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T M 9 - 2 3 2 0 - 2 0 9 - 1 0 - 1

TO 36A12-1B-1091-1

TECHNICAL MANUAL

O P E R AT I O N , I N S TA L L AT I O N A N D

REFERENCE DATA

OPERATOR LEVEL

21 /2 -TON, 6X6 , M44A1 AND M44A2 SERIES TRUCKS

(MULTIFUEL)

TRUCK, CARGO: M35A1 ,

M35A2, M35A2C, M36A2; TRUCK,

TANK, FUEL: M49A1C, M49A2C; TRUCK, TANK,

WATER: M50A1, M50A2, M50A3; TRUCK, VAN,

SHOP: M109A2, M109A3; TRUCK, REPAIR SHOP:

M185A2, M185A3; TRUCK, TRACTOR: M275AI,

M275A2; TRUCK, DUMP: M342A2; TRUCK,

MAINTENANCE, PIPELINE CONSTRUCTION:

M756A2; TRUCK, MAINTENANCE,

EARTH BORING AND POLESETTING: M764

C h a p t e r 3Service UponReceipt of E q u i p m e n t

C h a p t e r 4O p e r a t i n gP r o c e d u r e s

Appendix AR e f e r e n c e s

Appendix BC o m p o n e n t sof End ItemList

Appendix CAdditionalAuthor iza t ionList

Appendix DE x p e n d a b l eS u p p l i e s a n dMater ia l sList

D E PA RT M E N T S O F T H E A R M Y A N T H E A I R F O R C E,S E P T E M B E R 1 9 8 0

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WARNING

EXHAUST GASES CAN BE DEADLY

Exposure to exhaus t gases produces symptoms of headache , d izz iness , loss of mus-cu la r cont ro l , apparen t d rowsiness , and coma. Permanent brain damage or death canre su l t f r om s ev e re exposu re .

Carbon monoxide occurs in the exhaus t fumes of fue l burn ing hea te rs and in te rna lcombus t ion engines , and becomes dangerous ly concent ra ted under condi t ions of in -ad e qua t e ve n t i l a t i on . The fo ll owing p r ecau t i ons mus t b e ob se rved t o i n su re t he s a fe tyof personnel whenever fue l burn ing hea te r ( s ) o r engine of any vehic le i s opera ted formain tenance purposes or t ac t ica l use .

Do not opera te hea te r o r engine of veh ic le in an enc losed a rea un less i t i s adequate lyv e n t i l a t e d .

Do not idle engine for long periods without maintaining adequate ventilation in per-sonnel compar tments .

Do not d r ive any vehic le wi th inspec t ion p la tes or cover p la tes removed unless neces-sary for main tenance purposes .

Be a le r t a t a l l t imes dur ing vehic le opera t ion for exhaus t odors and exposure symptoms.I f e i ther a re presen t , immedia te ly vent i la te personnel compar tments . I f symptoms per-sis t , remove affected personnel from vehicle and treat as fol lows: expose to fresh air ;keep warm; do not permi t phys ica l exerc i se ; i f necessary, adminis te r a r t i f i c ia lr e s p i r a t i o n .

I f exposed , seek prompt medica l a t ten t ion for poss ib le de layed onse t o f acu te lungc o n g e s t i o n . Administer oxygen if avai lable.

The best defense against exhaust gas poisoning is adequate venti lat ion.

Use ex t reme care when removing rad ia tor cap , espec ia l ly when tempera ture gageshows above 180F.

Always wear lea ther g loves when handl ing winch cab le . Never a l low cable to s l ipth rou gh ha n d s . Do not opera te w in ch w i th l es s t han fou r t u rn s o f ca b le on d ru m .

Do not d r ive t ruck unt i l the low a i r p ressure warn ing buzzer i s s i l en t and the a i rp r e s su re ga g e s hows a t l e a st 65 PSI . Th i s i s t h e min imum p re s su re r equ i r e d fo r sa feb r ak ing ac t i o n .

Do not use hand thro t t le to dr ive the vehic le .

Do not park t ruck wi th f ron t t ransmiss ion gearsh i f t l ever in gear.

If your vehicle class number is greater than the bridge class number, do not cross.

This vehicle has been designed to operate safely and efficiently with in the limits specified in t his TM.Operation beyond these limits is prohibited IAW AR 70-1 without written approval from the Commander,

U.S. Army Tank-Automotive Command, ATTN: AMSTA-CM-S, Warren, MI 48397-5000.

Change 2PIN: 046723-002

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TECHNICAL MANUALNO. TM 9-2320-209-10-1

TECHNICAL ORDERNO. 36A12-1B-1091-1

TM 9-2320-209-10-1

C2

CHANGE H E A D Q U A RT E R SDEPARTMENT OF THE ARMY

No. 2 Washington D. C., 3 0 N o v e m b e r 1 9 89

OPERATION, INSTALLATION ANDREFERENCE DATAOPERATOR LEVEL

2-1/ 2 TON, 6X6, M44A1 AND M44A2 SERIES TRUCKS(MULTIFUEL)

TRUCK, CARGO: M35A1,M35A2, M35A2C, M36A2; TRUCK,

TANK, FUEL: M49A1C, M49A2C; TRUCK, TANK,WATER M50A1, M50A2, M50A3; TRUCK, VAN,

SHOP: M109A2, M109A3; TRUCK, REPAIR SHOP:M185A2, M185A3; TRUCK, TRACTOR: M275A1,

M275A2; TRUCK, DUMP: M342A2; TRUCK,MAINTENANCE, PIPELINE CONSTRUCTION:

M756A2; TRUCK, MAINTENANCE,EARTH BORING AN D PO LESETTING: M764

TM 9-2320-209-10-1/ TO 36A12-1B-1091-1, da ted 26 Septem ber 1980, is changed as follows:

1. Change to n arrative material is indicated by a vertical bar in the ou tside margin of the p age. Added orrevised illustrations are ind icated by a vertical bar ad jacent to the identification nu mber.

2. Remove old pages and insert new p ages as indicated below..

3. File this change sheet in front of the publication for reference purposes.

Remove Pages Insert Pages

2-1 and 2-2 2-1 and 2-24-29 and 4-30 4-29 an d 4-30Cover and Warning Cover and Warning

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By Order of th e Secreta ry of th e Army

CARL E. VUONOGeneral, United States Army

Chief of Staff

Official:

WILLIAM J . MEEHAN II Brigadier General, United States Army

Th e Adjutant General

Distribution:To be distributed in accorda nce with DA Form 12-38-R (Block 201) Operator m aint enan ce requirement s

for Tru ck, Gasoline, 2 l/4-ton, 6x6, M44-series.

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*TM 9-2320 -209- 10-1

TO 36A12-1B-1091- 1

TECHNICAL MANUALNO. 9-2320 -209-10-1TECHNICAL ORDERNO. 36A12-1B-1091-1

TECHNICAL MANUAL

DEPARTMENTS OF THE ARMYA N D

THE AIR FORCEWashington, DC, 26 Sep tem ber 1980

OPERATION, INSTALLATIONOPERATOR

21/ 2-TON, 6X6, M44A1 AND

AND REFERENCE DATALEVEL

M44A2 SERIES TRUCKS

(MULTIFUEL)

Model

T r u c k , C a r g o

Tr u c k , Ta n k , F u e l

Tr u c k , Ta n k , Wa t e r

Truck , Van , Shop

Truck , Repa i r Shop

Tr u c k , Tr a c t o r

Tr u c k , D u m p

Tr u c k , M a i n t e n a n c e , P i p e l i n eCons t ruc t i on

Truck , Ma in t enance , Ea r thBor ing and Polese t t ing

M35A1M35A2M35A2CM36A2

M49A1CM49A2C

M50A1M50A2M50A3

M109A2M109A3

M185A2M185A3

M275A1M275A2

M342A2

M756A2

M764

NSN wi thout Winch

2320-00 -542-56332320-00 -077-16162320-00 -926-08732320-00 -077-1618

2320-00 -440-33492320-00 -077-1631

2320-00 -440-83072320-00 -077-16332320-00 -937-4036

2320-00 -440-83132320-00 -077-1636

4940-00 -987-87994940-00 -077-1638

2320-00 -446-24792320-00 -077-1640

2320-00 -077-1643

NSN with Winch

2320-00 -542-56342320-00 -077-16172320-00 -926-08752320-00 -077-1619

2320-00 -440-33462320-00 -077-1632

2320-00 -440-83052320-00 -077-16342320-00 -937-5264

2320-00 -440-83082320-00 -077-1637

4940-00 -987-88004940-00 -077-1639

2320-00 -077-1641

2320-00 -077-1644

2320-00 -904-3277

2320-00 -937-5980

* This manual, together with TM 9-2320-209-10-2, 26 September 1980; TM 9-2320-209-10-3,

26 September 1980; and TM 9-2320-209-10-4, 26 September 1980, supersedes TM 9-2320-209-10/1,

29 October 1976.

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REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you knowof a way to improve the procedure, please let us know. Mail your letter,

DA Form 2028 (Recommended Changes to Publication and Blank Forms) , orDA Form 2028-2 located in the back of this manual direct to: Commander,U.S. Army Tank Automotive Materiel Readiness Command, ATTN : DRSTA-MBA, Warren, Michigan 48090. A reply will be furnished to you.

CHAPTER 1. INTRODUCTIONScope . . . . . . . . . . . . . .Forms and Records . . . . . . . . .Equipment Improvement Report and

Maintenance Digest (EIR MD) andEquipment Improvement Report andMaintenance Summary (EIR MS) . . .

Reporting Improvement RecommendationsMetric System . . . . . . . . . . .Destruction to Prevent Enemy Use . . .Manual Organization . . . . . . . .Vehicle /Bridge Classification . . . . .

CHAPTER 2. DESCRIPTION AND DATASection I. Functional Description

General . . . . . . . . . . . . .Overall Equipment Functional Description

. .

. .

. .

. .

. .

. .

. .

. .Engine . . . .Clutch . . . .Electrical SystemFuel System . .Cooling System.Exhaust System

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .Transmission System . . . . . . . . .Transfer System . . . . . . . . . . .Transmission Power Takeoff System . . .Transfer Power Takeoff System . . . . .Propeller Shafts . . . . . . . . . . .Steering System . . . . . . . . . . .Brake System . . . . . . . . . . .Axle, Wheels and Hubs . . . . . . . .Auxiliary Equipment and Accessories . . .

Section II. Physical Description . . . . . . . . . . .General . . . . . . . . . . . . . . .Overall Equipment Physical Description . . .

Engine . .Clutch.................................Electrical System . . . . . . . . . . .Fuel and Air Intake System . . . . . . .

Paragraph Page

1-11-2

1-31-41-51-61-71-8

2-12-22-2 a2-2 b2-2 c2-2 d2-2 e2-2 f2-2 g2-2 h2-2 i2-2 j2-2 k2-2 12-2 m2-2 n2-2 o

2-32-42-4 a2-4 b2-4 c2-4 d

1-11-1

1-11-11-11-11-61-6

2-12-12-12-12-12-12-12-12-12-12-12-12-12-12-22-22-22-22-22-22-22-22-52-62-7

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Section III.

Cooling System. . . . . . . . . . . .Exhaust System . . . . . . . . . .Transmission . . . . . .Transmission Power Takeoff. . . . .TransferTransfer Power Takeoff . . . . . . . . . .Propeller and Drive Shaft Systems . . . .Steering System. . . . . . . . . . . .Brake System . . .Axles, Wheels, and Hubs . . ..............

Tabulated Data . . . . . . . . . . . . .General . . . . . . . . . . . . . .Weight . . . . . . . . . . . . .Dimensions: . . . . . . . . . . . . .Capacities . . . . . . . . . . . . . .Tire Inflation Data . . . . . . . . . . .Environmental Characteristics . . . . . .Functional Characteristics . . . . . . . .Components of End Item List . . . . . . .Additional Authorization List . . . . . . .Expendable Supplies and Materials List . .

CHAPTER 3.

CHAPTER 4.Section I.

SERVICE UPON RECEIPT OF EQUIGeneral . . . . . . . .Break-in Operation . . . .

General . . . . . . . .Break-in . . . . . . .Road Test. . . . . . .After the Road Test . . .

OPERATING PROCEDURES . .

PMENT. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .

Description and Use of Operators Controlsand Indicators . . . . . . . . . . . . .

General . . . . . . . . . . . . . .Chassis Controls and Indicators . . . . .

Instrument Panel Controls andIndicators . . . . . . . . . . . .

Windshield Controls and Indicators . . .Drivers Compartment Controls and

Indicators . . . . . . . . . . . .Front Winch Controls and Indicators . .Trailer Brake Controls and Indicators. .

Equipment Bodv Controls and Indicators . .Fuel Tank Trucks (M49A1C and M49A2C)

Controls and Indicators . . . . . .Water Tank Trucks Controls and

Indicators . . . . . . . . . . . .Shop Van and Instrument Repair

Shop Trucks Controls and Indicators .

Paragraph

2-4 e2-4 f2-4 g2-4 h2-4 i2-4 j2-4 k2-4 12-4 m2-4 n

2-52-6

2-72-82-92-102-112-122-132-14

3-13-23-2 a3-2 b3-2 C3-2 d

4-14-2

4-2 a4-2 b

4-2 c4-2 d4-2 e4-3

4-3 a

4-3 b

4-3 c

Page

2-82-92-142-142-142-142-152-182-192-202-212-212-21

2-212-212-212-212-212-212-212-21

3-13-13-13-13-23-2

4-14-14-2

4-24-4

4-54-94-104-11

4-11

4-13

4-15

. . .

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Tractor Trucks Controls and Indicators . .Dump Truck Controls and Indicators

Pipeline Construction Truck Controlsand Indicators . . . . . . . .Earth Boring Machine and Polesetter

Truck Controls and Indicators . .Spec ia l Kits Controls and Indicators . .

Hot Water Personnel Heater Kit Controls

. . .

. . .

. . .

. . .

. . .

and Indicators . . . . . . . . . . .Arctic Winterization Kit Controls

and Indicators . . . . . . . . . . .Deep Water Fording Kit Controls

and Indicators . . . . . . . . . . .Electric Brake Kit Controls

and Indicators . . . . . . . . . . .Section II. Operation Under Usual Conditions

Scope . . . . . . . . . . . . . . . .General Operating Procedures . . . . . . .

Before Engine Startup . . . . . . . . .Starting the Engine Above +20F . . . . .Cold Weather Starting Below +20F . . . .Placing and Keeping the Truck in Motion. .Stopping the Truck and Engine . . . . .

Operation of Front Winch . . . . . . . . .General . . . . . . . . . . . . . .Before Operating . . . . . . . . . . .Unwinding the Winch Line . . . . . . .Lifting or Pulling . . . . . . . . . . .Stopping the Winch . . . . . . . . . .Lowering Load or Unwinding Slack Cable. .Winding the Winch Line on the Drum . . .Locking the Front Winch for Travel . . .

Operation of Cargo Trucks . . . . . . . .General . . . . . . . . . . . . . .Removing the Front and Side Racks . . .Install ing the Front and Side Racks . . .Removing the Front and Side Racks from

Drops ide Type Cargo Trucks . . . . .Lowering the Dropsides on Dropside Type

Cargo Trucks . . . . . . . . . . .Removing the Dropsides, Tailgate

or Both. . . . . . . . . . . . . .Installing the Dropsides, Tailgate, Side

Racks and Front Racks . . . . . . . .Operation of Fuel Tank Trucks . . . . . . .

General . . . . . . . . . . . . . .Gravity Fill ing the Tank Sections . . . .Suction Filling the Tank Sections or Trans-

ferring Fuel from One Source toAnother through Pump . . . . . . . .

Pa ragraph

4-3 d4-3 e

4- 3f

4-3 g4- 4

4-4 a

4-4 b

4-4 c

4-4 d

4-54-64-6 a4-6 b4-6 c4-6 d4-6 e4-74-7 a4-7 b4-7 c4-7 d4-7 e4-7 f 4-7 g4-7 h4-84-8 a4-8 b4-8 c

4-8 d

4-8 e

4-8 f

4-8 g4-94-9 a4-9 b

4-9 c

Page

4-174-18

4-19

4-204-23

4-23

4-24

4-27

4-284-294-294-294-304-374-414-434-554-584-584-584-594-654-694-704-724-754-774-774-774-80

4-83

4-88

4-93

4-954-984-984-98

4-110

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Power Discharging the Tank Sections . .Checking Condition of Filter . . . . .Gravity Discharging the Tank Sections .Fording . . . . . . . . . . . . . .

Opera t ion o f Wate r Tank Trucks . . . . .General . . . . . . . . . . . . . .Gravity Filling the Tank Sections . . . .Suction Filling the Tank Sections and

Transferring Water from One Locationto Another . . . . . . . . . . . .

Hydrant Fil l ing the Tank Sections . . .Power Discharging the Tank Sections . .Gravity Discharging the Tank Sections .Operating Water Tank Trucks

During Freezing Temperatures . . . .Operation of Shop Van and Instrument Repair

Shop Van Trucks. . . . . . . . . . .Preparing Shop Van and Instrument Repair

Shop Van for Use. . . . . . . . .Supplying 115-Volt AC Power to Shop VanOperating the Exhaust Blower . . . . .Operating the Dome and Blackout Dome

Lights . . . . . . . . . . . . .Supplying Power to Moulding Receptacles

Operation of Tractor Trucks . . . . . . .General . . . . . . . . . . . . . .Coupling the Semitrailer . . . . . . .Uncoupling the Semitrailer . . . . . .

Operation of Dump Trucks . . . . . .General . . . . . . . . . . . . . .Rigging the Tailgate . . . . . . . .Loading the Dump Truck . . . . . . .Unloading the Dump Truck with Body

Down . . . . . . . . . . . . . .Unloading the Dump Truck by Dumping .Unloading the Dump Truck by Spreading

Operation of Pipeline Construction Truck . .General . . . . . . . . . . . . . .Operating the Rear Winch . . . . . . .Rigging the A-Frame for Rear Operation .Lowering the A-Frame and Preparing . .

Truck for Travel after Rear Operation .Rigging the A-Frame for Side Operation .Lowering the A-Frame and Preparing

Truck for Travel after Side Operation .Operation of Earth Boring Machine and

Polesetter Trucks . . . . . . . . . . .General . . . . . . . . . . . . . .Preparing the Truck for Boring Operation

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

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. .

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. .

. .

Paragraph

4-9 d4-9 e4 -9 f 4-9 g4-104-10 a4-10 b

4-10 c4-10 d4-10 e4 - l 0 f

4 - l 0 g

4-11

4-11 a4 - 1 l b4 - l l c

4 - l l d4 -1 l e4-124-12 a4-12 b4-12 c4-134-13 a4-13 b4-13 c

4-13 d4-13 e4-13 f 4-144-14 a4- 14 b4-14 c

4-14 d4-14 e

4-14 f

4-154-15 a4-15 b

Page

4-1314-1394-1434-1514-1564-1564-157

4-1614-1754-1864-192

4-195

4-202

4-2024-2094-210

4-2124-2164-2174-2174-2174-2314-2354-2354-2364-238

4-2444-2474-2524-2574-2574-2574-271

4-2784-291

4-302

4-3114-3114-311

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Raising, Leveling, and Lowering theDerrick Tube .

Operating and Securing the Rear Winch...Installing 9-inch, 12-inch, and 16-inchAugers . . . . . . . . . . . .

Installing 20-inch and 30-inch Augers .Operating the Earth Boring Machine. .Boring in Various Soils . . . . . . .Preparing Boring Machine for Travel .Dragging Poles. . . . . . . . . .Setting Poles. . . . . . . . . . .Pulling Poles. . . . . . . . . . .Operating Collapsible Cable Reel . . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .Operation of Hot Water Personnel Heater Kit. . .Operation of Arctic Winterization Kit . . . . . .

General . . . . . . . . . . . . . . .Operating the Winterfront Cover . . . . . .Using the Quilted Engine Compartment

Cover . . . . . . . . . . . . .Operating the Fuel Burning Personnel

Heater . . . . . . . . . .Operating the Fuel Burning Power Plant

Heater . . . . . . . . . . . . . .Using the Slave Receptacle . . . . . . . .

Operating the Deep Water Fording Kit . . . . .Operating the Electric Brake Kit . . . . . . .

Section III. Operation Under Unusual ConditionsScope . . . . . .

General . . . . . .Operation in ExtremelyGeneral . . . . .Related PublicationsWinterization Kits .Moving the Truck .Parking . . . . .Refueling . . . .

. . . . . . . . . . .

. . . . . . . . . . . .Cold Weather . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .Operation in Extreme Hot Weather . . . . . . .

General . . . . . . . . . . . . . . . .Cooling System . . . . . . . . . . . . .Batteries . . . . . . . . . . . . . . .Body and Chassis . . . . . . . . . . . .

Parking the Truck . . . . . . . . . .Operation on Unusual Terrain . . . . . . . .Deep Snow or Mud . . . . . . . . . . .Hard Baked Sand. . . . . . . . . . . .Ice . . . . . . . . .Dusty or Sandy Roads . . . . . . . . .Rocks and Boulders . . . . . . . . . . .High Altitudes . . . . . . . . . . . . .

Paragraph

4-15 c

4-15 d4-15 e4-15 f 4-15 g4-15 h4-15 i4-15 j4-15 k 4-15 l4-15 m4-164-17

4-17 a4-17 b

4-17 c

4-17 d

4-17 e4-17 f 4-184-19

4-20

4-214-224-22 a4-22 b4-22 c4-22 d4-22 e4-22 f 4-234-23 a4-23 b4-23 c4-23 d

4-23 e4-244-24 a4-24 b4-24 c4-24 d4-24 e4-24 f

4-315

4-3224-3294-3314-3374-3474-3524-3624-3654-3694-3734-3834-384

4-3844-384

4-385

4-386

4-3914-3954-3984-4034-4044-404

4-4044-4044-4044-4044-4044-4054-4064-4074-4084-4084-4084-4084-408

4-4094-4094-4094-4094-4094-4104-4104-410

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Fording Operation . . . . . . . . . . . . .General . . . . . . . . . . . . . . . .Fording . . . . . . . . . . . . . . . .Fording, Water Tank Trucks . . . . . . . .After Fording . . . . . . . . . . . . . .Care of Vehicle After Fording . . . . . . . .Accidental Submersion. . . . . . . . . . .

Emergency Procedures . . . . . . . . . .Using Slave Receptacle to Start the

Engine . . . . . . . . . .Using Jumper Cables to Start the

Engine . . . . . . . . .Towing the Truck to Start Engine .Highway Towing (M44A2 SeriesHighway Towing (M44A1 Series

. . . . . . .

. . . . . . .Trucks) . . . .Trucks) . . . .

APPENDIX A.Refe rence . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .

APPENDIX B .Section I .

Section II.Section III.

APPENDIX C .Section 1.

Section II.APPENDIX D.

Section 1.

Section II.

INDEX . . .

REFERENCESPublication Indexes and General

Military Publications Indexes .General Reference . . . .

Forms . . . . . . . . . .Other Publications . . . . .

Truck . . . . . . . . . .General . . . . . . . . .

COMPONENTS OF END ITEM LISTIntroduction . . . . . . . . . . . . . . .

Scope . . . . . . . . . . . . . . . . .General . . . . . . . . . . . . . . . . .Explanation of Columns . . . . . . . . . .Abbreviations . . . . . . . . . . . . . .

Integral Components of the End Item . . . . . .Basic Issue Items . . . . . . . . . . . . .ADDITIONAL AUTHORIZATION LISTIntroduction . . . . . . . . . . . . . . .

Scope . . . . . . . . . . . . . . . . .General . . . . . . . . . . . . . . . . .Explanation of Listing . . . . . . . . . . .

Additional Authorization ListEXPENDABLE SUPPLIES AND MATERIALS LIST.Introduction . . . . . . . . . . . . . . .

Scope . . . . . . . . . . . . . . . . .Explanation of Columns . . . . . . . . . .

Expendable Supplies and Materials List . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

4-254-25 a4-25 b4-25 c4-25 d4-25 e4-25 f 4-26

4-26 a

4-26 b4-26 c4-26 d4-26 e

A-1A-1 aA - l bA-2A-3A-3 aA-3 b

B-1B-2B-3B-4

C-1C-2C-3

D-1D-2

Page

4-4104-4104-4114-4134-4174-4184-4184-419

4-419

4-4194-4234-4264-428

A-1A-1A-1A-1A-1A-1A-2

B-1B-1B-1B-1B-3B-4B-6

C-1C-1C-1C-3

D-1D-1D-1D-2

Index 1

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CHAPTER 1.2.3.4.

CHAPTER 1.2.3.4.5.6.7.8.9.10.

11.

12.

13.

14.15.16.

17.

18.19.

20.

21.

VOLUME 2 of 4

SCHEDULED MAINTENANCE

Page

PREVENTIVE MAINTENANCE . . . . . . . . . . . 1-1CHECKOUT , ALINEMENT , AND ADJUSTMENT . . . . 2-1LUBRICATION . . . . . . . . . . . . . 3-1SCHEDULED MAINTENANCE OF MATERIAL USED

IN CONJUNCTION WITH MAJOR ITEMS . . . . . . 4-1

VOLUME 3 of 4

TROUBLESHOOTING

GENERAL INFORMATION 1-1TROUBLESHOOTING APPROACH . . . . . . . . . . . . . . . . . 2-1TROUBLESHOOTING INDEX 3-1TEST EQUIPMENT PROCEDURES INDEX . . . . . . . . . . . 4-1TROUBLESHOOTING ROADMAPS . . . . . . . . . 5-1FAULT SYMPTOM INDEXES 6-1SAMPLE TROUBLESHOOTING PROCEDURE. . . . . . . .. . . 7-1FUEL SYSTEM TROUBLESHOOTING PROCEDURES . 8-1COOLING SYSTEM TROUBLESHOOTING PROCEDURE . 9-1TRANSMISSION SYSTEM TROUBLESHOOTINGPROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1TRANSFER SYSTEM TROUBLESHOOTINGPROCEDURES . . . . . . . . . . . . . ...11-1

FRONT AXLE SYSTEM TROUBLESHOOTINGPROCEDURES 12-1

R E A R A X L E S Y S T E M T R O U B L E S H O O T I N GPROCEDURES . . . . . . . . . . . . . ...13-1

BRAKE SYSTEM TROUBLESHOOTING PROCEDURES . . 14-1WHEEL SYSTEM TROUBLESHOOTING PROCEDURES . . 15-1STEERING SYSTEM TROUBLESHOOTINGPROCEDURES 16-1

OUTRIGGER TROUBLESHOOTING PROCEDURES,TRUCK M764 . . . . . . . . . . . . . ...17-1

FRONT WINCH TROUBLESHOOTING PROCEDURES . . 18-1REAR WINCH TROUBLESHOOTING PROCEDURESTRUCK M764 . . . . . . . . . . . . . ...19-1

REAR WINCH TROUBLESHOOTING PROCEDURES,TRUCK M756A2 . . . . . . . . . . . . . ...20-1

DUMP TRUCK TROUBLESHOOTING PROCEDURES . . 21-1

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MAINTENANCE

CHAPTER 1.2.

Section I.I I .

III.IV.V.

VI.VII .

Figure

1-1

1-2

1-3

1-4

1-51-61-7

1-8

2-12-22-32-42-5

Page

GENERAL MAINTENANCE INFORMATION. . . . . . . . . . 1-1EQUIPMENT GROUP MAINTENANCE. . . . . . . . . . . . . . . . 2-1Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Engine Equipment Items Maintenance . . . . . . . . . . . . . . . 2-2Wheels Equipment Items Maintenance . . . . . . . . . . . . . . . 2-14Electrical Equipment Items Maintenance . . . . . . . . . . . . 2-32Winch Equipment Items Maintenance. . . . . . . . . . . . . . . . 2-35Body Equipment Items Maintenance . . . . . . . . . . . . . . . . 2-43Special Purpose Kits Equipment Items . . . . . . . . . . . . . .Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

LIST OF ILLUSTRATIONS

Title Page

Typical 2 l/2-Ton 6 x 6 Cargo Truck, M35A1, M35A2,M35A2C , M36A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Typical 2 l/2-Ton 6 x 6 Fuel Servicing Tank Truck (M49A1C , M49A2C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Typical 2 l/2-Ton 6 x 6 Water Tank Truck (M50A1,M50A2, M50A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Typical 2 l/2-Ton 6 x 6 Truck Mounted InstrumentRepair Shop (M185A2, M185A3) or Truck MountedVan (M109A2, M109A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Typical 2 l/2-Ton 6 x 6 Tractor Truck, (M275A1, M275A2). . . . 1-4Typical 2 l/2-Ton 6 x 6 Dump Truck (M342A2) . . . . . . . . . . . . . . . 1-4Typical 2 l/2-Ton 6 x 6 Pipeline Construction Truck (M756A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Typical 2 l/2-Ton 6 x 6 Earth Boring Machine andPolesette r Truck (M764) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Overall Equipment Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Engine Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Clutch Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Electrical System Component Locat ion . . . . . . . . . . . . . . . . . . . . . . . . 2-6Fuel and Air Intake System Components Location . . . . . . . . . . . . . 2-7

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Figure

2-62-72-8

2-92-10

2-11

2-12

2-13

2-142-15

2-162-172-18B-1

B-2B-2B-3B-4

B-4

B-5

B-5

B-5

B-5

B-6

B-6

B-7

x

Title

Cooling System Components Location . . . . . . . . . . . . . . . . . . . . . . . .Exhaust System Component Location (LDS 427-2 Engines). . . .Exhaust System Component Location (M50A1 and M50A2Trucks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System Component Location (LD 465-1-lC Engine). . .Exhaust System , Stack Type, Components Location

(LD 465-lC and LDT 465-lC Engines) . . . . . . . . . . . . . . . . . . . . . .Exhaust System Component Location (M49A 2C Fuel

Tankers and M275 Tractor Trucks) . . . . . . . . . . . . . . . . . . . . . . . .Transmission Power Takeoff Systems Component

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Propeller and Drive Shafts System Component Location(Trucks with Winch except M49, M50, and M764). . . . . . . . . . . .

Propeller and Drive Shafts System Component Location(M49, M50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Propeller and Drive Shafts System Component Location(M764) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering System Component Location . . . . . . . . . . . . . . . . . . . . . . . .Brake System Component Location . . . . . . . . . . . . . . . . . . . . . . . . . .Axles, Wheels, and Hubs System Component LocationRepair Shop Truck (M185A2, M185A3) Tools andEquipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Miscellaneous Tools and Equipment ( Sheet 1 of 2) . . . . . . . . . . . .Miscellaneous Tools and Equipment (Sheet 2 of 2) . . . . . . . . . . . .Fuel Truck (M49A1C , M49A2C) Tools and Equipment. . . . . . . . .Water Truck (M50A1, M50A2, M50A3) Tools and

Equipment (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . .Water Truck (M50A1, M50A2, M50A3) Tools andEquipment (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . .

Shop Van (M185A2, M185A3) Tools and Equipment(Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shop Van (M185A2, M185A3) Tools and Equipment(Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Shop Van (M185A2, M185A3) Tools and Equipment(Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shop Van (M185A2, M185A3) Tools and Equipment(Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipeline Construction Truck (M765A 2) Tools andEquipment (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . .

Pipeline Construction Truck ( M756A 2) Tools andEquipment (Sheet 20 of 2) . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

Earth Boring and Polesetting Truck (M764) Tools. . . . . . . . . . .

and Equipment ( Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

2-82-9

2-102-11

2-12

2-13

2-14

2-15

2-16

2-172-182-192-20

B-4B-6B-8B-10

B-12

B-14

B-16

B-18

B-20

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Figure

B-7

B-7

B-8

Number1-12-12-22-32-42-52-62-72-84-14-2

4-34-4

Title

Earth Boring and Polesetting Truck (M764) Toolsand Equipment (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Earth Boring and Polesetting Truck (M764) Toolsand Equipment (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipeline Construction Truck (M 756A 2) and EarthBoring and Polesetting Truck (M764) Tools andEquipment . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES

. . . . . . . . . . . . . . . . .

Title

Vehicle Class Information . . . . . . . . . . . .Weight (Pounds) . . . . . . . . . . . . . . . . . . . . .Dimensions (Inches) . . . . . . . . . . . . . . . . . .Operating Dimensions . . . . . . . . . . . . . . . .Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . .Tire Inflation Data . . . . . . . . . . . . . . . . . . .Permissible Fuels . . . . . . . . .Shifting Speeds in Mph . . . . . . . . . . . . . . .Engine and Radiator Data . . . . . . . . . . . .Vehicle Lights Chart . . . . . . . . . . . . . . . . .Weight of Material in Truck. . . . . . . . . . .

Boring Machine Controls . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

Gear Speed Settings for Soil Conditions . . . . . . . . . . . . . . . . . . . .

Page

B-30

B-32

B-34

Page

1-62-222-222-232-232-242-242-262-264-454-235

4-3394-341

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CHAPTER 1

INTRODUCTION

1-1. SCOPE. This Technical Manual contains operating instructions for the 2 l/2-ton,6x6 M44A1 and M44A2 series trucks (f igures 1-1 through 1-8) equipped with multifuelengines, and operator level maintenance instructions in accordance with the MaintenanceAllocation Chart. Operating instructions for special purpose kits used with these trucksare also included. The purpose of this manual is to give the operator the information heneeds for safe, trouble-free operation of the equipment under usual and unusual conditions.

1-2. FORMS A ND RECORDS. Maintenance forms, records, and reports which are to beused by maintenance personnel at all levels are listed in and prescribed by TM 38-750.

1-3. EQUIPMENT IMPROVEMENT REPORT A ND MAINTENANCE DIGEST (EIR MD)AND E QUIPMEN T IMPROVEMENT REPORT AND MAINTENANCE E SUMMARY (EIR MS).The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39series, contains valuable field information on the equipment covered in this manual. Theinformation in the TB 43-0001-39 series is compiled from some of the Equipment Im-provement Reports that you prepared on the vehicles covered in this manual. Many of thesearticles result from comments, suggestions, and improvement recommendations that yousubmitted to the EIR program. The TB 43-0001-39 series contains information on equip-ment improvements, minor alterations, proposed Modification Work Orders (MWOs),warranties (if applicable), actions taken on some of your DA Form 2028's (RecommendedChanges to Publications), and advance information on proposed changes that may affectthis manual. In addition, the more maintenance significant articles, including minoralterations, field-fixes, etc, that have a more permanent and continuing need in the fieldare republished in the Equipment Improvement Report and Maintenance Summary (EIR MS)for TARCOM Equipment (TM 43-0143). Refer to both of these publications (TB 43-0001-39series and TM 43-0143) periodically, especially the TB 43-0001-39 series, for the mostcurrent and authoritative information on your equipment. The information will help youin doing your job better and will help in keeping you advised of the latest changes to thismanual. Also refer to DA Pam 310-4, Index of Technical Publications, and Appendix A,References, of this manual.

1 -4 . R EP ORTI NG IM PR OVE ME N T R E CO MM EN DAT I ONS. If your truck needs improve-ment, let us know. Send us an EIR. YO U , the user, are the only one who can tell us whatyou dont like about your equipmen t. Let u s kn ow why you dont like t he des ign. Tell uswhy a procedure is hard to perform. Put it on an SF 368 (Quality Deficiency Report).Mail it to us at: Commander, U. S. Army Tank Automotive Materiel Readiness Command,ATTN: DRSTA-MT, Warren, Michigan 48090. Well send you a reply.

1-5. METRI C SYSTEM. The equipment/system described herein is nonmetric and doesnot require metric common or special tools. Therefore, metric units are not supplied.Tactical instructions, for sake of clarity, will also remain nonmetric.

1-6. DESTRUCTIO N TO PREVENT ENEMY USE. Follow procedures given inT M 7 5 0 - 2 4 4 - 6 f o r d e s t r u c t i o n o f A r m y m a t e r i e l t o p r e v e n t e n e m y u s e .

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Figure 1-1 . Typical 2 1/2-Ton 6x6 Cargo Truck (M35A1, M35A2, M35A2C, M36A2) .

Figure 1-2 . Typica1 21/2-Ton 6x6 Fuel Servicing Tank Truck (M49A1C, M49A2C).

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Figure 1-3 . Typical 2 l/2-Ton 6x6 Water Tank Truck (M50A1, M50A2, M50A3).

Figure 1-4, Typical 2 1/2-Ton 6x6 Truck Mounted Instrument Repair Shop (M185A2,M185A3) or Truck Mounted Van (M109A2, M109A3).

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Figure 1-5 . Typical 2 l/2-Ton 6x6 Tractor Truck (M275A1, M275A2) .

Figure 1-6. Typical 2 l/2-Ton 6x6 Dump Truck (M342A2).

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Figure 1-7 . Typical 2 l/2-Ton 6x6 Pipeline Construction Truck (M756A2).

Figure 1-8 . Typical 2 1/2-Ton 6x6 Earth Boring Machine and Polesetter Truck (M764)

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1-7. MANUA L ORGANIZATION. This manual is divided into four volumes. Volumes aredivided into chapters and sections depending on the amount of subject material. The contentof each volume is as follows:

Volume 1. TM 9-2320-209-10-1, Operation, Installation, and Reference Data.

Volume 2. TM 9-2320-209-10-2, Scheduled Maintenance.

Volume 3. TM 9-2320-209-10-3, Troubleshooting.

Volume 4. TM 9-2320-209-10-4, Maintenance.

1-8. VEHICL E /BRIDGE CLASSIFICATION. Refer t o table 1- 1 and find your vehicle classnumber. Table columns are marked as follows:

E - Class number of vehicle with no payload.

C - Class number of vehicle with cross-country payload.

H - Class number of vehicle with highway payload.

a. Bridges along your route may be marked with a class number. The bridge classnumber shows the-safe capacity of the bridge. If your vehicle class number is equal to orless than the bridge class number, the bridge will hold your vehicle. If your vehicle classnumber is greater than the bridge class number, your vehicle is too heavy for the bridge;DO NOT CROSS.

b. For more information refer to FM 5-36.

Table 1-1 . Vehicle Class Information

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Tab le 1 -1 . Veh ic l e C la s s In fo rma t ion - Con t

C l a s s N u m b e r

Ve h i c l e Mode l NSN E C H

Wa t e r Ta n k - C o n t M50A2 2320-00-077-1633 a n d 7 9 112 3 2 0 -0 0 -0 7 7 -1 6 3 4 7 9 11

M50A3 2320-00-037-4036 a n d 6 8 102 3 2 0 -0 0 -9 3 7 -5 2 6 4 6 8 10

Shop Va n M109A2 2320-00-440-8313 a n d 7 9 102320-00-440-8308 7 9 10

M109A3 2320-00-077-1636 a n d 7 9 102320-00-077-1637 7 9 10

Repair Shop M185A2 4940-00-987-8799 and 7 10 10

4940-00-987-8800 * * *M185A3 4940000771638 and 7 10 11

4940-00-077-1639 8 10 11

T r a c t o r M275A1 2 3 2 0 - 0 0 - 4 4 6 - 2 4 7 9 5

M275A2 2320-00-077-1640 a n d 5 8 112320-00-077-1641 5 9 11

D u m p M342A2 2320-00-077-1643 and 7 9 122320-00-077-1644 7 9 12

P ipe l ine Cons t ruc t ion M756A2 2 3 2 0 - 0 0 - 9 0 4 - 3 2 7 7 7 10 13

Ear th Bor ing and M764 2 3 2 0 - 0 0 - 9 3 7 - 5 9 8 0 9 9 10P o l e s e t t i n g

* Information to be supplied when it becomes available. Tractor only (without semitrailer).

Weight of semitrailer and payload must be knownto determine class n umber.

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CHAPTER 2

DESCRIPTION AND DATA

Section I. FUNCTIONAL DESCRIPTION

2-1. GENE RAL. The 2 l/2-ton, 6x6 M44A1 and M44A2 series trucks are tactical ve-hicles designed for use on all types of roads, highways, and cross country terrain. Theywill ford ha rd bott om water crossings up to 30 inches deep without special fording equ ip-ment. The following paragraphs are provided to give the operator an overall understandingof th e equipment a nd its ma in fun ctions. The descriptive text is keyed t o an overall equip-men t block diagr am , which shows each fun ctiona l group of the equipm ent as a block,Arrows are used to show the flow of power to and from each functional block on the diagram,

WARNING

This vehicle ha s been designed t o opera te sa fely and efficient ly with in t helimits specified in this TM. Operation beyond these limits is prohibited IAWAR 70-1 without writ ten a pproval from th e Comma nder , U.S. Army Tank-Automotive Command, ATTN: AMSTA-CM-S, Warren, MI 48397-5000.

2-2. OVERAL L EQUIP MENT F UNCTIONAL DESCRIPTION. (Se e Fig. 2- 1,)a .Engine. The engine fun ctions to supply power to move th e tru ck a nd operat e equip- ment and accessories.

b. Clutch. Th e clut ch by mean s of mecha nical link age, connects power pr oduced by t heengine, to the tr ansm ission. The clutch also separates power from the transm ission whennot needed, or while shifting transmission gears.

c. Electrical System. The electrical system supplies electrical curr ent to star t theengine, operate lights, equipment and accessories, and to charge the batteries.

d . F u e l S y s t e m . The fuel system functions to store fuel in t an ks, deliver fuel to theengine, as required, and retur n excess fuel to the tan ks.

e . Cooling System. The cooling system functions to remove excess heat producedwhile the engine is runn ing, and to keep th e engine at normal operat ing temperatu re. Thecooling system a lso supplies heat to warm th e cab or personnel compa rt men t, when r equired.

f. Exhaus t System. The exhaust system functions to collect and remove exhaust gassesproduced when t he engine is operat ing. The exhaust system also supplies heat necessary toheat wat er in water ta nk tr ucks, when required.

g . Tran smission System. The t ra nsm ission system gives the operat or a choice of fiveforward gear combinations (speeds), reverse, and neutral position for operating the truck efficiently at all speeds and conditions.

h . Transfer System. The t ra nsfer system sen ds power from t ra nsm ission t o propellershafts to drive front an d rear wheels. The system gives an additional gear combination(speed) for each transmission speed.

i. Transmission Power Take-off System. This system transmits power to propellershafts to operate auxiliary equipment.

j . Transfer Power Take-off System. This system transmits power from the transferunit to propeller shafts to operate auxiliary equipment and accessories.

k . P ropeller Sh a ft s. Propeller shafts are used to transmit power from transmissionto the t ran sfer system an d from t ran sfer system to axles. Pr opeller sha fts a lso tr an smitpower from power take-off assemblies to auxiliary equipment and accessories.

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l . Steering System. When the operator turns steering wheel, the steering systemsends this action to front wheels. This system functions to control direction of truck while in motion.

m. Brake System. When the operator steps on service brake pedal, brake systemfunctions to slow down or stop truck. A handbrake, when set to up position by theoperator, is used for parking vehicle.

n . Axles, Wheels, and Hubs. The axles support the weight of the truck a n dtransmit power to the hubs to turn the wheels. The front and both rear axles are powered (live) axles.

o . Auxiliary Equipment and Accessories. These components perform required tasks,such as pull ing, lifting, earth b oring, heating, towing and fording.

Section II. PHYSICAL DESCRIPTION

2-3. GENERA L. Three basic wheelbase chassis are available for mounting various

body types, (cargo, dump, tankers, vans, tractor, earth boring and pole setting, andpipeline construction bodies). The following paragraph will describe systems, units,and components of the various trucks. The diagrams show location of these items onthe vehicle.

2-4. OVERALL EQUIPMENT PHYSICAL DESCRIPTION.

a. Engine. M44A1 and M44A2 series trucks are equipped with US Army LDS 427-2,LD 465-1, and LD465-lC six-cylinder in-line, liquid-cooled. multifuel engines. The multi-fuel engine (fig. 2-2 ) uses the fuel injection compression ignition principle which permitsthe use of various grades of fuel. Refer to Table 2-6, for fuel grades to be used.

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Figure 2-1. Overall Equipment Block Diagram.

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1. Man ifold 5. F lywheel h ousing

2. Block 6. Oil pan

3. Cylinder head 7. Crankcase

4. Oil filter

Figure 2-2. Engine Components Location.

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b. Clutch. The clutch (fig. 2-3 ) has two plates (disks), one attached to the flywheel of the engine, the other connected to the transmission. The disks are pressed together by apressure plate . When the engine is running, the disk attached to the flywheel drives thedisk attached to the transmission, turning the gears in the transmission. The plates areseparated when the operator steps down on the clutch pedal. The gears in the transmissionstop turning to let the operator shift gears.

1. Clutch pedal

2. Clutch linkage

3. Clutch

Figure 2-3. Clutch Components Location.

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c. Electrical System. The electrical system (fig. 2-4 ) is a 24-volt dc system .Two 12-volt storage batteries are connected in series with the negative terminalgrounded. The engine start er motor operates directly from the 24-volt source. Thesystem uses a belt-driven, 24-volt generator having an output capacity of 25 amperes.A battery-generator indicator is located on the instrument panel. Wiring harnessesare used to carry current to operate equipment and accessories. Circuit breakers areincluded to protect circuits from overload.

1.

2.

3.

4.5.

6.

7.

Trailer coupling

Horn button

Gages and controls

RegulatorManifold air heater ignition unit

Star ter

8. L i g h t s

9. G e n e r a t o r10. Oi l pressure gage sending unit

11. Batteries12. Ground strap13. Fuel level gage sending unit

Water temperat ure gagesending unit

Figure 2-4. Electrical System Component Location

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d. Fuel and Air Intake System.intake ma nifold heater , air cleaner,filters, injection pump, nozzle, fuelengine stop, and hand throttle.

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The fuel and air int ake system ( fig. 2-5) includes anfuel tanks, fuel pump, primary and secondary fuellines and fittings, accelerator pedal and linkage,

TA 044898

1. Fuel tank 8. Filters

2. Fuel lines 9. Turbocharger

3. Air cleaner 10. supply pump

4. Throttle control 11. Fuel injector nozzles and holder

5. Engine stop control 12. Fuel return connectors6. Manifold heater 13. Accelerator controls and linkages

7. Injection pump 14. Fuel pump

Figure 2-5. Fuel and Air Intake System Components Location.

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e. Coolin g Syst em . The cooling system (fig. 2- 6) is a sealed-type system madeup of the radiator, fan, drive belts, thermostat, water pump , temperature gage,pressure-type filler cap, thermostat bypass line connecting the radiator to the engine,and the water pump.

1. Thermostat housing

2. Shroud

3. Radiator and cap

4. Fan and fan belt

5. Water pump

Figure 2-6. Cooling System Components Location.

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f. Exhau st System. There are different exhau st system setups used on the t ruckscovered in this manual. The following paragraphs note the differences in exhaust systemsused with pa rticular engines, or with certain tru cks.

(1) On vehicles with LDS 427-2 engines (fig. 2-7 ), the exhaust ma nifold emptiesdirect ly into the tu rbo-supercharger. The pressurized exhaust gasses dr ive the turbo-

supercha rger an d pass from the tur bo-supercharger outlet thr ough a n exhau st pipe assembly.The pipe assembly extends back along the right side of the truck, to the outlet, locatedbetween t he right ta ndem wheels.

1. Turbo-supercharger 2. Exhaust pipes

Figure 2-7. Exha ust System Component Locat ion (LDS 427-2 En gines).

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(2) The M50A1 an d M50A2 (fig . 2-8) w ater tan k t r ucks have an exhau st bypass valvean d a bypass fording valve. The exhaust bypass valve is opened to let exhau st gasses h eatthe water in the tanks. The bypass fording valve is used to close off the heating chamber.under the tanks, while fording.

1.

2.

3.

Manifold

Exhaust pipe

Exhau st bypass valve

Bypass fording valve(deep water fording only)

Figure 2-8. Exhaust System

4. Muffler

5. Tailpipe

Component Location (M50A1 and M50A2 Trucks).

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(3) On earlier model M44A2 series trucks with LD465-1 and LD465-lC engines,the exhaust system (fig. 2- 9) is made u p of front a nd r ear exhaus t pipes, muffler, and t ail-pipe. The exhau st pipes ar e conn ected d irectly to th e ma nifold.

1. Manifold2. Exhaust pipe

3. Muffler4. Tailpipe

Figure 2-9. Exha ust System Componen t Locat ion (LD 465-1-1C En gine).

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(4) On later model M44A2 series t ru cks with LD465-1C an d LDT 465-1C engines(except M50A2 water tankers), a stack-type exhaust system is used. The upper exhaustpipe (sta ck) is m ount ed on th e right side of truck a nd extends a bove cab t op.

Figure 2-10. Exhaust System Stack Type, Component location, (LD 465-1Cand LDT 465-1C Engines).

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(5) The exhau st system on M49A2C fuel ta nker an d M275 tractor tr ucks(fig. 2-11 ) includes a spar k-arr estor-type mu ffler, which t ra ps exhau st spa rk s from th eengine.

1. Exhaust shield

2. Lower exhau st p ipe

TA 0 4 4 9 0 4

3. Muffler

4. Upper exhaust pipe

Figure 2-11. Exhaust System Component Location (M49A2C FuelTankers and M275 Tractor Trucks).

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g . Transmission. The transmission (fig. 2-12 ) is a ma nu ally opera ted synchromeshtype, moun ted on th e rear of th e engine. The transmission supplies one reverse and fiveforward speeds.

h . Tr a ns mis sion P ower Tak eoff (Fig. 2-12 ). All tr ucks except du mp t ru ck, havesingle-ended transmission power takeoff units. The dump tru ck h as a double-ended unit .

(1) Single-ended unit is a two-speed-and-reverse drive, mounted on the left side of th e tr an smission. The power t akeoff supplies power to th e front winch. The power t ak eoff is contr olled by a s hifting lever in th e cab.

(2) Double-ended unit is mounted on the left side of the transmission. The forwardout put sha ft is a t wo-speed-an d-reverse drive to the front winch with shifting lever in th ecab. The rear accessory drive shaft drives the hydraulic hoist pump on dump trucks andis controlled by the drivers hydraulic hoist control lever in the cab.

i . Tra ns fer. The t ran sfer ( fig. 2-12 ) is a two-speed synchromesh unit driven by thetra nsmission thr ough a propeller sha ft . The transfer drives propeller shafts connected tothe front a nd rear wheels. The han dbrake drum is mount ed on th e tran sfer rear outputcompanion shaft.

j . Transfer Power Takeoff. The transfer power takeoff (fig. 2-1 2) is att ached to therear of the tr an sfer, an d is cont rolled by a lever in t he cab. The unit fun ctions t o supplypower to auxiliary equipment.

1 . Front transmission gear shift lever2. Transmission power takeoff shifting

3. Tra ns fer power t ak eoff lever (allexcept M342A2)

4. Tr an sfer a ssem blylever 5. Transmission assembly

6. Transmission powertakeoff assembly

4. Hydr au lic hoist contr ol lever (on M342A2)

Figure 2-12. Transmission Power Takeoff System Component Location.

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k. Pr opeller an d Drive Sha ft Systems. Except on M49 an d M50 tank tr ucks, alldrive shafts a re double universal joint t ype. Tank trucks shafts a re solid and supportedon each end by a flange and pillow-block with a bearing assembl y. Figures 2- 13, 2-14,an d 2-15 give th e sha fts an d locations for th e different model trucks.

1. Front axle propeller shaft assembly

2. Intermediate propeller shaft(except M342A2)

3. Rear axle propeller drive shaft

Figure 2-13. Propeller and Drive Shafts System ComponentLocat ion (Tru cks with Winch except M49, M50, and M764).

4. Hydrau lic hoist pu mp d rive shaft(on M342A2)

5. Transfer propeller shaft assembly

6. Front drive shaft assembly

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1.

2 .

3.

4 .

Front axle propeller shaft assembly 5. Delivery pump intermediate drivesha ft (M49 only)

Forward rear axle propeller shaft6 . D elive r y p u m p fr on t d r ive sh a ft

Rear rear axle drive shaft (M50 only)

Delivery pump rear drive shaft 7 . Tr a n sfe r p r op elle r s h a ft a s se m bly

Figure 2-14 . Pr opeller a nd Drive Sha fts System Componen t Locat ion (M49, M50).

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Front axle propeller shaft assembly

Power-divider drive shaft assembly

Forward rear axle drive shaft

Rear rear axle drive shaft

Figure 2-15 . Propeller and Drive Shafts System Component Location (M764).

2 - 1 7

1.

2.

3.

4.

5. Earth boring machine drive shaft

6. Transfer propel ler shaf t assembly

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1. Steering System. The steering system ( fig. 2-16) consists of a steering wheel, ahelical cam and lever-type steering gear, pitman arm, drag link and tie rods. Turningmotion applied to the steering wheel is sent through these components to steer the frontwheels .

1. Steering wheel 4 . P i tma n a rm

2. Tie rods 5. Helical cam

3. Drag link 6. Steering gear

Figure 2-16. Steering System Component Location.

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m. Brake System. The brake syste m (fig. 2- 17) includes the service brak es an d a han d-brake. The compressed air system is covered here since it is part of the brake system.

(1) The service brake system, is an air-hydraulic system made up of a mastercylinder, a ir-hydra ulic cylinder, in dividual hydra ulic wheel cylinders, an air compr essor,air reservoirs, air lines, hydraulic lines and linkage, and trailer brake connections andcontrols. The master cylinder contains hydraulic fluid. Pressure on the brake pedal is

transmitted to the air-hydraulic cylinder. The air-hydraulic cylinder increases pressureto the wheel cylinders. The wheel cylinders expand an d press t he bra ke sh oes against thedrum to slow or st op th e tru ck.

(2) The ha ndbra ke system consists of a bra ke dru m, mount ed on t he rear out putsha ft of the tra nsfer, an d inner an d outer bra keshoes operat ed by a single shoe lever. Acable atta ched to th e brake sh oe lever run s th rough a pr otective casing to the h an dbrak elever a t t he left of the dr iver s sea t.

(3) The compr essed a ir system is used t o supply air to th e air-hydra ulic cylinder ,windshield wiper m otors, and tra iler a irbrakes. This system can a lso be used in an emer-gency to clean th e air cleaner an d inflate t ires. When a ir pressur e in th e air r eservoir ta nksis low, a buzzer is set off in th e driver s compa rt men t t o war n t he operat or.

1. Brake peda l 7. Master cylinder2 . Air r eser voir t a nk s 8 . Air hydraul ic master cyl inder3. Brake lines 9 . Ser vice br a ke s hoe4 . Trailer brake connection 10 . Linkage5 . Wh eel cylin der 11 . Compressor6 . Handbrake assembly

Figure 2-17. Brake System Component Location.

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n. Axles, Wheels and Hubs (Fig. 2-1 8).

(1) The front axle is made up of a housing, differential and pinion, axle shaft, withuniversal joint, and steering knuckle. Power is sent from the differential to the wheels,through the axle shaft. Universal joints permit continuous del ivery of power to the wheelswhile the truck is turning right or left.

(2) Both rear axles are made up of a housing, differential and carrier assembly,and an axle shaft. Forward rear and rear rear axles are mounted, one behind the other,with torque rods on each side of the interconnecting axles. Power is sent from the transferto the front rear differential by a propeller shaft, and from the forward rear axle to the rearrear axle differential by another propeller shaft. Axle shafts transmit power from thedifferential to the wheels.

(3) The wheels are disk-type, secured to six studs on the wheel hubs. The wheelsare completely interchangeable. Trucks with dual wheels use 9x20 size tires. Singlewheels use llx20 tires. Single wheels can be used on dual wheel trucks if there is enoughclearance between the tire and body under full payload.

(4) The wheel hubs are mounted on roller bearings. Each hub is secured to its

axle with two adjusting nuts and an adjusting nut lock. All hubs have inner seals, and rearhubs also have an outer seal.

1.2.3.4.5.6.

2-20

Differential and carrier 7. Front axleRear rear axle 8. HousingTorque rods 9. TiresSteering knuckle 10. WheelsAxle shaft with universal joint 11. Hubs (behind wheels)Differential 12 . Front rear axle

Figure 2-18. Axles, Wheels, and Hubs System Component Location.

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Section III. TABULATED DATA

2-5. GENE RAL. This section cont ains reference data , in ta ble form , for use by t heoperator when using the equipment. Dat a is given for t he following ar eas:

a . Ph ysical dat a

b. Functional characteristics

c. Capabilities and limitations

d. En vironmenta l chara cterist ics

2-6. WEIGH T. Table 2- 1 gives the weight of all trucks covered in this manual undervarious conditions. Column Net w/wn means trucks with winch.

2-7. DIMENSION S. Tables 2 -2 and 2-3 give overall an d operat ing dimensions for alltru cks covered in t his ma nua l.

2-8. CAPACITIES. Table 2-4 g ives the liquid capacities for various systems.

2-9. TIRE INFLATION DATA. Table 2-5 g ives tire inflation data for all trucks coveredin this manual.

2-10. ENVIRONMENTA L CHARACTERIS TIC S. Table 2- 6 l ists th e fuels tha t can be usedin all tru cks u nder var ious t emperat ure conditions.

2-11. FUNCTIONA L CHARACTERIS TICS . Tables 2- 7 an d 2-8 give data relating to thefunctional characteristics of all trucks covered in this manual.

2-12. COMPONENT S OF E ND ITEM LIST. Integral components an d basic issue i temsrequ ired for 2 l/2-ton t ru cks a re listed in appendix B.

2-13. ADDITIONA L AUTHOR IZATION L IST. Additiona l item s au th orized for t he su pportof 2 l/2-ton trucks are listed in appendix C.

2-14. EXPENDABLE SU PP LIES AND MATERIALS LIST. Expenda ble supplies an d ma ter-ials needed to operat e an d ma intain the 2 1/2-ton tr ucks are l isted in appendix D.

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Table 2-1. Weight (Pounds)

Gros s Pa yloa d TowedTruck Net Gross C r o s s - Pa yloa d Cr os s - Load Towed LoadType w/ wn High wa y Cou n tr y High wa y Cou n try High wa y Cross-Count ry

M35A1 13,530 23 ,530 18,530 10,000 5 ,000 10,000 6 ,000M35A2 13,530 23 ,530 18,530 10,000 5 ,000 10,000 6 ,000M35A2C 13,530 23 ,530 18,530 10,000 5 ,000 10,000 6,000M3 6A2 15,750 2 5 ,51 0 2 0 ,7 50 10,000 5 ,000 10,000 6 ,000M49AlC 16 ,107 23 ,665 1,200 gal 600 gal 10,000 6,000M49A2C 14,740 22 ,840 1,200 gal 600 gal 10,000 6 ,000M50A1 15,255 2 3 ,85 5 1 ,000 ga l 40 0 ga l 10,000 6 ,000M50A2 14,589 22 ,930 1,000 gal 400 gal 10,000 6 ,000M50A3 15,150 23 ,450 1,000 gal 500 gal 10,000 6 ,000M109A2 16 ,296 20 ,642 19,992 7 ,500 5 ,000 10,000 6 ,000M109A3 15,430 22 ,930 19,930 7,500 5 ,000 8 ,000 6 ,000M185A2 17,485 2 2 ,48 7 2 2 ,0 67 5 ,3 5 0 5 ,00 0 10,000 6 ,000M185A3 17,300 24 ,800 22 ,300 7,500 5 ,00 0 8 ,0 00 6 ,0 00

M275A1 12,534 23 ,124 19 , 124 12,000 7 ,000 36 ,000 17,000M275A2 12 ,226 24 ,226 18,790 12,000 7 ,000 36 ,000 17,000M342A2 15,500 2 5 ,5 00 2 0 ,5 00 10,000 5 ,000 10,000 6 ,000M756A2 16,960 24 ,020 18,960 8 ,000 2 ,000 10,000 6 ,000M764 19,490 24 , 690 18,690 8 ,000 2 ,000 10,000 6 ,000

Subtract 500 pounds for t rucks not equipped with front winch.

Table 2-2. Dimensions (Inches)

Length HeightTruck Overal l Height Reduced Width Pintle GroundType w/ wn Overal l Minimum Overal l Height Clearance

M35A1 27 7 11 2 8 1 96 35 1 2 1 / 2M35A2 2 78 1 / 4 112 8 1 96 3 6 1 / 8 1 0 1 5/ 1 6M35A2C 2 78 1 / 4 112 8 1 96 3 6 1 / 8 1 0 1 5/ 1 6M36A2 3 4 3 1 / 2 1 2 4 3 / 8 8 1 9 6 3 6 1 / 8 1 0 1 5 / 1 6M49A1C 2 7 7 9 7 8 8 9 6 3 7 1 2 1 / 2M49A2C 2 7 7 1 01 1 / 2 9 2 9 6 3 6 1 / 8 1 0 15 / 1 6M50A1 2 7 7 97 9 0 9 5 3 6 13M50A2 27 7 1 01 1 / 2 9 2 9 5 3 6 1 / 8 1 0 1 5/ 1 6M50A3 2 7 7 1 01 1 / 2 9 2 9 5 3 6 1 / 8 1 0 1 5/ 1 6M109A2 27 7 130 130 99 3 4 13M109A3 28 2 130 130 9 8 2 6 1 / 8 1 0 1 5/ 1 6M185A2 27 7 130 9 0 95 36 13M185A3 28 2 130 130 98 3 6 1 / 8 1 0 1 5 / 1 6M275A1 24 2 99 8 1 93 3 5 1 2 1 / 2M275A2 24 2 1 01 1 / 2 8 1 9 3 3 6 1 / 8 1 0 1 5 / 1 6M342A2 2 7 4 105 81 9 6 3 6 1 / 8 1 0 1 5/ 1 6M756A2 2 8 7 1 1 3 108 9 6 3 6 1 / 2 1 0 1 5 / 1 6M 7 6 4 3 05 108 9 4 9 6 1 0 1 5 / 1 6

Subtract 14 inches from length for t rucks not equipped with front winch.

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Table 2-3. Operat ing Dimensions

Wheel Depar tu re Turning Radius

Truck Type Bas e (in. ) Angle (deg) W/WN WO/WN (ft )

Cargo M35 type 154 40 37 ft 6 in. 36

Cargo M36 type 190 24 46 ft 45Fuel tank 154 40 37 ft 6 in . 36Water tank 154 40 37 ft 6 in. 36Shop van 154 40 37 ft 6 in. 36Repair sh op 154 40 37 ft 6 in. 36Tractor 142 73 36 ft 35Dump 154 70 37 ft 6 in . 36Pipeline construction 154 40 37 ft 6 in. 36Ear th boring an d polesetter 154 40 37 ft 6 in. 36

Note: The approach angle for all trucks covered in this manual is 40 degrees withwinch and 47 degrees without winch.

Table 2-4. Capacities

Description Capacity Truck(s)

Coolin g system All t rucksLDS427-2 34 qtLD-465 & LDT465 28-32 qt

Crankcase 22 qt All tr ucksDifferentials (each) 6 qt All tr ucks

Fuel tank 50 gal All trucksTran smission 1. W/PTO 10-1/2 pt All tru cksTra nsmission 2. WO/PTO 8-1/2 p t All trucksTransfer 7 qt All tru cksFront winch worm housing 1-1/4 pt All tru cks equipped with front winchFront winch end bearing fram e 1 pt All tru cks equipped with front winchRear winch worm housing 7 pt M764Power divider 3-1/2 qt M764Earth boring machine

intermediate case 5 qt M764Earth boring machine

clutch an d brak e case 5 qt M764Earth boring machine

borin g cas e 10 qt M764Ou t r igger h ydrau lic syst em 6 ga l M764Rear winch cable level winder

speed reducer housing 1-3/4 pt M764Rear winch jaw clut ch h ousing 1-3/4 pt M756A2Rear winch worm gear h ousing 2-3/4 pt M756A2

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Table 2-5. Tire Inflation Data

Condition/Tire Size Pressu re (psi)

Highwa y 9 x 20 50Highwa y 11 x 20 70Cross-country 35Mud, snow, and san d 15

Table 2-6. Permissible Fuels

Ambient Temperature Fuel

Primary F uels

No Limit Diesel fuel, VV-F-800, grade DF-A(NATO code no. F-54)

Above -51 F Turbine fuel, MIL-T-5624, grade JP-5(NATO code no. F-44)

Above -10F Diesel fuel, VV-F -800, grade DF-1(NATO code no. F-54)

Above +32 F Diesel fuel, VV-F-800, grade DF-2(NATO code no. F-54)

Alternate Fuels

Above -76F Aviation gasoline, MIL-G-5572,AVGAS 80/87 (NATO code no. F-12)

* Comm ercial aviat ion ga soline(ASTM D91 0), gra de 80/87

* Commercial gasoline, leaded, low -lead, or unleaded, when researchocta ne nu mber (RON) is 89 or below,or octa ne n um ber displayed onret ail gasoline pum ps in CONUS is85 or below

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Table 2-6. Permissible Fuels - Cont

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Ambient Temperature Fuel

Alternat e Fuels

Above -58 F Turbine fuel, aviat ion, k erosene-type, MIL-T-83133, grade JP-8(NATO code n o. F-34)

Above -46 F Tur bine fuel, low volat ility,MIL-T-38219, grade JP-7

* Commercial aviation turbine fuel(ASTM D1 655), jet A an d jet A-1

Above -10 F Commercial diesel fuel (ASTM D975)1-D an d n o. 1

Above +15F Diesel fuel, MIL-F-16884(NATO code no. F-75 or F-76)

Above +32 F Commercial diesel fuel(ASTM D975 ), 2-D an d n o. 2

Above +40 F Distillate fuel, MIL-F-24397, ND(NATO code n o. F-85)

* Any mixtu re of prima ry a nd/oralternate fuels listed above

* Any t emper at ur e at which th e fuel will flow.

CAUTION

Oth er fuels ma y be used t o ru n m ultifuel engines. If engine runs rough when using a new fuel, add 10% to 30%diesel fuel to smooth engine perform an ce. Failur e toadd diesel fuel to sm ooth engine perform an ce will resu ltin burned pistons.

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Table 2-7. Shifting Speeds in Mph

Transmission Transfer Low Transfer High

1st gear2nd gear3rd gear4th gear5th gearReverse

58

142228

5

Table 2-8. Engine and Radiator Data

Attribute

Cylinders (in-line)Brake horsepowerIgnition systemFiring orderCoolingThermostat:

Start to openFully open

916274456

9

Specification

6126-140 (gross at 2,600 rpm)Compression1-5-3 -6-2-4Liquid

180 F200 F

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(8) Avoid operat ing the engine or the power t rain at ful l speed.

CAUTION

During road tes t , do n o t go fas te r o r opera te the t ru ck continuously at the maximum al lowable speeds shown onthe t ruck ins t ruc t ion and cau t ion da ta p la te .

c. Road test . All t rucks received by the using organizat ion must be road tested tocheck their operat ion and condit ion. For al l new or recondit ioned trucks, except thosedriven 50 miles or more during del ivery, the road test wil l be a minimum of 50 miles .For us ed t ru cks a nd t ru cks dr iven 5 0 m iles or m ore du r ing de l ivery, the r oad tes t willbe long enough to observe t ruck operat ion and condit ions. The operator wil l look at theinstrument panel and gages, as of ten as possible , for s igns of unsat isfactory performance.Stops wil l be made at least every 10 m iles to g ive th e opera tor a ch an ce to ins pec t the t r u ck for possible coolant , oi l , fuel or exhaust leaks and any signs that may show the engine,t ransmiss ion , whee l hubs , b rakedrums, ax le d i ffe ren t ia l o r t ransfer assembl ies a re over-hea ted . The t ru ck mu s t be checked throu ghly for any cont r o l ha rd to opera te an d an y

ins t ru men t n o t opera t ing proper ly. Unusual noises and vibrat ions wil l be noted. Allunusual condit ions wil l be reported to organizat ional maintenance uni t .

d . After the Road Test . After the road test , f ix any faul ty condit ion which can bedone a t opera tor ' s m ain tena nce leve l. Tel l organizat ional maintenance uni t about anyother faulty conditions.

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CHAPTER 4

OPERATING PROCEDURES

Section 1. DESCRIPTION AND USE OF OPERATORS CONTROLSAND INDICATORS

4-1. GENERA L. Before trying to operate equipment, be sure you know where all con-trols and indicators are located, what each control does, and what information eachindicator is giving.

NOTE

Controls and indicators described in this section are gener-ally the same for all trucks covered in this manual, exceptw h e r e s p e c i f i c a l l y n o t e d .

In this manual the term "left" is the driver 's side. Thet e r m " r i g h t " i s t h e o p p o s i t e s i d e .

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4-2. CHASSIS CONTROLS AN D INDICATORS.

a. Instrument Panel Controls and Indicators.

INSTRUMENT PANEL LEFT SIDE

1. Hand THROTTLE control. Sets 5. Engine START button (on trucksengine to any speed without stepping with LD 465-1 engines). Whenon accelerator pedal. When hand pressed in , rou tes cu rren t to s t a rt e rTHROTTLE control knob is pulled to crank engine. On trucks without it locks in any position. Turning LDS 427-2 engines the start buttonknob right or left unlocks it. is mounted on the cab floor. (Refer

2. ENG. STOP control. When pulled to para 4-2 c, Drivers Compartment

out, stops engine by cutting off fuel. Controls and Indicators.)

3. ACCESSORY power switch. When in 6. Air filter indicator. Shows red when

the ON position, routes power to the engine air filter needs cleaning.starter system, instrument panel 7. Windshield wiper control knob. Whengages, fuel pump and low pressure turned to on position, starts wind-warning buzzer. shield wipers.

4. Light switch. Turns truck lights 8. MANIFOLD HEATER SWITCH. Whenon or off. set to ON position, starts manifold

hea ter . Manifold heater is used tohelp start and warmup the enginewhen outside temperature is below+20F .

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a. Instrument Panel Controls and indicators - Cont .

INSTRUMENT PANEL CENTER

1. FUEL level gage. Shows fuel level NOTEin fuel tank. A warning buzzer will be

2. Speedometer/Odometer. Shows heard when engine is startedspeed and total mileage. and will stop when safe op-

Tac h ome te r. crating pressure is reached.3 . Shows engine speed inrevolut ions per minute (rpm). Shows 7. FRONT WHEEL DRIVE lever.engine operation time in hours and When in the IN position, starts fronttenths of hours. wheel driving power.

4. Water temperature gage. Shows 8. FRONT WHEEL DRIVE indicatortemperature of engine coolant. light. Goes on when front wheelNormal operating temperature is drive is operating.between 180F ancl 200 F. 9. OIL pressure gage. Shows engine

5. Battery generator indicator. Shows oil pressure when engine is running.

when the battery is charging ord ischarg ing . 10. HIGH BEAM indicator. Goes onwhen headlights are on high beam.6. AIR pressure gage. Shows pressure

in the air reservoir tanks. Normalpressure is 105 pounds per squareinch (psi).

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b . Windshield Controls and Indicators .

1. Windshield locking handle. Locks 4. Windshield wiper motor resetwindshield in closed position. button. When in the out position,

2. Windshield wiper lever. Gives awiper motor will not operate.Press in before turning windshield

way to move the windshield wipermanually. wiper control knob to on position.

3. Windshield clamping screws. Lockswind shield in any open position.

.

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c. Driver s Compart ment Cont rols a nd Indicat ors.

1. Accele ra tor peda l . Cont ro l s eng ine 4 . Engine STAR T button (on trucksspeed. with LDS 427-2 engines). When

2. Dimmer switch. Raises or lowerspressed in, routes current to starter

head light beam.to crank engine. (On trucks withLD 465-1 engines the start button is

3. Clutch pedal. Is pressed in before mounted on the instrument panel .shifting gears. Refer to para 4-2 a, Instrument Panel

Left Side Controls and Indicators.)

5. Service foot brake. When pressedin, slows down and stops truck.

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c. Drivers Compa rt men t Contr ols an d Indicators - Cont.

1. Horn button. When pressed in, 3. Steering wheel. Controls directionsounds horn. of the truck.

2. Directional turn signal and flashercontrol lever. Turns on turn s ignaland emergency flasher lights.

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c. Driver s Compart ment Contr ols an d In dicat ors - Cont .

1. Cowl ventilator. When open, lets 3. FRONT TRANSMISSION gearshiftair flow int o the dr ivers compa rt - lever. Used to place the trans-me n t . mission in one of five forward

2. Air supply valve. Is an emergency positions, reverse or neutral.

source of compressed air for 4. Spring tension control lever.inflating tires, clean ing a ir filt er s, Tu rned t o make sea t ha rder oretc . softer.

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c. Drivers Compa rt men t Contr ols an d Indicators - Cont .

1. TRANSFER CASE shift lever. 7. Tran sfer POWER TAKE OFF LEVER.Moved t o (DOWN) LOW for hea vy Sup plies power to opera te au xiliary

load conditions and to (UP) HIGH for equipment when in the up position.light load conditions. 8. Ha ndbra ke cont rol lever. Is pulled2. Backrest control lever. Used to up to set han dbrak e. The knob at

change position of the lower section the t op of the han dle is turn ed toof th e backrest. set bra ke cable tension.

3. Seat cushion control lever. Used to 9. Shifting lever hinge lock. Locksmove rear portion of seat cushion up transmission power take-off leveror down. in neutral position.

4. Seat horizontal control lever. Used 10. POWER TAKE OFF SHIF TS LEVER.to move seat forward or backward. Is moved forward to HIGH or LOW

5. Slotted bracket. Used to move front position t o give power t o fron t win ch

of seat cushion up or down.for reeling in a load. Moved to REV(reverse) position to release or lower

6. Locking bar. Locks power take-off a load.lever in off position when bar isturned to up and down position.

~f L.

TA 044947

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d. Front Winch Controls and Indicators.

1. Front winch drum lock knob. Is 2. Front winch CLUTCH control lever.used to lock drum when winch is Is moved to IN position (toward rightnot in use. When knob is pulled side of truck) to put winch into gearout and up drum is unlocked. and to OUT position (left side of

truck) to take it out of gear.

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e . Trailer Brake Controls and Indicators.

1. Trailer air valve handles (two). Areturned to send compressed air to

the trailer brake system.N O T E

The trailer air valve handles are located on rear part of chassisframe on right and left sides. Position of valve handle isdifferent on some trucks.

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4-3. EQUIPMENT BODY CONTROLS AND INDICATORS.

a . Fuel Tank Trucks (M49A1C and M49A2C) Controls and Indicators.

1.

2.

3.

4.

5.

6.

M49A1C

M et e r. Records amoun t (no. of 7.gallons) of fuel pumped out.

Counter control lever. Is moved upor down to return numbers on meter 8.to zero.

Pressure gage . Shows condit ion of filter elements by showing differ- 9.ence in pressure between inlet andoutlet side of filter.

Pressure gage handle. Is turned toNo. 1 position (right) to take pressure 10.

readings on inlet side of valve. Isturned to No. 3 position (left) to takereadings on outlet side of valve. 11.Dump valve control (l-inch line). Isturned left to open automatic dumpvalve, which dumps water separatedfrom fuel by filter segregator unit.

Manual drain valve control (l/2-inchline). Is turned left to open manualdrain valve to drain sump assembly.

Gravity delivery line gate valve. Isturned left to let fuel flow throughgravity delivery line.

Pump delivery line gate valve. Isturned left to let fuel flow throughpump and dispenser line.

Discharge valve control levers. Arepulled back to open discharge valveswhich control flow of fuel from tank sections.

Liquid level gage. Is dipped into

tank sections to measure liquidlevel .

Remote control handle. Is pulledforward in an emergency to tripoperat ing levers and return them tothe closed position.

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a. Fuel Tank Trucks (M49A1C and M49A2C ) Controls and Indicators - Cent,

M49A2C

1. Meter. Records amount (no. of 7. Gravity delivery line gate valve. Isgallons ) of fuel pumped out. turned left to let fuel flow through

2. Counter control lever. Is moved up gravity delivery line.

or down to return numbers on meter 8. Pump delivery line gate valve. Isto zero. turned left to let fuel flow through

3. Pressure gage. Shows condition of pump and dispenser line.

filter elements by showing difference 9. Discharge valve control levers. Arein pressure between inlet and outlet pulled back to open discharge valvesside of filter. which control flow of fuel from tank

4. Pressure gage handle. Is turned to sections.

No. 1 position (right) to take pressure 10. Liquid level gage. Is dipped intoreadings on inlet side of valve. Is tank sections to measure fuel level.

turned to No. 2 position (left) totake readings on outlet side of valve. 11. Remote control handle. Is pulledforward in an emergency to trip5. Dump valve control (l-inch line). Is operating levers and return them

turned left to open automatic dump to closed position.valve, which dumps water separatedfrom fuel by filter segregator unit.

6. Manual drain valve control (1/2 -inchline). Is turned left to open manualdrain valve to drain the sump assembly.

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b. Water Tank Trucks Controls and Indicators.

1. Gravi ty de l ivery l ine suc t ion va lve . 3 . 400 gallon compartment valve leverIs turned left to let water flow through and 600 gallon compartment valvegravity delivery line. lever. Are pulled back to open dis-

2. Pump delivery line discharge valve. charge valves which control flow of Is turned left to let water flow through water.

pump delivery line. 4. Water level gage. Is dipped intotank sections to measure water level.

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b . Water Tank Trucks Cont rols and Ind ica tors - Cont .

1. Exhaust bypass valve control. Is 2. Exhaust bypass fording valve. Is

pulled out to open exhaust bypass closed to prevent outside watervalve and allow exhaust gases to from entering tank heating chamberenter heating chamber under tank. during fording operations.

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c . Shop Van and Instrument Repair Shop Trucks Controls and Indicators,

1. OPERATION BLACKOUT SWITCH 4. EXH. BLOWER switch. Controls115V. -A. C. SYSTEM. Controls dome power to exhaust blower.lights in the 115 volt AC system.

5. Converter SELECTOR switch. Is2. Circuit breaker box. Has four used to choose desired voltage.circuit breakers which control vanbody circuits.

3. POWER SWITCH 115V. -A. C. Controlsall power to van body electrical cir-cuits except the 24 volt AC-to-DCconverter for exhaust blower.

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c . Shop Van and Instrument Repair Shop Trucks Controls and Indicators - Cont.

1. DOME LIGHT SWITCHES 24 VOLTS 2. DOME LIGHTS SWITCHES 24 VOLTSO N - O F F s w i t c h . C o n t r o l s t h e NORMAL-BLACKOUT switch. Lets24-vol t dome l ight system. you control dome lights in normal

or blackout condition.

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d. Tractor Trucks Controls and Indicators.

1. Airbrake hand control lever. Con- 3 . F ift h wh e el op er a t in g h a n d le . I st rols sem it ra iler a ir br ak e s yst em . pu lled for wa rd t o u nlock ja ws a nd

Wh en lever is moved down , br akes sepa ra te sem it r ailer fr om t ra ctor .are on. 4. Safety la t ch . Makes sure that there2. Airbrake hose coupling shut-off- is a positive locking of the fifth

cocks. Are turned on (up position) whee l jaws . The sa fe ty l a tch mus tto let air enter semitrailer brake be moved left or right to movesystem after it is hooked up and operating handle.must be turned off (position shown)before trailer is unhooked.

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e . Dump Truck Controls and Indicators.

1. Tai lga te hand lever. I s pu l led for- 3 . Safety lock. Locks control lever inward and down to open tailgate. dum p body down p osition when

2. Hydraulic hoist control lever. Is turned to side position.moved forward to raise dump body,and backward to lower dump body.

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f. Pipeline Contruction Truck Controls and Indicators.

1. S a fe t y br a k e a d j u st m e n t s cr e w. I s 3. D r u m clu t ch le ve r . Is placed r ightturned right (from under the truck) to make drum ready to turn and lef tto tighten brake bands which prevent to set drum free.lowering of the load when the clutch 4. Winch drumlock.is set free.

. Is pulled out andturned 90 to unlock drum.

2. Drag brake adjustment screw. Isturned r ight (from under the t ruck)to increase drag and prevent freespooling.

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g. Earth Boring Machine and Polesetter Truck Controls and Indicators.

1. Rear winch control lever. Is moved 3. Power divider control lever. Isforward to operate rear winch, and shifted as needed to give power to

to the rear to stop rear winch. rear winch or earth boring machine.2. Hinge lock. Locks rear winch con-

trol lever in the off position whennot in use.

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g. Earth Boring Machine and Polesetter Truck Controls and Indicators -Cont.

1. OUTRIGGERS control valve levers. Fr om opera tors position, r ightAre moved forward (DOWN) to lower lever controls left outrigger legoutrigger legs and to the rear (UP) and left lever controls right leg.to raise legs.

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g. Earth Boring Machine and Polesetter Truck Controls and Indicators - Cont.

1. Leveling bubble. S h o w s t h a t e a r t h 4 . Earth boring machine drive controlauger is in st r aigh t up and down lever . Cont r ols the tu rn ing of theposition when bubble is centered. ear th auger. Is used together with

2. Power-leveler shifting handle. Used the feed control lever.

with boring machine feed and drive 5. Locking latch. Gives positive lock-con tr ol lever s, t o con tr ol u p a nd in g of dr ive a nd feed con tr ol lever sdown and side to side movements of in braking position.earth boring machine and polesetter 6.der r ick . Outrigger safety latch. Gives

positive locking of outrigger leg3. Earth boring machine feed control when in up position.

lever. Controls up and down move-ment of earth auger, when used to-gether with the drive control lever.

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4-4. SPECIA L KITS CONTROLS AND INDICATORS.

a . Hot Water Personnel Heater Kit Controls and Indicators.

1. HEATER blower switch. Is placed 3. DEFROSTER knob. Is pulled out all

in H I or LO posit ion t o con tr ol flow t he wa y t o sen d t he flow of h ot a irof for ced a ir i nt o per son nel com - on to win dsh ield t o pr even t fr ost in g.par tment . 4. Air bleeder valve. Is opened

2. Damper control knob. Is pulled out (turned to left) while coolant isall the way to give maximum amount of flowing through the cooling systemhea t t o per sonnel compa r tmen t . t o let a ir ou t and pr even t a n a ir

pocket from forming in heater hotwater t ank .

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b. Arctic Winterization Kit Controls and Indicators.

1. HI-LO switch. Controls the rate of fuel burning and speed of blower inpersonnel heater.

2. Red indicator light. Is on when thepersonnel heater is operating.

3. START-OFF-RUN switch. Is setto START position to start personnelheater. Set to RUN position to runheater and to OFF to stop heater.

4. Air control knob. Is pulled all theway out to get maximum air flow,is pushed in to lower or shut off air flow.

5. DEFROSTER control knob. Ispulled all the way out for maximumdefroster operation. Is pushed infor maximum heater operation; isplaced half way out for combinationdefroster heater operation.

6. EMERGENCY switch. Is for emer-gency conditions only. When switchis placed in down position, fuel flowto heater