ARMY TM 9-2320-365-10
AIR FORCE T.O. 36A12-1B-1095-1
TABLE OF
OPERATOR’S INSTRUCTIONS CONTENTS ii
MANUAL
M1078 SERIES, 2-1/2 TON, 4x4, HOW TO USE
THIS MANUAL v
LIGHT MEDIUM TACTICAL
VEHICLES (LMTV) EQUIPMENT
DESCRIPTION 1-10
DESCRIPTION AND USE OF
MODEL NSN EIC OPERATOR’S CONTROLS
AND INDICATORS 2-3
TRK, CAR., LMTV, M1078
W/WN 2320-01-360-1898 BHH PREVENTIVE
W/O WN 2320-01-354-3385 BHD MAINTENANCE CHECKS
TRK, VAN., LMTV, M1079 AND SERVICES
W/WN 2320-01-360-1891 BHG (PMCS) 2-30
W/O WN 2320-01-354-3384 BHE
TRK, CHAS, LMTV, M1080 2320-01-353-9098 BHC
TRK, CAR., LMTV, AIR DROP OPERATION UNDER
M1081 USUAL CONDITIONS 2-126
W/WN 2320-01-360-1899 BHJ
W/O WN 2320-01-355-3064 BHF
OPERATION UNDER
UNUSUAL CONDITIONS
2-292
TROUBLESHOOTING
INSTRUCTIONS 3-2
MAINTENANCE
PROCEDURES 3-72
LUBRICATION
INSTRUCTIONS F-1
ALPHABETICAL INDEX
INDEX-1
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENTS OF THE
ARMY AND THE AIR FORCE
JUNE 1998
TM 9-2320-365-10
Section II. PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS)
2-11. PMCS INTRODUCTION
This section provides information to guide the vehicle Operator/Crew in performing required
PMCS functions. Table 2-1. Preventive Maintenance Checks and Services lists and
describes PMCS procedures applicable to all models of the vehicle and specifies
maintenance intervals to ensure that the vehicle is ready to perform the intended mission.
Tables 2-2 and 2-3 list and describe PMCS procedures applicable to specific models of
the vehicle and specify maintenance intervals to ensure that the vehicle is ready to perform
the intended mission.
2-12. PMCS PROCEDURES
a. General. Tables 2-1 through 2-3. Preventive Maintenance Checks and Services
(Operator/Crew PMCS) are provided so you can keep your vehicle in good operating
condition and ready for the primary mission.
b. Warnings and Cautions. Always observe the WARNINGS and CAUTIONS
appearing in your PMCS table. WARNINGS and CAUTIONS appear before applicable
procedures. You must observe these WARNINGS and CAUTIONS to prevent serious
injury to yourself and others or prevent your vehicle from being damaged.
c. Explanation of Table Entries.
(1) Item Number Column. Numbers in this column are for reference. When completing
DA Form 2404 (Equipment Inspection and Maintenance Worksheet), include the Item
Number for the Check/Service indicating a fault. Item Numbers also appear in the order
that you must perform Checks and Services for the intervals listed.
(2) Interval Column. This column tells you when you must perform the procedure in the
procedure column. BEFORE procedures must be performed before you operate or use
the vehicle. DURING procedures must be performed during operation of the vehicle.
AFTER procedures must be performed immediately after you have operated the vehicle.
Weekly procedures must be performed every seven days. Monthly procedures must be
performed approximately every 30 days.
(3) Location Item to Check/Service Column. This column provides the location and the
Item(s) to be checked or serviced.
(4) Procedure Column. This column provides the procedure to check or to service the
item(s) listed in the check/service column.
2-30
TM 9-2320-365-10
(5) Not Fully Mission Capable If: Column. This column tells you what faults will keep
your vehicle from being capable of performing the primary mission. If you perform check
and service procedures that show faults listed in this column, do not operate the vehicle.
Follow standard operating procedures for maintaining the vehicle or reporting equipment
failure.
d. Other Table Entries. Be sure to observe all special information and notes that
appear in the table.
e. Shortened Intervals. Shorten intervals if operating the equipment under adverse
conditions, including longer than usual operating hours. An asterisk will come before the
Interval. A footnote will explain the asterisk and the reason for the shortened Interval.
f. Weekly Intervals. When a Check/Service procedure is required for both WEEKLY
and BEFORE Intervals, you do not have to perform the procedure twice if the vehicle has
been operated during the week.
g. Leakage Criteria. Leakage Criteria is included in the "Not Fully Mission Capable If:"
Column.
2-13. GENERAL MAINTENANCE INSTRUCTIONS
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can
give off harmful vapors, and are harmful to skin and clothing. Keep
away from open fire and use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or clothing, wash
immediately with soap and water. Failure to comply may result in
serious injury or death to personnel.
a. Cleanliness. Dirt, grease, oil, and debris only get in the way and may cover up a
serious problem. Use Dry Cleaning Solvent (Item 15, Appendix D) on metal surfaces
where directed.
b. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, and
missing, bent, or broken conditions. Look for chipped paint, bare metal, or rust around bolt
heads. If any part seems loose, tighten it or notify Unit Maintenance.
c. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded
together. If a bad weld is found, notify Unit Maintenance.
d. Electrical Wires and Connections. Look for cracked or broken insulation, bare
wires, and loose or broken connectors. Tighten loose connectors and make sure wires are
in good shape. If a bad wire or connector is found, notify Unit Maintenance.
2-31
TM 9-2320-365-10
2-13. GENERAL MAINTENANCE INSTRUCTIONS (CONT)
e. Hydraulic Lines and Fittings. Look for wear, damage, and leaks; make sure clamps
and fittings are tight. Wet spots show leaks. A stain around a fitting or connector can
mean a leak. If a leak comes from a loose fitting or connector, tighten it. If something is
broken or worn out, notify Unit Maintenance.
f. Damage. Damage is defined as any condition that affects safety or would make the
vehicle unserviceable for mission requirements.
2-14. FLUID LEAKAGE
It is necessary to know how fluid leakage affects the status of fuel, oil, coolant, and
hydraulic systems. The following are definitions of the different types of leakage that can
determine the status of the vehicle. Learn, then be familiar with them, and REMEMBER-
WHEN IN DOUBT, NOTIFY UNIT MAINTENANCE!
CAUTION
• Equipment operation is allowable with minor leakage (Class I or Class II).
Fluid levels of items with Class I and Class II leaks must be checked often
so proper levels can be kept. Consideration must be given to the fluid
capacity in the item/system being checked/ inspected. Failure to comply may
result in damage to equipment.
• Class III leaks must be reported to Unit Maintenance. Failure to comply may
result in damage to equipment.
Fluid leakage is classified and defined as follows:
CLASSIFICATION IDENTIFICATION
Class I Seepage of fluid (indicated by wetness or discoloration)
not great enough to form drops.
Class II Leakage of fluid great enough to form drops but not
enough to cause drops to drip from item being
inspected.
Class III Leakage of fluid great enough to cause drops to drip
from item being checked.
2-32
TM 9-2320-365-10
2-15. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
TABLE (ALL MODELS)
Refer to Table 2-1. Preventive Maintenance Checks and Services (PMCS) for Operator/
Crew procedures for all models of the vehicle. The PMCS routing diagram is shown
below. It shows the vehicle PMCS routing track which matches the sequence of PMCS
given in Table 2-1.
PMCS ROUTING DIAGRAM
2-33
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
NOTE
Operating vehicle with damaged windshield may violate AR 385-55.
1 Before Windshield, a. Check windshield for a. Windshield is
Windshield damage that would cracked suffi-
Wipers, and impair Operator's vision. ciently to impair
Washer Operator's vision.
Reservoir
b. Check for missing or
damaged windshield
wiper blade. Notify Unit
Maintenance if
windshield wiper blade is
missing or
unserviceable.
c. Check windshield
washer reservoir fluid
level. Add windshield
washer fluid as required
(Appendix F).
2-34 Change 2
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
1.1 Before Front and Check that shackle pins are
Rear not loose.
Shackles
1.2 Before Cab Air Verify cab air springs are
Springs unpinned and pin is stowed
in stowage bracket.
2 Before Exterior of Look under vehicle for Class III leak is
Vehicle signs of fluid leakage (fuel, evident.
oil, and coolant).
Change 2 2-35
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
WARNING
Extreme care should be taken when removing coolant fill
cap if temperature gage reads above 180 F (82 C). Contact
with steam or hot coolant under pressure may result in
injury to personnel.
Pressure in radiator overflow tank must be released before
removing cap. Failure to comply may result in injury to
personnel.
Do not operate vehicle if radiator cap is damaged or
missing. Failure to comply will result in injury or damage to
equipment.
3 Before Coolant a. Check coolant level. a. Coolant level
Coolant level should be below lower
between upper sight- sightglass.
glass and lower sight-
glass on radiator
overflow tank with
engine not running. Add
coolant as required
(Appendix F, Note 4).
2-36 Change 2
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
Before Coolant b. Check for engine oil in b. If engine oil is
coolant. present, Notify
Unit
Maintenance.
c. Check radiator cap. c. Radiator cap
damaged or
missing, notify
Unit
Maintenance.
Change 2 2-36.1/(2-36.2 Blank)
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
WARNING
Diesel fuel is flammable. Do not fill fuel tank with engine
running, while smoking, or when near an open flame. Never
overfill tank or spill fuel. If fuel is spilled, clean it up
immediately. Failure to comply may result in serious injury or
death to personnel.
4 Before Fuel Tank a. Remove fuel cap and
fuel strainer.
b. Check for presence of
fuel in fuel tank.
c. Install fuel strainer
and fuel cap.
2-37
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
5 Before Spare Tire a. Check that spare tire
Strap strap is tight.
b. Check that spare tire
strap is not torn,
frayed, or damaged.
c. Check that SPARE
TIRE knob is in
RAISE position.
d. Check that CAB knob
(Air Springs) is
pushed in. If not, push
knob in and turn to
the right.
2-38
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
6 Before Cab Check that cab hydraulic If cab will not
Hydraulic latch indicator button is in securely latch.
Latch the latched position.
7 Before Air/Hydraulic Check oil level on dipstick.
Power Unit Add oil as required
(Appendix F, Note 6).
Change 2 2-39
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
NOTE
• Operating the vehicle with inoperative seat belts may violate AR 385-
55.
• If vehicle mission requires three personnel, all three seat belts are
required to be in good working condition.
8 Before Seat Belts Check all three seat belts Drivers seat belt
for security, damage, and and at least one
proper operation. other seat belt
not in good
working condition.
9 Before Driver’s Seat Check operation of Forward/
forward/backward backward
adjustment control. adjustment is
broken or
missing.
10 Before Fire a. Check for missing or a. Fire
Extinguisher damaged fire extinguisher is
extinguisher. damaged or
missing.
2-40 Change 1
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
b. Check that fire b. Fire
extinguisher pressure is extinguisher
approximately 150 psi pressure gage
(1034 kPa). needle is
within
discharge
band.
c. Seal is
missing.
Change 1 2-40.1/(2-40.2 Blank)
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
NOTE
PARK BRAKE and EMERGENCY BRAKE indicators will not
illuminate if SYSTEM PARK control is not pulled out. REAR
BRAKE AIR and FRONT BRAKE AIR indicators will not illuminate if
air system pressure exceeds 65 psi (448 kPa).
11 Before Lighted a. Position master power
Indicator switch to on.
Display
b. Check that the following b. Any of the
indicator lights are listed indicator
illuminated: lights is not
illuminated.
1. STOP
2. PARK BRAKE
3. EMERGENCY
BRAKE
4. REAR BRAKE AIR
5. FRONT BRAKE AIR
6. ENGINE OIL
PRESSURE
Change 1 2-41
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
11.1 Before Windshield, a. Check windshield
Windshield washer switch for
Wipers, and proper operation.
Washer Notify Unit Maintenance
Reservoir if windshield washer
(Cont) switch is inoperative.
b. Check windshield wiper
switch for proper
operation. Notify Unit
Maintenance if
windshield wiper switch
is inoperative.
2-42 Change 1
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
CAUTION
If engine oil pressure indicator does not illuminate momentarily, or
illuminates and stays on, vehicle is not fully mission capable.
Failure to comply may result in damage to equipment.
NOTE
If OIL PRESS gage reads in red zone (0-7 psi) (0-48 kPa) and
engine oil pressure indicator is not illuminated, shut down engine,
then restart engine. Indicator should illuminate momentarily to
indicate proper function. If engine oil pressure indicator illuminates
and then goes out, continue with the mission.
12 Before OIL PRESS a. Start engine (para 2- a. Gage indicates
Gage 21a or b). in red zone and
engine oil
pressure indicator
is illuminated.
Change 1 2-42.1/(2-42.2 Blank)
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
NOTE
• Oil pressure will increase when engine speed increases and will
decrease when engine speed decreases.
• Engine oil pressure will be lower when engine is at maximum operating
temperature (WATER TEMP gage reads 230 F (110 C).
12 Before OIL PRESS b. Check that engine OIL b. Gage indicates
Gage (Cont) PRESS gage indicates less than 15 psi
between 15-80 psi (103 kPa).
(103-552 kPa).
NOTE
Perform check (13) only if vehicle is equipped with tachometer.
13 Before Tachometer Check that tachometer
indicates between 750-850
rpm while engine is at idle.
If tachometer indicates
engine rpm outside of 750-
850 rpm range, notify Unit
Maintenance.
Change 1 2-43
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
NOTE
• At idle, WATER TEMP gage may not reach 160 F (71 C).
• If high engine temperature indicator is illuminated and WATER TEMP
gage reads 160 - 230 F (71 - 110 C) and engine fan is NOT running
continuously, continue with the mission.
14 Before WATER Check that WATER TEMP WATER TEMP
TEMP Gage gage indicates between gage indicates in
160 - 230 F (71 - 110 C). red zone and
high engine
temperature
indicator is
illuminated.
2-44 Change 1
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
15 Before AIR FILTER Check AIR FILTER AIR FILTER
RESTRIC- RESTRICTION GAUGE. RESTRICTION
TION Press reset button if gauge GAUGE reads
GAUGE reads greater than 25 in. greater than 25
(in red area). If gauge still in. (in red area).
reads in red area after
reset button is pressed,
shut down engine and
service air filter (para 3-9).
Start engine (para 2-21a or
b). Notify Unit
Maintenance if gauge still
reads in red area.
Change 1 2-45
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
16 Before FRONT Check that FRONT BRAKE Either gage
BRAKE AIR AIR and REAR BRAKE indicates less
and REAR AIR gages read between than 65 psi (448
BRAKE AIR 65-120 psi (448-827 kPa). kPa), FRONT
Gages BRAKE AIR or
REAR BRAKE
AIR indicators
illuminate, or
audible alarm
sounds.
17 Before VOLTS Check that VOLTS gage VOLTS gage
Gage reads between 26 and 30 indicates more
volts. than 30 volts or
less than 26
volts.
2-46 Change 1
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
18 Before FUEL Gage Check FUEL gage for
proper operation.
Compare FUEL gage
reading with observed level
of fuel in fuel tank (from
item 4).
CAUTION
Check SYSTEM PARK control while vehicle is stopped. Failure to
comply may result in damage to equipment.
19 Before SYSTEM a. Pull out SYSTEM
PARK PARK control.
Control
b. Set WTEC II TEPSS or b. Vehicle moves
WTEC III TPSS to any with SYSTEM
forward gear (para 2- PARK control
21e) while engine is at on.
idle (approximately 750
rpm). Vehicle should
not move.
Change 1 2-47
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
20 Before WTEC II Check that WTEC II One gear range
TEPSS or TEPSS or WTEC III TPSS does not operate
WTEC III operates properly in all properly or LED
TPSS gears (para 2-21e). display indicates
service message
which cannot be
reset.
21 Before Turn Signal Check turn signal control
Control and indicators for proper
operation.
2-48 Change 1
TM 9-2320-365-10
Table 2-1. Preventive Maintenance Checks and Services (All Models) (Cont)
Location
Item Interval Item to Crewmember Not Fully
No. Check/ Procedure Mission Capable
Service If:
NOTE
Checking condition of hazard lights switch is a safety task that
would not be performed in a tactical mission. See AR 385-55.
22 Before Hazard Check hazard lights switch
Lights Switch for proper operation.
CAUTION
All gages must maintain normal readings as listed in BEFORE
checks during vehicle operation. Operating the vehicle for an
extended period of time with any of the gages reading outside of
normal limits may result in damage to equipment.
23 During Controls and Monitor all gages, warning Warning lights or
Indicators lights, and warning buzzers buzzers indicate
during operation. a malfunction and
immediate
corrective action
by the Operator
will not correct
the problem.
Change 1 2-49
