RP0910 - PERFORM PMCS ON M SERIES VEHICLE PURPOSE. The purpose of the next period of instruction is to provide you, the operator the knowledge on correctly performing Preventive Maintenance Checks and services or PMCS and what to check in accordance with the technical manual during PMCS. This

LEARNING OBJECTIVES: TERMINAL LEARNING OBJECTIVES. (1) Provided with an operational M series vehicle, required tools and equipment, and references, perform preventive maintenance checks and services on M series vehicle, to maintain operability and identify corrective maintenance actions, per the references. (RP00.09.12) ENABLING LEARNING OBJECTIVES (1) Given a M1123, TM 2320-10/6B and LO 9-2320-280-12, and a Vehicle and Equipment Operational Record (NAVMC 10627), all required tools and supplies, perform "Before Operation" preventive maintenance checks and services (PMCS) on the vehicle, per information contained in the references. (RP00.09.12a)) (2) Given a M1123, TM 2320-10/6B and LO 9-2320-280-12, and a Vehicle and Equipment Operational Record (NAVMC 10627), all required tools and supplies, perform "During Operation" preventive maintenance checks and services (PMCS) on the vehicle per information contained in the references. (RP00.09.12b) (3) Given a M1123, TM 2320-10/6B and LO 9-2320-280-12, and a Vehicle and Equipment Operational Record (NAVMC 10627), all required tools and supplies, perform "After Operation" preventive maintenance checks and services (PMCS) on the vehicle, per information contained in the references. (RP00.09.12c) (4) Given a M1123, TM 2320-10/6B and LO 9-2320-280-12, and a Vehicle and Equipment Operational Record (NAVMC 10627), all required tools and supplies, perform "Weekly" preventive maintenance checks and services (PMCS) on the vehicle, per information contained in the references,. (RP00.09.12d) (5) Given a M1123, TM 2320-10/6B and LO 9-2320-280-12, and a Vehicle and Equipment Operational Record (NAVMC 10627), all required tools and supplies, perform "Monthly" preventive e maintenance checks and services (PMCS) on the vehicle, per information contained in the references,. (RP00.09.12e) (6) Given a M1123, TM 2320-10/6B and LO 9-2320-280-12, and a Vehicle and Equipment Operational Record (NAVMC 10627), all required tools and supplies, perform lubrication on the vehicle, per information contained in the references. (RP00.09.12f) PERFORM PREVENTIVE MAINTENANCE CHECKS AND SERVICES. a. The Purpose of the Preventive Maintenance Checks and Service or PMCS is to ensure 1st Echelon Maintenance or operator responsibility, preventive maintenance b. a.

checks and services are conducted on the prescribed equipment, and to identify defects with equipment that may require other levels of maintenance. b. When the TM manual is opened to the table of contents, which is on page ii. L checks and services, which will be on page 2-60. (Or look through the index, under PMCS.) Once the PMCS section is located in the TM, the following information can be found: (1) The "Before Operation" PMCS are the listed checks and services and must be perform each day before the vehicle is operated. (2) The "During Operation" PMCS must be performed while operating the vehicle. (3) The "After Operation" PMCS are the checks and services that must be performed when the use of the vehicle is completed or at the end of the day. (4) The "Weekly" PMCS are a list of additional checks and services that are not necessary on a daily basis, but must be completed once a week. (5) The "Monthly" PMCS are a list of checks and services that must be completed once a month. (6) Fluid Leakage. Wetness around seals, gaskets, fittings, or connections indicates leakage. If a fitting or connection is loose, tighten it or report it. Fluid leaks are classified three ways. They are: (a) Class I. Leakage is indicated by wetness or discoloration not great enough to form drops. (b) Class II. Leakage is great enough to form drops, but not enough to cause drops to drip from the item being checked or inspected. (c) Class III. Leakage is great enough to form drops that drip from the item. (7) The vehicle can be operated with Class I or II leaks except for leaks in the brake system. When operating vehicle with Class I or II leaks, fluid levels must be checked more frequently. If there is evidence of any brake fluid leaks, the vehicle will not be used and must be reported to your supervisor or unit maintenance. (8) Table 2-1 PMCS Listing for M998 Series Vehicles. Table 2-1 is divided into five columns to guide you in the performance of PMCS. The columns are: (a) Item No. The PMCS are numbered in the sequence that is to be performed. (b) Interval. The second column, or interval, identifies when the service must be performed on the particular PMCS. These PMCS are also listed in the sequence that is to be performed. (c) Location/Item to Check/Service. The third column identifies the location and item that must be checked.

(d) Crew Member Procedure. The forth column describes the procedure for checking or inspecting an item. This column also lists notes, warnings, and cautions about the item that must be inspected. Remember; always pay particular attention to all warnings and cautions to avoid damage to the vehicle and injury to your self or personnel. (e) Not Fully Mission Capable. The last column identifies a vehicle is not mission capable if a certain condition exists such as a class III leak or missing or unserviceable tires. If during the PMCS it is discovered a problem with the vehicle that makes it not mission capable, the vehicle must not be used until it has been repaired and the supervisor or unit maintenance is notified. (f) Additional PMCS will be listed for specific models in the M998 series. The instructions for the different models will be listed in the crewmember procedures column. PMCS a. The PMCS table in the operator's manual will serve as a guide to instruct on what PMCS to perform. The preventive maintenance checklist will be used to annotate the PMCS performed and to note any discrepancies that cannot be corrected by the operator. b. If you are the assigned operator of the vehicle but have not operated the vehicle since the last "Weekly" PMCS was performed, or if you are operating the vehicle for the first time, you would perform a "Weekly" PMCS as well as the "Before Operation" PMCS. (1) Damage, Pilferage. Visually check for obvious damage to the vehicle's body and components for anything that might impair operation of the vehicle. If the vehicle is damaged before operating it, you don't want to receive the blame, be sure to check the vehicle closely. Note all the discrepancies found and if it is something major ensure and notify your supervisor. (2) Leaks. Look under the vehicle for evidence of fluid leakage such as fuel, oil, coolant and brake fluid. If there is a brake fluid leak, a fuel leak or a Class III leakage of oil or coolant, do not operate the vehicle. Report these leaks to organizational maintenance. (3) Tires. Visually check for under-inflated and unserviceable tires. Check the tires for leaks, cuts, gouges, cracks or bulges. Remove all penetrating objects. (4) Mirrors. Check for missing, cracked, broken or fogged glass. Check adjustment bolts and tighten if necessary. (5) Fuel. Check the vehicle for fuel to ensure there is enough to complete the trip. This can be done by turning on the ignition switch and watching movement of the fuel gage.

(6) Oil. After raising the hood, check the engine oil level. The oil dipstick is located on the left side of the engine to the rear of the alternator. To remove the oil dipstick first loosen it by turning the "T" handle counterclockwise. (a) First, check the engine oil before starting the engine to determine if there is sufficient oil. (b) It is not unusual for the oil level to show overfull at this time. This is caused by the oil in the oil cooler, which is mounted on top of the radiator, draining back down into the engine. (c) After checking the oil in this manner, replace the oil dipstick, start the engine and let it idle for one minute. Shut the engine off, wait one minute and then check the oil level again. The oil level should be between the "FULL" and "ADD 1 QT" mark on the dipstick. (d) If the engine oil is low, remove the filler cap, which is located at the front of the engine, and add OE/HDO 15W-40W oil as required. Do not overfill as this could damage the engine, especially the seals. (e) Replace the filler cap, tighten securely and wipe away any excess oil. (f) Be careful and do not allow dirt, dust or grit to enter the dipstick tube or filler opening. Engine damage may result if the oil becomes contaminated. (7) Water. Check the coolant level in the surge tank located at the right rear of the engine. (a) Visually check the coolant in the surge tank. The level should be at the "COLD FILL LINE" before operation and slightly above the "COLD FILL LINE" after operation. (b) If the coolant level is low, remove the surge tank filler cap by turning it counterclockwise and add coolant until the level is at the "COLD FILL LINE." 1 Extreme care should be taken if the engine temperature is above 165 degrees Fahrenheit. Do not add coolant to a hot engine unless it is running, and then add it slowly as steam or hot coolant under pressure could erupt causing injury. If time permits it is best to wait until the engine is cooled before removing filler cap and adding coolant. 2 If the engine is hot, place a thick cloth over the surge tank filler cap and turn the cap counterclockwise to its first stop to allow the pressure to escape. 3 After the pressure is vented, push down and turn the cap counterclockwise to remove the cap. Add coolant until the level is at the "COLD FILL LINE." (c) Start the engine and run it for one minute. (d) Stop the engine and recheck the coolant level. If it's low, add coolant until the level is at the "COLD FILL LINE."

(e) Repeat this procedure until the coolant level remains at the "COLD FILL LINE." (f) The coolant is a combination of water and ethylene glycol. The specific mixture of the two fluids will vary in accordance with expected temperatures. 1 For temperatures above +15 degrees Fahrenheit use a mixture of 1/4 ethylene glycol and 3/4 water. 2 For temperatures in the range of +40 degrees Fahrenheit to -15 degrees Fahrenheit, use a mixture of 2/5 ethylene glycol and 3/5 water. 3 For temperatures in the range of +40 degrees Fahrenheit to -65 degrees Fahrenheit, use a mixture of 3/5 ethylene glycol and 2/5 water. (8) Engine warm-up. To make proper instrument checks and for smooth operation, the vehicle should be warmed up to operating temperature before attempting to move it. Remember the steps for starting the engine. (a) lamp to go out. (b) started. (c) Allow the vehicle to idle until it reaches approximately 190 degrees Fahrenheit, when the thermostat starts to open. (9) Instruments. While the engine is warming up an inspection check of the instruments can now be accomplished to ensure the gauges are working properly and the instrument readings shown are within the normal operating range for that vehicle. (a) The oil pressure gage should display 10 psi for the M1123 and 15 psi for the M998/1038 with the engine at idle. At no time should the oil pressure read below 6 psi. If it does, shut down the engine immediately and contact unit maintenance. (b) The coolant temperature gage should register between 190 degrees Fahrenheit and 230 degrees Fahrenheit for normal operating temperature. (c) The voltmeter should display in the green area. (d) The fuel gage should display the correct amount of fuel in the fuel tank. (e) The yellow indicator in the air restriction gage should not register in the red zone. (f) The parking brake warning light should be on because the parking brake should be applied at this time. (10) Safety Devices. Before attempting to operate the vehicle on the road, an inspection of the following safety devices should be completed: (a) (b) lights and reflectors warning triangles Turn the switch to "START" and release it once the engine has -to-

(c) (d) (e) (f) (g)

horn windshield wipers and washer parking brake fire extinguisher troop safety strap

(11) Tools and equipment. The tools and equipment would be the jack, wheel wrench and operator's tool bag with various BII tools depending on the model of vehicle and unit additional authorized tool list. Your unit Motor Transport Officer will dictate which items of equipment are maintained on each vehicle. ATION PMCS. The next PMCS that is performed is the "During Operation" PMCS. This portion of the "Daily" PMCS is a continuous observation from the time the vehicle is started until it is shut down for the day or the trip ticket is closed out by the operator and turned in to the unit motor pool. a. Brakes. Ensure and perform a brake check for proper operation before leaving the motor pool or departing on the road. To check, depress the brake pedal, place the transfer case and transmission in gear, depress the accelerator pedal slightly and see if the vehicle moves or if the brake pedal goes to the floor. If it does, do not operate the vehicle and notify unit maintenance. When driving and bring the vehicle to a stop, check for pulling, grabbing or abnormal operation. b. Parking Brake.

(1) To check the parking brake for proper adjustment, chock the wheels and release the parking brake handle. (2) Turn the adjustment knob on the end of the handle clockwise as tight as possible. (3) Apply the parking brake handle. (4) If the parking brake cannot be applied, turn the adjusting knob counterclockwise until the parking brake can be applied. (5) Do not over tighten the parking brake because the brake pads will remain snug against the brake rotor after the handle is released, causing friction, heat buildup and eventual burning of the brake pads and rotor. (6) Test the parking brake by; (a) Removing the chock blocks. (b) Depress the service brake pedal and start the engine. (c) Place the transfer case shift lever in "H" (high) and shift the transmission to "D" (drive). (d) Slowly let up on the service brake pedal. The parking brake should hold the vehicle stationary at an idle.

(7) After operating in mud or sand, it is important to wash the parking brake components. Use a low pressure water source to make sure that the parking brake pads, rotor, guide pins, and push pins are thoroughly cleaned of mud, sand or other debris. Lubricate the guide pins and push pins to keep them from corroding and sticking. c. Steering. As the vehicle is driven, pay particular attention to how the vehicle steers. Does the vehicle "wander" or "drift"? Does it pull to the left or to the right? Does it seem too loose or does it seem too tight? d. Engine operation. Observe the engine performance during both an idle and while under a load. Does it start easily, run smoothly and stop immediately when the ignition switch is turned off? e. Shock absorbers. While you are driving observe any unusual dip, sway or unstable handling that may indicate worn out shock absorbers. f. Seat belts. As you use your seat belt, check it for proper operation of the buckle and clasp ends. Ensure the mechanism is secure, free of paint and is in the locked position. g. Transmission. Check for stiffness or binding in the shift lever by applying the service brake and shifting the transmission through all the operating ranges. h. Transfer case. To check the transfer case, apply the service brake and shift the transmission to "N" (neutral). Shift the transfer case through all the operating ranges and check for stiffness or binding in the shift lever. i. Exhaust system. As you are operating the vehicle, listen for exhaust system leaks and be alert for the odor of exhaust gases. j. Drive line components. Be alert for unusual noises or vibrations from the transmission, transfer case, differentials, propeller shafts, axle shafts, geared hubs or wheels. k. Unusual noises. Listen for unusual noises anytime the engine is running. You will get acquainted with the sound of your vehicle and should be able to immediately recognize any unusual sound(s). l. Windshield and windows. Check the windshield for cracks and serviceability. Check the condition of weather seals and stripping. Check the windows for cracks or tears. Check the zipper operation for proper closure during bad weather. m. Windshield wiper arms and blade. Check to see the wiper arms are secure and not bent. Ensure the wiper arms hold the wiper blade snug against the windshield. Check the wiper blade to see that the rubber is not frayed, cracked or dry rotted.

. performed after you are secured from the run and return to the motor pool and ensure the vehicle does not require any maintenance. a. Lights and reflectors. The lights and reflectors are checked for proper operation and state of repair. Check for burned out bulbs and missing, cracked or broken lens. b. Safety devices. Once more check the following safety devices: (1) (2) (3) (4) (5) Horn Windshield wiper and washer Parking brake Fire extinguisher Troop safety strap

c. Brakes. The brakes will be checked a final time to ensure they are working properly. d. Fuel, oil and water. The fuel, oil and water will be replenished to the "full" levels to ensure readiness for the next trip. Procedures for this were covered earlier in the class. e. Locking and fastening devices. Check door latches for proper operation. Check all canvas fastening straps and rear canvas zipper for serviceability. f. Cooling fan. Inspect the cooling fan blade assembly for security, cracks and/or damage. If there is any evidence of cracks or damage the vehicle should not be used again until the defects are repaired. g. Fuel filter. The fuel filter drain cock is located on the left side of the engine compartment under the windshield washer reservoir. (1) Start the engine and place a container under the drain cock to catch the draining fluid. (2) Open the drain cock and drain approximately one pint of fuel or until fuel runs clear. (3) Close the drain cock and check for fuel leaks. (4) If contaminated fuel continues to be evident, notify organizational maintenance. h. As instructed earlier, "Weekly" as well as "Daily" PMCS would be accomplished if you are the assigned operator but have not operated the vehicle since

the last "Weekly" PMCS or if operating the vehicle for the first time. The following items would be included in the PMCS: (1) Drive belts inspection. (2) Battery level. (3) Antifreeze. (4) Tires. (5) Cleaning the vehicle. (6) Operation PMCS listed in the PMCS table in the operator's manual do not correspond to what is listed on the PMCS at the bottom of the trip ticket. This is true with all the vehicles. You will still perform all the PMCS as stated in the operator's manual and on the trip ticket and you will use the bottom portion of the trip ticket and the preventive maintenance checklist to annotate the results of the PMCS. PERFORM "WEEKLY" AND "MONTHLY" PMCS. The preventive maintenance checklist will be used to annotate all discrepancies you must also perform the Daily (before, during, and after) PMCS. a. Trouble Spots. We have so-called "trouble spots" found throughout the vehicle. A general overall inspection is required to inspect these items. (1) Dirt, oil, or debris may cover up a serious problem. Clean the vehicle before you inspect and then clean as you check. Use dry cleaning solvent (SD-2) on all metal surfaces and soap and water on the plastic and rubber surfaces. (2) Check all bolts, nuts, screws, and fittings. If they are loose, bent, broken, or missing, either tighten or replace them. (3) Inspect for chipped paint, rust, or cracks at all welds. The chipped paint or rust could indicate a crack. Remove the rust and loose paint and spot paint as required. If a cracked weld is found, annotate it on the PM checklist and notify your supervisor. (4) Inspect all electrical wires and connectors for cracked or broken insulation, bare wires and loose or broken connections. Tighten all loose connections and annotate and report all other discrepancies. (5) Check hoses and fluid lines for wear, damage, and leaks. Ensure all clamps and fittings are tight. b. Exterior of Vehicle.

(1) Locking/fastening devices. Check all locking and fastening devices such as door hinges and handles, tailgate, and hood latches. (2) Towing pintle. Check the towing pintle for damage, proper operation and the presence of the pintle pin and chain. (3) Tires:

(a) Gage all the tires for correct air pressure and adjust the pressure as necessary. The front tires are inflated to 15 psi and the rear tires to 18 psi with the vehicle unloaded. (b) 1 The tread should not be worn beyond the level of the wear bars. The wear bars are molded across the tread pattern and are only noticeable between the center rib and the inner lugs. 2 The letters "TWI", meaning tire wear indicator, are molded onto the tire sidewall to help you locate the wear bars. 3 The inner and outer lugs are reinforced with tie-bars. Do not confuse these tie-bars with the wear bars. 4 Check for missing or loose wheel stud nuts and lug nuts. (4) Shock absorbers. Visually inspect the shocks for leaks, damage, and security of mounting. c. Engine Compartment

(1) Serpentine belt/Drive belts. Check the alternator and power steering pump belts for cracks, frays, and breaks. (2) Power steering reservoir. Check the power steering reservoir for proper fluid level. (a) Pull out the cap/dipstick and check the fluid level. (b) If the engine is warm, the level should be between the "HOT" and "COLD" marks. (c) If the engine is cool, the level should be between the "ADD" and "COLD" marks. (d) In either condition, fluid must be added if the level is below the "ADD" mark. Fill the reservoir to the proper level with Dexron III. (3) Air intake. Inspect the air intake weather cap, the air cleaner assembly, and the air intake hose for damage and proper mounting. Air cleaner service is required if the air restriction gage so indicates or if the vehicle has been operating in extremely dirty conditions (a) Loosen the clamp bolt and remove the clamp and cover from the air cleaner assembly. (b) Remove the nut and washer securing the filter element to the stud and pull the element from the air cleaner assembly. (c) Place the cover and clamp back on the air cleaner to prevent dirt and dust from entering the air induction system while cleaning the filter element. Do not operate the engine with the air filer element removed or you may damage the engine.

(d) Hold the filter element so the open end faces the ground and gently tap completely around the element with the hand to free trapped dirt. (e) Remove the clamp and cover and reinstall the filter element. (f) Install the cover and clamp, ensuring the clamp bolt is positioned at the bottom of the air filter assembly. (4) also. (a) Remove the cover and check the fluid level. It should be approximately 1/8 inch from the top of the reservoir. (b) If fluid is required, fill to the proper level with silicone brake fluid (BFS). (5) Transmission fluid level. Another fluid level that needs to be checked is the transmission fluid level. (a) The transmission must be at normal operating temperature before checking the fluid level. (b) Start the engine, apply the service brakes and move the transmission shift lever through all the ranges, then check the fluid level with the transmission in "P" (park) and the engine at idle. Pull out the dipstick and check for proper level. The level should be at the crosshatch marks. Using Dexron III, add fluid slowly and recheck until the level is correct. Do not overfill this transmission; serious damage will result. d. Interior of Vehicle. Now we'll move into the interior of the vehicle and make some checks. (1) Batteries. The first items checked are the batteries. Do not perform any battery systems checks or inspections while smoking or near fire, flames, or sparks, especially if the battery caps are off. The batteries may explode causing injury to personnel or equipment. (a) and battery box. (b) distilled water. (c) Check the battery box for corrosion and clean the debris from the battery box drain holes. (2) Seat belts. This vehicle is equipped with seat belts so check them for operation and security of mounting. e. Special Purpose Kits Check the electrolyte level. If the level is low, refill the cells with You'll need to remove the companion seat to check the batteries Brake master cylinder. The master cylinder fluid level will be checked

(1) Deep water fording kit. This vehicle is equipped with a deep water fording kit. Check all exhaust and intake extensions and tubes for security. (2) Troop seat kit. Remember the troop seat is a kit. (a) (b) Inspect the seats for missing or damaged lock pins. Inspect the seats and backrests for security and mounting.

f. Accessory Items. The last category of checks is listed under accessory items and the only one is the soft top enclosure. (1) Inspect the vinyl coated nylon pieces for tears, punctures and ripped seams. (2) Inspect the windows for cracks and scratches. (3) Inspect the bows and mounting brackets for security of mounting and for damage. (4) Inspect the footman loops and straps for tears, frays, and security of mounting. TACTICAL VEHICLE LUBRICATION a. Each vehicle has its own Lubrication Order (LO) or Lubrication Instruction (LI). The technical manual also known as a TM-10 for each vehicle also covers some specific lubrication responsibilities to be performed. All lubrication checks and services will be performed using the appropriate LO, LI and TM-10 only. (1) Organizational Maintenance. Organizational maintenance is responsible for: (a) bearings. (b) Draining, flushing, and refilling the differentials, transmission, and transfer case with gear oil. (c) Draining engine oil, changing filters and refilling the engine oil. (d) Lubricating all lube fittings with a grease gun and GAA. (2) Operators. Operators are responsible for checking lubricant levels and, if necessary, topping off lubricant levels in the: (a) (b) (c) Engine Transmission Power steering reservoir. Disassembly, cleaning, inspecting and repacking all wheel

(3) Although it is an organizational maintenance responsibility to perform the majority of lubrication services on tactical motor vehicles, the operator will be required to assist the mechanic while they are actually performing these services. You are being taught these procedures so you can assist the maintenance section.

(4) We will be discussing lubrication principles using the M1123 as an example. What you learn in this lesson will apply to all tactical vehicles. Remember a current LO or LI will be used to ensure the vehicle is lubricated correctly. b. Checking Lubricant Levels

(1) levels are checked, an inspection for contamination such as water or excessive dirt should also be conducted. If any contaminates are found, that lubricant must be drained, flushed, and refilled to the proper level with new lubricant by organizational maintenance personnel. c. Engine Oil Level

(1) The engine oil level must be checked daily before operation. (2) Check the level with the dipstick which is located at the left rear of the engine. Loosen it by turning the "T" handle counterclockwise and pulling outward. (3) There are two marks on the dipstick: "Full" and "Add 1 Qt." The oil level should never be allowed to go below the "Add 1 quart" mark during operation. Before operating the engine each day add oil to bring it up to the full mark if required. (4) Do not overfill the engine as it could result in damage to seals and gaskets. (5) If the oil level is above the "Full" mark, it may be caused by the oil draining back down into the engine from the oil cooler. In this case, start the engine, let it idle for one minute, shut it down, wait one minute and check the level again. (6) Refill the engine with oil through the filler tube at the front of the engine. d. Power Steering Reservoir. The power steering reservoir and filler cap are located on the left front of the engine between the alternator and mount. There is a new type of Power Steering Reservoir that is mounted in the middle of the engine and it has a sight glass to check the fluid level of the power steering. (1) Turn the filler cap counterclockwise and remove it. The fluid level dipstick is attached to the cap, for the old style Reservoir and the sight glass for the new style. (2) The only fluid used in the power steering system of this vehicle is Dexron III. (3) You must check the power steering fluid level monthly and adjust the level when it is necessary. (4) When the fluid is cool, the fluid level must be between the "Add" and "Cold" marks on the dipstick.

(5) If the fluid is hot, the fluid level must be between the "Cold" and "Hot" marks on the dipstick. (6) You must add fluid to a cold system to the cold mark only and in a hot system to the hot mark only. Do not overfill the reservoir. (7) In either case the level of fluid must be above the "Add" mark. e. Draining Engine Oil

(1) An engine oil drain plug is located on the left rear of the oil pan. When the oil is being drained, check for water or metal particles. If either is present, stop and notify the mechanic working with you. Remember, draining engine oil is an organizational maintenance responsibility. If there is a requirement to drain the oil, the operator will assist a mechanic from the unit organizational maintenance when there is a need to drain the engine oil. (a) There are currently two authorized types of oil for tactical vehicle diesel engines during normal temperatures of +15oF and above. 1 OE/HDO 30 and OE/HDO 15W 40. 2 When all stocks of OE/HDO 30 are used up, OE/HDO 15W 40 will be used exclusively. (b) is used. (c) During extremely cold weather operations at -65 F to +15 F OEA which stands for Oil Engine Artic is used. o o

During cold weather operations at -15oF to 40oF OE/HDO 10 oil

(2) The oil filter is located on the left rear of the engine and will be changed when the engine oil is changed. f. Brake Master Cylinder. The brake master cylinder is located inside the left engine splash guard. (1) Remove the cap by lifting and pulling the bale clip off of the cap. (2) The level should be maintained at approximately 1/8 inch from the top edge of the master cylinder housing. (3) The fluid used is DOT V. It does not require periodic changing, but must be checked during before operations checks and services. g. Transmission. The engine must be running to check the transmission fluid. The transmission oil dipstick is located on the right side at the rear of the engine. (1) Check and fill the transmission to the proper level during before operations checks and services or weekly PMCS. (2) Operate the transmission through all the operating ranges to fill the cavities and fluid passages.

(3) With the vehicle positioned on level ground, allow the engine to idle, shift the transmission to park, and apply the parking brake. (4) To check the fluid level on the dipstick, pull the tab that is turned to the right up and then pull out. (5) The fluid level should be within the crosshatch marks under these conditions. (6) Fluid will be changed at 12,000 miles or biennially, whichever occurs first in accordance with the LO/LI. The transmission filter must be replaced each time the transmission is drained and refilled with 6 quarts of Dexron III. This will be accomplished by unit maintenance personnel only. h. Transfer case. The transfer case is located under the vehicle and is bolted to the rear of the transmission. The transfer fill plug is located on the left rear side of the transfer case, with the transfer drain plug located directly below. (1) Check the transfer fluid level every 3,000 miles or semiannually, whichever occurs first. (2) Remove the fill plug and gasket. The fluid should be within 1/2 inch of the filler opening. (3) Fill the transfer case with Dexron III. (4) Change the fluid at 12,000 miles or 24 months, whichever occurs first. This will be accomplished by unit maintenance personnel only. i. Differentials. The front and rear differentials are located in the center of the vehicle frame. The filler plugs are located approximately half way up on the side of the differentials. The drain plugs are located on the bottom of the differentials. A special 3/8 inch hexagon wrench must be used to remove and replace the plugs. Do not over tighten the plugs. (1) The fluid type used in the differentials is "GO" (Gear Oil). GO 80/90 is used during expected temperatures to -15oF. For colder temperatures GO 75 is used. Ensure and use LO/LI to use the correct lubricant. (2) Check the gear lubricant every 3,000 miles or semiannually, whichever occurs first. (3) The differential level should be within 1/4 inch of the fill plug opening when the fluid is cold and to plug level when the fluid is hot. (4) Change the gear oil lubricant only when it is required by maintenance repair action, or if it becomes contaminated by water or other foreign material. This will be performed by maintenance personal only. j. Front and rear geared hubs. The front and rear geared hubs are located on the inside of each wheel. The fill plug is located on the bottom half of the inspection plate bolted to the rear of the hub and the drain plug is located in the bottom of the hub. (1) The fluid used in the geared hub is GO 80/90 gear oil.

(2) Check the gear lubricant every 3,000 miles or semiannually, whichever occurs first. (3) The lubricant level should be 1/2 inch from the fill plug opening when the lubricant is cold and even with the plug opening when the lubricant is hot. (4) Change the gear lubricant only when it is required to perform maintenance or when it is contaminated by water or other foreign material. This will be accomplished by maintenance personnel only. LUBRICATION OF LUBE POINTS. For an interim period, both GAA (Grease Automotive and Artillery) and Navy Grease will be available for use at the using unit level. Both types of grease are authorized for use until stores of "GAA" are exhausted. Although the two types of lubricants are compatible, it is preferred that they are not mixed. Lubrication points where a lube fitting is installed are lubricated at 3,000 miles or 6 months, whichever occurs first. Normally, enough new grease should be pumped into the fitting to force the old grease out. a. Ball joints. The front and rear upper control arm ball joints are located on the top of the geared hub and have one fitting at each wheel. b. Tie-rod ends. Tie-rod ends are located on the inside rear of the front wheel and connect the front wheels to the steering system. (1) There are two lube fittings; one on each end of the tie rod. (2) Wipe off all lube fittings before lubricating the fittings and lubricate with only two full pumps of the grease gun. This will prevent over lubricating and bursting the rubber grease boots. c. Idler arm. The idler arm is located under the right side frame. It supports the steering link that connects to the tie rods at each end. There are two fittings to be lubricated on the idler arm. d. Pitman Arm. The pitman arm is located on the left side and supports the steering link. It connects to the steering gear box. There is one fitting to be lubricated. e. Steering shaft. The intermediate steering shaft connects the steering box to the steering wheel. There are two fittings at the universal joints and one fitting on the slip joint of the shaft. f. Propeller shafts. The front and rear propeller shafts connect the transfer case to the front and rear differentials. There are four lube fittings on the front and three on the rear propeller shaft. They are lubricated every 3,000 miles or semiannually, whichever occurs first. g. Radius rods. The radius rods are located inside the front of the rear wheels and connect the rear geared hubs to the frame. There is one fitting on each radius rod.

h. Tow pintle. The tow pintle is located at the rear of the vehicle and is used to tow trailers. It has one grease fitting at the bottom of the rear plate. OIL CAN POINTS a. Use seasonal grade OE/HDO oil. Lubricate the hood hinges, door hinges, door handles, service brake pedal push rod stud, transfer case shift linkage, and transmission shift linkage. This service is performed every 3,000 miles or semiannually, whichever occurs first. b. Every 6,000 miles or annually, remove the tow pintle hook and latch pivot bolts and inspect them for serviceability. Clean the bolts with a wire brush and lubricate them with seasonal grade engine oil. c. Special Purpose Lubrication of the Parking Brake Components.

(1) The parking brake lever, parking brake cam, parking brake push pins, and parking brake guide pins will be lubricated with WTR (Grease, Aircraft, Wide Temperature). This is used to provide free-moving parking brake components throughout all temperature ranges. (2) The parking brake must be used and once it is applied, it must also be able to release in order to keep from overheating the components and possibly starting a fire, which could destroy the vehicle. (3) The lubrication of the parking brake components must be accomplished by the mechanic because it must be disassembled, lubricated, reassembled and adjusted.
REFERENCES: TM 2320-10/6B