terminals and cable clamps in similar manner. (4) Connect cables and waterproof terminals by coating with heavy asbestos grease (GK). e. Installation. (1) Running board batteries. fa) Position both batteries in battery box with positive (+) terminals toward front of vehicle (fig. 2120). (b) Install five holddown bolts by hooking into slits at base of box. Position holddown frame over batteries securing with five nuts. (c) Connect interconnecting cable cireuit No. 68 (fig. 2-128) between batteries by positioning ter- minal clamp over (+) positive battery terminal on rear battery, and (—) negative terminal on front battery. Tighten clamp nut. (d) On M123, M123C and M125 connect cable circuits Nos. 4, 48, 49, and 81 (fig. 2-150) to front battery positive (+) terminal post. On M123A1C and ‘M123E2 connect cireuits Nos. 6, 10, 49, 68, 503 and 569 (fig. 2-128) to front battery positive ( + ) terminal. fe) On M123, M123C and M125 connect cable circuits Nos. 7, 50 and 73 (fig. 2-150) to rear battery negative (—) terminal post. On MI23A1C and M123E2 connect cable circuits Nos. 7 and 50 (fig 2-128). Waterproof battery terminals (d.(4) above), (2) Underseat batteries — MI28A1C, M123E2 2-128). fa) Position batteries in battery box. (b) Install battery retaining frame and secure with four hex nuts. (c) Connect battery cable circuits Nos. 7 (ground), 68 (positive to positive) from running board batteries, and 68 (positive to negative) battery inter- connecting cable, Waterproof battery terminals d.(4) above. fd) Install battery box cover and secure four latches. fe) Install companion seat. (fig. 2117 6sare sarteny 30x DOOR Waste POSITIVE NEGATIVE TERMINAL jy INTERCONNECTION ) Came AT 34699 E igure 2-127. Batteries — M128, M123C, M12 NOTE: DISCONNECT TERMINAL ‘CLAMP CABLE BOLT TO BREAK BOTH SETS OF BATTERY GROUND CABLES, NOTE: NUMERALS INDI ELECTRICAL CIRCUIT NUMBERS, | ' I | 1 I | I I | 0 AT 3464 Figure 2.128, Batterien — M128A1C, MI2SE2. 2-121. Battery Cables @. General — M128, M12SC, M125. The battery cable system is composed of the following cables (fig. 2-150). (1) Battery-to-ground (circuit No. 7). From negative (—) post on rear battery to frame side- member. 2118 (2) Battery-to-battery (circuit No. 68). From negative (—) post on forward battery to positive (+) post on rear battery. (3) Battery-to-magnetic switch (circuit No. 81). From positive (+) post on forward battery to contact, on magnetic switch. (4) Battery-to-generator-regulator (circuit No. 4). From positive (+) post of forward battery to A ter- minal four-contact connector of regulator. (5) Battery-to-radio receptacle (circuit No. 48). From positive (+) post on forward battery to ter- minal A on radio receptacle. (6) Battery-to-slave receptacle (circuit No. 49). From positive (+) post on forward battery to slave receptacle. (1) Radio receptacle-to-battery ground (circuit No. 78). From terminal B on radio receptacle to negative (—) post on rear battery. (8) Slave receptacle-to-battery ground (cirouit No. 50). From slave receptacle to negative (—) post on rear battery. b. General — M128A1C, M12SE2. The battery cable system is composed of the following cables (fig. 2-151). (1) Running board battery-to-starter (circuit No, 6). From positive (+) post on forward running board battery to starter. (2) Running board battery-to-frame ground (cir- cuit No, 7). From negative (—) post on rear running board battery to vehicle frame. (3) Underseat battery-to-running board battery ground (circuit No. 7). From negative (—) post on outboard underseat battery to negative (—) post on rear running board battery. (4) Running board battery-to-slave receptacle (cireuit No. 49). From positive (+) post of forward running board battery to slave receptacle. (5) Slave receptacle-to-running-board battery ground (circuit No, 50). From slave receptacle to negative (—) post on rear running board battery. (6) Running boord battery-to-master switch (cireuit No. 10). From positive (+) post of forward running board battery to master switch. (1D Running board battery-to-underseat battery (circuit No. 68). From positive (+) post of forward running board battery to positive (+) post of inboard underseat battery. (8) Forward running board battery-to-rear run- ‘ning board battery (circuit No. 68). From negative (—) post of forward battery to positive (+) post of rear battery. (9) Underseat battery-to-underseat battery (cir- cuit No. 68). From positive (+) post of outboard bat- tery to negative (—-) post of inboard battery. (10) Running board battery-to-cold start panel (cireuit No. 569, 12-volt). From positive (+) post of ¢ ¢rear running board battery to cold weather starting switch. (11) Running board battery-to-alternator (cir- cuit No. 508). From positive (+) post of forward run- 0 ning board battery to positive (+) terminal on alter- nator. ¢. Repair. Each battery cable is of specified length and assembled with specific terminals. Refer to TM 9-2320-206-20P manual for specified lengths and ter- minals and proceed as follows: (1) Cut cable to proper length including stripping. (2) Strip cable back and set stripped cable into base of terminal. Crimp in place. (3) Cut length of insulation sleeve (electrical) as specified in TM 9-2320-206-20P and slip over ter- minal. Install cable end. 2-122. Battery Box and Supports. a. Removal. (1) Battery box (running board) (fig. 2-127). (a) Loosen wing screws at base of box securing locking clamps in position. (b) Swing clamps down clear of battery box and pull box out of compartment onto running board. (c) Disconnect battery ground cable (d) Remove batteries (para 2-120c.). (e) Remove battery box. d (2) Battery bor supports (fig. 2-121). (a) Remove battery box ((1) above) (b) Remove four nuts and screws securing sup- port to step mounting bracket and lift off support. (c) Remove battery box clamps by removing two nuts, bolts, and spring washers securing clamps tosupport. (3) Battery bor (underseat). (a) Remove batteries (para 2-120c.). (b) Remove four bolts securing battery box to cab floor and remove battery box. Inspection and Repair. (1) Inspect all components for damage and cor- rosion. Replace if necessary. (2) Most components of battery box assembly are of welded construction and must be replaced. ¢. Installation. (1) Battery boe supports. (a) Install battery box clamps on support and secure with two bolts, nuts, and spring washer (fig. 2-127). (b) Position support on step mounting brackets and secure with four eapscrews and nuts (fig. 120). (c) Install battery box ((2) below. (2) Battery box (running board). (a) Place battery box on running board and in- stall batteries (para 2-120e.). (6) Connect battery eables, (c) Push box into battery compartment making certain holddown angle bracket at base of rear panel fits into clamps on box support. (d) Lift up clamps from support and hook over wing screws. Tighten wing screws in place (fig. 2-127). (3) Battery box (underseat). (a) Position battery box under companion seat and secure with four bolts. (b) Install batteries (para 2-120e.). 2-123. Headlights @. Sealed Beam Lamp Unit. (1) Adjustment. (a) Headlight aiming chart is used to adjust headlight beam. (b) Cover one headlight while adjusting the other. (c) Remove headlight door ((2Xa) below) (fig. 2-129). (d) Turn top screw to adjust beam vertically, le serew to adjust beam horizontally (fig. 2- (2)Removal, (a) Unscrew three screws on headlight door and remove door (fig. 2-129). The screws will remain in door. (>) Unscrew three screws in inner retaining ring, and remove retaining ring (fig. 2-131). (c) Remove sealed beam lamp unit, and dis- connect cables and waterproof connectors (fig. 2-131). (8) Installation. (a) Connect cables at connectors and position sealed beam unit in headlight body (fig. 2-131). (b) Position retaining ring, and secure with three screws. (c) Position headlight door and fasten with three screws and washers (fig. 2-129). HEAD LIGHT LAMP UNIT HEADLIGHT DOOR| RETAINING SCREW Figure 2129. Headlight and blackomt driving light. 2119VERTICAL, B) ADJUSTING screw Figure 2-130, Headlight adjuntment. RETAINING WATERPROOF Bigg CONNECTORS P HEAD LIGHT iD As ASSEMBLY HEADLIGHT Ph Figure 2-181, Remoring or instaling headlight sealed beam wit, 2-120b. Headlight Assembly. (1) Removal. (a) Remove headlight door ((2Xa) above). (b) Remove eight screws and lockwashers securing headlight assembly to headlight panel (fig. 2-181). (c) Pull headlight assembly from headlight panel, disconnect three cables at connectors, and remove. (2)Installation. (a) Connect three cables to connectors at rear of headlight panel. (b) Refer to lighting cireuit diagram (fig. 2-41) and make sure cables are matched correctly. (c) Position headlight assembly and gasket in, headlight panel and secure with eight screws and lockwashers (fig. 2-131). DOOR RETAINING BRACKET LOCKWASHER SCREWS SCREWS = Q (d) Adjust headlight beam (a.(1) above). (e) Position headlight door and secure with three screws and lockwashers (fig. 2-129), 2-124, Blackout Driving Light. a, Sealed Beam Lamp Unit. (1) Removal. (a) Loosen three door retaining screws and remove door (fig. 2-132). The three screws will re- main in door. () Pull door and sealed beam unit assembly forward and remove connectors from mounting slips (fig. 2-132). (c) Disconnect waterproof connectors (fig. 2- 133). (d) Remove sealed beam unit retaining spring and remove sealed beam unit from door (fig. 2-133). SEALED BEAM LAMP UNIT AT 34644 Ww) Fiyure 2-182, Removing or instalting blackout sealed beam unit 2421(2) Installation. (a) Position sealed beam unit in door and se- cure with three retaining springs (fig. 2-133). (b) Connect cables to waterproof connectors (fig. 2-133). {c) Fasten cable connectors to mounting clips and mount door and sealed beam unit assembly on blackout driving tight body (fig. 2-132). (d) Secure door with three serews and lock- washers (fig. 2-132). 6. Blackout Driving Light Assembly. (1) Removal, (a) Disconnect two cables behind blackout driv- ing light assembly (fig. 2-207). (b) Remove four screws, lockwashers, and nuts securing blackout driving light bracket to left head- light panel. Remove blackout driving light with bracket attached (fig. 2-132). (c) Remove nut, lockwasher, and bearing wash- er securing blackout driving light assembly to bracket and separate light assembly from bracket. (2) Installation, (a) Position blackout driving light assembly on bracket and install nut, lockwasher, and bearing washer. (0) Position blackout driving light assembly with bracket on headlight panel and secure with four serews, lockwashers, and nuts (fig. 2-132). (c) Connect two cables to rear of blackout driving light (fig. 2-207) (d) Refer to circuit diagram (fig. 2-41) and make sure cables are connected correctly. ¢ 2-125, Blackout Marker, Parking, and Directional Lights. @. Lamp Bulbs. (1) Removal. fa) Loosen six door (cover) retaining screws (fig. 2-134). The screws will remain in door. (6) Lift out blackout marker light and door seal gasket. (c) Push lamp in and turn counterclockwise to remove lamp from socket. (2) Installation, (a) Insert lamp in socket and turn clockwise to lock in place. (6) Test lamps by turning on light or directional switch. (c) Install door seal gasket and door (fig. 2-134), (d) Secure door by tightening six screws. ©. Blackout Marker Light Assembly. (1) Removal. (a) Disconnect two cables (three with direction- al signals) from behind blackout marker light as- sembly. Figure 2.133. Removing or installing blackout driving light 2122BLACKOUT MARKER LIGHT DOOR DOOR SEAL GASKET BAYONET TYPE LAMP BULBS AT 34646 Figure 2-145, Removing or installing Blackout marker lamp, (b) Remove two serews and lockwashers secur- ing blackout marker light to mounting bracket and remove blackout marker light assembly (fig. 2-134). (2) Installation. (a) Position blackout marker light assembly on mounting bracket and install two bolts and lock- washers (fig. 2-134). (6) Connect two cables at connectors behind blackout marker lights. Refer to circuit diagram (fig. 2-41). 2-126. Stoplight, Directional Signal, and Taillight. a. Lamp Bulbs, Refer to paragraph 2-125a, b. Stoplight, Directional Signal, and Taillight (fig. 2-135). (1) Removal, (a) Disconnect three cables (two cables on right hand side) behind service stoplight and taillight. (b) Remove two screws securing light to mount- ing bracket and remove taillight assembly. (2) Installation, (a) Position taillight assembly on mounting bracket and secure with two bolts and lockwashers. (b) Connect cables at connectors behind light (fig. 2-41). NOTE Right hand assembly may contain either the directional signal or the blackout stop- light. When directional signals are used, blackout stoplight will be mounted near the left taillight. ¢. Blackout Stoplight (fig, 2-135). (1) Removal. (a) Disconnect cable connection behind stop- light housing. (6) Remove one bolt and washer securing stop- light housing to mounting bracket and remove housing. (2)Installation. (a) Position blackout stoplight assembly on mounting bracket locating dowel and secure with one bolt and washer. (b) Connect cable connector to stoplight. 2-127. Traller Coupling Receptacle (Fig. 2-135). a. Removal. (1) Remove four nuts, lockwashers, and bolts securing trailer light receptacle bracket to rear crossmember. (2) Remove nut, bolt, and lockwasher securing receptacle ground cover to rear erossmember. (8) Loosen connector nut at rear of receptacle. (4) Remove trailer connection plug elip securing cable plug to receptacle and pull plug from connec tor. 2123b, Installation. (1) Push plug into receptacle from rear and se- cure with plug clip. Tighten connector nut. (2) Secure receptacle bracket to frame rear crossmember with four screws, lockwasher, and self-locking nuts. (8) Attach receptacle ground wire to rear cross- member with bolt, lockwasher, and self-locking nut. 2-128. Panel Lights a. Lamps. (1) Removal. (a) Remove panel light (b.(1) below). (b) Press body and cover assembly together, turn body counterclockwise, and separate assembly. (c) Press lamps and turn to remove from bayonet socket. (2) Installation. (a) Install replacement lamp, position cover on body, and turn to engage retaining pins in cover slots. (®) Place lamp assembly in instrument cluster from rear, and secure with two screws and lock- washers. (c) Connect cable connector. Place connector in clip at side of panel. 6. Panel Lights. (1) Removal. (a) Remove instrument cluster (fig. 2-136) from instrument panel (para 2-150a..). (®) Disconnect electrical connection at holder behind tachometer. 2124 Figure 2-145. Trailer coupling receptacle and combination stop. turn, and tailight, (c) Unscrew two screws from front of cluster and remove light from rear. (2) Installation. (a) Insert panel light behind cluster and sec- ure with two screws inserted from front. (b) Position electrical connection at holder behind tachometer and install instrument cluster (para 2-150b.).TEMPERATURE BATTERY GENERATOR INDICATOR GAGE TACHOMETER SSS AIR PRESSURE FUEL LeveL SPEEDOMETER el es HIGH BEAM, INDICATOR LIGHT GAGE AT 34648 Pigure 2136. Instrument chater: 2-129. High Beam Indicator Light Refer to paragraph 2-128 and figure 2-136. 2-130. Flood light — M123, M123C, M123A1C, M123E2. a. Sealed Beam Lamp Unit. (1) Removal. (a) Remove three screws securing door as- sembly to floodlight body. (b) Remove door and retaining spring. c) Disconnect two cables from terminal at rear of sealed beam unit and remove unit. (2) Installation. (a) Connect two cables to terminals at rear of unit. (0) Position unit in body with alining lug at bottom. (c) Install door assembly with alining socket at bottom and retaining spring to hold sealed beam unit in place and secure with three screws. b. Floodlight. (1) Removal. (a) Remove plug connectors from receptacles below floodlight switch, by removing nuts and pulling plugs out of receptacles. (b) Remove two nuts and washers from stud on mounting bracket securing floodlight to stanchion and lift off floodlight assembly. (2)Installation, (a) Position floodlight mounting bracket stud through stanchion and secure with two washers and one nut. NOTE Tighten only enough to allow free sidewise movement of floodlight in stanchion. (6) Install second nut, and lock two nuts to- gether by holding top nut in position with wrench and tightening lower nut against upper ni (c) Position cables as shown in wiring diagram. 1, M123 and M123C use cable circuit Nos. 496 and 87 (fig. 2-150). 2, MI23A1C and M123E2 use cable circuit Nos. 496 and 518 (fig, 2-151). 2-131. Light Switch a. Removal. (1) Remove plug connectors from both recepta- behind light switch by removing nuts with span- ner wrench and pulling plugs out of receptacles, (2) Unscrew four screws securing switch to in- strument panel, and remove switch from rear. 6. Installation, (1) Place switch in instrument panel from. the rear, with receptacle down, and install four serews. (2) Connect plug connectors to receptacles and tighten connector nut with spanner wrench. 21252-132. Dimmer Switch a, Removal, (1) Remove four screws, flat washers, and lock- washers, securing shield on underside of toeboard and remove shield. (2)Disconnect three cable connectors. (3) Unserew two mounting serews from top of toeboard and remove switch. ©. Installation. (1) Position dimmer switch below toeboard and install two screws. (2) Make three cable connections, circuit Nos. 16, 17, and 18. Refer to lighting circuit diagram (fig. 241), (8) Position shield and secure with four screws, flat washers, and lockwashers. 2-133. Stoplight Switch @. Removal. (1) Disconnect two waterproof bayonet type con- nectors. (2) Disconnect air lines by removing tubing nuts. (3) Remove two bolts, nuts, and lockwashers securing switch to left frame sidemember. ©. Installation. (1) Position switch on sidemember and secure with two bolts, lockwashers, and self-locking nuts. (2) Connect air lines to switch by tightening nuts. (8) Connect two waterproof bayonet type con- nectors. 2-134. Horn and Switch @. Horn (fig. 2-137). (1) Adjustment. MODELS MIZIAIC, MIZ3E2 SHOWN Figure 2187. Air horn — MIS8A1C. MISSE2. 2-126 (a) Loosen locknut on end of horn diaphragm housing and turn adjusting screw in or out to adjust to (>) Hold adjusting screw in position and tighten locknut. (2)Removal, fa) Open access panel below right front fender on models M123, M123C, and M125. Horn is acces- sible from top on models M123A1C and M123E2. () Disconnect air line at solenoid in center of horn (fig. 2-137). (c) Disconnect two cables from horn solenoid. (d) Remove two bolts and self-locking nuts securing horn assembly to mounting bracket, and remove horn. (3) Installation, (a) Position horn on mounting bracket and secure with two bolts and self-locking nuts (fig. 2- 137). (6) Install air tube in horn solenoid and tighten nut to connect air line. (c) Connect two cable cireuit No. 25 (fig. 2- 150) to solenoid. (d) Close access panel and lock in place on models M123, M123C, and M125. b. Horn Switch (fig. 2-188). (1) Removal, fa) Remove rubber horn button cover in center of steering wheel. (®) Press horn button in and turn counterelock- wise to disengage. (c) Unserew three screws attaching base plate to steering wheel. (a) Remove four screws and lockwashers se- curing contact brush cover to steering column above steering angle drive. (e) Lift cover and remove two serews and washers securing horn cable to brush plate. (A Lift base plate with horn cable from steer- ing wheel and pull horn cable from steering column. (2) Installation. (a) Position base plate with switch wire over steering wheel and feed horn cable down through steering column to brush plate. (®) Position horn cable through brush with two screws and lockwashers. (c) Position cover over steering column and secure with four serews and lockwashers. (d) Secure base plate to steering wheel with three self-tapping screws. (e) Position horn button in steering wheel, press in and turn clockwise to secure. () Install rubber horn button cover in center of steering wheel. 4 (> 2-135. Directional Signal Light Switch (Fig. 2-139). (1) Disconnect four electrical disconnects under instrument panel. (2) Remove eable clamp securing directional signal light switch cable to steering wheel column. (3) Remove cable clamp securing directional signal light switch cable to instrument panel. (4) Remove clamp securing directional signal light switch to steering wheel column. . Installation. (1) Position directional signal light switch on steering wheel column and secure clamp. (2) Install cable clamp which secures direc- tional signal light switch cable to steering wheel column. (3) Install eable clamp which secures directional signal light switch cable to instrument panel, (4) Connect four electrical disconnects under instrument panel. HORN UTTON omy cane conntuTto® b cOnTaer Car/aurtON ano WORN CoveR ASSEMBLY Nur HORN CABLE ‘CONTACT BRUSH ASSEMBLY CONTACT aRUSH cover SEAL ‘AT 34650 Figure 2.188, Horn switch wiring 2-136. Circuit Breakers (ig, 2-124), a, Removal. (1) Disconnect two terminal connectors by twist- ing counterclockwise. (2) Unscrew two mounting screws and remove circuit breakers. 6. Installation, (1) Position cireuit breaker on firewall and secure with two self-tapping screws, and connect two ter- minal connectors. (2) For proper connection refer to lighting circuit diagram figure 2-41 and harness diagram figures 2- 152 and 2-153, 2-137. Slave Receptacle (Fig. 2-140). @. Removal. (1) Remove electrical connections from behind slave receptacle, mounted on cab just behind pas- senger door opening, between the upper and lower hand grips. NOTE Slave receptacle electrical connection is ac- cessible from inside the cal (2) Remove four bolts, locknuts, and washers, Remove slave receptacle. 6 Installation. (1) Position slave receptacle to cab and secure with four bolts, locknuts, and washers, (2) Connect electrical leads behind ceptacle. je ree ELECTRICAL DISCONNECTS ime 2.139, Directional signal light witch. 2127[UPPER HAND GRIP SLAVE RECEPTACLE LOWER HAND GRIP LOCKNUT LOCKWASHER Figure 2.140, Slave receptacle Section XXI. SPECIAL LIGHTING — M123A1C, M123E2. 2-138. General ‘The special warning lights consist of composite, marker, warning and taillights, directional signals and toggle switch. NOTE Refer to wiring diagram figure 2-149 for electrical connections. NOTE In all instances where two identical items are to be installed, instructions for only one like item will be included. 2128 2-139. Composite Light (Fig. 2-141). a. Lamp. (1) Removal. (a) Loosen five door (cover) retaining screws (1, fig. 2-141) and remove door (2). The screws will remain in door. (b) Remove composite light gasket (3). (c) Push lamp (4) in and turn counterclock- wise to remove lamp from socket. (2) Installation, ((a) Insert lamp (4) in socket and turn clockwise to lock in place. (b) Position door seal gasket (3) and door (2). (c) Secure door by tightening five door retain- ing serews (1). . Composite Light. () Removal, (a) Remove four capscrews (5) and self-locking nuts (6) securing lamp hood (7), body assembly (8), and protector box (9) to front fender. (6) Slide protector box (9) back on cable and disconnect three electrical leads (10) from behind ‘composite light. Remove lamp hood (7), body assem- bly (8), and protector box (9). (c) Remove two capscrews (11) and washers (12) securing body assembly (8) to lamp hood (7). Remove body assembly (8). (2) Installation. (a) Attach body assembly (8) to lamp hood (7), with two capscrews (11) and lockwashers (12). (0) Position lamp hood (7) and body assembly (8) to fender. Connect three electrical leads (10) behind body assembly (8). Position protector box (9) and secure lamp hood (7), body assembly (8), and protector box (9) to fender with four capserews (5) and self-locking nuts (6). 2-140. Marker Light (Fig, 2-142). a. Removal, (1) Remove two machine screws (1, fig. 2-142) securing door (2) and lens (3) to plate (4) and remove door, lens and gasket (5). (2) Remove lamp (6) by pushing lamp in and turn counterclockwise. Remove lamp from socket. (3) Remove four machine screws (7) and self- locking nuts (8) securing protector box (9) to marker light bracket (10) and remove protector box. (4) Disconnect electrical lead (11) behind marker light plate (4). (5) Remove four machine screws (12) and self- locking nuts (13) securing plate (4) and mounting pad (14) to bracket (10) and remove plate and pad. ©. Installation. (1) Position mounting pad (14) and plate (4) to bracket (10) and secure with four machine serews (12) and self-locking nuts (13). (2) Connect electrical lead (11) behind marker light plate (4). (8) Position protector box (9) to marker light bracket (10) and secure with four machine screws (1 and self-locking nuts (8). 1 Door retaining crew 2Door aasembiy Gasket 5 Caper 3 Capecrew 8 Selocking nut Thapptoos 4 Body assem 9 Protector box. 10 Electrical lead 11 Capecrew 12Leckwasher Figure 2.141. Composite light — exploded view. 21298 Self-ocking nut 5 Protector box AT 34654 10 Bracket U1 Bleetrieal lead 12Machine screw 13 Selflocking nut 14 Mounting pad igure 2.142, Marker light — exploded view. (4) Insert lamp (6) in socket and turn clockwise to lock in place. (5) Install gasket (5), position lens (3) and door (2) to plate (4) and secure with two machine screws a. 2-141. Turn Signal Light (Fig. 2-143). a. Lamp. (1) Removal, (a) Remove four machine serews (1, fig. 2-143) securing lens (2) to body assembly (3). Remove lens and gasket (4). (b) Remove lamp (5) from body assembly (3). (2) Fnstallation. (a) Insert lamp (6) in socket and lock in place. (6) Install gasket (4) and position lens (2) to body assembly (3) and secure with four machine serews (1). b, Turn Signal Light. (1) Removal, 2130 (a) Remove four capscrews (6), lockwashers (7), and self-locking nuts (8) securing lamp hood (9), body assembly (3), and protector box (10) to front fender. (0) Slide protector box (10) back on cable and disconnect electrical leads (11) from behind body as- sembly (3). Remove lamp hood (9), body assembly (8), and protector box (10). (@) Remove two capscrews (12), flat washers (13), and self-locking nuts (14), securing body as- sembly (3) to lamp hood (9). Remove turn signal light. (2)Installation. (a) Position body assembly (3) to lamp hood (9) and secure with two capscrews (12), flat washers (18), and self-locking nuts (14). (6) Position lamp hood (9) and body assembly (8) to fender. Connect electrical lead (11) behind turn signal body assembly (3) and position protector box (10) to fender. Secure lamp hood (9), body assembly (8), and protector box (10) with four capscrews (6), lockwashers (7), and self-locking nuts (8). (0 4 8Self-locking nut ‘9 Lamp hood 10 Protector box 11 Electrieal ead 12.Capecrew 13 Flat washer 14 Self-loeking nut Figure 216, Turn xignal light — exploded view, AT 34655 1 Machine serew 3 Body asembly iG 8 Capecrew ‘Kockwather 2-142. Taillight @. Lamp. (1) Removal (a) Unscrew six door (cover) retaining screws (1, fig. 2-144) and remove door (2). The screws will remain in door. (b) Remove taillight gasket (3). (c) Push lamp (4) in and turn counterelock- wise to remove lamp from socket. (2) Installation. (a) Insert lamp (4) in socket and turn clock- wise to lock in place. (b) Install new gasket (3) and position door (2) bocy assembly (5) and secure by tightening six door retaining serews (1). ©. Taillight. (1) Removal, (a) Remove four capscrews and washers se- curing protector box to taillight bracket. Remove pro- tector box (fig. 2-145). (b) Disconnect four electrical leads (6, fig. 2- 144) from behind body assembly (5). (c) Remove two capscrews (7) and lockwashers (8) securing body assembly (5) to taillight bracket 9). (2) Installation. (a) Position body assembly (5) to taillight bracket (9) and secure with two capserews (7) and lockwashers (8). (&) Connect four electrical leads (6) behind body assembly (5). (¢) Position protector box to taillight bracket securing with four capscrews and washers (fig. 2- 145). ¢. Reflector (fig. 2-145). (1) Removal. Remove two capscrews securing reflector to taillight bracket and remove reflector. (2) Installation. Position reflector to taillight bracket and secure with two capscrews. 2131retainingserew fam 1 Capserew 2D oor assemble $3 Body asembiy 8 Lockerasher Casket eBicctnal lead S Bracket Figure 2144, Tuilligh — exploed view 2-143, Warning Light (Pig. 2-146). TAILLIGHT Figure 2.145, Taillight avd reflector 2-132 a. Removal, (1) Remove two straps securing electrical lead to warning light stand and disconnect electrical lead. (2) Loosen self-contained toggle bolts and re- move warning light from warning light stand. 6 Installation, (1) Position warning light on warning light stand and secure with self-contained toggle bolts. (2) Secure electrical leads to warning light stand with two straps. 2-144, Warning Light Toggle Switch (Pig. 2-147). a. Removal, (1) Remove connectors from behind warning light toggle switch. (WARNING Figure 2-146. Warning light (2) Remove two machine screws securing switch to instrument panel and remove switch. b. Installation. (1) Position warning light toggle switch to in- strument panel and secure with two machine screws. (2) Make cable connections behind toggle switch. 2-145. Directional Signal Control (Fig. 2-147). a. Removal, (1) Remove signal control cable from directional signal control. (2) Remove adjustable clamp securing spacer ‘and directional signal control to steering column. ©. Installation. (1) Position spacer and directional signal con- trol to steering column and secure with adjustable clamp. (2) Secure signal control cable to directional signal control. 2-146. Signal Control Flasher (Fig. 2-148). a. Removal. (1) Remove signal control cable from signal control flasher. (2) Remove machine screws and lockwashers securing signal control flasher to firewall. b. Installation. (1) Position signal control flasher to firewall and secure with machine screws and lockwashers. (2) Connect signal control cable to signal control flasher. 2433‘igure 2-148. Signal control flasher.oP (ci AT 34661 3 k A o ; a GO) xe VAY, © 7 @) v7 20) . 7 © ) ay é 9 ® @ ie) © . C u ‘4 Gi) 1 Ou 7 I 2 : (os) Gia) y 6 v . Apevecrn}—? Gs) © © a | v mi ~@) | | 0a D E 9 L © ° B K A 8 F a © w Cd 4 coral < 7 Hl Gs) 2 7 (ian ay) @& (2) ; r-@ (ss) 4) «)) 3 3 € K 4 L 2 ZB) @ fs @® & C ™ @ c D 22 N a) @)) ° 5 ® Lem S + 8 DNMHCESFIALK re > (90) 6 Figure 2-149. Wiring diagram — apecial lighting. 2135Key to figure 2-149, BO. marker, parking light, and directional signal 16 Light switch todimmer switeh iorn 17 Dimmer switch toheadlights high beam indicator Panel lights 18 Dimmer switch to headlights lower beam High beam indicator light 19 Light switch to 8.0. driving light Liane switeh 20 Light switch to B.O: marker lights 21/489 Light switch to service taillight, ler receptacles 2 itswitch to Lura signal distribution box B ta a ts % it 0 ts ight Stoplight switch % switch to stoplight switch ‘Trailer connector 90 Trailer receptacle to ground 91 Headlight ground 460 Solid tate flasher to right front and right rear ‘signal lights SeldtateManher ole front and lef rear sina Foedanpvitch an warning ht ewich wor Sg er tet frontand eft rear imal ‘ 490 Blackout clearance ht {$21 _Lightowitch to parking lights and side signa ichts StS Gitcuit breaker tonwitch and swith to warning Tight 518 Circuit breaker to floodlamp switch and switch to floodlamp. BS Section XXII. WIRING CIRCUITS AND HARNESSES 2-147. General wiring and connections to various electrical units are The electrical circuits are numbered in accordance contained in harnesses interconnected to form the with the ordnance system and can be identified from complete electrical circuit. ‘the diagram shown in figures 2-150 and 2-151. The 2.136‘RIM OE8IW SEIN — woul yronD Ouasny “OST-3 IMR 2137Key to figure 2-150; BO. marker and parking lights Hor Slave receptacle Fuel pump selector switch Fuel selector switch Fuel tank sender unit Electr fue pump — on fea eae Seo ce A ett ae Ee Ht boa ie itn See CaunewzErReZoamcam> ei rite Battery to regulator “A” terminal Regulator (shunt) to ercuit breakers Circuit breaker to igition switch (Teed) Magnetic starting switch to starting switch Cireuit breakers to light switch (feed Light switch to dimmer switch ce od 8 ° “ 2 2B 12 14 Ignition switch to ignition “ “ 4 “ “ “ “ “ 4 3 areiate nbasia 3 iciscit corte 2 tatiana 14 BE wera we 2 bteihoso etait ne sat me ABER 20 ates a a eee Bot geltixemesks foi coe, 2 4 SERRE oun PG ae 2 oi ieee Sof Seer a 4% 14 Lightswiteh ta instrament lehia 2 i eee $ ] Eerste g > Reims HE Sb ee 5 vy Light switch to stoplight switch B of Hehe Ft re em tay aot RESeemiacna, soi Ge Bt 21 See, Bt ees fe ii Ee ,: Se i cae. goof emitorniley@ “BASEL ‘OI WESIN — mOdbONp yma OMI “TST-2 Bm 2-139eereeee BENEE 8 2-140 Key to figure 2-151: Headlights He 7 HESS anie Eaeete, oe Soares Se a ee oie sites Ente carat Seas scores Heme ressure gage ‘beam indicator light Fuel gage Battery-generator indicator Panel ight SecunmevzErRLZOmmson> Cire Daription Battery tostarter solenoid Battery ground eables Battery to horn circuit breaker and light circuit breaker Power feed to and from master switch Master switch to starter witch Light awitch circuit breaker to ight switch (power feed) Light switeh to dimmer switeh Dimmer switch to headlights high beam Dimmer switeh to headhgnts iower beam Light switch to blackout driving light Light awiteh to front blackout marker lights Light switch to service taillight and trailer receptad Light switch to distribution box (service and stop) ‘Turn indicator circuit to right service (rear) ee ‘Turn indicator eireuit to left service (rear) ‘and trailer receptacle Light awitch to blackout stoplight and trailer receptacles Light switch to blackout taillights Gireuit breaker to horn to horn button Master switch to cireuit breaker to instruments Puel sending unit to fuel gage ‘Water temperature transmitter to temperature sage sure transmitter tooll pressure age switch to instrument panel lights Battery to slave receptacle (+ Slave receptacle to batters (—-) Master switch to ful shutoff solenoid valve attery interconnect Light switch to stoplight switch X_ Directional light switch ¥ ibation box 2 Semi-trailer connector AA. Floodlamp switeh ‘AB Tail stop, directional, blackout service light ‘AC Fuel traller connector AD Blackout, stoplight ‘AE. Fuel level sender AF Stoplight (ar) switch A AM Maserowich yw air pressure awit AK Low air pressure buzzer. AL Dimmer switch AM Glow plug ‘AN Horn AP Alternator AQ. Fuel shutoff valve ‘AR. Blackout marker light ‘AS Blackout headlight es (Crest Deron & Master switch olow i presure switch to ‘air presoure indicator 20. Semitruilecand fll-rller receptacle ‘rounds 91 Headlights to ground 214 Starter to starter switch to cold weather starting panel relay 460 Turn indleator circuit, right service (front 461 Turn indicator circuit, left service (front) 490 Light switch to traler receptacles, blackout fai artnet 491 Light suiteh to parking lights 496 Flocdiamp ground cireuit, 503 Battery to alternator postive +.) terminal 504 Alternator negative (—) terminal to ground 518 Ploodlamp etre! 519 Dimmer switch to high beam indicator light ‘56 Master switch to battery generator indicator ‘568 Master switch to alternator (IGN) terminal ‘569 Battery to cold weather starting panel tole ‘witch (12 volta) 510 Tomatle switch to resistor Ri on cold weather ‘starting panel STL Togtle switch to indicator light to resistor ‘assembly on cold weather starting pane! 812 Towle switch to relay (terminal KZ)on cold ‘weather starting panel 518 Resistor assembly to terminal Bon cold ‘weather starting panel 514 Re ‘assembly to terminal Bon cold ‘weather starting panel 515 Tefminal Bot resto seembl to low plan 516 Resistor assembly to relay terminal K1) ‘on cold weather starting panel ¢2-148. Harnesses . General — M128, M128C, M125, The wiring sys- tem consists of four major harnesses fig. 2-152). (1) Front end wiring harness. This harness sup- plies electrical current to headlights (1, fig. 2-152), parking lights light switch (2), instrument cluster (3), blackout driving lights (4), blackout marker lights (5), dimmer switch (6), temperature sending unit (7), nd the fuel pump and fuel gage switches. (2) Generator harness. This harness extends from generator (9) to generator-regulator (10). (3) Generator-regulator wiring harness. This harness extends from generator-regulator (10) to the battery-generator indicator in instrument cluster (3), circuit breakers (11), and batteries (12). (4) Rear end wiring harness. This harness sup- plies electrical current to the trailer receptacles (13), service stop and taillights (14), blackout tail and lights (15), fuel pumps (16), and fuel gage send- ing unit (17). b. General — M128A1C, M12SE¥, The wiring sys- tem consists of two major harnesses (fig. 2-153). (1) Front end wiring harness. This harness sup- plies electrical current to headlights (1, fig. 2-153), horn solenoid (2), blackout marker, parking and signal lights (3), blackout driving light (4), alternator (5), fuel pump shutoff solenoid (6), starter switch (1, low air pressure horn (8), and cold weather start- ing panel (9) consisting of oil, temperature, fuel, and battery indicators. (2) Rear end wiring harness. This harness sup- plies electrical current to blackout, tail, signal and stoplight (10 and 11), floodlight (12), fuel gage send- ing unit (13), and both the full (14) and semi-trailer (15), trailer connector receptacles. ¢. Removal, All electrical harnesses and cables are removed as follows: (1) Disconnect cable or harness by unscrewing the plug coupling nut on two-piece connectors and pull plug from receptacle at each end of harness. (2)Remove clamps and remove cable or harness. d. Inspect and Repair. (1) Check harness cables and wires for broken wires and damaged or broken terminals and end connectors. (2) Repair broken wires by splicing and replacing damaged or broken terminals and end connectors. (3) For any further repairing notify supporting maintenance. e. Installation. (1) Position harness or cable and install clamps. (2) Position connector plug into receptacle and tighten coupling nuts. NOTE When installing connector plugs, position alining tongue on plug with groove in recep- tacle. Do not kink or twist harness or cable: tighten all clamps. To assemble the two halves of bell connectors, position rubber grommets and bushings before attempting to secure halves together. 2441VIEW LOOKING FORWARD AT REAR OF LIGHTS 1 Headlieht Service stop and alight 2Lightewteh 16 Blackout ti and staple UBlehoot See 17 Foe Engr end Blackout drivin jel ue sending unit 2 Blcoat marker ita sina i. immer switch ‘ Water em ina ai 20 Floedight Miz 4 Mee emperatre ending nit 22 Flndaht zt oly 5 Generator 22Low ar pressure horn 10 Generstor-requlator 23 Low ar presure atch ibauer SSomvuraereehiece Mise 18 Trailer receptacle 28 Magnetic switch oa ‘Figure £188. Harness diagram — M128, Mi23C. Mi8s, 2.142SECTION 8-8 Late Heat ag _ Been arin and aia ht iBaceut mete gat Hoes Fee oer se Se ere ant See and Sea otht 13 Fuel gage sending unit 1 ie Teceptacl 15 Semitrailer receptacle 16 Batteries 1TStoplight switch ABLight witch 19 Signal light switch 20 Starter and solenoid 21 Floodlight switeh 2instrument cluster 23 Master switch 24 Temperature sending unit Figure 2158, Harness diagram — MI2SA1C, MI23E2. 2143Section XXIII. INSTRUMENT CLUSTER, GAGES, BUZZER, AND SENDING UNITS 2-149. General The instrument cluster. mounted on the instrument panel assembly, contains the fuel level gage. air pressure wage, oil pressure gage. temperature gage. battery-eenerator indicator, high-beam_ indicator lights. and panel lights. It may be replaced as a com- plete unit or each unit may be replaced separately 2-150. Instrument Cluster (Fig. 2-136) a, Removal, (1) Disconnect battery: ground cable and release air pressure from reservoirs by opening drain cock located at base of reservoir. (2) Release four screws holding instrument cluster to instrument panel and pull instrument cluster forward. (3) Diseonneet eables leading from light switch to panel lights, dimmer switch to high-beam indicat- ing light, and ignition/ master switch to instruments at connectors behind instrument cluster. (4) Disconnect cables leading from fuel gage sending unit to fuel gage, oil pressure sending unit to oil pressure gage, temperature sending unit to temperature gage, and generator regulator to bat- tery generator indicator, at connectors behind the various gages and instruments. (5) Disconnect flexible shaft assemblies from tachometer and speedometer by unscrewing con- nector nuts. (6) Disconnect air line to air pressure gage. (7) Pull instrument cluster from panel. b. Installation. (1) M128, M128C, M125. (a) Position instrument cluster in front of instrument panel. () Connect cable (circuit No. 8) to battery- generator indicator cable (circuit No. 33) to temp- erature gage, cable (circuit No. 36) to oil pressure age, and cable (circuit No. 28) to fuel gage. Connect cables (circuit Nos. 27, 17 and 40) at connectors be- hind instrument cluster (fig. 2-36). (c) Connect flexible shaft assemblies to tacho- meter and speedometer by tightening connector nuts at rear of instruments (fig. 2-136). (a) Connect air line to air pressure gage. (e) Install and secure instrument cluster in instrument panel. () Connect battery ground cable and close drain petcock on air reservoirs. (2) MI28A1C, MI23E2. (a) Position instrument cluster in front of instrument panel. 2144 (6) Connect cable (circuit No. 567) to battery- generator indicator cable (circuit No. 33) to temper: ture gage, cable (circuit No. 36) to oil pressure gage, and cable (circuit No. 28) to fuel gage. Connect cables (circuit Nos. 27, 519, and 40) at connectors behind instrument cluster (fig. 2-36). (c) Proceed as in b.(1Me) thru (14 above. 2-151. Battery-generator Indicator (1) Disconnect battery ground cable. (2) Release four panel lock screws, one in each corner of cluster, and pull out instrument cluster. (3) nnect electrical connector behind indicator (fig. 2-36). (4) Remove two nuts and lockwashers behind indicator and remove indicator from front of instru- ment cluster (fig. 2-136), & Installation. (1) Position battery-generator indicator in instru- ment cluster from the front (fig. 2-136). (2)Install two nuts and lockwashers (fig. 2-196). (3) Connect cable (circuit No. 8 at M123, M123C. M125) and (cireuit No. 567 on M123A1C, M123E2) at connector behind indicator (fig. 2-36). (4) Position instrument cluster in instrument panel and tighten four panel lock screws. 4 (5) Connect battery ground cable. 2-152. Fuel Gage a. Removal. (1) Disconnect battery ground cable. (2) Release four panel lock screws, one in each corner of cluster, and pull out instrument cluster. (3) Disconnect two electrical connectors behind gage (fig. 2-36). (4) Remove two nuts and lockwashers behind gage, and remove gage from front of instrument | cluster (fig. 2-136), b. Installation. (1) Place fuel gage in instrument cluster from front. Install two nuts and lockwashers (fig. 2-136). (2) Connect two cables (circuit No. 28) at con- nectors behind gage (fig. 2-36). (3) Position instrument cluster in instrument panel and tighten four panel lock screws. (4) Connect battery ground cable. 2-153. Temperature Gage . a. Removal, Refer to paragraph 2-152. 6, Installation. Installation of temperature nef 1 is same as for fuel gage (para 2-152) except use | cuit No, 33 (fig. 2-36), |2-154. Oil Pressure Gage a. Removal, Refer to paragraph 2-152. 6. Installation. Installation of oil pressure gage is same as for fuel gage (para 2-152) except use cir- cuit No. 36 (fig. 2-36). 2-155. Air Pressure Gage a. Removal. (1) Disconnect battery ground cable. (2) Release air from reservoirs by opening drain- cock. (8) Release four panel lock screws, one in each corner of cluster, and pull out instrument cluster (fig. 2-136). (4) Disconnect air line by removing flare nut fit- ting. (5) Remove two nuts and lockwashers behind gage and remove gage from front of instrument cluster (fig. 2-136). &. Installation, (1) Place air gage in instrument cluster from front. Install two nuts and lockwashers (fig. 2-136). (2) Connect air line to age. (3) Position instrument cluster in instrument panel and tighten four panel lock screws (fig. 2-136). (4) Close draincock on air reservoir. (5) Connect battery ground cabl 2-156. Low Air Pressure Horn a. Removal. (1) Disconnect battery ground cable. (2) Disconnect terminal connectors of circuit ‘No. 85 at horn behind dash panel (fig. 2-36). (3) Remove three mounting screws, and nuts, securing horn to panel. 6. Installation. (1) Position horn behind dash panel and install three screws and self-locking nuts. (2) Conneet terminal connectors of circuit No. 85 (fig. 2-36). (3) Connect battery ground cable. 2-157. Low Air Pressure Switch a, Removal. (1) Disconnect battery ground cable. (2)Disconnect two terminal connectors from switeh (fig. 2-36). (3) Release air from air reservoirs by opening draincock at base of tank. (4) Unscrew coupling nut and remove air tube from low air pressure switch. (5) Remove two bolts, nuts, and lockwashers securing switch to firewall and remove switeh. ©. Installation. (1) Position low air pressure switch to firewall and secure with two bolts, nuts, and lockwashers. (2) Connect air line to switch and tighten coupl- ingnut. (8) Close draincock at base of air reservoir tank. (4) Connect two terminal connectors at switch (fig. 2-36). (5) Connect battery ground cable. 2-158, Sending Units a. Removal. (1) Temperature and oil pressure gage sending ‘units (fig. 2-78 and 2-154). (a) Disconnect battery ground cable. (b) Disconnect terminal connector from units (fig. 2-36). (c) Unscrew temperature gage sending unit from mounting (fig. 2-78). (d) Unserew oil pressure gage sending unit from mounting (fig. 2-154). (2) Fuel tank sending unit (fig. 2-155). (a) Disconnect battery ground cable. (6) Remove fuel tank (para 2-71 and 2-79). (c) Disconnect terminal connector at sending unit (fig. 2-36), (d) Remove five screws and copper washers and lift sending unit with float mechanism from tank, (fe) Discard gasket. 6. Installation. (1) Temperature and oil pressure gage sending units. (a) Place units on mountings and serew in to secure. () Connect terminal connectors at units (fig. 2:36), (c) Connect battery ground cable.(2) Fuel tank sending unit (fig. 2-155). (a) Place new gasket on top of fuel tank and install sending unit and float into tank. (c) Install fuel tank (para 2-71 and 2-79), (d) Connect terminal connectors at sending unit (fig. 2-36). (6) Secure unit to tank with five screws and (e) Connect battery ground cable. lockwashers. é Section XXIV. AXLES 2-159. General 2-162. Propeller Shaft Axle assemblies consist of front, rear tandem with power divider interaxle propeller shaft, and univer- sal joints. 2-160. Front Axle @. Servicing. (1) Draining. (a) Place vehicle on level surface and apply handbrake. (6) Block rear wheels. (c) Remove magnetic drain plug and drain oil from axle housing, (2) Filing, (a) Install drain plug. (b) Remove filler plug. (c) Fill housing with lubricant to proper level. Refer to Lubrication Order LO 9-2320-206-12. (a) Install filler plug. . Inspection. (1) Inspect axle for lubricant leakage. (2) Inspect housings for cracks; if cracked, notify supporting maintenance. ¢. Breather Vents. (1) Removal. Unscrew breather vents from front axle end assemblies and differential. (2) Inspection. Check breather vents for cracks, dirt, grease, and damaged threads. Replace if neces- sary. (8) Installation. Position breather vent on front axle end assembly and screw in to secure. 2-161. Rear Axie «a. Servicing. Refer to paragraph 2-160a. 6. Cleaning and Inspection. Refer to paragraph 2- 2.160b. ¢. Breather Vent. (1) Removal. Unscrew breather vents from for- ward and rear rear axle differentials and remove. (2) Inspection. Check breather vents for cracks, dirt, grease, and damaged threads. Replace if neces- sary. (3) Installation. Place breather vents in forward and rear rear axles and screw in to secure. 2146 a. Removal (fig. 2-156). (1) Front propeller shaft. Remove eight bolts and self-locking nuts at each end of shaft securing uni- versal joints to companion flange on front axle differential and transfer case companion flange, and remove propeller shaft. (2) Rear propeller shaft (fig. 2-157). (a) Remove eight bolts and self-locking nuts at rear end of shaft securing the universal joint to drive flange on forward-rear axle differential drive flange. (6) Unscrew 12 self-locking nuts at handbrake drum. Remove propeller shaft. (3) Interazle propeller shaft (fig. 2-158). (a) Disassemble universal joint by bending ears of lock plates away from bearing cap bolts. i (6) Remove eight bearing cap bolts, four Kk plates, and four bearing caps. (c) Tap against end of one bearing to force opposite bearing from yoke. (d) Drive exposed cross end of journal to re- move first bearing. FUEL TANK, SENDING UNIT" FUEL TANK Fer .15 Removing or atling sl aE EE Google(e) Tilt journal to clear one yoke lug for re- moval. (f) Repeat procedure with two remaining bearings. (g) Repeat above procedure for removal of opposite end. b. Installation. (1) Interarle propeller shaft (fig. 2-158). (a) Position propeller shaft between rear axles with slip joint at forward-rear axle. (0) Assemble universal joints by inserting one cross of journal into yoke lug, tilt journal until op- posite cross yoke and journal are in position. fc) Work lubricant into bearings until they are thoroughly lubricated. (d) Position bearing into yoke lu tap into place. Repeat operation with remaining bearings. (e) Install four bearing caps, eight bolts, and four lock plates. () Turn ears of lock plates up to lock bolts in position. Lubricate universal and slip joints. CAUTION Insert bolt from rear of transmission com- panion flange. This is essential for clearance between bolt and case boss. (2) Rear propeller shaft (fig. 2-157) (a) Position propeller shaft between companion [ ae? on forward-rear axle and transmission with ip joint toward transmission. TRANSFER SECTION COMPANION FLANGE] Figure 2-156. Front propeller shaft. () Install eight bolts and self-locking nuts at rear and install 12 self-locking nuts at brakedrum to flange connection. (3) Front propeller shaft (fig. 2-156). fa) Position propeller shaft between com- panion flange on front axle and transmission with slip joint toward transmission. () Install eight bolts and 20 self-locking nuts at each end. Tighten to 45 to 50 Ib-ft. 2-163. Universal Joints @. General. Universal joints should be repaired whenever excessive wear is indicated by looseness in bearing journal and yoke flanges. Repair kits which consist of journal with seals, four bearings and re- taining parts are available. 6. Disassembly (fig. 2-159). (1) Remove propeller shaft (para 2-162). (2)To remove slip joint, unscrew dust cap (1, fig. 2-159) from sleeve yoke (2) and remove sleeve yoke from propeller shaft (3). (3) Remove dust cap (1) cork washer (4) and flat washer (5) from shaft (3). (4) Remove universal joints by bending tangs of lock plates (6) away from bearing hex-head cap- screws (7). (5) Unserew two hex-head capscrews (7) securing each lock plate (6) and bearing retainer cap (8) to flange yoke (9) and sleeve yoke (2). Remove lock plate (6) and bearing retainer cup (8). (6) Tap yokes sharply with soft mallet to force needle bearing assemblies (10) from yoke (2). (7)Remove universal joint journal (11) by moving it to one side as far as possible and tilting to clear side of yoke. BOLT AND SELE-LOCKING NUT ‘Figure 2.157. Removing or installing rear propeller shaft. 2147AT 34670 igure 215%. Interasle propeller shaft (8) Remove four journal seals (12) and journal seal retainers (13). (9) Proceed to remai repeat above procedures. ing universal joints and 3 »—- 13 ee 1 ey ) 5 C/* ‘ 2 aS atari 1Dast ex Sock plate 11 Journal 2Bleeveyoke FHeckead Journal seat SBropeller shat Bearing retainer cap {Bdournal seal retainer . Cork washer S Flange voce Le Labrication fitting 3 Fiat washer 10Necdie bearing assembly 15 Presure relief valve ¢. Cleaning. (1) Clean all parts in dry-cleaning solvent or mineral spirits paint thinner. (2) Brush parts thoroughly with a small stiff brush. (3) Dry all parts with compressed air. ¢ d. Assembly (fig. 2-159). (1) Install lubrication fitting (14, fig. 2-159) and pressure relief valve (15) in journal. (2) With pressure valve (15) facing toward flanged yoke (9), insert one trunnion of universal joint journal (11) into yoke, tilt yoke until opposite trunnion clears yoke and universal joint journal is in position (3) Install four journal seal retainers (13) on universal joint journal (11). (4) On series 1700 and 1800, position a journal seal (12) on replacer (5 or 8, fig. 2-1) as shown in igure 2-160 and slide over trunnion of universal joint journal (11, fig. 2-19) and into journal seal. (5) On series 1350, install gasket in gasket re- tainer and slide gasket over journal and into retainer (13) sleeve yoke (2). Figure 2159, Propeller shaft and universal joint — exploded vier, 2-148(6) Work general purpose grease (GAA) into needle bearing assembly (10) until bearings are thoroughly lubricated. (7) Insert. needle bearing assemblies (10) into , yoke, tapping lightly with soft mallet. (8) Position four bearing retainer caps (8) on needle bearing assemblies (10) with integral key on bearing retainer cap engaged in keyway on needle bearing. (9) Position lock plate (6) on bearing retainer cap (8) securing with two hex-head screws (7). (10) Bend ears on lock plate (6) up against flats on heads of serews (7) to cock serews in place. (11) Lubricate universal joints LO 9-2320-206-12. e. Installation. (1) Slide dust cap (1, fig. 2-159) over splined end of propeller shaft (3). Place steel flat washer (5) and neoprene cork washer (4) in this order in dust cap a. (2) Aline blind spline on stub shaft (fig. 2-161) with blind spline in slip joint and slide slip joint over stub shaft. (3) Serew dust cap tightly to threaded slip joint. (4) Install propeller shaft assembly (para 2-162). JOURNAL SEAL STUB SHAFT AT 04873, Pigure 2161, Removing or installing slip joint Section XXV. BRAKES 2-164. General The brake system consists of two separate system: service brakes and handbrakes. The handbrake sy: tem is mechanical and consists of a handbrake lever, handbrake drum, handbrake shoe, and linkage. The service brake system is air operated. Major com- ponents of the service brake system are covered in the compressed air system, section XXVI. 2-165. Handbrake Drum a. Removal (fig. 2-162). (1) Block wheels and release handbrake lever. (2) Disconnect rear propeller shaft at transfer drive flange (para 2-159). (3) Remove 12 hex nuts from lock ring assembly D-- securing handbrake drum on main drive shaft drive flange and remove drum from flange. 6, Inspection. Check brakedrum for visible cracks or distortion, also for rough or scored braking surfaces, ¢. Installation (fig. 2-162). (2) Position handbrake drum on main drive shaft drive flange and secure with 12 hex nuts. (2) Connect rear propeller shaft to transfer drive flange (para 2-162). (3) Remove wheel blocks. 2-166. Handbrake Assembly (Fig. 2-163), @. Adjustment. (1) Minor. (a) To tighten turn cap on top of brake lever (4, fig, 2-164) clockwise. 2.149HAND BRAKE DRUM DRIVE FLANGE Bout AT 34674 Figure 2.162, Handbrake drum — exploded view, (b) To loosen turn cap counterclockwise. t hand lever is entirely used up, or when clevis pin is at top of slot, turn cap counterclockwise until clevis is at bottom of slot. (b) Jack up one wheel of each rear axle, making sure front axle drive is not engaged. (c) Rotate one of the free wheels until opening in face of drum alines with brake adjusting screw (star wheel), opposite lever (fig. 2-163). (d) Expand brakeshoes by turning adjusting serew with brake adjusting tool inserted through hole in drum. Moving outer end of tool away from propeller shaft expands the shoes; opposite move- ment retracts shoes. (e) Repeat (d) above until heel ends of both Vinings are within 0.010-inch of drum surface. Check shoe-to-drum clearance with 0.010-inch shim inserted between each brake lining and drum from open end of brake. ( Pull hand lever rearward and turn knob cap until tight. (g) Push lever forward and check drum for clearance as wheel is turned. b. Removal. (1) Remove brakedrum (para 2-164). (2) Disconnect brakeshoe return springs (fig. 2-163) and lift both shoe assemblies from support plate. 2-150 (3) Remove adjusting end spring and adjusting screw from brakeshoes. ¢. Inspection. New linings are 3/8-inch thick. Re- place shoe and lining assembly when lining is worn to 3/16-inch thickness. d. Installation, (1) Position adjusting serew between shoes and install adjusting spring. ‘ (2) Position assembly on support plate and in- stall return springs. (8) Install brakedrum (para 2-164). (4) Adjust handbrake (a. above). 2-167. Handbrake Cross-Shaft and Linkage a, Removal (fig. 2-164). (1) Block vehicle wheels and release brakes by pushing handbrake lever (4, fig. 2-164) forward. (2) Remove 20 bolts and lockwashers securing floor tunnel to eab floor (fig. 2-65). (3) Remove four knobs from control levers (fig. 2-65). (4) Remove screws securing boot assembly over control levers and remove each boot (fig. 2-65). (5) Place all levers in neutral position and lift off tunnel. (6) Remove cotter pin (1, fig. 2-164) and flat washer (2) securing handbrake control rod (3) to lever ).a CONTROL Lever BRAKE ACTUATING SAM SHOE ADJUSTING END SPRING. Figure 2168, Handbrake annem bly. (1) Disconnect handbrake control rod (3) from cam actuating lever (5) at center of cross-shaft (6) by removing cotter pin (7), flat washer (8), and clevis pin (9). Lift out handbrake control rod. (8) Remove yoke (10) and nut (11) from end of control rod (3). (9) Disconnect handbrake rod (12) at handbrake shoe lever (13) by removing cotter pin (14), flat wash- er (15), and clevis pin (16). (10) Disconnect handbrake rod (12), from cam actuating lever (17) mounted on end of cross-shaft (6), by removing cotter pin (18), flat washer (19), and clevis pin (20). Remove handbrake rod. Remove yoke (21) and nut (22) from each end of handbrake rod. (11) Remove two bolts (23) and lockwashers (24) securing each cross-shaft bracket (25) to trans- mission cover. Remove cross-shaft. (12) Remove two bushings (26) and bracket (25) from each end of cross-shaft (6) and remove cam actuating lever (5) from center of shaft and cam actuating lever (17) from one end. , Installation. (1) Position cam actuating levers (5) and (17), two brackets (25), and four bushings (26) on cross- shaft (6). (2) Position brackets (25) and cross-shaft (6) on transmission rear cover. Secure each bracket (25) with two bolts (23) and lockwashers (24). (3) Place nuts (22) and yokes (21) on each end of handbrake rod (12) and connect one end to cam actu- ‘ing lever (17), mounted on end of cross-shaft (6), with clevis pin (20), flat washer (19) and new cotter pin (18). (4) Connect opposite end of handbrake rod (12) to handbrake shoe lever (13) with clevis pin (16), flat washer (15), and new cotter pin (14). (5) Place nut (11) and yoke (10) on handbrake control rod (3). (6) Position handbrake control rod (3) to cam actuating lever (5) at center of cross-shaft (6) se- curing with clevis pin (9), flat washer (8), and new cotter pin (7). (1) Connect opposite end of handbrake control rod (3) to handbrake lever (4), securing with flat washer (2) and new cotter pin (1) (8) Place all control levers in neutral posi and install floor tunnel securing with 20 bolts and lockwashers (fig. 2-65). (9) Slide boot assembly over control levers and secure with screws (fig. 2-65). (10) Install four knobs on the control levers (fig. 2-65). (11) Remove blocks from vehicle wheels. 2-168. Handbrake Lever (Pig. 2-164), - a, Removal. (1) Block vehicle wheels and release brakes by pushing handbrake lever (4, fig. 2-164) forward. (2) Remove floor tunnel (para 2-167a. (2) through 6». (3) Remove cotter pin (1) and flat washer (2) from rod (3) at bottom of handbrake lever (4) and re- move rod end from handbrake lever. (4) Remove two self-locking nuts (27) and bolts (28) securing lever (4) to bracket (29). Remove lever. 6. Installation. (1) Position handbrake lever (4) so forward hole of bracket (29) alines with upper hole in lever se~ curing with two bolts (28) and self-locking nuts (27). (2) Insert rod end (3) in handbrake lever (4), in- stall flat washer (2) on rod end and secure with new cotter pin(1). (3) Install floor tunnel (para 2-167b.(6) through (en. (4) Adjust handbrake (para 2-166a... 2-169. Service Brakeshoe with Lining a. Adjustment (fig. 2-165). (1) With push rods in full release position, turn slack adjuster adjusting screw until linings are tight against drum. (2) Back off screw to first notch (a distinct click will be heard) and then three additional notches. Make sure locking ball is seated in notch. (8) Adjust opposite slack adjuster to obtain the ‘same push rod travel at each brake on one axle. b. Removal. 2151B AT 34676 1 Cotter pin 16 Clevis pin 2Flat washer 17Cam actuating lever ‘3 Handbrake control rod 18 Cotter pin ‘4Handbrake lever 19 Flat washer ‘5Cam actuating lever 20 Clevia pin 8 Croma-shaft a1 Yo ‘Cotter pin Benut 8 Flat washer 23Bolt 9 Clevis pin 24 Lockwasher 10 Yoke 25 Crose-shaft bracket Nut 26 Bushings 12Handbrake rod 21 Locknut Handbrake shoe lever 2B Bolt 14Cotter pin 2 Bracket 15 Flat washer Figure 165. Hond brake linkage — exploded view. 2152Figure 2188. Adjusting service brukexboes, (1) Remove wheel (para 2-188). (2)Remove brakedrum (para 2-189) (3) Disconnect brakeshoe retractor spring using, installer (fig. 2-166). , (4) Remove anchor pin lock plate by remo capscrews and lockwashers from rear of anchor (fi 2-167) (5) Remove anchor pin and remove brakeshoe with lining. . ion brakeshoe with lining on anchor pin (fig. 2-167). (2) Secure anchor pin with one capscrew and lockwasher (front), or with capserews and lock- washers (rear). (3) Connect brakeshoe retractor spring using installer (fig. 2-166). (4) Install brake drum (para 2-189). (5) Install wheel (para 2-188). 2-170. Slack Adjusters. (Fig, 2-165). @. Removal. (1) Pall cotter pin from clevis pin on push rod end, and remove elevis pin. (2) Turn adjusting serew to back arm of slack adjuster out of push rod yoke. (3) Remove bolt, lockwasher, and flat washer on end of brake eam, Lift out slack adjuster. . Installation. (1) Place slack adjuster on splined end of brake cam and install special flat washer, lockwasher, and bolt, (2) Turn adjusting serew until hole in arm alines with hole in push rod yoke. Install clevis pin with head toward center of axle and secure with new cotter pin. (3) Adiust brake (para 2-169a.). AT 34678 Figure 2-166, Removing or installing brakeshoe retractor spring, 2-153BRAKE SHOE RETRACTOR SPRING. BRAKE SHOE fp WITH LINING ra TANICHOR PIN LOCK PLATE Figure 2.187, Service brakenhoe disconnect points Section XXVI. COMPRESSED AIR SYSTEM (2-171. General The compressed air system includes the air com- pressor, governor, air reservoirs, trailer connections air supply valves, brake chambers and cylinders, tractor protection valve, various connecting lines, and fittings. 2-172. Air Compressor—M123, M123C, M125 NOTE Before performing any services on the air compressor, be sure to lock open hood in place. a, Water-Cooled. (1) Operating tests. (a) Failure of compressor to maintain air pres- sure in brake system of vehicle usually denotes loss of efficiency due to wear, provided leakage in re- mainder of system is not excessive. If after checking leakage, compressor fails to maintain pressure, re- place compressor. (b) Excessive discharge of oil from reservoir drain cocks is an indication of excessive oil passing by compressor and replacement is indicated. (2) Leakage tests. (a) Excessive leakage past discharge valves can be detected by fully charging system and then (with the engine stopped) listening at compressor for sound of escaping air. 2154 (b) With air brake system fully charged (100 to 105 psi), coat unloading box cover with soapsuds to check for leakage past unloading diaphragms. Leak- age in excess of 1-inch soap bubble in three seconds requires compressor replacement. (3) Unloader valve clearance adjustment (fig. 2.168). (a) With air brake system discharged (under 80 psi), remove two bolts and lockwashers securing unloader valve cover to cylinder head. Lift out cover making sure rocker arm is in loading position (free of valves). (b) Insert 0.012-inch feeler gage 80 as to en- gage both valve stems. With pivoting motion, check each tappet clearance. To adjust, loosen self-locking nut, turn adjusting screw until feeler gage is just snug, then tighten self-locking nut without further movement of adjusting screw. if damaged, replace. Posi- tion cover and secure with two screws and lockwash- ers. (4) Drive belt adjustment. Refer to paragraph 2-900. (5) Removal (fig (a) Remove (b) Open drain cocks on both reservoirs and allow pressure to exhaust before attempting to dis- connect any air tubes. q(c) Disconnect compressor governor air tube fitting nut at compressor, pull tube from connector, and move tube to right side. Remove connector, el- bow, and nipple as an assembly from compressor and install on tube. (d) Disconnect compressor discharge tube fitting nut at elbow and remove two nuts and lock- washers securing elbow fitting to compressor. Re- move elbow fitting and install on tube. e) Disconnect engine governor vent tube fitting at top of left engine air cleaner. Remove nut and washer securing tube clamp to compressor head, remove clamp, and install nut and washer on head. Disconnect tube fitting nut at engine governor and remove vent tube from area of operations. (P Disconnect coolant tube nut and remove elbow fittings at front and rear of compressor head. Install elbow fittings on tubes. (g) Remove drive belt (para 2-90). (h) Remove four nuts and lockwashers se- curing compressor to crankease cover. Remove com- pressor and discard gasket. () Remove cotter pin and castle nut from compressor drive shaft and pull pulley off the shaft. Retain key in shaft with friction tape and install nut on shaft. COMPRESSOR ‘GOVERNOR. Fire 2.168, Water-cnoled air compressor. 2155(6) Installation (fig. 2-169). (a) Position pulley on shaft with key and se- cure with castle nut. Install cotter pin and secure. (6) Position gasket on engine crankease cover and studs. Position compressor on studs and secure with four hex nuts and lockwashers. (c) Install drive belts (para 2-90). (a) Connect coolant tubes by installing fitting elbows in compressor head with gasket cement and connecting tube nuts. (e) Install engine governor vent tube by se- curing clamp under rearmost compressor cylinder head nut and lockwasher and connect tube fitting nuts at engine air cleaner and engine governor. @ Connect compressor discharge tube by in- stalling elbow fitting with two nuts and lockwashers, using a new gasket between elbow and compressor. Connect tube fitting nut to elbow. (g) Connect governor air tube by installing nipple, elbow, and connector assembly in compressor and connecting tube fitting nut. (h) Close reservoir drain cocks, start engine, and observe operation of compressor. (1) Air strainer (fig. 2-170). (a) Removal, Remove two bolts and copper washers securing strainer body to compressor and discard preformed packings. Remove strainer. (b) Disassembly. Remove four screws and lock- washers securing cover to strainer body. Remove cover and discard gasket. Lift out strainer baffle, curled hair, baffle, and spring. SCREW / STRAINER BAFFLE ~ COVER GASKET LOCK WASHER COVER AIR INLET GASKET (¢) Cleaning. 1. Wash all parts thoroughly in dry-cleaning solvent or mineral spirits paint thinner. 2, Squeeze curled hair dry, saturate with engine oil, and squeeze out excess. 4 (d) Assembly (fig. 2-170). 1. Install baffle and spring in body with ends of spring under lip of baffle. 2, Install curled hair into body. ‘S. Insert strainer baffle with mesh against hair. 4. Position new cover gasket on body and install cover with four screws and lockwashers. (3) Installation. Position new gasket on com- pressor and secure air strainer to compressor with two bolts, preformed packings and copper washers. . Air-Cooled. (1) Operating tests, Refer to a.(1) above. (2) Leakage tests. (a) Excessive leakage past discharge valves on unloader pistons can be detected by charging air brake system until governor cuts out and then (with engine stopped) listen at air strainer for sound of escaping air. (}) If leakage is excessive remove strainer and observe for leakage at unloader pistons by applica- tion of a few drops of oil around unloader stems. (¢) If no leakage is noticeable at the unloader pistons, discharge valves may be leaking. a (a) Remove head and apply air pressure at discharge port to check for discharge valve leakage. ‘AIR STRAINER BODY CAP SCREW COPPER WASHER ata q Figure 2.170, Water-cooled air compressor strainer. 2-186(e) If excessive leakage is noted, replace com- pressor. (3) Unloader piston adjustment, No adjustment is necessary due to preadjustment at assembly. (4) Drive belt adjustment. Refer to paragraph 2-90, (5) Removal (fig. 2-171). (a) Open drain cocks on both reservoirs and allow pressure to exhaust before disconnecting any air tubes. fb) Disconneet governor air tube by discon- necting tube fitting at compressor and hose connee- tion at governor mounted on firewall. (c) Disconnect compressor discharge tube fitting nut at elbow and remove two nuts and lock- washers securing elbow fitting to compressor. Re- move elbow fitting and install on tube. (d) Disconnect engine governor vent tube fit- ting at top of left engine air cleaner. Disconnect tube fitting nut at engine governor and remove vent tube from area of operations. (e) Remove drive belts (para 2-906). () Remove four nuts and lockwashers secur- ing compressor to crankcase cover. Remove com- pressor and discard gasket. (g) Remove cotter pin and castle nut from com- pressor drive shaft and pull pulley off the shaft. Re- tain key in shaft with friction tape and install nut on shaft. (6) Installation (Fig. 2-171) fa) Position pulley on shaft with key and se- cure with castle nut. Tighten to 100 lb-ft maximum torque. Install cotter pin and secure. (b) Position gasket on engine crankcase cover and studs. Position compressor on studs and secure with four hex nuts and lockwashers. (c) Install drive belts (para 2-90b.). (d)Install engine governor vent tube by con- necting tube nuts at engine air cleaner and engine governor. fe) Connect compressor discharge tube by in- stalling elbow fitting with two nuts and lockwashers, using new gasket between elbow and compressor. Connect tube fitting nut to elbow. NUT AND, LOCKWASHER ‘COMPRESSOR DISCHARGE ———, “— Be — AIR TUBE Figure 2.171. Air-cooled air compressor, 2-157CURLED HAIR WASHER BAFFLE SCREW cover ae nuer ‘Gasket Ss AT 34604 Figure 2.172. Air-cooled air compressor strainer — exploded view. ( Connect governor air tube by connecting tube fitting to connector fitting in compressor and hose fitting at governor. (9) Close reservoir drain cocks, start engine, ‘and observe operation of compressor. (1) Air strainer (fig. 2-172). Refer to a. (7) above. 2-173. Compressor Governor (Fig. 2-173). a. Test. (1) Operating test. (a) Start engine and after low air pressure warning buzzer quiets, observe air pressure gage not- ing reading when compressor unloads, stopping com- pression. This is the governor cut-out pressure and should be 95 to 120 psi. (6) With engine running, slowly reduce air pressure by depressing and releasing brake treadle and note pressure on gage at which the compressor resumes pumping. This is the governor cut-in pres- sure and should be 90 psi. (e) Check with accurate test gage if above readings are not obtained. (d) If test gage indicates incorrect cut-in or cut-out pressure, replace governor. (@) If test gage shows proper cut-in and cut- out pressure, replace dash gage. (2) Leakage teat — engine running. (a) With compressor unloaded, test for leakage 2158 of exhaust valve by applying soapsuds to exhaust vent breather fitting. If leakage exceeds 1-inch soap bubble in three seconds, replace governor. (®) With compressor loaded, test for leakage of inlet valve by applying soapsuds to the exhaust vent breather (fig. 2-178). Replace governor if in ‘excess of 1-inch bubble in three seconds. (c) Cost entire governor with soapsuds to de- tect diaphragm, gasket, and capscrew leakage. No leakage is permitted. ‘COMPRESSOR ‘GOVERNOR BOLTS AND, SELF-LOCKING NUTS ag Figure 2.178. Air compressor governor. «b. Removal (fig. 2-178). CAUTION Before performing any operations on the governor, the engine should be stopped and reservoir drain cocks opened to exhaust pressure from the system (1) Disconnect tube and hose at governor. Re- move two elbow connector fittings and vent valve. (2) Remove two bolts and self-locking nuts se- curing governor to firewall. ¢. Installation (1) Position governor on firewall, exhaust port pointing down, and secure with two bolts and self- locking nuts. (2) Install vent valve in exhaust port and two ‘elbow connector fittings. Connect hose line and tube. 2-174, Reservoirs a, Removal. (1) Open drain cocks and exhaust air pressure from system. (2) Disconnect propeller shaft flange at hand- brake drum by removing 12 self-locking nuts and move shaft clear. (3) Disconnect air tubes by unscrewing tube nuts. (4) Remove two self-locking nuts and rods securing mounting bracket halves together. (5) Supporting reservoirs: loosen bolts in each of the two lower bracket halves, move brackets aside and lower reservoir to ground. (6) Remove connector fittings from reservoir. Remove safety valve from No. 1 reservoir. 6. Installation. (1) Install connector fittings on new reservoir corresponding positions. Install safety valve No. 1 reservoir. (2) Raise reservoir into position, aline mounting brackets and install two bracket rods and self-lock- ing nuts to secure bracket together. (3) Tighten lower bracket mounting bolts. posi- tion reservoir in brackets and tighten bracket nuts. (4) Connect air tubes by tightening tube con- neetor nuts. (5) Position propeller shaft flange and install 12self-locking nuts. (6) Close drain cocks, start engine and check for air leaks by applying soapsuds. No leakage is per- missible. 2-175. Brake Application Valve (Fig. 2-174). a. Tests. (1) Operating tests. (a) Install an accurate test gage in service line outlet at rear of vehicle and open service line cock. (b) Depress treadle to floorboard. The test zaze should register same pressure as dash air pressure gage, if dash gage is accurate. Replace application, valve if pressures are not equ: (c) Depress brake pedal to several positions between fully released and fully depressed position and check to be sure delivered air pressure registered by test gage varies in accordance with treadle posi- tion, (2) Leakage tests. fa) With system fully charged, coat vent fit- ting on exhaust port of application valve with soap- suds, with pedal fully released and fully depressed. (b) Leakage in excess of a 1-inch soap bubble in either of these tests requires replacement of ap- plication valve. (c) Coat fitting connectors during fully depres- sed treadle test. No leakage is permissible. b, Removal (fig. 2-174) (1) Stop engine and open drain cocks on air reser- voirs to exhaust pressure. (2) Disconnect two air tubes at valve and remove fitting connectors. Remove exhaust check assembly from exhaust port. (3) Remove cotter pin and cle tion valve lever. (4) Remove four nuts, lockwashers, and bolts securing valve to bracket. and remove valve. ¢. Installation. (1) Position brake application valve on bracket and secure with four bolts, nuts, and lockwashers. (2) Install clevis pin in rod end and lever and secure with cotter pin. (8) Install fitting connectors and connect tube. Install exhaust check valve assembly (4) Close drain cocks, start engine and perform leakage test (a. (2) above). 2-176. Quick Release Valves (Fig. 2-175). a. Tests, (1) Operating test. Apply brakes and observe when the brakes are released, air pressure is quickly exhausted through the exhaust check valve installed on the exhaust port. There are three quick release valves, located as follows: (a) Front azle brakes. Inside frame left side- member adjacent to engine starter. (b) Forward-rear azle brakes. On rear of axle carrier. (c) Rear-rear ale brakes. On front of axle car- pin at applica- rier. (2) Leakage test. With brakes applied, coat ex- haust valve with soapsuds to detect leakage. Re- place quick release valve if leakage is in excess of 2-159COTTER PIN CONTROL ROD BRACKET Figure 2.174, Brake application vatve. 1-inch bubble in one second. No leakage is permitted at fitting connections. b, Removal (fig. 2-175). (1) Disconnect air lines and remove fitting con- nectors, (2) Remove exhaust check valve. (3) Remove two bolts and nuts, securing valve. Remove quick release valve. c. Installation (fig. 2-175). (1) Position quick release valve, then install two bolts and self-locking nuts. (2) Install exhaust check valve in exhaust port. (3) Install fitting connectors and connect lines. (4) Make brake application and check leakage (a. above). 2-177. Double Check Valves (Pig. 2-176). a, Test. (1) Operating test. 2-160 (a) Depress brake treadle and note that brakes apply both on tractor and towed vehieles. (b) Release treadle and note that brakes release on both vehicles. Figure 2.175. Quick release valve.(c) Pull hand control valve handle and note that brakes apply on towed vehicle only. (d) Push hand control valve handle and note that the brakes release on towed vehicle. (2) Leakage test. (a) Depress brake treadle and check for leak- ‘age at exhaust check valve in exhaust port of hand control valve. (6) Apply handbrake valve and check for leak- age at exhaust check valve in exhaust port of foot brake application valve, (c) Leakage of 1-inch soap bubble in one sec- ond is permissible in either of above tests. Replace valve if leakage exceeds 1-inch soap bubble in one second. b, Removal. (1) Disconnect air lines and remove fitting con- nectors and return to tubes. Remove exhaust check valve. (2) Remove two bolts, nuts, and lockwashers securing valve to frame sidemember and remove valve. ¢. Installation. (1) Position double check valve and secure with two bolts, and self-locking nuts. (2) Install exhaust check valve, fitting connec- tors, and connect lines. (3) Perform operating test (a. above) and leakage test. 2-178. Hand Control Vaive (Pig. 2-177). a, Test. (1) Operating test. (a) Connect an accurate test gage to service line outlet at rear of vehicle and open service line cock. (6) Pull valve handle to fully applied position and note reading on pressure gage. NOTE Hand control valve must deliver at least 75 psi. (c) Move the valve handle and observe the re- corded pressure variances in accordance with posi- tion to which handle is moved. (2) Leakage test. (a) With brake valve handle is released posi- tion, coat the exhaust check valve with soapsuds to check for leakage. (b) With brake valve handle in fully applied position, coat the exhaust check valve with soapsuds to check for leakage. (c) Leakage in excess of 1-inch bubble in one second requires replacement of the valve. b. Removal (fig. 2-177). ‘Ala LINE igure 2.176. Double check valve. (1) Open reservoir drain cocks to drain pressure. (2) Disconnect two tube fitting nuts. Remove fitting connectors and install on fitting nuts. (3) Remove exhaust check valve. (4) Unserew two socket head capscrews and re- move hand control valve. column to right and ten degrees forward to trans- verse line, securing with two socket head capscrews (fig. 2-178). (2)Install exhaust check valve using sealer. (3) Install two fitting connectors and secure with tube fitting nuts. (4) Close reservoir drain cocks. (5)Perform leakage test (a. above). 2-179. Differential Brake Control Valve (Fig. 2-179). a. Test. (1) Operating test. fa) Connect an accurate air-pressure gage in the delivery line of each control valve. (6) Move operating lever through several posi- tions between the released position and fully applied position on each valve. Check to be sure the delivered pressure registered by the test gage varies in ac- ‘cordance with each change in lever position. (c) The control valve must control all delivery pressures between two and 55 pounds of air pressure. 2-161TERING WHEEL BEAR AT 34690 Figure 2.178, Hand control valve position (2) Leakage test. (a) With lever in the neutral position, coat the exhaust port of each control valve with soapsuds to check for leakage. 2-162 (b) Repeat this process with the lever in the fully applied position. (c) Leakage of not more than 1-inch soap bubble in one second is permissible in either of these tests. (d) Excessive leakage in either test requires replacement of control valve assembly. b, Removal (fig. 2-179). (1) Drain air reservoir (para 2-174). (2) Disconnect air supply tube to control valve at fitting on lower valve by removing tube nut. (3) Remove delivery tube fitting nuts at elbows in delivery port of each control valve. (4) Remove two nuts and bolts securing control valve assembly to mounting bracket. Remove as- sembly. ¢. Installation (fig. 2-179). (1) Position control valve assembly to mounting bracket on steering column and secure with two bolts and self-locking nuts. (2) Attach delivery tube fitting nuts on air tubes at delivery ports of each valve. (3) Secure inlet air tube to tee fitting on lower control valve. (4) Close drain cocks (para 2-175b.). NOTE Both the operating and leakage test should be made after repairing or replacing the differential brake control valve assembly. 2-180. Tractor Protection Valve — M123A1C, M123E2 (Figs. 2-180 and 2-181). @. Test. (1) Operating test, Refer to Operator's Manual TM 9-2820-206-10. (2) Leakage test. (a) With the tractor protection two-way valve knob (fig. 2-181) in the normal operating position and the tractor system charged to normal operating pressure, coat the exhaust port of the tractor protec- tion valve (fig. 2-180) with soapsuds to check for leakage. Leakage must not exceed a 1/2-inch bubble in five seconds. (b) With the tractor protection two-way valve knob (fig. 2-181) in emergency operating position, break the trailer hose connections (fig. 2-180) and coat the trailer emergency supply hose coupling on the tractor with soapsuds to check for leakage. Leak- age must not exceed a 1/2-inch soap bubble in five seconds. {c) Coat the service supply hose coupling with soapsuds to check for leakage. No leakage is per- missible.STEERING ‘WHEEL DIFFERENTIAL BRAKE CONTROL Figure 2.179, Differential brake control vale. (a) With the tractor protection two-way knob (fig. 2-181) still in the emergency operating position. make a service brake application and hold the ap- plication fe) Coat the trailer service supply hose eoup- ling on the tractor with soapsuds to check for leak- awe. Leakage must not execed 1/2-inch soap bubble in five seconds. NOTE Leakaye exceeding tests will require re- placement of the tractor protection valve. TRAILER SERVICE BRAKE 2way CONTROL VALVE LINE SERVICE SUPPLY b. Removal (fig. 2-180). (1) Open drain cocks on both reservoirs and allow pressure to exhaust before attempting to disconnect, any air lines. (2) Disconnect five air lines from tractor pro- tection valve. (3) Remove two bolts and hex nuts securing tractor protection valve to cross member. ¢. Installation (fig. 2-180). (1) Position tractor protection valve against ‘erossmember and secure with two bolts and hex nuts, (2) Connect five air lines to tractor protection valve. (3) Perform operational ‘Manual TM 9-2320-206-10. check, Operator’ 2-181. Two-Way Control Valve — M123A1C, M123E2 (Fig. 2-181). a. Test. (1) Operating test. (a) Plug one delivery port and install air pres sure gage in the other delivery port. (b) Install a second air pressure gage in the air inlet line. fc) With the air connected to the inlet port, pull the knob to the emergency position. fd) The gage installed in the delivery port should read the same as the gage installed in the air inlet line. (2) Leakage test. fa) With air supplied to the inlet port and the knob in the released position, coat the exhaust open- ing at the top of the valve (where the knob enters the valve) with soapsuds to check for leakage. Leakage should not exceed a 1-inch soap bubble in five sec- onds. (b) Pull knob to emergency position and coat the exhaust opening with soapsuds to check for leak- age. Leakage should not exceed a I-inch bubble in five seconds. NOTE Leakage exceeding either test will require replacement of valve. b, Removal (fig. 2-181). (1) Open drain cocks on both reservoirs and allow pressure to exhaust before attempting to dis- connect any air lines. (2) Disconnect the two air lines from the two- way control valve under the instrument panel. (3) Remove pin securing knob to valve assembly. (4) Remove hex nut securing valve assembly to mounting bracket. (5) Remove valve assembly from mounting bracket. 2-163TWO WAY CONTROL VALVE DeLivery. KNOB HEX NUT ar sepa Figure 2.181, Two-way control valve — M128A1C, M123E2, ¢. Inatallation (fig. 2-181). (1) Position two-way control valve in mounting bracket. (2) Connect two air lines to valve assembly. Do not tighten. (8) Install hex nut securing valve assembly to mounting bracket. (4) Tighten two air lines connected in step (2). (5) Position knob on vaive assembly and install pin. 2-182. Tire Inflation Valve (Fig. 2-182). a, Test. (1) Operating test. With handle in normal oper- ating position (parallel to valve body of valve as shown), check to make sure governor operates. the handle turned to tire inflation position (right angles to valve body), check if air escapes through the vent hole in the handle and if air is available through the air supply outlet. (2) Leakage test. Place handle of the valve to the normal operating position and coat entire valve with soapsuds. Leakage at any part of the valve should not exceed 1-inch soap bubble in five seconds. 2-164 DASH PANEL AT 34694 BOLTS, LOCKWASHER, SELF-LOCKING NUTS Figure 2-188. Tire inflation valve, 6. Removal (fig. 2-182). (1) Open drain cocks and release pressure. (2) Disconnect two tube fitting nuts. (3) Remove two bolts, lockwashers, and self- locking nuts and lift out valve. c. Installation (fig. 2-182) (1) Position valve with handle up to dash panel ‘and secure with two bolts, lockwashers, and self- locking nuts. (2) Install one connector fitting and one elbow connector and connect two fitting nuts. (3) Close drain cocks. (4) Perform operating test (a.(1) above) and leakage test (a. (2) above). 2-183. Intervehicular Brake Connector Hose and Couplings. a. Hose Assembly (fig. 2-183). (1) Removal, Disconnect coupling at each end of hose. (2) Disassembly. (a) Unscrew hose coupling from each end of hose. (b) Unscrew nut from connector body at each end, and remove hose from connector bodies (fig. 2-184). (c) Remove sleeve nuts and spring guard from back end of hose. (d) Remove nuts from spring guard.CONNECTOR HOSE COUPLING HOSE COUPLING CONNECTOR GASKET Figure #188. Sectional views of hove assemblies. CONNECTOR wopy SPRING GUARD Hose Figure 2-181, Hove assembly — exploded view. (8) Cleaning and inspection. (a) Clean all metal parts in dry-cleaning sol- vent or mineral spirits paint thinner. (6) Inspect hose for abrasions, swelling, or , other damage. Replace hose if necessary. Discard sleeves and gaskets. (c) Check spring guard, nuts, and connector bodies for condition. Unless damaged, they can be used again. (4) Assembly (fig. 2-184). (a) Cut hose to desired length making sure the cut is made at right angles to outside wall of hose and ends of hose are smooth. 2-165Figure 2.185. Connector nut and sleeve positioned on hose. (b) Blow out hose with an air line to remove all cuttings. (c) Install spring guard on nuts (fig. 2-185) and insert hose through nuts and spring guard. (d) Position new sleeve on each end of hose, making sure the barbs on inside of sleeve point tow- ard end of hose. (e) Position new gasket over end of guide in connector body so side with removable protector covering (fig. 2-186) will be next to hose. @ Install gasket into bottom (fig. 2-187) of recess in connector body. (g) Insert hose in the connector body (fig. 2- 188) at each end, making sure ends of hose and gask- ets are against bottom of recess in coupling body. CONNECTOR ‘BODY COVERING, BLUNT NOSED [——~ screworiver CONNECTOR BODY. Ff ‘Figure 2-187, Installing gasket into bottom of recess in ‘connector body. (h) Move sleeves, if necessary, until they are against edge of coupling body; then tighten nuts at each end. It is only necessary to tighten nuts suf- ficiently to insure a good airtight joint. (i) Screw hose coupling onto each end of hose and tighten. (5) Installation. Connect coupling to coupling on tractor and coupling on opposite end of hose to coupling on trailer. Test hose for leakage (c. below). 6. Coupling Gasket (fig. 2-189). (1) Removal, Pry gasket out with flat blade screw. driver. (2) Installation. (a) Check groove into which gasket fits. This groove must be scraped thoroughly clean for proper seating of gasket. Figure 2-186, Removing protector cover from gasket. 2-166 Figure 2-188, Placing hove in connector body.(0) Partially collapse gasket with fingers and enter one side of gasket flange in groove of coupling (fig. 2-189). Then use flat blade serewdriver or some similar instrument to complete pushing the gasket in place. ¢. Testing Hose Assembly for Leakage. Coat en- tire hose assembly with soapsuds and apply brakes. If leakage is found as evidenced by soap bubbles at fittings, tighten the fitting nuts sufficiently to elim- inate leakage. If leakage is found in the hose body as evidenced by soap bubbles, replace hose. NOTE Never tighten a fitting nut so that it bottoms on threads of coupling body. 2-184, Brake Chambers — Front (Fig. 2-190). a Test. (1) Operating test. (a) Apply brakes and observe that push rods ‘move out promptly, without binding. (b) Release brakes and observe that push rods return to release position promptly, without bind- ing. (c) Check travel of push rods to be sure it is at minimum without brakes dragging. (2) Leakage tests. (a) With brakes fully applied, coat the clamp ring to plate joint with soapsuds to check for leak- age. No leakage is permissible. (b) With brakes fully applied, check for leakage through diaphragm by coating clearance hole around push rod and drain hole in non-pressure plate with soapsuds. No leakage is permissible. b, Removal (fig. 2-190). ‘Figure 2-189, Installing hose coupling gasket. AA AIR HOSE X MBLY Fiure 2-190. Brake chamber — front. (1) Remove cotter pin and clevis pin from push rod yoke and slack adjuster arm, and turn slack ad- Juster adjusting nut to back arm out of yoke. (2) Disconnect hose assembly at chamber. Re- move elbow and adapter. (3) Remove two nuts and lockwashers securing chamber to mounting bracket. Remove chamber. . Installation (fig. 2-190). (1) Position brake chamber in mounting bracket so that air inlet is facing center of truck. Install two lockwashers and nuts. (2) Turn slack adjuster adjusting serew until hose in arm alines with hole in push rod yoke. Install clevis pin with head toward center of axle and sec- ure with new cotter pin. (3) Install elbow and adapter using gasket cement and connect hose assembly. Adjust brake (para 2-169). 2-185. Brake Cylinders — Rear (Fig. 2-191). a. Test. (1) Operating tests. Refer to paragraph 2-184, (2) Leakage tests. With brakes fully applied, hold application and coat the push rod opening and 2-167mating surfaces and vent with soapsuds. No leak- age is permissible. Except for leak at air inlet port fitting, any leak passing piston, cup, and cylinder must be replaced b. Removal (fig. 2-191). (1) Remove cotter pin and clevis pin at push rod yoke. (2) Disconnect air hose and remove elbow fitting from cylinder. (3) Remove two nuts and lockwashers and re- move eylinder. c. Installation (fig. 2-191). (1) Position eylinder on bracket so breather is at top and secure with two lockwashers and nuts. (2) Install elbow fitting, using gasket cement and connect air hose. (3) Turn slack adjuster serew until hole in arm alines with hole in push rod yoke. Install clevis pin and secure with new cotter pin. (4) Adjust brakes (para 2-169). 2-186. Lines and Fittings Refer to paragraph 2-47. 2-187. General ‘The offset, disk-type wheels are attached to hub nuts with 10 nuts. Wheels are interchangeable on front or rear axles and opposite sides of vehicle. Standard pneumatic tires are mounted on disk rims with snap-on-type side ring. All hubs are mounted ‘on opposed tapered roller bearings. Rear hubs are secured on axles with adjusting nuts and locks. The front hub is integral with the front axle end assem- bly. 2-188. Wheel and Tire Assembly a. General. Single disc wheels are mounted at each end of the front axle. They are mounted on 10 fixed studs and retained by 10 special nuts. See b. below. The right hand wheel studs have normal right hand threads while the left hand side has left hand threads. ‘Two wheels are mounted at each end of the rear axles. The inner wheel is positioned so the wheel is over the brake drum. It is mounted on 10 studs and retained by special nuts that are threaded both on the inner and outer surface. The inner nut becomes 2-168 Figure 2-191, Brake eylinder — rear. WHEELS, DRUMS, AND HUBS ‘a stud to mount the outer wheel. The outer wheel is secured by 10 similar nuts similar to those used on the front axle. The rear axle aiso has right hand and left hand threaded nuts. It is necessary to insure that the inner wheel nuts are fully tightened before the outer wheel nuts can be tightened. b. Wheel Nuts (fig. 2-192). Two types of wheel mounting nuts are available. Wheel mounting nuts of the indented type cause gouging of wheel mount- ing nut outer ball seat recess in wheel assembly. when installed on front wheel hubs. To prevent dam- age to equipment, inspect front wheel mounting nuts; if they are the indented type, remove and re- place with the rounded radius type. NOTE When requisitioning wheel mounting nuts, right hand and left hand, stipulate the rounded radius type as shown in figure 2-192. c. Front Wheels. (1) Removal. (a) Set parking brake and block vehicle wheels. (INTERFERENCE OF HEXAGON | PORTION RH AND LH NUTS With Kal WHEEL HOSE BALL SEAT ROUNDED RADIUS TYPE NUT done ~ eS INDENTED TR SS Ci = 24704 ‘OUTER WHEEL STUD NUTS INNER WHEEL, STUD NUTS Figure 2-198, Removing or installing rear wheel assem ly (&) Loosen with socket wrench (2, fig. 2-1), 10 wheel stud nuts on wheel to be removed. (c) Place jack under axle near wheel to be re- moved and raise axle until tire clears ground. (d) Remove nuts and remove wheel. (2) Cleaning and inspection. (a) Inspect each outer balll seat recess for paint accumulation, burs and dirt. (6) Remove any foreign substance which would prevent good wheel-to-hub contaet. (3) Installation. fa) Mount serviceable wheel assembly on hub and fasten with 10 wheel stud nuts. Round face of nuts must be against wheel. (b) Alternately tighten wheel stud nuts to center wheel. (c) Lower and remove jack. (d) Tighten wheel stud nuts to 300-350 Ib-ft, using torque wrench. 4. Rear Wheels (fig. 2-193). (1) Removal. (a) Set parking brake and block vehicle wheels. (b) Loosen 10 large hex nuts securing outer wheel that is to be removed. (c) Place jack under axle near wheel to be re- moved and raise axle until tire clears ground. (a) Remove hex nuts and remove outer wheel. (c) Unserew 10 nuts securing inner wheel and remove wheel (2) Cleaning and inspection, Refer to paragraph ¢(2) above. (3) Installation, CAUTION In a dual wheel assembly both tires should be matched in diameter in order to prevent overloading one tire. If circumference be- tween inner and outer tire differs by more than %-inch or diameters by %-inch, wheels should be changed until a closer match is obtained. (a) Mount serviceable inner wheel assembly on hub studs and fasten with 10 inner wheel nuts. (b) Alternately tighten nuts to insure wheel is centered on axle. Tighten to 300-350 Ib-ft torque using torque wrench. NOTE The inner wheel nuts cannot be tightened further once the outer wheel nuts are attach- ed and securely fastened. Therefore, the i ner nuts must be fully tightened before mounting outer wheel and attaching nuts. (c) Mount serviceable outer wheel assembly on inner wheel nuts and fasten the 10 wheel stud nuts. Rounded face of nut must be against wheel. (d) Alternately tighten outer wheel nuts to insure wheel being centered. fe) Lower jack and remove. (f Tighten outer wheel nuts to 300-350 Ib-ft torque. using torque wrench. 2-189. Service Brakedrums a. Front. (1) Removal. (a) Remove wheel (para 2-188). (b) Drive off brakedrum until free of pilot on hub. Lift off drum. (2) Installation, (a) Clean pilot bore of drum and mating sur- face of wheel hub and slide drum into position. (b) Using two diametrically opposite wheel studs, nuts, and spacing washers approximately Y-inch thick, pull the drum onto the hub until firmly seated against the shoulder. (c) Remove nuts and spacing washers. (a) Install wheel (para 2-188). 2-169. Rear. (1) Removal. (a) Remove wheel (para 2-188). (6) Remove hub (para 2-190). (c) Remove six bolts, nuts, and lockwashers securing drum to hub. (2) Installation. (a) Pilot drum on hub, aline bolt holes. and secure with six bolts, nuts, and lockwashers. Tighten, to 134 to 148 Ib-ft torque. (6) Install hub (para 2-190). (c) Install wheel (para 2-188). 2-190. Hubs and Bearings a. Front. The front wheel hubs and bearings are removed only at disassembly of the front axle end Notify supporting maintenance personnel. . 2-194), (1) Removal. (a) Remove wheels with tires (para 2-188). (b) Remove eight nuts securing hub cap (1, fig. 2-194) to hub and remove hub cap and antistatic spring. (c) Install two 5/8-24x3 puller screws in flange adapter ring (2) puller holes and remove flange adapter and axle shaft (3) by tightening alternately on each puller screw. (d) Install two 3/8-16x1-1/2 puller screws in oil seal retainer (4) and remove retainer in similar manner. (e) Remove oil seal from spindle by prying gently on diametrically opposite sides with flat side of screwdriver end placed against seal washer ). (Cut locking wire (6), loosen clamp bolt nut (6). Using spanner wrench (1, fig. 2-1), remove ad- justing nut (7, fig. 2-194) and (8). (o) Remove hub and drum, making sure not to drop outer bearing cone. Remove inner bearing cone . (2) Cleaning and inspection. (a) Scrape sealing compound from hub eap, adapter ring, and wheel hub. (b) Blow out brake linkage with compressed air. (c) Clean bearings with dry-cleaning solvent or mineral spirits paint thinner and inspect bearing cones and cups for pitting, corrosion, and wear. Re- pack bearing cones. (a) Wipe grease from spindle and clean spindle and all parts thoroughly with dry-cleaning solvent or mineral spirits paint thinner to remove all traces of grease. Wipe dry with clean, dry (not oily) loth, (¢) Pack inboard cavity of seal retainer with grease. 2.170 ( Apply light coating of grease to retainer seal running surface (inside diameter of retainer). (q) Apply light coating of grease to seal lip and cavity of seal. (h) Coat inboard surface of adapter ring with, sealing compound. i) Inspect retainer preformed packing. Re- place if damaged. G) Inspect inside diameter of retainer (oil seal contact surface) for nicks or burs. Replace if necessary. (k) Inspect seal lip for signs of tearing or pitting. Replace if necessary. (Y Inspect inner seal. Replace if necessary. (3) Installation and adjustment. fa) Seat washer (10) against housing and in- stall inner bearing cone (9). (b) Place hub and drum on inner bearing cone and foree cone to seat against axle housing. Install outer bearing cone. (c) Position lock ring and adjusting nut (8). Back off slack adjuster to make certain brake shoes do not contact brakedrum. (d) Turn up adjusting nut, using spanner wrench (7), while rotating drum one or more revolu- tions in both directions until slight bind is felt. This will insure all bearing surfaces are in contact. (e) Back off adjusting nut (8) until an end- play of 0.002 to 0.008-inch is obtained at wheel hu ¢ measured with dial indicator. (f) If dial indicator is not available, back of adjusting nut 1/6 to 1/4 turn. This adjustment approximate the end-play specified in (e) above. (g) Tighten lock serew into the nearest lock ring notch (8) and tighten clamp bolt (7). (h) Install locking wire (6). (4) Slide on seal retainer (4) and oil seal washer ©). G) Place oil seal carefully over end of spindle and push into place. NOTE It is important to prevent seal from turning or moving in and out on spindle. (k) Place adapter ring (4) over wheel studs. (Y Install axle shaft (3). NOTE This may require movement of wheel to ease fit of adapter ring and axle shaft flange ser- rations. Jack up axle or move truck slightly with pry bar under tire. (m) Attach hub cap (1) and antistatic spring with eight selflocking nuts (1). (x) Install wheel (para 2-188).( 4 ( EL 1@ (Ce b\ A>2-191. Tires, Tubes, and Rims WARNING Make certain locking ring is seated properly against rim of wheel through its entire cir- cumference, before inflating tire. Do not stand in front of wheel when inflating. If wheel is not mounted. turn ring side down when inflating to reduce chance of ring be- ing dislodged. Failure to observe this warn- ing will result in personal injury. Safety chains can be loosely wrapped around two different points of the tire and rim to safe- guard against injury should the side ring release during inflation. a. Removal. (1) Jack up vehicle and remove wheel (para 2- 190). (2)Deflate tube by removing core. (3) Lay wheel and tire assembly flat with side ring facing upward, (4) Place one tire iron in notch in side ring and Pry ring upwards. Place another tire iron between disk and side ring and pry ring upwards, (5) Continue working all around tire until ring is loose. (6) Turn wheel and tire over. Dislodge tire from taper on rim base and remove rim. © Installation, (1)Install inner tube in tire. (2)Install tire flap, (3) Inflate sufficiently to prevent tube from being pinched during mounting. (4) Place wheel flat on floor, and install tire over wheel inserting valve stem through hole in wheel rim so stem points toward wheel disk. (5) With flange of tire locking ring to outside, start ring opposite notch in groove of rim. (6) Using wood block and hammer. force tire locking ring on wheel rim. (7) Inflate tire to specification listed on ser- vieing and publication data plate on instrument panel. (8) Install wheel (para 2-190). Section XXVIII. STEERING SYSTEM e 2-192. General The power steering system has the conventional steering wheel mounted on the column of an angle drive which actuates a hydraulic-powered steering gear through a drive shaft. The steering gear con- sists of a cam and lever type steering ear with an internal hydraulic control valve and a power cy- linder. Hydraulic pressure is supplied by an external pump driven by the vehicle engine. A drag link con- neets the steering gear pitman arm to the steering arm of the left front axle end assembly. 2-193. Steering Wheel a, Removal fig. 2-195) (1) Disconnect battery ground cable. (2) Remove horn button rubber cover. (3)Remove horn button by pressing down and turning to the right or left with palm of hand or vacuum cup, holding steering wheel firm. (4) Remove contact cap and spring. . (5) Remove three capserews holding horn button base plate. Leave horn wire in position and remove , retainer base plate. (6) Remove steering wheel nut. Use steering wheel puller and remove steering wheel. Installation. (1) Position steering wheel on shaft. Wheel should be installed so spokes are in shape of an in- verted Y when seated in operator's seat with front wheels straight-ahead. (2)Install steering wheel nut and tighten. (3)Position horn wire in horn button ret: plate and install three capscrews, (4) Position horn contact cap and spring. (5)Position horn button and press down and turn until locked in rubber retainers on base plate. Use vacuum cup or palm of hand to turn horn button. (6) Install rubber horn button cover. (7) Connect battery ground cable. 2-194. Drag Link (Pig. 2-196). a. Adjustment. (1) Turn adjusting plug in until solid resistance toturning is encountered. (2) Back off adjusting plug to first position at which a cotter pin may be inserted through tube and plug to secure. (3) If the first cotter pin holes aline after teverse rotation of less than 30 degrees, back off adjusting plug an additional 90 degrees to aline next cotter pin hole. 2173STEERING. Fire 2-195, Removing steering whee, b. Removal. (1) Remove cotter pin from each end of drag link and unscrew end plug. (2) Remove drag link from ball studs,on pitman SPRING SEAT arm and front wheel steering lever. (3) Remove spring guide, spring, two ball seats, and spring seat. ¢. Inspection and Repair. (1) Inspect spring seats, spring guides, and vai seats for eracks, chipping, or excessive wear. (2) Check tension of seat spring and replace if weak. (3) Examine threads in tube ends and threads on end plugs for condition. (4) Inspect tube carefully for cracks or distortion. (5) Replace damaged or worn parts. Do not at- tempt repairs. d. Installation. (1) Insert spring seat, two ball seats, spring and spring guide into ends of drag link tube. (2) Install one end over connection to front axle end assembly and secure in place with adjusting end plug and new cotter pin. (3) Install other end of drag link over pitman arm ball stud and secure similarly. BALL SEAT ALL SEAT SPRING GUIDE COTTER PIN BALL SEAT SPRING ‘ADJUSTING END PLUS ar sa709 Figure 2-196. Drag link annembly — exploded view. 2-195. Tie Rod 4a. Adjustment. (1) Checking toe-in. Inflate tires (para 2-191) to correct pressure and place vehicle on smooth, level surface with the wheels in straight-ahead position. Mark with chalk on inside of each front tire, at point of greatest section at hub level ahead of axle. Measure distance between marks with an alinement gage (fi 2-197), then move vehicle forward until marks are at same height behind axle, and measure distance between marks. If second measurement exceeds the first by 1/8-inch + 1/16-inch, — 0 inch, toe-in is 2174 correct; if not, adjust (2) below. (2) Adjusting toe-in. Loosen two clamping bolts (fig. 2-201) at each end of tie rod and rotate tube for minor adjustment. The left end has a 1% - 16 RH thread and right end has a 1-1/2-16 RH thread. If further adjustment is required, right hand ball stud must be removed from right hand steering lever in order to rotate retainer one revolution 360 degrees either way. Turning outward decreases distance between chalk marks behind axle. Tighten clamping bolts and recheck toe- < NOTE Six turns changes length at tie rod 1/8-inch.ALINEMENT GAGE SET POINTER AT "0" AT 710 Figure 2.197. Checking toesin with aye. AT 34711 Figure £198. Tern annem bly — right nde b. Removal. Remove cotter pin and back off nut securing tie rod assembly (fig. 2-201) to front axle end assembly at tie rod ball stud. Repeat operation at other end of tie rod, strike bosses on end assembly to release ball stud, and lift out tie rod assembly. ¢. Installation. Position tie rod with ball stud going down through bosses on front axle end assembly. Secure at each end with nut and lock with new cotter pin. Adjust toe-in (a. above). 2-196. Hydraulic Steering Pump — M123, M123C, and M125 CAUTION Opening the quick-disconnects will prevent power steering reservoir from draining. a, Removal. (1) Disconnect pump inlet line quick-disconnect located near steering gear. (2) Disconnect pump pressure line quick-dis- connect at pump. (8) Disconnect pump relief line quick-disconnect, at running board mounting bracket. (4) Remove pump inlet and pump pressure relief hoses from pump. (5) Remove two capscrews and washers securing pump to adapter plate mounted on timing gear cover, and remove pump. , Installation. CAUTION Over-tightening hydraulic pump capecrews will break snap ring on pump shaft. (1) Using a new gasket, position hydraulic pump to adapter plate on timing gear cover with gear meshing idler gear making sure that offset on pump body is pointed down. Secure with two capscrews and two lockwashers. NOTE Pump inlet port is nearest to engine block when installed. (2) Connect pump inlet and pump pressure relief hoses to pump. (3) Connect pump relief line quick-disconnect at running board mounting bracket. (4) Connect pump pressure line quick-disconnect at pump. 2a7s(5) Connect pump inlet line quick-disconnect near steering gear. (6) Check steering gear oil level. Fill as required. 2-197. Reservoir and Hydraulic Lines — M123, M123C, and M125 a. Reservoir. (1) Removal (a) Remove drain plug under reservoir at left front fender and drain oil from reservoir. (b) Disconnect reservoir air vent line. (c) Disconnect pump inlet line from steering gear control valve at lower fitting on right side of reservoir. (d) Disconnect pump pressure relief line at upper forward fitting at right side of reservoir. (e) Disconnect return line from steering gear at center fitting on right side of reservoir. (f Remove four bolts and self-locking nuts securing reservoir to left front fender and remove reservoir. NOTE é Cover ends of hoses and tubing to prevent entrance of foreign matter. (2) Installatic (a) Position reservoir on left front fender and secure with four bolts and self-locking nuts. (b) Connect pump pressure relief line at upper forward fitting on right side of reservoir. (c) Connect pump inlet line to lower fitting at right side of reservoir. (d) Connect return at center fitting on right side of reservoir. (e) Connect reservoir air vent line (A) Tighten drain plug under reservoir and fill 1 Engine radiator 2Pumpdrive belt 3 Belt tension adjusting strap 44 Flow control valve to filter hose 5 Filter to reservoir hose 6 Air horn line ‘Steering gear to filter hose {8 Reservoir to pump hose 9 Pump tocontrol valve hose 10 Flow control valve to steering gear hose 11 Flow control valve Figure 2-199, Power steering pump — MI2SA1C. Mi23E2. 2176Figure 2.200, Flow control valve. reservoir to proper level as indicated in lubrication order. ’. Hydraulic Lines. Refer to paragraph 2-47. 1 Pump mounting bracket 2 Hydraulic pumy 4S Pump drive belt Pulley 5 Selocking nut 2-198. Hydraulic Steering Pump — M123A1C and M123E2. a. Removal (1) Disconnect hydraulic lines from their re- spective components. Refer to paragraph 2-47 and figure 2-199. . (2) Remove two capserews and nuts securing flow control valve to engine oil filter support (fig. 2-200). (3) Loosen drive belt adjustment bolt. Loosen bolts securing hydraulic pump mounting bracket (1, fig. 2-204) to engine and pivot pump assembly (2) to remove drive belt (3) from pump pulley (4). (4) Remove self-locking nut (5) securing pulley (4)on pump shaft, Remove pulley from pump shaft. (5) Remove key (6) from pump shaft key way. (6) Remove two capscrews (7) and lockwashers (8) securing hydraulic pump (2) to mounting bracket (1), Remove pump, AT SPumpahattkey BLockwasher ‘9 Pump hose 10 Control valve hose Figure 2201. Power steering pump and mounting bracket — exploded view. 2177\--y @. A JFILTER, MOUNTING. IBRACKeT FILTER HEAD ©. ’ f & Ce, Figure 2.208, Power steering filter. (1) Unscrew filter from filter head (fig. 2-202). (8) Remove two capscrews and lockwashers securing filter head to filter mounting bracket, located on reservoir mounting bracket. Remove filter head (fig. 2-202), (9) Remove capscrew and nut securing reservoir bottom support to reservoir mounting bracket (fig. 2-208). (10) Remove capscrew, washer, and nut from each side of reservoir, securing reservoir to reservoir ‘mounting bracket. Remove reservoir (fig. 2-203). b. Installation. CAUTION ‘Over tightening hydraulic pump capecrews will break snap ring on pump shaft. (1) Position reservoir to mounting bracket and secure with two side mounting capscrews, washers, ‘and nuts (fig. 2-203). (2) Secure reservoir at bottom support with eap- screw and nut (fig. 2-203). (8) Position filter head to filter mounting bracket, located on reservoir mounting bracket, and secure with two eapscrews and lockwashers (fig. 2-202). (4) Serew filter on filter head (fig. 2-202). (5) Position pump (2, fig. 2-201) to pump mount- ing bracket (1) making sure that offset on pump body is pointed down. Secure with two eapscrews (7) and 2178 lockwashers (8). NOTE Pump inlet port is on right hand side (as viewed from rear of engine to front) when installed. NOTE To insure proper pump pulley alinement, it may be necessary to install suitable flat washers, between the pump and pump mounting bracket. (6) Insert key (6) in pump shaft keyway and in- stall pump pulley (4) on pump shaft and key. Secure pulley on pump shaft with self-locking nut (5). (7) Install pump drive belt (3) on pump pulley (4). (8) Adjust drive belt (para 2-91). (9) Tighten drive belt adjustment bolt and hy- draulic pump mounting bracket pivot bolts. (10) Position flow control valve on engine oil filter support securing with two capscrews and nuts (fig. 2-200). (11) Connect reservoir to pump hose (9, fig. 2- 201) to hydraulic pump inlet port and connect pump to control valve hose (10) to pump outlet port. (12) Connect remaining hydraulic lines to their respective components. Refer to paragraph 2-47 and figure 2-199.RESERVOIR, MOUNTING BRACKET surscernap NUT SELF-LOCKING NUT RESERVOIR SIDE SUPPORT FLAT WASHER AT MrI6 Figure 2.208. Power steering reservoir assembly — MI28A1C, M1232, Section XXIX. FRAME AND BRACKETS 2-199. General The frame is composed of two pressed steel side- members to which crossmembers, channel-type re- inforcements, steel gussets, and brackets are secured. The engine, mounts, front bumper, air reservoir and fuel tank supports, step hangers and battery box supports, pintle, fifth wheel, and spare tire carrier are also bolted to the frame. On M125 vehicles, the davit, drawbar, and winch are also bolted to the frame. Lifting shackles, located on each frame side- member above trunnion brackets, are of heavy-duty rigid bar type. Four towing shackles are used on the vehicle; two mounted on top of front bumper, and two located at rear of vehicle. On M123 vehicles, both rear towing shackles are mounted at rear of frame, attached to frame sidemembers. On M125 ehicles, right rear towing shackle is part of the Jéavit mounting bracket, and the left rear shackle is mounted as in M128 vehicles. 2-200. Upper and Lower Brush Guards @. Upper Brush Guard — M128, M12SC, M12SA1C and M12sE2. (1) Removal (fig. 2-94). Refer to paragraph 2-87a. (2) Installation (fig. 2-94). Refer to paragraph 281d. 6. Upper Brush Guard — M125. (1) Removal (fig. 2-94). Refer to paragraph 2- 87a, (2) Installation (fig. 2-94). Refer to paragraph 281d. ¢, Lower Brush Guard — Mi2s, M128C, M12SA1C, and M128E8 (fig. 2-94). (1) Removal. Remove two self-locking nuts and bolts securing lower brush guard to each frame side- member and remove guard. (2) Installation. Secure lower brush guard to frame with four bolts and self-locking nuts. 21792-201. Front Bumper — M123, M123C, M123A1C, and M123E2. a, Removal (fig. 2-94). (1) Remove three self-locking nuts and bolts securing each upper gusset to the frame sidemember. (2) Loosen four self-locking nuts on left and right bottom gussets, and using hoist remove bumper. . Installation (fig. 2-94). (1) Using a hoist, lift bumper into position and secure to top of frame sidemembers with six bolts and self-locking nuts. (2) Secure to bottom of frame sidemembers with four bolts and self-locking nuts. 2-202. Upper Radiator Shield Support a, Removal (fig. 2-94). Refer to paragraph 2-87a. . Installation (fig. 2-94). Refer to paragraph 2- 87d. 2-203. Davit — M125 (Fig. 2-204), a. Removal. (1) Remove safety pin securing locking pin through mounting bracket and remove locking pin. (2) Remove bolt, lockwashers, and nut securing locking bracket to davit below mounting bracket. Figure 2-204, Davit locked in travel position — M125, 2.180 (3) Using hoist, lift davit up through body floor and remove to ground. (4) Remove eight bolts and nuts securing mount- ing bracket to right frame sidemember and remove, bracket. q 6. Installation. (1) Position mounting bracket over holes in frame sidemember and install eight bolts and self- locking nuts. (2) Position davit tube through floor of body, ‘and set tube into mounting bracket. (3) Position lock bracket over end of davit tube below the mounting bracket and secure to tube with bolt, lockwasher, and nut. (4) Lock davit in position by alining locking pin holes and install locking pin through locking bracket on davit to mounting bracket. Secure locking pin with safety pin. 2-204. Spare Tire Carrier — M123, M123C, M123A1C, and M123E2. a, Removal. (1) Remove spare tire retainer and nut. (2) Attach tire hoist rope to tire and lower to ground. (3) Remove five nuts and bolts securing carrier to right side of winch bracket and remove tire carrier. b. Installation. (1) Position tire carrier on winch bracket secure with five bolts and self-locking nuts. (2) Raise tire to carrier and secure to carrier with clamp and clamp nut. 2-205. Fifth Wheel (Fig. 2-205). a. Removal, (1) Remove 22 nuts and bolts securing fifth wheel to frame and side brackets. (2) Position chain sling under bedplate hoist fifth wheel clear of frame and lower to ground. NOTE On high mounted fifth wheel, remove spacers as part of fifth wheel assembly. 6. Installation. (1) With chain sling under bedplate, hoist fifth wheel over frame. Position on frame. (2) Aline mounting holes in fifth wheel with holes in mounting bracket and frat (3) Install 12 bolts on the inside and 10 bolts on the outside. Secure with 22 self-locking nuts. Tighten nuts. 2-206. instruction for Changing Height of Fifth Wheel ¢ NOTE The following procedure provides instruc-, FRAME SIDERAIL Figure 2.208, Removing or installing fh wheel tions for changing the height of fifth wheel on M123 vehicles from 68 inches to 64 inches a. Removal. (1) Remove fifth wheel (para 2-205). Retain nuts and bolts. (2) Remove nuts and bolts securing two sup- ports to fifth wheel. Remove the supports. (3) Remove two nuts and bolts securing upper right and left approach plates to lower approach plates. (4) Remove eight nuts and bolts securing upper approach plates through lower approach plates to frame. (5) Remove four nuts and bolts securing upper approach plate to upper approach plate crossmember. (6) Remove approach plates. . Installation. (1) Secure lower right and left approach plates to frame with eight bolts and nuts removed in a(4) above. (2) Mount fifth wheel (para 2-205). Centerline of fifth wheel should be approximately four inches for- ward of chassis bogie centerline. If mounted correct- ly, end of fifth wheel will rest on approach plate crossmember. 2-207. Lifting and Towing Shackles a. Front (fig. 2-206). (Removal. (a) Remove three nuts and bolts securing tow- ing shackle and spacer to top of bumper. (b) Remove shackle and spacer. (2) Installation, (a) Position spacer and shackle over mounting holes on top of front bumper. (b) Install three bolts, and secure with three self-locking nuts. 6, Rear — M128, M128C, M128A1C, and M1232. (1) Removal. Remove three bolts and self-locking nuts securing shackle bracket to frame sidemember and remove bracket and shackle. (2) Installation. (a) Position bracket over mounting holes in frame sidemember. (6) Install three bolts and secure with three self-locking nuts. ©. Rear — M125. (1) Removal (right rear), Removal and installa- tion of the right rear towing shackle is facilitated by removal and installation of the davit mounting bracket (para 2-203). (2) Removal (left rear). Remove three bolts and self-locking nuts securing shackle bracket to left frame sidemember and remove bracket and shackle. (3) Installation (left rear). (a) Position bracket over mounting holes in frame sidemember. (b) Install three bolts and secure with three self-locking nuts. 2-208. Towing Pintle Assembly a. Removal (fig. 2-207). (1) Remove safety pin securing locking nut to pintle shaft on inside of rear crossmember. (2) Insert bar through pintle jaw to prevent turning and remove locking nut and large flat washer from pintle. (3) Pull pintle toward rear of vehicle to remove from its mounting. 6, Disassembly (fig. 2-210), (1) Drive out hook latch pin. (2) Pull cotter pin out and remove hex nut from hex-head bolt holding hook lock to pintle hook. Re- ‘move bolt and lock. (3) Remove cotter pin, hex nut, and flat washer from shaft end of pintle hook and pull hook from bracket, (4) Remove capscrews and nuts holding pintle bracket, Remove bracket from frame. ¢. Cleaning and Inspection. (1) Cleaning. Clean all parts in dry-cleaning solvent or mineral spirits paint thinner. (2) Inspection, {a) Inspect pintle hook shaft for signs of ex- cessive wear or damage. 21812. BOLTS AND SELF-LOCKING NUTS sett Pt ep hit ‘ DRAWBAR AND YOKE BLOCK ASSEMBLY SAFETY PIN Nur Ar 94720 WASHER Figure 2.207. Pintle, drawbar, and yoke block assembly — M125. 2-182 HOOK LATCH PIN "3" HOOK HOOK LATCH SPRING. HOOK LATCH eo ER PINTLE HOOK \ weir com pn ext ara721 q Figure £.208, Pintle assembly — exploded view. Ca 3) Hex-Ho BOLT RIVE SCREW CHAIN(b) Inspect hook, lock, and lateh for damage. Replace defective parts. d. Assembly (fig. 2-208). e (1) Position hook lock on hook and nd nut. stall bolt (2) Position latch spring and hook lateh in lock. and press pin in place. (3) Position pintle bracket, and install capscrews and nuts. (4) Install shaft end of hook in bracket and in- stall washer, hex nut, and cotter pin. e. Installation. (1) Lubricate pintle shaft according to lubrica- tion order. (2) Position pintle shaft through mounting bracket on frame rear crossmember. (3) Insert bar through pintle jaw to prevent turning and install a large flat washer and locking nut on inside end of pintle shaft. (4) Tighten locking nut until pintle binds when rotated; then back nut off until pintle can be turned freely and safety pin can be inserted. » 2-209. Towing Pintle Stowage (Fig. 2-208) a. To Remove Pintle from Rack. (1) Remove two spring-loaded wing serews from clamp securing pintle assembly in rack. (2) Unhook safety chain passing through pintle jaws, (3) Lift off upper clamp with bolt and compres- sion spring and remove pintle. 6, To Install Pintle in Rack. (1) Position pintle in rack and install locking clamp over pintle shaft and through mounting rack with compression spring between upper clamp and mounting rack. (2) Install two wingnuts on bolts on underside of each and tighten to secure. (3) Secure pintle safety chain through jaw. 2-210. Drawbar and Yoke Block — M125 (Fig, 2-207). Since the drawbar and yoke block assembly is readily interchangeable with the pintle, replacement of the drawbar and yoke block is accomplished in the same manner as the pintle. Refer to paragraph 2-208. Section XXX. FRONT SPRING SUSPENSION 2-211. General 4 LASHING Gras HOOK HANDLE aan Figure 2-238. Cab cover — lashed in place. (8) Position cover on hood with front bead at windshield (fig. 2-241). Slide front bead of cover from either side into weatherstrip channel in top of windshield frame. (4) Draw cover (fig. 2-239) over crossbars and slide side beads of cover into weatherstrip channel in bow posts. (5) Fasten cover at upper corners of wind- shield frame and secure to each roof sidemember with six fasteners (fig. 2-239). (6) Lash rear of cover to lashing hooks on rear of cab and secure lashing rope to grab han- dles (fig. 2-238) at each side of the cab, 2.214. Windshield Wiper Assembly (Pig. 2-214), a, Removal. (1) Remove blind nut securing wiper blade arm to wiper motor serrated shaft. (2) Remove wiper blade arm. (3) Disconnect air hose from pipe on wiper assembly. (4) Remove two serews and lockwashers securing wiper assembly to mounting bracket. b. Installation. (1) Position windshield wiper assembly on mounting bracket and secure with two screws and lockwashers, Figure 2-239. Installing cab cover — side bead. 2.205WEATHERSTRIP CHANNEL Figure 2-240. Cab cover and top frame. (2) Position wiper blade arm over serrations on wiper assembly shaft and secure in position with blind nut. (8) Connect air hose to pipe on assembly. 2-245. Rear View Mirrow a. Removal. (1) Remove nut and bolt securing min bracket brace to mounting bracket located on side of cowl. (2) Remove two nuts and bolts securing mir vor bracket to door hinges. Remove mirror bracket and mirror. b. Installation, wiper Sec! 2-247. Speedometer a, Removal. ) Speedometer, (a) Disconnect battery ground cable, (b) Release four panel lockserews, one in each corner of cluster, and pull out instrument cluster. (c) Disconnect flexible shaft from speed- ometer (2) belov (2) Remove two mounting nuts and lock- hers, and remove speedometer from front of instrument cluster. 2) Plerible Shajt Assembly. («) Unscrew connecting nut from speed- ometer drive unit mounted at rear of transfer. (b) Disconnect shaft mounting clips. (©) Unserew connecting nut from speed ometer. 2-206 (1) Position mirror bracket with mirror to door hinges and secure with two nuts and bolts. (2) Position mirror bracket brace to mount- ing bracket and secure with nut and bolt. 2-246. Vehicle Data Plates a, Removal, 1) Plates mounted on the vehicle instrument panel are removed by removing two (or four) self-tapped serews. (2) Plates mounted on the winch are re- moved by removing four drive screws. b. Installation. (1) Install plate mounted on the instrument panel using two (or four) self-tapping or cross- recess panhead screws, (2) Winch, caution, and instruetion plate are installed using four roundhead drive screws. Figure 2-241, Installing eab cover — front bead. yn XXXVI. GAGES (NONELECTRICAL) MEASURING DEVICES (d) Remove flexible shaft assembly. (3) Flecible Shaft Core. (a) Note that end of flexible shaft core at speedometer has a square end, and core end at drive unit has a keyed end. (b) At keyed end of core, pull core slightly out of connecting nut and remove C-ring retaining core in nut. (c) At square end of core, pull core com- pletely out of flexible shaft assembly. NOTE ‘The flexible shaft core may be removed without removal of the flexible shaft case. b, Instalaltion. (1) Speedometer. (a) Position speedometer and install two nuts and lockwashers.AT 3755 Figure 2-242. Rear view mirror. (b) Connect flexible shaft to speedometer ( (8) below). (c) Position instrument cluster in instru- ment panel and tighten four panel lockscrews. (d) Connect battery ground cable. (2) Flexible shaft core. (a) Hold end of flexible shaft case in left hand, with hand filled wilth proper core lubricant. (b) Feed core through lubricant, into core, keyed end first. (c) Push through to opposite connecting nut and install C-ring in groove on keyed drive end. (8) Flezible shaft assembly. (a) Aline keyway in drive unit, with keyed end of shaft core and insert core. Tighten con- necting nut. (b) Install shaft mounting clips on vehicle chassis. (c) Pass flexible shaft assembly through firewall to instrument cluster on dash panel. (d) Insert square core end into speedom- eter and tighten connecting nut. 2-248. Tachometer a, Removal. (1) Tachometer. The procedure for tachom- eter removal is the same as speedometer removal (para. 2-247.). (2) Flexible shaft. (a) Loosen wingnuts on access panel under right front tire and remove panel by pushing toward rear of vehicle (M123, M123C, and M125). (0) Unscrew conecting nut from tachom- eter drive unit mounted behind idler pulley, figure 2-243 (M123, M123C and M125). (c) Unscrew connecting nut from tachom- eter drive unit mounted on fuel injector drive pump, figure 2-244 (M128A1C, M123E2). (d) Disconnect shaft mounting clips. (©) Unserew connecting nut from rear of tachometer and pull flexible shaft assembly through firewall to remove. (3) Flexible shaft cor: 2.24Ta. (3). b. Installation, (1) Tachometer. The procedure for tachom- eter installation is the same as for speedometer installation. (para 2-247b.) (2) Flexible shaft core. Refer to paragraph 2-247, (3) Flexible shaft. (a) Aline keyway in drive unit with keyed end of shaft core and insert core. Tighten connect- ing nut. (b) Install shaft mounting clips on vehicle chassis. (c) Pass flexible shaft assembly through firewall to instrument cluster on dash panel. (d) Insert square core end into tachometer and tighten connecting nuts. (e) Fasten clip to secure flexible shaft to top rear of engine. (f) Aline hinge pins of access panel door with hinges under right front fender and push access door into hinges toward front of vehicle. Secure panel by tightening wingnuts (M123, ‘MI123C, and M125). Refer to paragraph Figure 2-243. Tachometer cable disconnect points. 2-207Figure 2-244, Tachometer drive — MI23A1C, MI23E2. 2.249. Drive Adapters a. Removal. (1) Speedometer drive. (a) Disconnect speedometer cable. (b) Unscrew speedometer driven gear 2-208 sleeve at rear of transfer and lift out speedometer drive gear. (2) Tachometer drive —M123, M128C, and M125. (a) Disconect tachometer cable (fig. 2-248). (b) Unserew tachometer drive from gear cover behind idler pulley (fig. 2-243). Remove tachometer drive. (3) Tachometer drive adapter — M128A1C, M123E2. (a) Disconnect tachometer cable. (b) Remove two capscrews and lockwash- ers securing adapter to fuel injector drive pump. Remove adapter with cap. . Installation. (1) Speedometer drive. (a) Position speedometer drive gear at rear of transfer and screw in to secure. (b) Connect speedometer cable. (2) Tachometer drive — M123, M123C, and M125, (a) Position tachometer drive to gear cover behind idler pulley. Screw in to secure (fig. 2-243). (b) Connect tachometer cable (fig. 2-248). (3) Tachometer drive adapter — M123A1C, M123E2. (a) Install adapter with cap on fuel i jector drive pump. Secure with two capscrews and lockwashers. (b) Connect tachometer cable. ¢CHAPTER 3 SPECIAL PURPOSE KITS Section |. PERSONNEL HOT WATER HEATER KIT — M123, M123C, AND M125, 3-1. General ‘The hot water personnel heater is a blower-type hot water heater. It is bolted to the top of the left fender splash shield in the engine compartment. Heater air is distributed from the heater to vehicle cab and/or windshield defroster by a blower and heat diverter. Heat is controlled by AIR and DE- FROSTERS knobs on the instrument panel, which in turn operate butterfly or damper valves in the heater diverter assembly and air inlet adapter elbow. Refer to figure 3-1 for heater wiring diagram. 3.2. Heater Assembly @ Removal. (1) Disconnect electrical connector (fig. 8-2) at heater assembly. (2) Loosen two clamps securing heater inlet and outlet air hoses to heater assembly (fig. 3-3). (8) Drain engine radiator (para 2-87a.) (4) Loosen two clamps securing heater inlet and outlet water hoses to heater assembly (fi 32). (5) Remove the 4 bolts securing heater as- sembly to mounting brackets (fig, 3-8). (6) Remove heater assembly. 6, Installation. (1) Position heater assembly on mounting brackets and secure with four bolts, hex nuts, and lockwashers. (2) Connect two water hoses to heater as- sembly and tighten hose clamps. The water hose from the thermostat by-pass housing should be connected to the top connection on the heater assembly. The water hose from the exhaust mani- fold should be connected to the bottom connection ‘on the heater assembly (fig. 3-2). (3) Connect two air hoses to heater assembly and tighten clamps. (4) Connect electrical assembly. (5) Fill radiator (para 2-874.). (6) Operate engine until coolant reaches normal operating temperature. Open water bleed cable at heater valve (fig. 8-8) on heater assembly and expel all air from cooling system. Close bleed valve when a steady stream of coolant is expelled. (7) Refill radiator as required, 3-3. Diverter Assembly a, Removal, (1) Loosen three clamps securing air inlet, hose and two defroster air hoses to diverter assembly (fig. 3-4). (2) Remove screw securing defroster control cable to diverter assembly (fig. 3-4). (8) Remove four bolts, hex nuts, and lock- washers securing diverter assembly to firewall (fig. 8-4). switch CIRCUIT BREAKER TO HEATER RESISTOR CALE CABLE TO EXISTING “Y" CONNECTOR ‘CIRCUIT BREAKER CABLE TO END OF CABLE NO. 25 AT 758, Figure 3-1. Hot water personnel heater wiring diagram.6. Installation. (1) Position diverter against firewall and secure with four bolts, hex nuts, and lockwashers. (2) Install defroster control cable clamp. Make sure control knob is fully depressed and é erter damper/butterfly valve is fully closed prior to tightening control cable clamp. (8) Connect air inlet hose and two defroster hoses. Tighten hose clamps. 3-4. Control Cables a. Removal, (1) Remove cable clamp securing defroster EATER ASSEMBLY. and/or air control cable to diverter and/or elbow WATER OUTLET adapter (figs. 3-4 and 3-5). a = (2) Remove control cable hex nut securing Mt control cable to control bracket under instrument E panel (fig. 3-5). (3) Remove control cable. Z b Installation. Y (1) Route control cable (with identification bY S plate) through control bracket and secure with hex nut. (2) Install control cable clamp, Make sure cable knob is fully depressed and damper /butter- fly valves are fully closed prior to tightening cable clamp. me A VALVE Figures, Inlet and antl wie hae connections,DEFROSTER CONTE CABLE, Figure 3-4. Diverter assembly. Section Il. GASOLINE HEATER KIT — M123, M123C, AND M125 3-5. General The gasoline heater is electrically operated and uses the vehicle’s gasoline for heating fuel. The heater assembly is mounted on the right fender. The heater kit facilitates starting and aids to maintain near-normal engine operating tempera- ture during standby periods. Heater exhaust gases from the front pass through tubing to the oil pan shroud for warming the crankcase lubricant. Hot air from diverter at rear of heater passes through tubing to front and rear manifold deflectors. Hot air is also diverted to battery box and inside of eab for personnel and to windshield defrosters. ‘The kit includes covers which cover the engine hood, brush guard, and the hood left-side panel to help retain heat in the engine compartment. Refer to figure 8-6 for electrical wiring diagram. 3-6. Heater Assembly a. Removal. (1) Open heater housing and hood side panel assembly. (2) Loosen hose clamps securing three air hoses to diverter and remove hoses (figure 3-7). (3) Disconnect two electrical connectors from heater assembly (fig. 3-7). (4) Disconnect fuel line from heater assem- bly (fig. 3-7), (5) Remove shield assemblies under right fender. (6) Loosen exhaust diverter clamp bolt under fender (figure 3-8). (7) Loosen battery box heat tube clamp at elbow under fender (fig. 3-8). (8) Remove four heater assembly mounting bolts, hex nuts and lockwashers (fig. 3-7). (9) Remove heater assembly. 6. Installation. (1) Position heater assembly on fender and secure with four bolts, hex nuts and lockwashers. (2) Connect battery box heat tube elbow (under fender) to heater diverter and tighten clamp. (3) Connect exhaust diverter (under the fender) to heater diverter and tighten clamp. (4) Install shield assemblies under right fender. 33I AIR INLET CONTROL VALVE DEFROSTER VALVE ~ AND CONTROL Figure 3-5. Control bracket and air defroster cable installation. (5) Connect fuel line to heater assembly. (6) Connect two electrical connectors to heater assembly. (7) Connect three air hoses to heater di- verter and tighten clamps. (8) Close and secure heater housing and hood side panel assembly. 3-7. Igniter Assembly a, Removal. (1) Remove capscrew securing control cover assembly to heater assembly (fig. 3-7). (2) Remove nut securing electrical lead to igniter (fig. 8-9). (8) Remove igniter from heater assembly. b, Installation. (1) Install igniter in heater assembly using a new gasket. (2) Connect electrical lead to igniter and tighten nut. 34 (3) Install control cover assembly and tight- en capserew. 3-8. Fuel Pump (Fig. 310). a. Servicing. (1) Place absorbent material under fuel pump. (2) Remove fuel pump cover (turn clock- . viewed from the top). (3) Remove cover, strainer sasket. (1) Wash sereen in dry-cleaning solvent or mineral spirits paint thinner. (5) Replace new gasket, sereen and cover. b. Removal. (1) Disconnect battery ground cable and tape connections. (2) Disconnect: electrical disconnect on fuel pump mounting bracket (fig. 3-10). (8) Disconnect inlet and outlet fuel lines from fuel pump (fig. 3-10). (4) Remove two fuel pump mounting bolts, hex nuts, and lockwashers (fig. 3-10). ¢. Installation. (1) Position fuel pump and electrical discon- nect bracket on fuel pump mounting bracket. Secure with two bolts, hex nuts, and lockwashers. (2) Connect inlet and outlet fuel lines to fuel pump. (3) Connect electrical disconnect. (4) Connect battery ground cable. . Fuel Filter (Fig. 3:10). a, Servicing. (1) Place absorbent material under fuel filter. (2) Remove fuel filter sediment bowl from filter. (3) Discard filter element and gasket. (4) Install fuel filter sediment bowl using a new gasket and filter element, b. Removal. (1) Place absorbent material under fuel fil- ter. Close shutoff valve at fuel pump outlet. (2) Disconnect fuel filter and outlet lines. (3) Remove two mounting bolts securing fuel filter to mounting bracket. Remove fuel filter. ¢. Installation. (1) Position fuel filter on mounting bracket and secure with two bolts, hex nuts and lock- washers. (2) Connect fuel filter inlet and outlet lines. (3) Open fuel shutoff valve at fuel pump, outlet. 3-10. Priming Pump (Fig. 3-10). a, Removal. screen and+ AND # 4 pressure! ee [ x i REGULATOR i i PR. 7 cu | ea aloe Vis pos: my ‘Oo IZ b> Dy NF CONTROL fy ‘COVER ASSEMBLY Figure 3-7. Heater assembly and diverter.Figure 3-8. Exhaust diverter assembly. (1) Disconnect two fuel lines connected to primer pump. (2) Remove hex nut securing primer pump to mounting bracket. Remove primer pump. b, Installation. (1) Position primer pump in mounting bracket and secure with hex nut. (2) Connect two fuel lines to primer pump. FUEL FILTER IONITER Ar 766 Figure 3-9. Igniter. 3-11. Control Cables — Typical (Fig. 3-1). Removal. (1) Remove control cable clamp securing control cable to control valve. (2) Remove control cable hex nut securing control cable to control bracket under instrument, panel. Remove control cable. 4 Figure 3-10. Fuel pump and filter.CONTROL CABLE BRACKET CABLE TYPICAL HEX NUT AT 34768 Figure 3-11, Primer and pump and control cables b, Installation, (1) Route control cable (with identification plate) through the control bracket and secure with hex nut. (2) Install control cable clamp at control valve. Be sure control cable knob is fully depressed and control valve damper/butterfly valve is either full open or closed position as required. 3-12. Cold Weather Covers (Fix. 3-12). a, Remoral, To remove covers unhook spring clips and untie the tie straps. Remove covers. NOTE Hood cover does not have to be removed to open the hood. b. Installation. Position covers and secure with spring clips and tie strap 37TIE STRAPS Figure 3-12. Right and left side hood covers and winterfront radiator covers—installed. Section Ill. WINTERIZATION HEATER KIT — ARCTIC ZONE — M123A1C, AND M123E2 3-13. General The winterization heater kit incorporates a per- sonnel heater mounted on the left front fender and a coolant heater installed in compartment on right hand running board. Fuel for both heaters, is supplied by a common fuel pump mounted on the steering gear housing (fig. 8-14). A hard top closure kit and thermal barrier kit are included to aid in the winterization of the vehicle. 3-14. jonnel Heater (Fig. 3-13). a, Removal, 38 (1) Open hood and left side heater panel assembly. (2) Disconnect electrical harness at heater connector, (3) Disconnect fuel line from fuel inlet elbow. (4) Loosen clamp securing heat duet tubing to heater adapter and remove tubing. (5) Remove heater mounting clamps secur- ing heater to mounting saddles. (6) Remove heater assembly from saddles and remove preformed packing and flat washer for heater exhaust adapter outlet. (fig. 3-15). «:Figure 3-13. Personnel heater assembly —M123A1C, M123E2. b. Installation. (1) Install two heater mounting clamps through heater mounting saddles. (2) Place washer and preformed packing over exhaust adapter outlet and position heater assembly on mounting brackets. Tighten clamps. (3) Place heat duct over heater outlet adapt- er and secure in place with hose clamp. (4) Connect fuel line to fuel inlet elbow on heater. (5) Connect heater harness to electrical con- nector on heater. (6) Close left side heater panel assembly and lower hood. 3-15. Fuel Pump (Fig. 3-14), a. Servicing. (1) Place absorbent material under fuel pump. (2) Remove fuel pump cover, strainer screen Oe gasket. (3) Wash screen in dry-cleaning solvent or mineral spirits paint thinner. (4) Replace gasket, screen and cover. b, Removal. (1) Turn fuel shutoff cock to the OFF Position. (2) Disconnect electrical disconnect at fuel pump. (8) Disconnect outlet and inlet fuel lines from fuel pump. et (4) Remove two screws, nuts, and lockwagh- ers securing fuel pump to mounting bracket and remove pump. ¢. Installation. (1) Position fuel pump and circuit breaker as shown in figure 3-14. (2) Secure pump and circuit breaker to mounting plate with two screws, nuts, and lock- washers. (3) Connect fuel inlet and outlet lines to fuel pump. (4) Connect electrical lead to fuel pump lead. (5) Open fuel shutoff cock. cadFigure 3-14. Heater fuel pump—MI23AIC, M123F2. 3-16. Fuel Lines and Fittings (Fig. 3-14). a. Fabrication. Refer to paragraph 2-47. b. Removal. COTTER AN EXHAUST TUBE Figure 3-15. Heater exhaust tube—M123A1 3-10 (1) Disconnect fuel line at shutoff cock elbow. (2) Disconnect main fuel line from adapter. (3) Remove shutoff cock, adapter, tee and / or elbow for replacement as required. ¢. Installation. (1) Install elbow, tee, adapter and shutoff cock as shown in figure 3-14. (2) Connect main fuel line to adapter. (3) Remove cotter pin securing exhaust. (4) Connect fuel pump line to shutoff cock elbow. 3-17, Personnel Heater Exhaust Tube (Pig. 3-15). a, Removal. (1) Remove cotter pin securing exhaust tube to exhaust elbow. (2) Remove cotter pin securing exhaust ex- tension to exhaust tube and remove extension. (3) Remove five screws, nuts and washers securing tube to fender and remove exhaust tube. (4) Remove five clamps from exhaust tube. M1232.8. Installation. (1) Position exhaust tube over exhaust elbow and aline drilled hole in tube and elbow. NOTE ‘When installing new exhaust tube onto elbow the tube must first be drilled. Determine location of drilled hole in el- bow and drill corresponding 8/16 inch hole in tube. (2) Install cotter pin through exhaust tube and elbow. (8) Position five clamps over exhaust tube and secure to fender with five screws, nuts and washers (fig. 3-15). (4) Install exhaust extension as outlined in (1) above. 3-18. Defroster and Air Controls (Fig. 3-16). a, Removal, (1) Loosen serew securing defroster cable to diverter and remove cable from cable clamp. (2) Slip cable from end of control lever on diverter. (8) Remove nut and washer securing cable to mounting plate; pull cable through opening in plate and remove name plate. (4) Remove air control cable in similar manner. b. Installation, (1) Position nameplate over hole in bracket and insert defroster cable through hole; install nut and washer. (2) Push defroster cable knob fully in and connect looped end of cable to diverter control lever. (3) Position cable in cable clamp so that di- verter control lever is to extreme right; tighten cable clamp. (4) Install air control cable in similar man- ner as in (1) above. Connect looped end of cable to elbow control arm. (5) Push air control knob fully in and posi- tion cable in cable clamp so that elbow baffle is closed. Tighten clamp. COOLANT HEATER ‘CONTROL BOX (ARCTIC KIT) WASHER Figure 3-16. Heater controls—M123A1C, M123E2. BanPERSONNEL HEATER CONTROL BOX COOLANT HEATER ‘CONTROL BOX EMERGENCY SWITCH ASSEMBLED. HARNESS, LEAD (TEMPERATE ZONE ONLY) Y-CONNECTOR (ARCTIC ZONE ONLY) GROMMET PERSONNEL HEATER P- VEHICLE circ BREAKER ASSEMBLED HARNESS LEAD TEMPERATE ZONE ONLY AT 34774 Figure 3-17. Winterization kit wiring schematic —MI23A1C, MI23E2. r Emergency Switch (Fig. 316) 4, Removal. (1) Disconnect electrical leads from back of switch. (2) Remove two nuts and lockwashers secur- jing switch to guard and remove switch. b. Installation. ’ (1) Attach emergency switch to switch guard with two nuts and lockwashers. NOTE Be sure switch ON position is toward top of switch. (2) Connect electrical leads to switch as shown in figure 3-17. 3-20. Heater Control Box @, Removal (fig. 3-18). (1) Disconnect wiring harness and electrical lead at back of control box. (2) Remove two nuts securing control box to mounting bracket and remove control box. b. Disassembly (fig. 3-18). (1) Remove two serews securing control box to case assembly and remove case. (2) Remove locknut securing switches to eontrol box and pull switches through cover. 3-19, He 312 4 (8) Remove electrical leads from switches and remove switches from control box. NOTE Mark electrical leads to ensure proper connections at time of assembly (4) Remove electrical leads from circuit breaker; remove two screws and locknuts securing circuit breaker to control box. Remove circuit breaker. (5) Remove light assembly using procedures outlined in (2) and (3) above. ce. Assembly (fig. 3-18). (1) Position light assembly in control box. Connect electrical leads. (2) Secure light assembly to control box with locknut, (3) Position cireuit breaker to control box. connect electrical leads and secure with two screws and locknuts. (4) Position switches to control box, connect electrical leads, and secure with locknut. (5) Install control box in case assembly and secure with two screws, d. Installation. (1) Position control box on mounting brackel and secure with two nuts.(2) Connect wiring harness to electrical con- nector on back of control box. (3) Connect electrical lead as shown in fig- ure 3-17. 21. Heater and Defroster Ducts @. Removal. Loosen clamps securing duct to el- bow, diverter, or defroster as applicable. Remove duct. b. Installation. Position duct to elbow, diverter, or defroster as applicable. Secure with hose clamp. 3-22. Coolant Heater Assembly (Fig. 3-19). a. Removal. (1) Turn fuel shutoff cock to the OFF posi- tion. (2) Turn water shutoff cocks at engine water pump and thermostat housing (fig. 3-20), to the OFF position. (8) Disconnect wiring harness from elec- trical connector on coolant heater. (4) Remove screw and nut securing heater ground wire to heater shroud. (5) Loosen clamps securing coolant hoses to heater and circulating pump; remove hoses. (6) Disconnect fuel line at heater and shut- off cock and remove fuel line. (1) Remove cotter pin securing exhaust el- bow to heater; remove elbow. (8) Remove clamps securing heater to mounting brackets and remove heater. . Installation, (1) Position coolant heater on lower heater mounting bracket with exhaust outlet facing in- board. Install mounting clamps. (2) Slip exhaust elbow over exhaust outlet on heater and install cotter pin. (3) Connect one end of 18 inch long water hose to elbow instilled’ in inboard outlet of heater and other end to side of circulating pump. Secure hose in place with two hose clamps. (4) Connect 102-inch hose to elbow installed in outboard opening of heater with hose clamp. (5) Connect other 18 inch long hose to top opening of pump and to battery pad with two addi- tional hose clamps. (6) Install fuel line between elbow on fuel valve and fuel shutoff cock. (7) Connect wiring harness to electrical con- nector on heater; secure ground lead of harness with one heater shroud bolt and nut. (8) Turn coolant shutoff cocks, located at vehicle water pump, in a counterclockwise direc- tion to the fully open position. (9) Turn fuel shutoff cock to the ON posi- tion (handle parallel with cock). 3-23. Circulating Pump (Fig. 3-19). a. Removal. (1) Turn coolant shutoff cocks to the OFF Position. (2) Disconnect circulating pump ground lead from top of pump. Figure 3-19. Coolant heater and circulating pump— ‘M123AIC, M123E2. Bas(3) Loosen coolant hose clamps and remove hoses from pump. (4) Remove clamp securing pump to mount- ing bracket and remove pump. b, Installation, (1) Postion circulating pump on mounting bracket as shown in figure 3-19, Install mounting clamp. (2) Connect 18 inch long hose coming from rear outlet of heater to side outlet on pump. (8) Connect battery pad 18 inch long coolant hose to top outlet on pump. * (4) Secure hoses with two hose clamps. (5) Install pump ground wire to terminal ‘on top of pump. (6) Open collant shutoff cocks (fig. 3-20). Figure 3-20. Heater coolant lines—M123A1C, MI23E2. 314 3-24, Coolant Heater Exhaust Tube a. Removal. (1) Remove cotter pins securing exhaust tube to heater elbow and to oil pan shroud. (2) Remove three screws and nuts securing tube clamps to mounting brackets (fig. 3-21). NOTE Coolant hose clamps must be removed from tube clamps before removal of exhaust tube, (3) Remove exhaust tube from under ve- hicle; slip clamps off tube. b. Installation. (1) Route exhaust tube from oil pan shroud, over axle, under frame and over edge of splash shield to heater exhaust elbow. NOTE Prior to installation of new exhaust tube, drill two 3/16 inch holes for installation of cotter pins. (2) Position end of tube over oil pan shroud and install cotter pin. (8) Secure tube to mounting brackets and running board support with three clamps, screws, and nuts (fig. 8-21). (4) Secure coolant hose clamps to tube clamps as shown in figure 3-21. (5) Position end of exhaust tube over heater exhaust elbow and secure with cotter pin, € 3-25. Coolant Hoses and Shutoff Cocks a. Removal. (1) Drain engine radiator (para 2-94). (2) Loosen two clamps securing inlet and outlet hoses to shutoff cocks (fig. 3-20); remove hoses. (3) Remove shutoff cocks from water pump and thermostat housing. (4) Remove two screws and nuts securing coolant hose clamps to engine (fig. 3-20). (5) Remove lower coolant hose (fig. 3-21). (6) Loosen clamps securing hoses to heater, circulating pump and battery pads (fig. 8-19); remove hoses. 6, Installation. (1) Connect coolant hoses to heater, cireu- lating pump and battery pads (fig. 3-19). (2). Install lower shutoff cock into side outlet of vehicle water pump with outlet facing toward rear of vehicle. Install upper shutoff cock as shown in figure 8-20. (8) Route heater outboard hose along ex- haust tube and secure to exhaust tube clamps (fig. 3-21). Connect to lower shutoff cock with hose clamp.TRANSMISSION INSPECTOR Figure 3-21. Coolant heater exhaust tube and coolant hose—MI23A1C, M123E2. (4) Connect upper coolant hose to shutoff cock with hose clamp. Secure hose clamps to mounting brackets (fig. 3-20). (5) Route upper coolant hose under vehicle along top of transmission and connect to battery pad outlet protruding through transmission tun- nel. Install hose clamp. (6) Install radiator coolant (para 2-94). 3-26. Battery Heating Pads a, Removal. (1) Close coolant hose shutoff cocks. (2) Remove batteries (par. 2-120c.). (3) Disconnect coolant hoses. Refer to para- graph 3-25. (4) Remove battery pad. 6. Installation. (1) Position battery pad in battery box with outlets extending through holes in battery box. (2) Connect coolant hoses. Refer to para- graph 3-25, (8) Install batteries (par. 2-120e. and fig. 3-22). (4) Open collant hose shutoff cocks. 3-27. Cold Weather Covers Refer to paragraph 3-12. 315ATTACH GROUND LEADS TO EXISTING SHIELD MOUNTING SCREWS, COLD STARTING LEAD LEAD SLAVE RECEPTACLE ¢ AT ure Figure 3-22. Batteries installed—winterization kit —MI23A1C, M123E2, Section IV. ELECTRIC BRAKE 3.28. General The two main components of the electric brake kit are the controller assembly (fig. 3-23) and the theostat (fig. 3-24). The controller assembly is waterproof, 24-volt capacity, and air operated. It transmits an electric current to the truck trailer receptacle. The controller is mounted inside the left side frame member just rear of the eab (fig. 3-28). The rheostat has a 24-volt capacity and regulates electric current to the controller. The rheostat setting corresponds to the capacity of the electric brake system on the towed or trailer load. The rheostat is mounted on instrument panel flange and to right of steering column (fig. 3-24) on the M123, M123C and M125, and on the steer- ing column on the M123A1C, M123E2 (fig. 3-25). 3-16 3-29. Controller Assembly and Rheostat a, Tests and Adjustments. The rheostat setting is directly dependent on the towed load. The light- er the towed load, the smaller the numerical rheo- stat setting. The heavier the towed load, the greater the numerical rheostat setting. The pre- cise setting of the rheostat for a given load would be determined through operation experience. NOTE Maximum braking effort is obtained with the highest rheostat setting and with 56 to 66 psi pressure, in the com- pressed air system. b. Removal. (1) Open air reservoir drain cocks. (2) On truck tractors M123 and M128E2BOGIE (CROSS MEMBER CONTROLLER. ASSEMBLY, Figure 3-23. Controller installed. only, remove intermediate tread plate. (3) Remove rheostat — M128, M128C, M125. (a) Disconnect rheostat harness and con- troller cable from rheostat. (b) Remove screw securing operating lever to rheostat (fig. 8-24). (c) Remove retaining nut and name plate securing rheostat to bracket. Remove rheostat (fig. 3-24). (4) Remove rheostat — M1231C, M128E2. (a) Disconnect rheostat harness and con- troller cable from rheostat (fig. 3-25). (b) Remove two machine bolts, lockwash- ers, plain nuts, and four flat washers securing STEERING COLUMN Figure 3-24. Rheostat installed om flange — M123, M123C, M125. ancostar () HARNESS y STEERING, COLUMN, MOUNTING BRACKET, AT 34782 Figure 3-25. Rheostat installed on steering column — MI23AIC, M123E2. theostat bracket assembly to steering column. Remove bracket assembly (fig. 8-25). (c) Detach rheostat from bracket. (5) Disconnect controller tube from control- ler and from tee on air line (fig. 3-23). (6) Remove three nuts and washers from controller studs securing controller to bogie cross- member. Remove controller (fig. 3-23). ¢. Installation, (1) Position controller to bogie crossmember and secure with three nuts and washers on con- troller studs. (2) Position and connect controller tube to tee and to controller with elbow (fig. 3-23). (8) Install tee to air line, using nuts and sleeves (fig. 3-23). (4) Install rheostat — M123, M123C, M125. (a) Position rheostat to back of mounting bracket. Install name plate and lockwasher. Secure to bracket with retaining nut (fig. 3-24). (b) Insert positioning pin in small hole at bottom of bracket and name plate (fig. 3-24). (c) Install operating lever on rheostat and secure with screw (fig. 3-24). (d) Connect rheostat harness and control- ler to rheostat. (5) Install rheostat — M123A1C, M123E2. (a) Attach rheostat to mounting bracket (fig. 3-25). (b) Install bracket assembly on steering column and secure with two machine bolts, lock- washers, plain nuts, and four flat washers (fig. 3-25). (c) Connect rheostat harness and control- ler cable to rheostat. (6) Close air reservoir cocks. (7) Install intermediate tread plates on M123 and M123E2 models. 317@ APPENDIX A REFERENCES A-1. Publication Indexes ‘The following indexes should be consulted frequently for latest changes or revisions and for new publica- tions relating to material covered in this technical manual. Index of Army Motion Pictures, and Related Audio Visual slides. Index of Administrative Publications. Index of Blank Forms. Index of Doctrinal, Training, and Organizational Publication: Military Publications: Index of Technical Manuals, Technical Bulletins, Supply Manuals (Types 7, 8 and 9) Supply Bulletins and Lubrication Orders A-2. Forms DA Pam 108-1 DA Pam 310-1 DA Pam 810-2 DA Pam 810-3 DA Pam 810-4 Refer to DA Pam 310-2 for current and complete list of blank forms. TM 88-750, The Army Mainten- ance Management Systems (TAMMS), contains instructions on the use of maintenance forms pertaining to this material. A-3. Other Publications Operation and Mafntananes of Army Materia! fm Extreme Cold Weather, 0° to—65° F., (TO 36-1-40) Change 1. Painting Instructions for Field Use. Operator’s Manual: Welding Theory and Application. Operator’s Manual for Truck Tractor, 10-Ton, 6x6, M128, M128C, ‘M123- AIC, M123E2, and Truck, Cargo, 10-Ton, 6x6, M126. : Organizational Maintenance Spare Parts and Special Tools Li Tru Tractor. 10-Ton, 6x6, M123, M128C, M123A1C, M123E2, and Truck Cargo, 10-Ton, 6x6, M125. : Operator, Organizational, DS, and GS Maintenance Manual: Storage Bat- teries: Lead-Acid Type. Lubrication Order for Truck Tractor, 10-Ton, 6x6, M123, M128C, M123- AIC, M128E2, and Truck, Cargo, 10-Ton, 6x6, M125... General Supply: Winterization Kits for Army Tank-Automotive Material.... General Supply: Deep-Water Fording Kits for Ordnance Tank-Automotive Material Tires and Tubes, Pneumatic, Except Aircraft. FSC 2630 Tires, Solid and Cushion. FSC 2640 Tire Rebuilding and Tire and Tube Repair Material Wheeled Vehicles: Inspection, Care, and Preservation During Storage, Change 3. : ‘Tank-Automotive Gasoline Engines: Lubrication Before Use. Ordnance Tracked and Wheeled Vehicle Hull and Chassis Wiring: Rep: of Cracked or Peeled Plastic, Natural Rubber, or Synthetic Rubber- Covered Conduit Cables. Ordnance Gasoline Engines: Correcting Compression Pressure Readings. TM 9-207 TM 9-218 ‘TM 9-237 ‘TM 9-2820-206-10 ‘TM 9-2820-206-20P ‘TM 9-6140-200-14 LO 9-2820-206-12 SB 9-16 SB 9-155 C2610 IL. 2630/40 IL TB 9-300-2/1 TB ORD-392 TB ORD-650 TB ORD-1083 ALAPPENDIX B MAINTENANCE ALLOCATION CHART Section |— INTRODUCTION B-1. General ‘The maintenance allocation chart (MAC) indi- cates specific maintenance operations performed at the proper maintenance levels, on the basis of time, tools, and skills normally available to various maintenance levels in combat situations and influ- enced by maintenance policy and sound maint. ance practices as outlined below. B-2. Maintenance functions ‘The maintenance allocation chart designates over- all responsibility for the maintenance function of an end item or assembly. Repair and/or overhaul of major assemblies is designated by authority of the Commanding Officer, except for the specific functions listed in the maintenance allocation chart. Deviation from maintenance operations al- located in the maintenance allocation chart is authorized only upon approval of the Command- ing Officer. Maintenance functions will be limited to and defined as follows: «, Inspect. To determine serviceability of an item by comparing its physical, mechanical and electrical characteristics with established stan- dards. b. Test. To verify serviceability and to detect electrical or mechanical failure by use of test equipment. ¢. Service. To clean, to preserve, to charge, and to add fuel, lubricants, cooling agents, and air. d. Adjust. To rectify to the extent necessary to bring into proper operating range. ¢. Aline, To adjust specified variable elements of an item to bring to optimum performance. f. Calibrate. To determine the corrections to be made in the readings of instruments or test equip- ment used in precise measurement. Consists of the comparison of two instruments, one of which is a certified standard of known accuracy, to de- tect and adjust any discrepancy in the accuracy of the instrument being compared with the certi- fied standard. g. Install, To set up for use in an operational environment such as an emplacement, site, or vehicle. h. Replace. To replace unserviceable items with serviceable like items. i. Repair. Those maintenance operations neces- sary to restore an item to serviceable condition through correction of materiel damage or a spe- cific failure. Repair may be accomplished at each category of maintenance. J. Overhaul. Normally, the highest degree of maintenance performed by the Army in order to minimize time work is in process consistant with quality and economy of operation. It consists of that maintenance necessary to restore an item to completely serviceable condition as prescribed by maintenance standards in technical publications for each item of equipment. Overhaul normally does not return an item to like new, zero mileage, or zero hour condition, k, Rebuild. The highest degree of material maintenance. It consists of restoring equipment as nearly as possible to new condition in accordance with original manufacturing standards, Rebuild is performed only when required by operational considerations or other paramount factors and then only at the depot maintenance category. Re- build reduces to zero the hours or miles the equip- ment, or component thereof, has been in use. 1. Symbols. The uppercase letter placed in the appropriate column indicates the lowest level at which that particular maintenance function is to be performed. B-3. Explanation of Format The format for the maintenance allocation chart contains five columns and incorporates the use of symbols to represent the five maintenance cate- gories. Purpose and use of the columns and sym- bols are explained as follows: a. Column 1, Group Number. This column lists group numbers, the purpose of which is to identify components, assemblies, sub-assemblies, and mod- ules, with the next higher assembly. b. Column 2, Funetional Group. This column lists the noun names of components, assemblies, sub-assemblies, and modules on which mainten- ance is authorized. ¢. Column 32, Maintenance Functions. This col- umn carries a heading for each of the maintenance functions, defined in paragraph B-2 of this section, 61d. Use of Symbols. Each symbol used in this column represents one of the five categories of maintenance defined as follows: C—Operator/crew O—Organizational maintenance F—Direct support maintenance ‘H—General support maintenance D—Depot maintenance Section e. Column 4, Tools and Equipment, This column specifies by code, those tools and test equipment required to perform the designated maintenance function. f. Column 5, Remarks. This column will list any é special information or instructions required, but defined elsewhere, and required for performance of the designated maintenance function. MAINTENANCE ALLOCATION CHART Maintenance Allocation Chart For Truck Tractor, 10-Tow, 626 And Truck, Carga, 10-Ton, 6 “GROUP 01-ENGINE (DIESEL) ENGINE ASSEMBLY MOUNTING, Engine INSULATORS, Engine mounting HEAD, Cylinder BLOCK SLEEVE, Cylinder BEARINGS, Crankshaft CRANKSHAFT DAMPER, Vibration PULLEY, Drive FLYWHEEL |GEAR, Ring flywheet HOUSING, Fiywheet PISTON & Connecting Rods, Bearing GEARS, Timing /SEALS, Oil, timing gear cover VALVES, Springs, & guides CAMSHAFT PUMP, Oil main and scavenger REGULATOR VALVE, Presure ELEMENT, Oil filter FILTER, Oil Engine JOIL COOLERS ° CRANKCASE BREATHER VALVE LINES AND CONNECTIONS ° PAN, Oil MANIFOLDS ° ‘ACCESSORY DRIVE PUMP. Pr 000 104 ono 0106 sue tteeetsTOOrEs ‘GROUP 01-ENGINE (GASOLINE) ENGINE ° MOUNTING, Engine ° INSULATORS, Engine mounting | © HEAD, Cylinde ° F ° ° o1o1 SLEEVE, Cylinder [COVER. Cylinder block ICOVER, Cylinder head BLOCK 0102 | BEARINGS, Crankshaft F B2 THOT OOOO OR TE TUE EET TTOOREEETOOT EEOCCEOOO™row We o103 o104 ‘10s 106 o108| 0109] 0200] 0202 0301 GROUP 01-ENGINE (GASOLINE) Continued JCRANKSHAFT DAMPER, Vibration PULLEY FLYWHEEL IGEAR, Ring, ywheet HOUSING, Flywheel PISTONS & Connecting Rods, Bearings VALVES, Guides, Springs SEAL OtL TIMING GEAR COVER BEARING, Camsbaft CAMSHAFT Jom SEAL TIMING GEAR COVER PUMP, Oi, engine ELEMENT, Oi fter FILTER, Olt, engine SCREEN, Crankease breather vate ]VALVE, Breather, crankcase LINES AND CONNECTION (EXTERNAL) LINES AND CONNECTIONS JGNTERNAL) MANIFOLDS ACCESSORY DRIVE GROUP 02-CLUTCH HOUSING, Catch BEARING, Pilot DISC, Drives, clutch PLATE, Pressure BEARING, Relewe ciatch |CONTROLS AND LINKAGE, Chueh] FORK, Clutch release bearing BEARING, Chtch crow shaft GROUP 03-FUEL SYSTEM INJECTOR, Feel (died ICARBURETOR (quoline) PUMP, Fuel (gtotine) PUMP, Fuel (dies) |CLEANER, Air (dy, diesel) CLEANER, Air (ol, gsotine) HOSE, Clesner TANK, Foe! FITTINGS, Lines |GOVERNOR, Engine (gxotie) FUEL, Filter ELEMENT, Feet STRAINER GLOW PLUG (diese) RESISTORS (diesel) PRESSURE GAGE (diesel) mzmm0O7 00 © omnmEzr=mo an con zo 20 oo007 on TIT TET IOOE SCCTTIEE LOTT TTT D SOOCSCOTOOOOO TOOT FT mam 7 ” 1528] Pemeree401! 0501 0802 003 0504 osos| 0601 GROUP 03-FUEL SYSTEM-Continued CONTROLS. Choke and throttle (gasoline) CONTROLS, Throttle (diese) ‘CONTROLS, and linkage, accelerator ‘GROUP 04-EXHAUST SYSTEM MUFFLERS AND PIPES ‘GROUP 05-COOLING ‘SYSTEM RADIATOR ‘SHROUD, Radiator fan HOSE, Radiator ‘THERMOSTAT PUMP, Water PULLEY BELT, Fan BLADE, Fan PULLEY, Hub ‘GROUP 06-ELECTRICAL SYSTEM ALTERNATOR GENERATOR BELTS, Drive REGULATOR (M123, M123C, ‘AND M125) STARTER SWITCH, Push button 4123410) DISTRIBUTOR POINT SET CAP, Distributor ‘SPARK PLUGS CAPACITOR ROTOR SHAFT, Distributor ‘con CABLES BREAKER, Circuit BUZZER, Waring, Low pressure INSTRUMENTS. LAMPS LIGHT, Indicator ‘SWITCH, Master and ignition SWITCH, Light and floodlight ‘SWITCH, Dimmer SWITCH, Brake warning ‘SLAVE RECEPTACLE TURN SIGNALS e000 ° DTOOSCOOOO OOOO MOOOOOS Repair in- ‘straighten-LIGHT, Flood (61123, M123C and 1M123A1C) 0610 0611 0612 °° HANGERS AND COVERS, Battery IcaBuzs, 0613] CONNECTOR RECEPTACLE, rater WIRING HARNESSES ° 0615] RADIO SUPPRESSION ‘GROUP 07-TRANSMISSION AND TRANSFER 0700] TRANSMISSION W/TRANSFER SCREEN, Oi strainer BREATHER, Vent PLUGS, Drain e LINE, Oi pump, retum 0701] TRANSMISSION SHAFTS, BEARINGS, SEALS AND GEARS PUMP, Oi POWER TAKEOFF 0704] COVER, Dust, gear shift levers ICOVER, Traner top COVER, Transmission top ‘GROUP 09-PROPELLER SHAFT 0900] SHAFT, Propeter ° JOINT, Univeral GROUP 10-FRONT AXLE 1000] AXLE. BREATHERS, PLUGS 1002] DIFFERENTIAL. FLANGE, Drive 1004] BEARINGS, SEALS ° KNUCKLE, Steering LEVERS, Cros tering END, Drive, front axle SHAFT, Axle GROUP 11-REAR AXLE 1100] AXLE SHAFT, Axle VENTS, Breather ° 1102] DIFFERENTIAL PLANGE, Drive GROUP 12-BRAKES 1201] CAM, Actuatng JCAMSHAFT, Actoatng @ LINKAGE, Brake DRUM, Brake emergency ° °° coo 7 7 00 eooomn0e 0 an SOUT ATOM TTT TTT OTTLDLGED[PEL « GROUP 12-BRAKES- Continued SHOE, Brake ° ° SPRING, Retum CAMSHAFT SHOE, Brake, service ADJUSTER SLACK, Brake LINES AND FITTINGS, Air system ‘CHAMBER BRAKE. RESERVOIRS, AIR c VALVES, Air system c ‘TRACTOR PROTECTION clo VALVE COMPRESSOR, Air (gasoline) ° COMPRESSOR, Air (diesel) GOVERNOR, Air ° LINES AND FITTINGS, ‘Trailer brake COUPLING, Trailer brake assembly ‘VALVE, Hand control ° GROUP 13-WHEELS, HUBS, ‘AND DRUMS BEARING, Hub, front axle BEARING, Hub, rear axle DRUM, Brake, service HUB, Wheel, front HUB, Wheel, rear ° o}o SEALS, Oil hub bearing, front SEALS, Oil hub bearing, rear STUDS AND NUTS, Hub and wheel WHEEL TIRES. clele TUBES GROUP 14-STEERING LINK, Drag DRIVE, Ange, stering STEERING DRIVE PROPELLER SHAFT ‘TIE ROD AND END ojo WHEEL, Steering UNIT, Power steering o|olfo PUMP, Hydraulic steering LINES AND FITTINGS Hydraulic CYLINDER, Power RESERVOIR, Hydraulic, ° 0 steering pump VALVE, Control, steering F F ‘GROUP 15-FRAME AND BRACKETS, FRAME rir BUMPER GUARD, Radiator PINTLE ° ° SHACKLE, Lifting °° SS SSMS SSO SOOTOO °° °° oe m0 o= °° oo SOTSS BIS OOO OCOTOTOOT ° ” SOCoF ount I GROUP 15-FRAME AND BRACKETS~Continued 1504 SPARE WHEEL CARRIER AND TIRE LOCK, WHEEL, Fifth GROUP 16-SPRINGS AND ‘SHOCK ABSORBERS 1601] SPRING, Front SPRING, Rear TRUNNION, Rear spring BUMPERS, Rear spring 1604] ABSORBERS, Shock JOINT, Ball, shock absorbers link 1605] ROD, Torque GROUP 18-BoDY, ‘CAB AND HOOD 1801] BOARD, Running FENDER SHIELD, Mud HOOD CAB Doors WINDSHIELD ‘CUSHION, Seat SEATS STOWAGE RACKS, Boxes and ‘Straps BODY, Cargo TAILGATE RACKS. SEAT, Troop GROUP 20-WINCHES 2001] WINCHES BAND, Brake CABLE, Winch BLOCKS, Pillow LINES, Air (CHAINS, Drive JOINT, Universal ‘SHAFTS, Drive ‘SPROCKETS GEAR BOX CHAMBER, Winch air brake CHAMBER, Tension control VALVE, Control TROLLEY, Winch FAIRLEAD TENSIONER GROUP 22-BODY CHASSIS AND] ‘ACCESSORY ITEMS. 2201] Bows (125) COVER, Body (M125) COVER, Cab top 2202] ARM AND BLADE,Windshield wipe MOTOR, Windshield wiper MIRROR, Rear view 210] PLATES, Vehicle data 1s Matouenane funtion i Halil’ of ofo o fo ° ° ° ofa ° ° ofolo ° ° ° ° ° 8 ° ° DOSOMOO So Soa aaa oom TATOOS TOOOOOOO OF ooo O00 °° oman ebule Hii Remaree 7GROUP 33-SPECIAL PURPOSE KITS 3303] KIT, Winterization (arctic kit) (Diesel) KIT, Winterization (personnel kin) Diesel) KIT, Winterization (dual purpose axctic ki) (gasoline) KIT, Winterization (personnel heates kin (hot wate) HEATER ASSYS (diesel and ‘asoline) HEATER ASSY, Engine and coolant (diesel) HEATER ASSY, Personne! heater (hot water) IGNITER (diesel and gasoline) MOTOR, Heater blower (diesel and gasoline) FUEL CONTROL VALVES FITTINGS, Screens and wicks TUBE, igniter SWITCH, Flame detector SWITCH, Overheat RESISTOR (diesel and gasoline) SWITCH, Limit controt SWITCH, Toggle control box. PUMP, Engine priming BOX, Control (diesel and gasoline) THERMOSTAT, Water (arctic and dual purpose kit) WIRING, Electrical (artic and dual purpose kit) PUMP, Electrical fuel ELEMENT, Fuel filter FILTER, Fuel HOSES AND CLAMPS (sir duct) HOSES, Rubber and clamps (hot water, engine and coolant heaters) COVERS, Radiator, hood and side panels KIT, Electric brake CONTROLLER, Electric, air 3307 operated RHEOSTAT, Electric, brake control ‘GROUP 47-GAGES (nonelectrical) MEASURING DEVICES |SPEEDOMETER ADAPTER, drive ICORE, drive shaft SHAFT, Flexible TACHOMETER 4701 | 2000 °° a) Oo SOOT T TATA o oo000a Accelerator linkage and controls MI23A1C, M1232: ae al ‘Throttle control : 21a 296 ‘Treadle assembly 214 2st Adapter sets tester 219 2a ‘Adjustments: Brakes, hand 2.1660 29 Brakes, service 2.1600 2109 Carburetor 2.600 280 Cluteh : 2-50 2-60 Compressor unloader valve 2m 2184 Distributor and breaker points 2-02 2.108 Drive belts — M128, M1230, M125 2.90 2.99 Drive belts — MI28A1C, M123E2: 20 2.108 Headlights 2123 219 Horn zis 2.126 Tenition timing 2101 2.106 Spark plogs 2104 2110 ‘Throttle and accelerator linkage 21 2.86 Tierod 21954 21m Torin 2.1954 2am Valve tappets M123, M129, M125 253 269 inches 2a 2198 Administrative Storage 15 MM Air cleaner — M123, MIZ9C, M125: Cleaning 2-666 278 Installation 266 278 Removal 2660 278 Air cleaner — M123A1C, MI2SE2: Tnstallation 28% 296 Removal 210 285 ‘Air compressor — M123, M123C, M125: Air-cooled 2.172 2.156 Water-cooled 2170 254 Air pressure gage Installation 2.1580 2145 Removal 2155e 245 ‘Alternator — MIZBA1C, M123E2: Installation 21186 216 Removal 2.1880 26 ‘Alternator Srstem — MI23A1C, MI23E2: Description zat 206 ‘Testing 2 230 Aprons, splash (See Splash aprons, M125, ‘Axles 2159 2146 ‘Axle assembly. front: Breather vents 2-160 1146 Inspection 2.1605 246 Servicing 2.180 2146 ‘Axle assembly. rear: Breather vents 2461 216 Cleaning and Inspection 21610 216 Servicing 261 216 B Batteries: Cleaning 2120 att Installation 21206 2ait Removal 2120 zat Servicing, 2120 216 ‘Tenting 21200 216 4B Continued Battery boxes: Running board Underseat—MI3A1C, M123E2 Battery cables Battery - generator i Installation Removal Battery heating pads, winterization heater: Installation Removal ‘Bearingy, hubs and (See Hubs and bearings Blackout driving light: Installation Lamp installation Lamp removal Removal Blackout marker light: Installation Lamp installa Lamp removal Removal Blackout stoplight Bows, tarpaulin, and end curtains — M125: Bows End.curtains ion ‘Adjustment Brakeshoes Cromshaft and linkage : Drum _ Lever. Brake kit, eletrie: General Controller assembly Rheostat Brakes, service ‘Adjustment Brake chambers (front) Brake eylinders (rear) Brakedrums. Brakeshoes Slack adjusters Brake adjustment, hand Brake adjustment, service Brake application valve: Installation Leakage test Operating test Removal Brake band, winch safety See Safety brake hand, winch) Brake chambers (front: Installation Leakage test Operating teat Removal Brake connector hove and couplings: Coupling wasket replacement Hose assembly Testing hose assembly Brake eylinders rear: nat 2 21220 21220 2121 251 215le 3-280 3-260 24%b Blea Dida 21Mb 2.125 21250 21250 2125 21266 22420 22420 2242 2166 2.1660 2166 2167 2.165 2168 328 3 2169 2.1680 2.184 2185, 219 2169 2170 21660 21690 ae 21a 21a 21 2A8te 21840 2180 2.184b 2.188 21834 2.183 2.185 2419 2ne 2418 aaa 2a 315 ans 2421 2a 2az zag 2aze 2az zag 2a 2123 2204 29 219 219 2150 2148 251 a6 a6 3.16 2151 2151 2467 267 2169 251 258 29 2451 2139 2.159 2.189 2.159 261 2a6t 261 2A6t 2166 2164 267 2468B—Continued Leakage test Operating test Removal Brakeshoe, hand brake: Tnstallation Removal Brakeshoes and lining service: ‘Adjustment Installation Removal Breather valve, erankease — MIZSAIC, MIZ3E2: Installation Removal Servicing Brush guards, upper and lower Bumper, front — M128, MI2SC, MI23A1C, MIZE. Installation Removal Buzzer, low alr pressure: Installation Removal ‘Cab components Cabeover Cabseats Windshield ‘Windshield wiper assembly Cabeover: Installation Removal Stowing (Cab seats, cushion: Installation Removal (Cable, winch: ‘Adjustment Installation Removal (Carbaretor — M128, M129C, M125: ‘Adjustment Cleaning. Installation Removal Testing... . Carburetor controls and linkage: ‘Choke control ‘Throttle control ‘Treadle assembly (Cargo body components — M125... ‘Bows, tarpaulin, and end curtains. ‘Spare tire carrier Spare tiredavit ......... ‘Stowage racks, boxes, and: ‘Towing pintle stowage ‘Troop seats. (Caution plates (See Name, caution, and instruction plates) ‘Chambers, front brake (See Brake chambers, froat) (Check valves, double: Installation Leakage teat Operating test Removal ..... ‘Choke control 21850 2185 2.1850 266d 21666 21680 21686 21696 22016 220le oe: i 3 GSS3 EERE GDP F evi RES BBB 2aTte 217 21% 2177 26a 267 2st 2168 2.150 2.150 2ast 2.453, 25 2179 2190 2.190 215, 215, 2461 2160 2.160 2161 29© —Continued Circuit breakers: Installation Removal Circulating fuel pump — MI23A1C, MI23E2: Installation Removal Clutch controls and linkage: Adjustment Installation Removal Coil. ignition (See Ignition coil assembly Cold weather covers, winterization kit Composite light — MI23A1C, MI23E2: Installation Lamp replacement Removal Compressed air system Compression tests — M123, MI23C, M125 Compressor governor: Installation Leakage test Operating test Removal Control cables, xasoline heater Control cables, hot water heater Control valve, hand: Installation Leakage test Operating test Removal Control valve, two-way — MI23A1C, M123E2 Controller assembly, electrie brake: Installation Removal Test and adjust Controls, clutch (see Clutch assembly) Coolant heater assembly — MI2BAIC, MI23E2: Installation Removal Coolant heater exhaust tube — MI23A1C, M123E2: Installation Removal Coolant hose and shutoff cock — MI23A1C, M123E2: Installation Removal Cooling system — M123, M129C, M125: Deseription Servicing Cooling aystem — MI28AIC: Deseription Servicing Covers, rankease — M123, M123C, M125: Cleaning and inspection Installation Removal Cross-ahaft and linkage, hand brake: Tnetallation Removal ‘Curtains, and (See Bows, tarpaulin and end curtain) (Cylinder head — M123, 1128, M125: Inspection Installation ry 2.1986 2.1360 3.230 2.500 2.50 2.500 32 2.139 2.1380 21396 2471 254 24T8 21780 21%%0 2473 aul 34 2.178 21T8e 2.1T8« 2178 2181 3.2% 3296 3.290 az 2a au 313, 315 2190 ry 2190 2.54 2m 2.159 2-188 2.188 2.159 32 261 261 261 261 2.163 316 36 316 313 Sry su a au au 2401 2101 aT 278 2m 273 2ast 2.180 2m 213C—Continued Removal Cylinders, rear brake (See Brake cylinders, rear) D o---: eaten M23, M129, MIES— (ee Vibration damper, M8, 10,85) Damp tentinn MIBIAIC MINES ~ ne Vinton Sur MIA MISES oo ise ‘mune or Devt opr tie se Spr tie ee ees oes a Deep aad Dn uae Facer Deerccon of hrm materi preva ebm nS 608168) Stren wtcconvovahe traagetat paar eae meee eas or Direct! spa cor iaai6 Mis enue oa Directina salt ov hae = Det! sli ron os it, M25) tional signal lights (rear) Distributor and ignition coil assembly: Installation Removal Diverter assembly, hot water heater — M123, M129C, M125 Drag li ‘Adjustment Inspection and repair Installation Removal Drawbar and yoke block — M125 Drive belts — M128, M1230. M125: ‘Adjustment Inspection Installation Removal Drive belts — M123A1C, M1232: ‘Adjustment Inspection Installation Removal Drive chain, winch: ‘Adjustment Installation Removal Drom, hand brake: Inspection Installation Removal 318 $184 11 16 2178 21198 21798 21796 213% 21828 2145 21450 2.138 21354 21356 21250 2.1250 2126 2128 2102 21028 219e 216 219d 2194b 2910 291 291d 29% 22810 2281e 2231b 2165 2.165. 2.1650 21 2.180 2.180 an an MM MM 262 2161 2161 2162 2106 216 2.188 2138. Por 2am 2a iz ize 2128 2128 2107 2107 2am 2am 2am 21m 2103 2103 2.108 2103 2.196 3-196 2.196 29 249 29D—Continued Drum, service brake: Installation (front Installation (rear? Removal front) Removal (rear? Electrical troubleshooting, Alternator Batters Generator Glow plug — MI23A1C, M123E2 Ignition — M128, M123C, M125, Lighting Monitor gages and sending units Power loss test — M123, MIZ3C, M125 Power loss test — MIZSAIC, MIZ3E2 Regulator, voltage Starter — M123, M1230, M125 Starter — MI23A1C, MI23E2 Starter switch test — M123, MI23C, M125, Engine — M123, M123C, M125: Data Description Engine — M123A1C, MIZ3E2: Date Description Engine maintenance, in vehicle — M123, M123C, M125, Air cleaners, remove, service and replace Carburetor. adjust, remove and replace ‘Compression test ‘Compressor, adjust and replace ‘Compressor air strainer, replace ‘Compressor governor, adjust and replace ‘Crankease covers, replace Crankease ventilation regulator, replace and service Cylinder head and cylinder head gasket, replace tor, adjust and replace itor breaker points, adjust or replace Distributor capacitor, replace Drive belts, adjust and replace Engine mounts, replace Fan, replace Fuel lines and fittings Fuel pumps, test or replace Gaskets (manifold, replace Generator, replace Generator regulator, replace Hydraulic lines, replace Hydraulie pump, replace Hydraulic reservoir, replace Ignition wiring, replace Manifolds, replace filter, service and replace Radiator assembly, service, clean, and replace Radiator hose, replace ‘Spark plugs, clean, adjust or replace Starter, replace ‘Thermostat, test and replace ‘Vacuum test ‘Valves, adjust 6 EESREGRRER spends Siegat RGRGRRESESEES PettE Continued ;ngine maintenance, in vehicle — MI23A1C, M123E2 ‘Air cleaners, remove, service and replace Alternator, replace ‘Compressor governor, adjust or replace ‘Crankease breaker valve, service and replace Drive belts, adjust or replace Engine mounts, replace Fan blades, replace Fan pulley, replace Fuel lines and fittings Fuel shut-off solenoid, replace Hydraulie pump, replace... — Manifolds, replace Oil cooler, test and replace Oil filter full-flow and element, service and replace. Oil filter by-pass and element, service and replace. Radiator assembly, replace ‘Thermostat, tet and replace : ‘Throae and severator contraband inka, art androplace Vibration damper, replace ‘Water pump, replace Engine starting aids — M123A1C, MI23E2 Glow plug Pressure gage Resistor Errors, reporting of: Exhaust pipe — M123, M1280, M125: ‘Cleaning and Inspection Installation?-Ste Removal Exhaust pi ‘Cleaning and Inspection Inatallation Removal Exhaust system, description of, Fan — M128, M1290, M125: Installation Removal Fan — Mi22A1C, M1Z3E2: Installation Filter, by-pass oil — MI23A1C, Mi2aE2: Element replacenient Filter body replacement Filter, full-flow oil — MI23A1C, M128E2: Element replacement Filter body replacement Filter, gasoline heater fuel — M128, M1290, M125: lement replacement. Filter body replacement Filter, triple stage fuel — M123A1C, M123E2 (See Triple stage fuel filter M128A1C. M123E2) 2118 216 2.158 2-108 2104 2104 281 aan 258 255 255 2401 2102 2a 2.102 g BEE 2.90 g ML 254 2m 2Floodlight — M128, M123C, M123A1C, 12362: Installation Lamp replacement. Removal Forms, records, and reports Frame uel eage: Installation Removal Testing Fuel lines and connections — M123, M1123C, M125 Fuel lines and fittings, heater — MI23A1C, M123E2: Fabrication Installation Removal Fuel pump, gasoline heater Fuel pump, heater — MI28AIC, M1292 Installation Removal Servicing. Fuel pumps — M123, M123C, M125: Cleaning. Installation Fuel shutoff solenoid — MI23A1C, M123E2: Installation Removal Fuel system — M123, M1290, M125, Description of Fuel system — MI23A1C, M129E2, Description of Fuel tanks — M123, M123C, M125: Draining. Filling Installation Removal uel tanks MI23A1C, 12362: Installation Removal Gages Gear box roto-chambers: ‘Adjustment Installation Removal Generator and generator pulley — M123, M123C, M25: Installation Polarization Removal Generator system — M128, M1290, MIZ5: Deseription Testing Glow plug — MIZ3A1C, MIZ3E2: Installation Removal Governor. compressor (See compressor governor) Handbrake lever: Installation Removal ry F Continued 2.1305 2.1300 2.1806 12 2199 152 21528 2160 Bee 166 abe 185 $150 2.100 270d 2.108 2.100 2.166 2.160 2m ane 2n6 2m ane 219 2280 228% 2231 218 2ANbe 2a 2a 2H 21% 21a 2.168 21684 2125 r es 36 215H—Continued Harnesses — M123, M123C. M125: Inspect and Repair Installation Removal Harnesses — MIZ3AIC, MI23B2: Inspect and Repair Installation Removal Headlights: Adjustment stallation Lamp unit installation Lamp unit removal Remoral Heater assembly, yasoline Heater assembly, hot water heater Heater control box — MIZ3AIC, M123E2: ‘Assembly Disassembly Installation Removal Heater and defroster ducts — MI23A1C, MI23E2 Installation Removal Heater emergency switch — MIZ3A1C, MI23B2: Installation Removal Heater, personnel — MIZ8AIC, M123E2: Installation Installation Removal Heater kit, gasoline: Cold weather covers Control cables Fuel filter Fuel pump Heater assembly laniter assembly Priming pump Heater kit, hot water personnel: Control cables Diverter assembly Heater assembly Heater kit, winterisation — arctic zone — MIZ3AIC, MI23B2 Battery heating pads Circulating pump Cold weather covers Coolant heater assembly Coolant heater exhaust tube Coolant hose and shutoff cock Defroster and air controls uel lines and fittings Fuel pump General Heater control bos Heater and defroster ducts Heater emergency switch Personnel heater Personnel heater exhaust tube High beam indieator light 21480 2lded 2ldse 2ds_ 21486 248d 21de 2dBe 21230 2128 21288 21280 2.128 32 3200 321b 32a 3.19 3.190 310 3140 31% te 312 3 39 38 31 310 ae 312 312 312 a3 313 az a2 35, 3, 35, 33, aa au aa 10 9 a2 a3, a2 10 Bap 19H—Continued Horn Adjust Installation Removal Horn switch: Installation Removal Hoses, water: Inspection Removal Hubs and bearings: Installation and removal (front) Refer to TM 9-2320-206-4 Installation and Removal rear Hydraulic steering pump — M123, M129C, M125: Installation Removal Hydraulic steering pump — M128A1C, M123E2: Installation Removal Hydraulic reservoir — M123, MI29C, M125: Hydraulic Lines Installation Removal Hydraulic reservoir — MI23A1C, MI23B2: Installation Removal Identification and Tabulated Data Idler pulley — M128, M1230, M125: Installation Removal Igniter assembly, gasoline heater Ignition coil assembly Ignition switeh: Installation Removal Testing Ignition system — M123, M1230, MI: Deseription and data Testing, Ugnition timing — M123, M1230, M125 Instruction plats (Ser Name, caution, and instruction pte Instrument cluster Installation Removal Instrument cluster, gages, buzzer, and sending units, deveription of L Lever, hund brake (Ser Hand brake leve Light site Installation Removal Lighting, special —-MIZIAIC, Composite light Directional signal control Marker light control flasher Taille Turn xxl tight Warning light Warning lit tone site Liuhting system: Deseri Testing ‘ao 21840 21340 21340 2184b 218 2.1906 2.1906 2.1966 2.1960 2.198 2.1980 219 2910 2I9te 28h 21980 7 29 29a 37 210m 2.108 2105 2b 2100 23 2101 26 2125 2126 2126 2.126 2am 2176 21% 2am 217 MW 210 298 2-10 20 2110 2L—Continued Q on wie = es = Magnetic swi Installation Removal Maintenance allocation (See appendix B) Maintenance forms and records. Maintenance, preventive General procedures Recording repairs Specific procedures. ‘Manifolds, intake and exhaust—M123, MIZBAIC, M125: Installation Removal Manifolds, intake and exhaust—M123A1C, M123E2: Cleaning and inspeetion Installation (exhaust) Installation (intake? Removal exhaust) Removal (intake? Marker light—MI23A1C, MI23B2: Installation Removal e Master switch—M123A1C, MI23E2: 9, Starter —M128, M12IC, M125: Installation Removal ‘Materiel used in conjunction with major item: Gasoline heater kit Hot water personnel heater Mirror, rearview: Installation Removal Mounts, engine—M123, M123C, M125: Installation Removal Mounts, engine—M123A1C, MI23E2: Installation Removal Mutfier: Cleaning and Inspection Installation. Removal ‘Name, caution, and Installation Removal Oil cooler—MI23A1C, MIZ8E2: Installation Removal Testing Oil pressure wage: Installation Removal | Testing 24te 24% 241d ate 28 2.1086 21080 12 29 2 210 212 248 2485 2.1405 21400 21a 21180 at 2.2456 ERE TE EEE i 2.2460 fe EEE uEE i phbesPanel lights: Installation Lamp replacement Removal Parking lights: Installation Lamp installation Lamp removal Removal Parts, maintenance repair Paulin (See Bows, tarpaulin, and end curtains M125) Pintle assembly: ‘Assembly ‘Cleaning and Inspection Disassembly Installation Removal Pillow blocks: Cleaning and Inspection Installation Removal Pressure xage—| Installation Removal Primer pump: Installation Removal Propeller shafts Installation Removal Slip joint removal and installation Universal joint repair Pulley, idler—M123, M1290, M125: Installation Removal Pump, fuel priming Pump, gasoline heater priming Pump, hydraulic (See Hydraulie pump, M128, M129C, M125) Pump, hydraulic (See Hydraulic pump, M128A1C, MI2SE2) Pump, water (See water pump) 123A1C, MIZ3E: @ Quick release valves: Installation Leakage test Operating test Removal Radiator—Mi23, M128C, M125: Inspection Installation Removal Shroud Replacement Radiator—MI23A1C, M123E2: Tospection Iostallation Removal : a Shroud replacement. : +12 2128 21280 2128 2795 2.19% 2496 249 2162 2162 21628 2163 2163 291b 2910 249 10 21166 21160 2160 2.116 zat etd 2ete 28Te 2946 2.940 2c 28s 218s 2st 2a 2st 2.195, 29 2a 20 296 2.102 2.102! 24101 2102Continued Radiator shield support, upper: Installation Removal Radio interference suppression—M123, M129C, M125 Bonding Generator Ignition and starting : Receptacle, trailer coupling (See Trailer coupling receptacle) References (See appendix A) Relator. wenerator—M123, M123C, M125: Installation Removal Testing — Regulator. ventilation—M123, M123C, M125 (See Ventilation regulator —M128, M129C, M125) Repairs, recording Reporting of errors Reservoirs, air: Installation Removal Reservoir, hydraulic (Sev Hydraulic reservoir—M123, M129C, M125) Resistor, starting aid—MIZ8AIC, MI23E2: Installation Removal Rheostat, electric brake: Installation Removal ‘Test and adjust Rocker arms—M123, M1230, M125: Installation Removal 8 Safety brake band, winch Scope ‘Seats, cab (See Cab seats) ‘Seats, troop (See Troop seats, M125) ‘Sending units Installation Removal Testing Service: Correction of deficiencies Preliminary services ‘Shackles, towing (See Towing shackles) Shaft, steering drive (See Steering drive shaft) Shafts, propeller (See Propeller shafts) Shafts, rocker arm—M123, M123C, M125 Shearpin, winch: Installation Removal Spare tire davit— M125: Installation Removal Spark plugs: ‘Adjustment Cleaning and inspection Installation Removal Spark plug cables: Installation Removal Speedometer: Installation Removal 220% 231/38 2am 21a 2536 220Kb 2220 22a» 22a 206 210% 210M 21040 2036 2.103 227 22a v 2.180 2.180 at 251 281 251 2s 25. 259 2159 ait 3.16 316 13.‘8—Continued ‘Speedometer drive adapter: Inguallation Removal ‘Speedometer flexible di Installation Removal ‘Spring suspension, front ‘Spring suspension, rear ‘Springs front: Installation Removal Springs rear: Installation Starter—MIZ3AIC, MI23E2: (Cleaning and Inspection Installation Removal ‘Starter solenoid—MI23A1C, M123E2: ‘Starter awiteh—MIZ3AIC, MI23E2: Installation Removal Starter system—MI23, M1230, M125: Starter system—MIZIAIC, MIZE: Description Testing Steering system ‘Steering wheel: Installation Removal ‘Spotlight ‘Stoplight wwiteh: Installation Removal ‘Storage instructions, (See TM 740-9041) ‘Stowage racks, boxes, and xtrape: Installation Removal Stowage rack, towing pintle (Ser Towing ‘Suspension, spring (See Spring suspension? Switch, low air presure: de stowage rack, M125) Tables, list of: Table 2-1 Special too Table 2-2, Preventive maintenance checks and service ‘Table 23. Spark plug cables Table2-4. Instrument pane! circuits ‘Tachometer: Installation Remoral 414 2.2496 22490 2241 22a ant 2215 2212 22120 221% 22114 2232 2280 210% 21016 24106 210% 21108 2110e 21100 24th 2atla 2112 21 2.108 2100 219 29h 21988 2125 2.13% 215 2225b 245% 2A5te 2108 2.105, 2248 2280 2.186 2186 2196 2196 2a 22 zu 2a ana 2113 2u3 2a 2u3 aan 2 an 231 23 27 2 2B 2a 28 2136 2188 2.188 2145 215, 2.109 2ano| 220 2201Tachometer drive adapter: e Tnoalaon Removal Tacoma xine instalation Removal raion Tali —MiZBAiC, Mize Tatlin Lamp repncment Removal Tate lealng and inapctin | Installation Renova Topps M19, WIRD, MiB, eaten of Temperatre ae: Tonalaton Removal Teng enlace ee Cal tno Temi conta chanber innallaton Removal Teseauipment Ter ow voltae cc Tater uncon and we enealintrctos Thermontat IER MIRC Ms Installation e Teme Teating ‘Thermostat—M123A1C, M123E2: Installation Removal Testing ‘Throttle control—M123, M1230, M125 ‘Throttle control—MI23A1C, MI23E2 Tie rod: ‘Adjustment Installation Removal - Tire carrier. spare (See Spare tire carrier, M123) Tire carrier. spare (See Spare tire carrier, M125) Tire inflation valve: Installation Leakage test Operating test Removal ‘Tires, tubes, and ris Inflation Installation Removal ‘Toe-In adjustment ‘Tools and equipment ‘Tools and equipment, special Torque rods: Installation Removal: Torque specifications ‘Towing pntie stowage—M 125: Instatation Removed T —Continued 22496 2.2490 22486 2.2480 2126 2142 2124 2142 282 2.153 21534 2.239 2.2380 217 218 220 289 2890 2.96 2.966 261 2a 2.1950 2.195 21956 2182 2.1824 21828 2.1825 2191 21916 21916 2.195, 25 2.2166 2.2160 Me 2.2086 22080 2208 220 2a 2131 2st 231 291 289 2a Me 2202 29 220 22 22 2.108 2102 2.108 2am 2115 2175 2.164 2-164 2.164 2.164 2173 2173 273 2am 2 2 2.185, 2.185, 15. 2183 2.183 415T—Continued Rear—M123, M123C, MI2SA1C, and M123B2 Rear—M125 ‘Tractor protection valve—MIZ3AIC, M123E2 ‘Trailer coupling receptacle: Installation Removal ‘Transfer (See Transmission, transfer, and power takeoff) ‘Transmission, transfer, and power takeoff ‘Servicing ‘Tread plates, winch (See Winch tread plates) ‘Treadle assembly—M123, M123C, M125, ‘Treadle assembly—MI23A1C, M123E2 ‘Triple stage fuel filter—MI23A1C, M123E2 ‘Troop seats—MI25: Installation Removal ‘Troubleshooting: Blectrical system Vehicle ‘Troubleshooting table, vehicle ‘Tubing and fittings: ‘Turn signal light —M128A1C, M123E2: Installation Lamp replacement Removal Universal joint: ‘Assembly Cleaning Disassembly General ‘Vacuum vest—M123, M1280, M125 Valve, brake application (See Brake application valve) Valve, erankease breather (See Breather valve, crankcase) Valve, differential brake control (See Differential brake control valve) Valve, double check (See Check valve, double) Valve, hand control (See Control valve, hand) Valve, quick release (See Quick release valve) Valve, tire inflation (See Tire inflation valve) Valve, tractor protection (See Tractor protection valve) Valve, two-way control (See Control valve, two-way) Valve clearance adjustment— M128, M128C, M125 Ventilation regulator—M123, M123C, M125: Installation Removal Servicing Vibration damper—M128, M123C, M125: Installation Removal Vibration damper—MI23A1C, MI23E2: Installation Removal ‘Warning light—M123A1C, M1232: Installation Removal 16 220 2207 22016 2.180 21% 2120 281 28% 2b 245 2.222 216 213 244 2a4ib 2dle 21416 2.168 21636 2.168 2.1630 258 261e 26a 2616 2.580 242 21436 28a 2ast 2st 2st 2-162 zaat 218 279 2ast 2181 29 28 281 2130 2130 2130 nu 248 zur zur an 215 215 275 244 244 24 & 21g‘W—Continved Installation Removal Water pump—M123, M128C, M125: Installation Remov ‘Water pump—MI23A1C, M1232: Installation Removal ‘Wheel, fifth ‘See Fifth wheel) steering (See Steering wheel) Wheel and tire assembly: General Installation front axle) Installation rear axle) Removal front axle) Removal rear axle) Wheel Nut Wheels, drums, and hubs Winch air valves: Installation Removal Winch, Air lines Winch brake— M123, M123C, M125, and M12BA1C: ‘Adjustment Installation Removal Winch brake—MI23E2: ‘Adjustment Installation Removal Winch tread plates: Installation Removal Winch universal joint: ‘Assembly Disassembly Winches and components Winches, adjustment of, Windshield: Installation Removal Windshield wiper assembly: Installation Removal Wiper assembly, windshield (See Windshield wiper assembly Wiring cireuits Yoke block (See Dravsbar and yoke block, M125) Mab Bide 2925 2.995 2.1880 2.1886 288d 2188 21884 2.188 2187 2238 2238 22416 2ule 2234b 22340 2235 22m 22196 221% 22ub 2a 233 232 2.100 2.100 2.105, 2.105 2.168 2-168 2169 2168 2.169 2.168 2.168 zat 2am 2190 2198 2ast 2M 2.205, 2205, «a73 Order of the Secretary of the Army: 6 W. C. WESTMORELAND. | General, United States Army Official: Chief of Staff. VERNE L. BOWERS, Major General, United States Army, The Adjutant Generul DISTRIBUTION: ‘To be distributed in accordance with DA Form 12-88, organizational maintenance requirements for Truck, Tractor, 10Ton, 6x6, and Truck, Cargo, 10 Ton, 6x6, M128, and M125. % U.S, GOVERMENT PRINTING OFFICE : 1990 0 - 261-872 (20573)PIN : 027234-000 IQ Ie