freightliner con ddec.pdf

TM 9-2320-302-20

UNIT MAINTENANCE MANUAL

FOR

TRUCK, TRACTOR, LINE HAUL:52,000 GVWR, 6 X 4, M915A3

(NSN 2320-01-432-4847)

Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

May 2001

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTENOTEA vertical line in the outer margins of the page indicates the portion of text affected by the change. Changesto illustrations are indicated by miniature pointing hands. Change to wiring diagrams is indicated by shadedareas.

Dates of issue for original and change pages/work packages are:

Original 28 May 2001Change Not Applicable

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 52 AND TOTAL NUMBER OF WORK PACK-AGES IS 236 CONSISTING OF THE FOLLOWING:

Page/WP *Change

No. No.

Cover (Back Blank) 0A (B Blank) 0a to h 0i to vii (viii Blank) 0WP 0001 00 to 0236 00 0Index-1 to Index-18 0FO-1 and FO-2 0Authentication Page (Back Blank) 0Sample DA Form 2028-2 0Blank DA Form 2028-2 0Metric Conversion Chart 0Back Cover 0

* Zero in this column indicates an original page or work package.

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This Page Intentionally Left Blank.

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WARNING SUMMARYWARNING SUMMARYThis warning summary contains general safety warnings and hazardous materials warnings that must be understood and

applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injuryor death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical man-ual.

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses thatpresent a danger to life or health.

CHEMICAL - drops of liquid on hand shows that the material will cause burns or irritation tohuman skin or tissue.

EAR PROTECTION - headphones over ears shows that noise level will harm ears.

ELECTRICAL - electrical wire to arm with electricity symbol running through human body showsthat shock hazard is present.

EYE PROTECTION - person with goggles shows that the material will injure the eyes.

FIRE - flame shows that a material may ignite and cause burns.

FLYING PARTICLES - arrows bouncing off face with face shield shows that particles flyingthrough the air will harm face.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential fromimproper lifting technique.

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HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life orlimb.

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.

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FOR INFORMATION ON FIRST AID, REFER TO FM 21-11.

WARNINGWARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body ofoxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms ofheadache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damageor death can result from severe exposure.

Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide canbecome dangerously concentrated under conditions of inadequate ventilation. The following precau-tions must be observed to ensure safety of personnel when engine of truck is operated.

1. DO NOT operate truck engine in enclosed areas.

2. DO NOT idle truck engine without adequate ventilation.

3. DO NOT drive truck with inspection plates or cover plates removed.

4. BE ALERT for exhaust poisoning symptoms. They are:

Headache

Dizziness

Sleepiness

Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:

Remove person from area.

Expose to fresh air.

Keep person warm.

Do not permit physical exercise.

Administer cardiopulmonary resuscitation (CPR), if necessary.

Notify a medic.

6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection will not protect you from car-bon monoxide poisoning.

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

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WARNINGWARNING

ADHESIVES AND SEALING COMPOUNDS

Adhesives and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin andclothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If adhesive orsealing compound contacts skin or clothing, wash immediately with soap and water.

WARNINGWARNING

AIR LINES AND FITTINGS

DO NOT disconnect any air system lines or fittings unless vehicle engine is shut down and air systempressure is relieved. Failure to follow this warning could result in serious injury to personnel.

Ensure that all air lines and fittings are clear of debris and excess pipe sealing compound does not enterair lines or fittings. Failure to follow this warning could result in injury to personnel and damage toequipment.

Always wear eye protection when disconnecting air lines. Residual air will be expelled. Failure to fol-low this warning may result in serious eye injury.

WARNINGWARNING

BATTERIES

To avoid eye injury, eye protection is required when working around batteries. DO NOT smoke, useopen flame, make sparks or create other ignition sources around batteries. If a battery is giving offgases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches,and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating,injury to personnel, and damage to equipment.

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makescontact with skin, eyes or clothing, take immediate action to stop the corrosive burning effects. Failureto follow these procedures may result in death or serious injury to personnel.

1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immedi-ately.

2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attentionas required.

3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Followwith milk of magnesia, beaten egg or vegetable oil. Seek medical attention immediately.

4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with bak-ing soda or household ammonia.

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WARNINGWARNING

BRAKES

When caging brakes, block wheels to keep truck from moving when brakes are released. Failure to fol-low this warning may result in death or injury to personnel or damage to equipment.

Brake chamber contains spring under great pressure. To prevent personnel injury, never work directlybehind chamber. If caging bolt will not engage properly, spring may be broken.

DO NOT remove clamp ring around spring brake chamber. It is under tension and can cause personnelinjury if released.

When spring brakes are applied, vehicle will stop quickly which could result in injury to personnel.Also, vehicle cannot be driven again until malfunction is repaired and enough air supply is present foroperation of service brakes.

WARNINGWARNING

COMPRESSED AIR

Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi(207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to person-nel.

WARNINGWARNING

DIESEL FUEL HANDLING

DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames orsparks. Fuel may ignite, causing injury or death to personnel and damage to vehicle.

Fuel vapors are toxic. Avoid prolonged exposure or breathing of fumes. Work in a well-ventilated area.Failure to follow this warning could result in serious injury to personnel.

WARNINGWARNING

ETHER QUICK-START SYSTEM

Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilatedarea away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes andavoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantitiesof clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation.Failure to follow this warning may cause death or serious injury to personnel.

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WARNINGWARNING

FIRE EXTINGUISHER

Discharging large quantities of dry chemical fire extinguisher in cab may result in temporary breathing diffi-culty during and immediately after the discharge event. If at all possible, discharge fire extinguisher fromoutside the cab. Ventilate cab thoroughly prior to reentry.

WARNINGWARNING

HAZARDOUS WASTE DISPOSAL

When servicing this vehicle, performing maintenance, or disposing of materials such as engine coolant,transmission fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardouswaste disposal center or safety office for local regulatory guidance. If further information is needed, pleasecontact The Army Environmental Hotline at 1-800-872-3845.

WARNINGWARNING

HEARING PROTECTION

Hearing protection is required when operating vehicle at more than 45 mph (72 kph) with windows open foran extended period of time. Hearing protection is also required when personnel are within 1 meter (3.1 ft) ofvehicle when operating at low engine idle (600 rpm) and within 3.5 meters (11 ft) of vehicle when operatingat high idle (1600 rpm). Failure to follow this warning may result in hearing damage.

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WARNINGWARNING

NBC EXPOSURE

If NBC exposure is suspected, all air cleaner media should be handled by personnel wearing protectiveequipment. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.

To order this NBC decal use:National Stock Number (NSN) - 7690-01-114-3702Part Number (PN) - 12296626Commercial and Government Entity Code (CAGEC) - 19207

WARNINGWARNING

PRESSURIZED COOLING SYSTEM

DO NOT remove radiator cap or drain antifreeze unless engine is cold. Remove radiator cap in two steps.First, place a thick cloth over cap and slowly turn cap left to first stop. Pause and allow pressure to escape.Turn cap further left until it can be removed. This is a pressurized cooling system and escaping steam, hotwater or coolant will cause serious burns.

WARNINGWARNING

R-134A REFRIGERANT

Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Use careto prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if youcome in contact with refrigerant.

Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with com-pressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, whichcould cause personnel injury.

DO NOT work in an area where refrigerant may contact an open flame or burning material such as acigarette. When refrigerant contacts extreme heat, refrigerant breaks down into poisonous phosgene gaswhich, if breathed, causes severe respiratory irritation. DO NOT breathe fumes from an open flame leakdetector.

WARNINGIF NBC EXPOSURE IS SUSPECTED ALL AIRFILTER MEDIA WILL BE HANDLED BY PER-SONNEL WEARING FULL NBC PROTEC-TIVE EQUIPMENT. SEE OPERATOR/MAINTENANCE MANUAL.

7690-01-114-3702

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WARNINGWARNING

SLAVE STARTING

When slave starting truck, use NATO slave cable that DOES NOT have loose or missing insulation.

DO NOT proceed if suitable cable is not available.

DO NOT use civilian-type jumper cables.

WARNINGWARNING

TIRE CHANGING

Whenever wheel lug nuts require tightening or a wheel has been removed and replaced, lug nuts must betightened to the required torque. Failure to follow this warning may result in serious injury to personnel anddamage to equipment.

WARNINGWARNING

TOWING

Brakes will be released when air is applied to a disabled vehicle. DO NOT connect air lines to a disabledvehicle without blocking wheels and connecting tow bar between vehicles. Failure to follow this warningcould result in death or injury to personnel and damage to equipment.

WARNINGWARNING

WORK SAFETY

Hydraulic jack is intended only for lifting truck, not for supporting vehicle to perform maintenance.DO NOT get under truck after it is raised unless it is properly supported with blocks or jackstands.Failure to observe this warning may result in death or injury to personnel.

Use extreme caution when handling heavy parts. Provide adequate support and use assistance dur-ing procedure. Ensure that any lifting device used is in good condition and of suitable load capac-ity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning mayresult in death or injury to personnel.

Improper use of lifting equipment and improper attachment of cables to vehicle can result in seri-ous personnel injury and equipment damage. Observe all standard rules of safety.

ALWAYS install hood prop after opening hood. Failure to follow this warning could result insevere injury to personnel.

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TECHNICAL MANUAL HEADQUARTERSTM 9-2320-302-20 DEPARTMENT OF THE ARMY

Washington, D.C., 28 May 2001

UNIT MAINTENANCE MANUAL

FOR

TRUCK, TRACTOR, LINE HAUL:52,000 GVWR, 6 X 4, M915A3

(NSN 2320-01-432-4847)

Table of Contents

PageNumber

Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aHow to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION

WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1WP 0002 00 Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1WP 0003 00 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

CHAPTER 2 UNIT TROUBLESHOOTING PROCEDURES

WP 0004 00 Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1WP 0005 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1WP 0006 00 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1WP 0007 00 DDEC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-1WP 0008 00 Exhaust System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1WP 0009 00 Cooling System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1WP 0010 00 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1WP 0011 00 Transmission and Driveline Systems Troubleshooting . . . . . . . . . . . . . . . . . . . 0011 00-1WP 0012 00 Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1WP 0013 00 Anti-lock Brake System (ABS) Troubleshooting and Testing . . . . . . . . . . . . . 0013 00-1

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the pro-cedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment TechnicalPublications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internetaddress is http://aeps.ria.army.mil. If you need a password, scroll down and click on ACCESS REQUESTFORM. The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill outthe form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your com-ments and better manage the DA Form 2028 program. You may also mail, fax or e-mail your letter, DA Form2028 direct to: AMSTA-LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is: [email protected]. The fax number is DSN 793-0726 orCommercial (309) 782-0726.

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Table of Contents - Continued

PageNumber

WP 0014 00 Air System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1WP 0015 00 Steering System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1WP 0016 00 Chassis and Fifth Wheel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1WP 0017 00 Air Conditioning System Troubleshooting and Testing . . . . . . . . . . . . . . . . . . 0017 00-1WP 0018 00 Collision Warning System (CWS) Troubleshooting . . . . . . . . . . . . . . . . . . . . . 0018 00-1

CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS

WP 0019 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1WP 0020 00 Unit Preventive Maintenance Checks and Services (PMCS) Introduction . . . . 0020 00-1WP 0021 00 Unit Preventive Maintenance Checks and Services (PMCS). . . . . . . . . . . . . . . 0021 00-1WP 0022 00 Oil Fill Tube Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1WP 0023 00 Oil Level Dipstick, Tube, and Adapter Replacement . . . . . . . . . . . . . . . . . . . . 0023 00-1WP 0024 00 Oil Filter Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1WP 0025 00 Oil Cooler and Oil Filter Adapter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1WP 0026 00 Oil Sample Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1WP 0027 00 Air Compressor Discharge Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1WP 0028 00 Air Compressor Governor Replacement and Adjustment . . . . . . . . . . . . . . . . . 0028 00-1WP 0029 00 Air Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1WP 0030 00 Fuel Hoses and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1WP 0031 00 Fuel Strainer and Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1WP 0032 00 Fuel Filter Adapters Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1WP 0033 00 Fuel Tank and Mounting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0033 00-1WP 0034 00 Fuel Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1WP 0035 00 Automatic Ether Starting Aid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1WP 0036 00 Air Cleaner, Air Intake Duct, and Turbo Bypass Valve Maintenance. . . . . . . . 0036 00-1WP 0037 00 Air Intake Tubes and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1WP 0038 00 Charge Air Cooler and Air Recirculation Shield Replacement . . . . . . . . . . . . . 0038 00-1WP 0039 00 Exhaust System Muffler, Stack, and Heat Shield Replacement . . . . . . . . . . . . 0039 00-1WP 0040 00 Exhaust System Flex Pipe, Clamps, and Heat Shield Replacement . . . . . . . . . 0040 00-1WP 0041 00 Drain and Fill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1WP 0042 00 Coolant Hoses, Pipes, and Clamps Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1WP 0043 00 Thermostat and Thermostat Housing Cover Replacement . . . . . . . . . . . . . . . . 0043 00-1WP 0044 00 Radiator Support Rod Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1WP 0045 00 Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 00-1WP 0046 00 Fan Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1WP 0047 00 Fan Impeller and Shroud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1WP 0048 00 Fan Clutch Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00-1WP 0049 00 Fan Clutch and Drive Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1WP 0050 00 Water Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-1WP 0051 00 Water Filter Adapter and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1WP 0052 00 Water Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1WP 0053 00 Spindle and Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1WP 0054 00 Alternator Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1WP 0055 00 Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1WP 0056 00 Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1WP 0057 00 Voltage Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1WP 0058 00 Battery Equalizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1WP 0059 00 Starter Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1

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PageNumber

WP 0060 00 Left Panel Gages and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1WP 0061 00 Center Gage Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1WP 0062 00 Right Gage Panel and Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1WP 0063 00 Upper Right Dash Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00-1WP 0064 00 Left Hand Switch Panel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1WP 0065 00 Right Hand Switch Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1WP 0066 00 Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1WP 0067 00 Heater and Air Conditioning Control Panel Replacement . . . . . . . . . . . . . . . . . 0067 00-1WP 0068 00 12V Power Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1WP 0069 00 Fiber Optic Light Source Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1WP 0070 00 Check Engine Switch and Jumper Harness Replacement . . . . . . . . . . . . . . . . . 0070 00-1WP 0071 00 Fuse, Relay, Circuit Breaker, and Holder Replacement . . . . . . . . . . . . . . . . . . 0071 00-1WP 0072 00 Master Battery Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1WP 0073 00 Turn Signal Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1WP 0074 00 Electronic Throttle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1WP 0075 00 Electronic Control Module Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1WP 0076 00 NATO Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1WP 0077 00 Utility Power Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1WP 0078 00 Trailer Electrical Receptacles Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1WP 0079 00 Parking Brake Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1WP 0080 00 Water Level Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1WP 0081 00 Water Level Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1WP 0082 00 Headlamp Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1WP 0083 00 Headlamp and Headlight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1WP 0084 00 Blackout Drive, Marker Light, and Wiring Harness Replacement . . . . . . . . . . 0084 00-1WP 0085 00 Right Front Blackout Marker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1WP 0086 00 Rear Blackout Marker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1WP 0087 00 Taillight Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1WP 0088 00 Side Marker/Turn Signal Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1WP 0089 00 Clearance Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1WP 0090 00 Utility Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00-1WP 0091 00 Interior Light Unit and Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1WP 0092 00 Fuel Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1WP 0093 00 Fuel Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1WP 0094 00 Fuel Level Sending Unit Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1WP 0095 00 Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1WP 0096 00 Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1WP 0097 00 Oil Pressure Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1WP 0098 00 Water Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1WP 0099 00 Water Level Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1WP 0100 00 Fan Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1WP 0101 00 Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1WP 0102 00 Turbo Boost Sensor (TBS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1WP 0103 00 Timing Reference Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1WP 0104 00 Synchronous Reference Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1WP 0105 00 Air Pressure Sending Units (Primary/Secondary) Replacement . . . . . . . . . . . . 0105 00-1WP 0106 00 Front Anti-lock Brake System (ABS) Sensor Replacement . . . . . . . . . . . . . . . 0106 00-1

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WP 0107 00 Rear Anti-lock Brake System (ABS) Sensor Replacement . . . . . . . . . . . . . . . . 0107 00-1WP 0108 00 Anti-lock Brake System (ABS) Electronic Control Unit Replacement . . . . . . . 0108 00-1WP 0109 00 Brake Light/Trailer Brake Light Sending Unit Replacement . . . . . . . . . . . . . . 0109 00-1WP 0110 00 Collision Warning System (CWS) Antenna Alignment . . . . . . . . . . . . . . . . . . 0110 00-1WP 0111 00 Collision Warning System (CWS) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1WP 0112 00 Electric Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1WP 0113 00 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1WP 0114 00 Battery Box Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1WP 0115 00 Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1WP 0116 00 Stop/Tail/Backup Lights Wiring Harness Replacement . . . . . . . . . . . . . . . . . . 0116 00-1WP 0117 00 Automatic Ether Starting Aid Wiring Harnesses Replacement . . . . . . . . . . . . . 0117 00-1WP 0118 00 Cab-to-Frame Ground Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0118 00-1WP 0119 00 Electrical Connectors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1WP 0120 00 Shift Selector and Shift Tower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1WP 0121 00 Transmission Oil Fill/Level Check Tube Replacement . . . . . . . . . . . . . . . . . . . 0121 00-1WP 0122 00 Transmission Oil Cooler Lines and Fittings Replacement. . . . . . . . . . . . . . . . . 0122 00-1WP 0123 00 Transmission Oil Filter Elements Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1WP 0124 00 Transmission Electronic Control Unit (ECU) Replacement . . . . . . . . . . . . . . . 0124 00-1WP 0125 00 Transmission Electronic Control Unit (ECU) Wiring Harness Replacement . . 0125 00-1WP 0126 00 Transmission Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1WP 0127 00 Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1WP 0128 00 Transmission Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1WP 0129 00 Driveline Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1WP 0130 00 Driveline U-Joints and Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1WP 0131 00 Front Axle Toe in Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1WP 0132 00 Front Axle Stop Cushion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1WP 0133 00 Rear Axle Breather Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1WP 0134 00 Brake Pedal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1WP 0135 00 Front Brakeshoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1WP 0136 00 Front Brake Spider and Brake Chamber Bracket Replacement. . . . . . . . . . . . . 0136 00-1WP 0137 00 Rear Brakeshoe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1WP 0138 00 Rear Brake Spider and Brake Chamber Bracket Replacement . . . . . . . . . . . . . 0138 00-1WP 0139 00 Slack Adjuster Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1WP 0140 00 Slack Adjuster and S-cam Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1WP 0141 00 Front Air Brake Chamber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1WP 0142 00 Rear Air Brake Chamber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1WP 0143 00 Primary I Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1WP 0144 00 Primary II Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1WP 0145 00 Secondary Air Tank and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1WP 0146 00 Air Supply Tank And Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1WP 0147 00 Air Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00-1WP 0148 00 Constant Air Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1WP 0149 00 Cab Air Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1WP 0150 00 Tractor Protection Valves Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1WP 0151 00 Rear Relay Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1WP 0152 00 Front Service Brake Relay Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1WP 0153 00 Front Gladhands Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1WP 0154 00 Rear Gladhand Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00-1

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WP 0155 00 Front Quick-release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1WP 0156 00 Rear Quick-release Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1WP 0157 00 Air Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1WP 0158 00 Air Dryer Canister Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1WP 0159 00 Trailer Hand Brake Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1WP 0160 00 Parking Brake and Trailer Air Supply Valve Replacement . . . . . . . . . . . . . . . 0160 00-1WP 0161 00 Foot Brake Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1WP 0162 00 Front Anti-lock Brake System (ABS) Air Solenoid Replacement. . . . . . . . . . . 0162 00-1WP 0163 00 Rear Anti-lock Brake System (ABS) Air Solenoid Replacement . . . . . . . . . . . 0163 00-1WP 0164 00 Front and Dual Rear Wheel Lug Nut Installation . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1WP 0165 00 Front Hub, Drum, Wheel Bearings, and Seal Replacement . . . . . . . . . . . . . . . . 0165 00-1WP 0166 00 Rear Hub, Drum, Wheel Bearings, and Seal Replacement . . . . . . . . . . . . . . . . 0166 00-1WP 0167 00 Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1WP 0168 00 Universal Shaft Replacement and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1WP 0169 00 Pitman Arm and Drag Link Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1WP 0170 00 Power Steering Reservoir and Hose Maintenance . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1WP 0171 00 Right Step Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1WP 0172 00 Left Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1WP 0173 00 Left Side Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1WP 0174 00 Right Rear Step Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1WP 0175 00 Front Bumper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1WP 0176 00 Spare Wheel Hoist Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1WP 0177 00 Rear Tie Down Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1WP 0178 00 Fifth Wheel Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1WP 0179 00 Pintle Hook Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1WP 0180 00 Towing Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1WP 0181 00 Taillight Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1WP 0182 00 Front Shock Absorber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1WP 0183 00 Rear Shock Absorber Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1WP 0184 00 Brush Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1WP 0185 00 Engine Hood Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1WP 0186 00 Hood Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1WP 0187 00 Hood Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1WP 0188 00 Hood Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1WP 0189 00 Hood Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1WP 0190 00 Hood Prop and Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1WP 0191 00 Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-1WP 0192 00 Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1WP 0193 00 Seat Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1WP 0194 00 Front Splash Guard and Fender Extension Maintenance . . . . . . . . . . . . . . . . . . 0194 00-1WP 0195 00 Rear Fender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-1WP 0196 00 Mud Flap Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1WP 0197 00 Personal Gear Storage Box and Mounting Bracket Replacement . . . . . . . . . . . 0197 00-1WP 0198 00 Basic Issue Items (BII) Storage Box and Mounting Bracket Replacement . . . . 0198 00-1WP 0199 00 Storage Box Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1WP 0200 00 Rear Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1WP 0201 00 Floor Mats Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1

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WP 0202 00 Cab Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1WP 0203 00 Head Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1WP 0204 00 Cab Overhead Storage Compartment Replacement . . . . . . . . . . . . . . . . . . . . . . 0204 00-1WP 0205 00 Steering Column Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1WP 0206 00 Cab Door Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1WP 0207 00 Transmission Tunnel Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1WP 0208 00 Rear View Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-1WP 0209 00 Spotter Mirror Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1WP 0210 00 Windshield Wiper Motor and Linkage Replacement . . . . . . . . . . . . . . . . . . . . . 0210 00-1WP 0211 00 Windshield Washer Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00-1WP 0212 00 Windshield Wiper and Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . 0212 00-1WP 0213 00 Vehicle Jack Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0213 00-1WP 0214 00 Air Horn and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-1WP 0215 00 Data and Instruction Plates Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1WP 0216 00 M16 Rifle Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216 00-1WP 0217 00 Cup Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0217 00-1WP 0218 00 Cab Roof Air Deflector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1WP 0219 00 HVAC Air Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219 00-1WP 0220 00 HVAC Blower Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00-1WP 0221 00 HVAC Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221 00-1WP 0222 00 Air Conditioner Resister Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-1WP 0223 00 Air Conditioner Thermostatic Switch Replacement . . . . . . . . . . . . . . . . . . . . . 0223 00-1WP 0224 00 Air Conditioner Binary Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00-1WP 0225 00 Air Conditioner Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00-1WP 0226 00 Air Conditioner Compressor Magnetic Clutch Replacement . . . . . . . . . . . . . . 0226 00-1WP 0227 00 M13 Decontamination Kit Mounting Bracket Replacement . . . . . . . . . . . . . . . 0227 00-1WP 0228 00 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00-1WP 0229 00 Arctic Heater Replacement (WEBASTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00-1WP 0230 00 Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230 00-1WP 0231 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231 00-1

CHAPTER 4 SUPPORTING INFORMATION

WP 0232 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0232 00-1WP 0233 00 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . 0233 00-1WP 0234 00 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234 00-1WP 0235 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-1WP 0236 00 Tool Identification List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0236 00-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1DDEC III/IV Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-1OEM Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-2

TM 9-2320-302-20

vii

HOW TO USE THIS MANUAL

This manual is designed to help you maintain the M915A3 Tractor Truck.

FEATURES OF THIS MANUAL:

A Table of Contents is provided at the beginning of this manual.

WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlightedin BOLD print as a visual aid.

WARNINGWARNINGA WARNING indicates a hazard which results in death or serious injury.

CAUTIONCAUTIONA CAUTION is a reminder of safety practices or directs attention to usage practices that may resultin damage to equipment.

NOTENOTEA NOTE is a statement containing information that will make the procedures easier to perform.

Statements and words of particular importance are printed in CAPITAL LETTERS to create empha-sis.

Instructions are located with illustrations that show the specific task on which the mechanic is work-ing.

Dashed leader lines used in illustrations indicate that called out items are not visible (i.e. they arelocated within the structure). Dashed leader lines in the Lubrication Chart indicate that lubrication isrequired on BOTH sides of the equipment.

Technical instructions include metric units in addition to standard units. A metric conversion chart isprovided on the inside back cover.

An alphabetical index is provided at the end of the manual to assist in locating information not readilyfound in the Table of Contents.

FOLLOW THESE GUIDELINES WHEN YOU THIS MANUAL:

Read through this manual and become familiar with its contents before attempting to maintain thevehicle.

A Warning Summary is provided at the beginning of this manual and should be read before attemptingto maintain the vehicle.

TM 9-2320-302-20

viii


TM 9-2320-302-20

CHAPTER 1INTRODUCTORY INFORMATION WITH

THEORY OF OPERATION

TM 9-2320-302-20


TM 9-2320-302-20

0001 00-1

GENERAL INFORMATION 0001 00

SCOPE

1. Type of Manual. This manual is for use in performing Unit Maintenance on the M915A3 Tractor Truck.

2. Equipment Name and Model Number. Truck, Tractor, Line Haul: 52,000 GVWR, 6 X 4, M915A3.

3. Purpose of Equipment. The M915A3 Tractor Truck is a 6 X 4 prime mover of semitrailers used primarily to transportcontainers, bulk cargo, and petroleum products over primary and secondary roads under worldwide climatic conditionsin a military environment.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738-750,Functional Users Manual for the Army Maintenance Management System (TAMMS), as contained in the Maintenance Man-agement Update.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS)

If your truck needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you dontlike about your equipment. Let us know why you dont like the design or performance. Put it on an SF Form 368 (ProductQuality Deficiency Report) . Mail it to us at: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN:AMSTA-LC-CIP-WT, Rock Island, Illinois 61299-7630. We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

1. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosionproblems with this item be reported so that the problem can be corrected and improvements can be made to prevent theproblem in future items.

2. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such asrubber and plastic. Unusual cracking, softening, swelling or breaking of these materials may be a corrosion problem.

3. If a corrosion problem is identified, it can be reported using SF Form 368 (Product Quality Deficiency Report). Use ofkey words such as corrosion, rust, deterioration, or cracking will ensure that the information is identified as aCPC problem. The form should be submitted to the address specified in DA Pam 738-750.

OZONE DEPLETING SUBSTANCES (ODS)

Listing to be provided by requiring activity.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-6.

PREPARATION FOR STORAGE OR SHIPMENT

For preparation for storage or shipment procedures, refer to TM 740-90-1 and MIL-V-62038D.

WARRANTY INFORMATION

The vehicle is warranted by Freightliner Corporation in accordance with TB 9-2320-302-15. Warranty starts on the date foundin block 23, DA Form 2408-9 in the logbook. Report all defects in material or workmanship to your supervisor, who will takeappropriate action.

TM 9-2320-302-20

0001 00-2

GENERAL INFORMATION - CONTINUED 0001 00

NOMENCLATURE CROSS-REFERENCE LIST

COMMON NAME OFFICIAL NOMENCLATURE

Cold Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ether Quick-start System

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antifreeze, Ethylene Glycol Mixture

Gladhand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Disconnect Coupling

Jake Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Brake

Komfort Loc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat Belt Adjustment

TufTrac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension System

LIST OF ABBREVIATIONS

NOTENOTERefer to MIL-STD-12D for standard abbreviations.

ABBREVIATION DEFINITION

ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-lock Brake System

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centigrade or Celsius

CEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check Engine Light

CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Inch Displacement

cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter

CWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Collision Warning System

DDEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detroit Diesel Electronic Controlled

DDL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Data Link

DDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diagnostic Data Reader

ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Control Unit

F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit

GCWR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Combination Weight Rating

GVWR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight Rating

kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram

km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilometer

kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal

kph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour

kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilowatt

l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liter

lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pound

lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound foot

lph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters per Hour

m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter

mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter

MTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movement Tracking System

TM 9-2320-302-20

0001 00-3

GENERAL INFORMATION - CONTINUED 0001 00

LIST OF ABBREVIATIONS - CONTINUED

ABBREVIATION DEFINITION

Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meter

PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services

psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pounds per Square Inch

rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Revolutions per Minute

TM 9-2320-302-20

0001 00-4


TM 9-2320-302-20

0002 00-1

EQUIPMENT DESCRIPTION AND DATA 0002 00

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

1. Characteristics.

a. The M915A3 Tractor Truck is used to transport M871, M872, and M1062 semitrailers on line haul missions.

b. It has a Gross Vehicle Weight Rating (GVWR) of 52,000 lb (23,608 kg) and is equipped with a two-way oscillat-ing, sliding fifth wheel compatible with a two-inch kingpin. Maximum towed load on kingpin is 30,000 lb (13,620kg).

2. Capabilities and Features.

a. While operating on Class I roads, the fully loaded M915A3 can maintain a speed of 65 mph (105 kph) on levelroads and 29 mph (47 kph) while ascending a 3 percent grade. It has a minimum turning diameter, curb-to-curb, of53 ft 9 in (16.4 m).

b. Average cruising ranges at Gross Combination Weight Rating (GCWR) with a full tank of fuel will vary based onconditions (e.g., varying loads, prolonged idle, and climatic conditions). Cruising range is optimally 400 miles(640 km).

c. The M915A3 is equipped with an instrument panel mounted speedometer and tachometer which register truckground speed and engine speed.

d. The M915A3 has the following capabilities and features:

(1) air-activated front and rear non-asbestos cam brakes with a four-channel anti-lock brake system (ABS) toprovide significantly improved handling and braking during emergency stops

(2) operation in temperatures from -25F (-32C) to +125F (+52C), and to -40F (-40C) with arctic kitinstalled

(3) start and climb capability of a 20 percent grade at GCWR in both forward and reverse directions

(4) fording capability up to 20 in (51 cm) deep for 5 minutes without damage or requiring maintenance beforeoperations can continue

(5) two-passenger aluminum corrosion-proof cab with a 90 degree tilt-forward hood for service accessibility

(6) six cylinder, 12.7 liter, 430 horsepower, in-line turbocharged diesel engine built by Detroit Diesel

(7) Allison HD 4560P six-speed automatic transmission

(8) Collision Warning System (CWS) that warns the driver of potentially dangerous driving situations by acti-vating visual and audible alerts.

e. For operation in arctic conditions, the M915A3 can be equipped with an arctic heater mounted under the cab,above the battery box. This provides heat for the cab and engine cooling system. The arctic heater may be operatedprior to starting the engine to provide preheating of engine block.

TM 9-2320-302-20

0002 00-2

EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

KEY COMPONENT DESCRIPTION

1 Marker Clearance Lights

Indicate outline of truck.

2 Side Mirrors (Heated) Provide driver with a view of sides of truck andsemitrailer, if towing.

3 Grabhandles Provide a hand hold for personnel climbing on truck.

4 Utility Power Receptacle

Supplies power for work lights. Located on both sides oftruck.

5 Air Horn Provides an audible alert.

6 Master Battery Switch Provides battery power to truck.

7 Spare Wheel and Tire Extra wheel and tire used in case of a flat tire.

8 Battery Box and Steps Holds vehicle batteries and provides steps to access cab.

9 Front Service Lights Include headlights and turn signals.

10 Bumper Extensions Provide adjustable attachment point for slings.

11 Blackout Lights Used during blackout conditions. Include marker anddrive lights.

12 Towing Eyes Provide attachment points for towing device.

1

2

3

45

7

89101112

10

14

15

6

13

TM 9-2320-302-20

0002 00-3


LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED


13 CWS Antenna Forward looking collision warning system antenna.

14 Brush Guard Protects front of hood and components under hood fromdamage.

15 Spotting Mirrors Provide added visibility to sides and front of truck.

TM 9-2320-302-20

0002 00-4




16 Ramp Sloped surface serves as an approach to fifth wheel andfacilitates coupling of semitrailer.

17 Fifth Wheel Coupling device for semitrailers with kingpins.

18 Utility Lights Illuminate area in back of cab. There is one light on eachside of cab.

19 Strobe Warning Light Strobe light alerts other vehicles of presence of truck.

20 IntervehicularReceptacles Installation

Contains 12-volt commercial, 24-volt military, andtrailer ABS receptacles.

21 Antenna Mount Mount for radio antenna.

22 Exhaust Muffler Deadens noise of engine exhaust.

23 Hood Latch Locks hood closed. Located on both sides of hood.

24 CWS Side Sensor Side looking collision warning system sensor.

25 Fuel Tank Holds fuel. Steps mounted to tank provide access to cab.

26 Storage Boxes Provide stowage area for BII and other items.

27 Mud Flaps Prevent water and debris from spraying up on passers byor towed semitrailer.

1617

1819 20

22

23

25

2627

293031 29

21

28

24

TM 9-2320-302-20

0002 00-5




28 Blackout Lights Used during blackout conditions.

29 Trailer Gladhands Provide air supply for trailer brakes.

30 Pintle Hook Coupling device for trailers with lunettes.

31 Taillights Contain composite tail, stop, backup, and turn signallights.

TM 9-2320-302-20

0002 00-6


EQUIPMENT DATA

Dimensions:

Length (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 in (701 cm)

Height (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 in (300 cm)

Width (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in (254 cm)

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 in (411 cm)

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 in (23 cm)

Angle of Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Weights:

Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,080 lb (8662 kg)

GVWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52,000 lb (23,608 kg)

GCWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105,000 lb (46,670 kg)

Front Axle (Loaded). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 lb (5448 kg)

Rear Axle (Loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000 lb (18,160 kg)

Capacities:

Engine Oil (Refill w/Filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 qt (38.8 l)

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 qt (61.5 l)

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 gal. (378.5 l)

Power Steering Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 qt (1.9 l)

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 qt (48 l)

Rear Axle (Forward/Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/14.5 qt (12.3/13.7 l)

Engine:

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detroit Diesel

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-stroke, in-line

turbocharged diesel

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DDEC IV

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755 CID (12.7 l)

Torque @ 1200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 lb-ft (1898 Nm)

Maximum Horsepower @ 2100 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 (320.6 kW)

Maximum Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm

Oil Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 full flow,

replaceable elements

Oil Filter Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fuel System:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel fuel injected

Fuel Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 primary, 1 secondary

replaceable element

Air Cleaner:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry elementQuantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM 9-2320-302-20

0002 00-7


EQUIPMENT DATA - CONTINUED

Cooling System:

Radiator Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 psi (69 kPa)Coolant Inhibitor Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 replaceable element

Electrical System:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual 12/24 voltBatteries:

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt

Transmission:

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AllisonModel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HD 4560PType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-speed automaticShift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pushbutton

Front Axle:

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RockwellType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-beam, FF961Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 lb (5448 kg)Maximum Steering Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rear Axle (Tandem):

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell, RT 40-145PRated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,000 lb (17,252 kg)Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44:1Inter-axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bevel gearTraction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air controlled

Brake System:

Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air-mechanicalPressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120 psi (414-827 kPa)Airbrake Chambers:

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 on front axleFailsafe (Spring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 on forward-rear

and rear-rear axlesABS (Anti-lock Brake System):

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-channelLocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . front axle and rear-rear axle

Wheels:

Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 x 8.25 inNumber of Studs/Stud Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/1.125 in

Tires:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tubeless, radialon-highway

Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11R22.5Ply Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14PRLoad Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H

TM 9-2320-302-20

0002 00-8



Tires - Continued:

Inflation Pressure (Maximum Load):Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 psi (724 kPa)Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (690 kPa)Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 psi (724 kPa)

Steering:

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRWSteering Gear Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . single gearActuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic power boosterPower Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton B165RTurning Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 ft 9 in (16.4 m)Steering Column and Wheel:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tilt, telescopingTilt Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Telescoping Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5/8 in (67 mm)

Suspension:

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single leaf springw/shock absorbers

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TufTracw/shock absorbers

Towing Attachments:

Pintle Hook:Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HollandModel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no. 760Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 tons

(27.2 metric tons)Towing Eyes:

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 front, 2 rearMaximum Load Capacity, Each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,000 lb (27,240 kg)(Up to 45 Angle Front Long. Axis)

Fifth Wheel:Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HollandType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 in (91.4 cm)

diameter, 2-wayoscillating, low lube

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000 lb (13,620 kg)Height (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 in (132.1 cm)Pitch (Fwd/Aft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/10Kingpin Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 in (5.1 cm)

Cab:

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FreightlinerConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminumType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-passenger,

tilt-forward hoodAir Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adjustable

TM 9-2320-302-20

0002 00-9



Accessories:

Utility Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 fixed, top rear of cabAir Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, under cab

Military Load Classification:

Vehicle w/o Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Vehicle w/Trailer:

M871. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/35(unloaded/loaded)

M872. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/46(unloaded/loaded)

M1062. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/34(unloaded/loaded)

TM 9-2320-302-20

0002 00-10


TM 9-2320-302-20

0003 00-1

THEORY OF OPERATION 0003 00

INTRODUCTION

1. The M915A3 Tractor Truck consists of the following functional systems: drive train, fuel system, exhaust system, cool-ing system, electrical system, air system, brake system, steering system, traction control system, suspension system, airconditioning system, and collision warning system.

2. This work package explains how the components and systems of the M915A3 work together. A functional description isprovided for each major component and system.

DRIVE TRAIN

The drive train of the M915A3 consists of a Detroit Diesel, DDEC IV engine and an Allison 6-speed automatic transmissionconnected to RT 40-145P rear tandem axles.

FUEL SYSTEM

1. Fuel to power the engine is pumped out of the fuel tank by an engine-mounted fuel pump. The engine fuel system con-sists of one electronic unit injector per cylinder, a transfer pump, low-pressure fuel lines, and primary and secondaryfuel filters.

2. The engine is governed by an electronic control system. The system controls idle speed and limits engine maximumspeed. The driver controls engine speed through the position of the electronic throttle position sensor (foot pedal).

3. Fuel filters are spin-on types. The primary fuel filter has a hand fuel primer pump and a water drain.

4. Fuel may be drained from the tank through the drain port located on the bottom of the tank.

5. There is a computer-controlled ether quick-start system for use in cold weather.

ENGINE

TRANSMISSION

FORWARD-REAR AXLE

REAR-REAR AXLE

TM 9-2320-302-20

0003 00-2

THEORY OF OPERATION - CONTINUED 0003 00

FUEL SYSTEM - CONTINUED

EXHAUST SYSTEM

The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flowinto exhaust pipes and a muffler to the atmosphere above the cab.

CYLINDER

PRIMARY

WATERDRAIN

RESTRICTEDFITTING

SECONDARYFUEL FILTER

FUEL FILTERWITH HANDPRIMER

FUEL TANK

PUMPFUEL

(UPPERFITTING)

HEAD

EXHAUST PIPES

MUFFLER

EXHAUST MANIFOLD

TURBOCHARGER

TM 9-2320-302-20

0003 00-3


COOLING SYSTEM

The cooling system consists of one circulating pump, a remote-mounted coolant filter, two 180F (82C) thermostats for con-trolling fluid flow, a transmission oil cooler, a radiator, and a belt-driven fan. The cooling system cools the engine by circulat-ing pressurized ethylene-glycol based coolant through the engine and radiator.

ELECTRICAL SYSTEM

1. Four 12-volt batteries connected in series-parallel supply the 12-volt electrical system and provide 24 volts for thestarter motor, blackout lights, accessories, and trailer connectors.

2. The Dual Voltage Alternator Control (DUVAC), mounted on the firewall in the engine compartment, regulates the dis-tribution of 12 and 24 volts.

TWO

DDEC IV ENGINE

CIRCULATING

INLET(FROM RADIATOR)

PUMP

THERMOSTATS

TM 9-2320-302-20

0003 00-4


ELECTRICAL SYSTEM - CONTINUED

TM 9-2320-302-20

0003 00-5


AIR SYSTEM

The air system consists of the air compressor, air dryer, air reservoirs, and various air lines. Also included in the air system areair pressure gages, located on the instrument panel, for monitoring air pressure for safe operation of all air-operated compo-nents of the vehicle.

BRAKE SYSTEM

1. The dual air brake system consists of two independent air brake systems that use a single set of brake controls. Each sys-tem has its own reservoirs, plumbing, and brake chambers. The primary system operates the service brakes on the rearaxle and the secondary system operates the service brakes on the front axle. On tractor-trailer configurations, servicebrake signals from both systems are sent to the trailer.

2. Loss of air pressure in the primary system causes the rear service brakes to become inoperative. Front brakes will con-tinue to be operated by secondary system air pressure. In addition, trailer brakes will be operated by the secondary sys-tem. Loss of secondary system air pressure causes the front axle brakes to become inoperative. Rear service brakes andtrailer brakes will be operated by the primary system.

HOLDING TANKSAIR COMPRESSOR

AIR GAGES

PRIMARY SECONDARY

342-008

TM 9-2320-302-20

0003 00-6


BRAKE SYSTEM - CONTINUED

3. The warning light and buzzer inside the cab are activated if air pressure drops below 64 psi (441 kPa) in either brakesystem. If this happens, check air pressure gages to determine which system has low air pressure. Although vehiclespeed can be reduced using the foot brake control pedal, either the front or rear service brakes will not operate, resultingin a longer stopping distance. Bring vehicle to a safe stop and have the air system repaired before continuing.

4. If the primary brake system becomes inoperative, the spring parking brakes automatically apply when air pressure dropsto 35-45 psi (241-310 kPa).

5. The vehicle has a four-channel anti-lock brake system (ABS) and cam-operated service brakes with non-asbestos brake-shoes.

6. The M915A3 has automatically adjusting slack adjusters. On all axles, brake chambers have a stroke alert indicatorwhich allows the operator to monitor brakeshoe wear.

AIR CONTROLS

TRAILER PARKING

COMPRESSOR

REAR AXLE SPRINGBRAKE CHAMBERS

BRAKECONTROL

FRONT AXLEBRAKE CHAMBERS

HAND BRAKETRAILER

AIRBRAKE

342-008

TM 9-2320-302-20

0003 00-7


STEERING SYSTEM

1. The power steering system consists of an integral steering gear (which includes a manual steering mechanism andhydraulic control valve), hydraulic hoses, power steering pump, reservoir, and other components.

2. The power steering pump, driven by the engine, provides the power-assist for the steering system.

TRACTION CONTROL SYSTEM

The inter-axle differential lock is controlled by the air operated lever labeled INTER-AXLE DIFFERENTIAL on the driversinstrument panel. Under normal driving conditions, the control lever should be in the UNLOCKED position. During poor driv-ing conditions, the control lever may be moved to the LOCKED position to improve traction. When the inter-axle differentiallock is applied, the drive shaft becomes a solid connection between the two rear axles.

STEERING GEAR

RESERVOIR

POWER STEERING PUMP

TM 9-2320-302-20

0003 00-8


REAR SUSPENSION SYSTEM

The TufTrac rear suspension system consists two parabolic taper-leaf springs and two shock absorbers per side and an arrange-ment of torque rods. The suspension system is designed to provide a high degree of ground clearance and articulation whilemaintaining an equal load over each wheel. Ride characteristics are similar, whether loaded or unloaded.

TM 9-2320-302-20

0003 00-9


AIR CONDITIONING SYSTEM

1. The air conditioning unit is part of the heater and is mounted under the glove compartment. It is a single unit consistingof a heater core, air conditioning evaporator coil, blower motor, control valves, and air ducts.

2. The system is turned on by the mode control lever on the instrument panel in the cab. The four-speed blower switch con-trols flow rate.

3. An even cab temperature is maintained by controlling the coolant flow through the heater core, or refrigerant flowthrough the evaporator coil.

CONDENSER

THERMOSTATICSWITCHHEATER

COREEXPANSION

VALVE

EVAPORATORCOIL

RECEIVERDRYER

COMPRESSOR

TM 9-2320-302-20

0003 00-10


COLLISION WARNING SYSTEM (CWS)

1. The Collision Warning System (CWS) consists of an antenna assembly, central processing unit, driver display unit, sidesensor, side sensor display, and wiring harness.

2. The CWS is a forward and side looking radar system that transmits and receives signals reflected off of objects to thefront and side of the tractor.

3. The forward looking antenna assembly determines distance, azimuth, and approximate speed of vehicle forward of thetractor.

4. The side sensor detects vehicles or objects from two to ten feet, moving or stationary, alongside the tractor.

SIDESENSOR

DRIVERDISPLAY UNIT

CENTRALPROCESSING UNIT

WIRING HARNESSANTENNA

ASSEMBLY

SIDE SENSORDISPLAY

TM 9-2320-302-20

CHAPTER 2UNIT TROUBLESHOOTING PROCEDURES

TM 9-2320-302-20


TM 9-2320-302-20

0004 00-1

TROUBLESHOOTING INTRODUCTION 0004 00

INTRODUCTION

Troubleshooting procedures are grouped by work packages, containing information you need to fault locate malfunc-tions on the M915A3 Tractor Truck. A troubleshooting symptom index in WP 0005 00 is provided to aid in locating a mal-function or symptom and direct you to the appropriate troubleshooting table (work package) containing a listing ofmalfunctions, test and inspection procedures, and corrective actions. The corrective action column further directs you to therequired corrective maintenance procedure within this manual by work package number. However, if the required mainte-nance procedure is beyond Unit Maintenance capabilities, the direction is to notify Direct Support Maintenance.

PRELIMINARY TROUBLESHOOTING PROCEDURES

NOTENOTEFluid leaks are classified as either Class I, Class II or Class III

Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.

Class II: Leakage of fluid great enough to form drops, but not enough to cause drops to drip from itembeing checked/inspected.

Class III: Leakage of fluid great enough to form drops that fall from item being checked/inspected.

Before starting any specific troubleshooting procedures, perform the following:

a. Visually check for ruptured oil hoses or tubes and for Class II or Class III leaks.

b. Check for mechanical jamming or binding caused by rocks or other foreign matter.

c. Check fluid levels in subject area and service as required (TM 9-2320-302-10 or WP 0021 00).

ELECTRICAL TROUBLESHOOTING

1. Analyze the symptoms and conditions and use common sense and logic to determine the most likely cause for the prob-lem, then troubleshoot that circuit first. The more information you have concerning the problem, the easier it will be totroubleshoot.

2. Isolate to the subsystem level (in cases where more than one subsystem is involved); next isolate the problem to a singlecircuit

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