Chapter 7. ELECTRICAL SYSTEM MAINTENANCE

TM 9-2320-366-20-3

ELECTRICAL SYSTEM MAINTENANCE

RESTRICTED MAINTENANCE NOTICE

Units not authorized SC 4910-95-CL-A72 (SHOP EQUIPMENT, COMMON NO. 2) in their T.O.E. may

be unable to perform some of the maintenance tasks described in this chapter. If the required tools

are not authorized, the equipment must be submitted to DS Maintenance for repair.

Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Section II. MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 7-5

7-2. 100 AMP ALTERNATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 7-5

7-3. ALTERNATOR BELTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11

7-4. ALTERNATOR BRACKETS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

7-5. 100 AMP VOLTAGE REGULATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . .

7-20

7-6. AUXILIARY STARTER SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . .

7-23

7-7. STARTING MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-27

7-8. AUXILIARY PANEL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-34

7-9. CIRCUIT BREAKER, DIODE, AND RELAY REPLACEMENT . . . . . . . . . . . . . . . .

7-38

7-10. WTEC II DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . .

7-39

7-11. WTEC III DASHBOARD CABLE ASSEMBLY REPLACEMENT/REPAIR . . . . . . . .

7-64

7-12. DIMMER SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-88

7-13. WTEC II TRANSMISSION ECU PUSHBUTTON SHIFT SELECTOR (TEPSS)

DIMMER MODULE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 7-89

7-14. ELECTRICAL GAGES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 7-91

7-15. INSTRUMENT PANEL ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . .

. 7-93

7-16. LIGHTED INDICATOR DISPLAY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . .

7-110

7-17. MAIN LIGHT SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-112

7-18. ROCKER SWITCHES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-114

7-19. START INHIBIT PUSHBUTTON SWITCH REPLACEMENT . . . . . . . . . . . . . . . . .

7-119

7-20. STARTER PUSHBUTTON SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

7-121

7-21. TACHOMETER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-122

7-22. COOLANT TEMPERATURE LIGHT SWITCH REPLACEMENT . . . . . . . . . . . . . . .

7-124

7-23. M1090/M1094 DUMP BODY SWITCH REPLACEMENT/ADJUSTMENT . . . . . . . .

7-127

7-24. FAN AND DIFFERENTIAL LOCK SOLENOIDS REPLACEMENT . . . . . . . . . . . . .

7-131

7-25. FLASHER UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-134

7-26. TURN SIGNAL SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-135

7-27. M1084/M1086 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . .

7-138

7-28. M1089 JUNCTION BOX ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . .

7-159

7-29. SHUNT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-180

7-30. 100 AMP REVERSE POLARITY RELAY REPLACEMENT . . . . . . . . . . . . . . . . . .

7-184

7-31. FREQUENCY ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-188

7-32. CRANE REMOTE CONTROL BOX REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-190

7-33. M1089 TERMINAL BOARD ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . .

7-198

7-34. M1089 WRECKER CONTROL PANEL TOGGLE SWITCH REPLACEMENT . . . . .

7-202

7-35. M1089 WRECKER REMOTE CONTROL BOX REPAIR . . . . . . . . . . . . . . . . . . . .

7-207

7-36. BACKUP LIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . .

7-211

7-37. BLACKOUT DRIVE LIGHT REPLACEMENT/REPAIR . . . . . . . . . . . . . . . . . . . . . .

7-217

7-38. CLEARANCE AND MARKER LIGHT ASSEMBLIES REPLACEMENT . . . . . . . . . .

7-219

7-39. COMPOSITE TAILLIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . . . .

7-225

7-40. COMPOSITE FRONT LIGHT ASSEMBLY REPLACEMENT/REPAIR . . . . . . . . . . .

7-233

7-41. HEADLIGHT AND HOUSING REPLACEMENT/REPAIR/ADJUSTMENT . . . . . . . .

7-236

7-42. M1088/M1089 STATIONARY WORKLIGHT ASSEMBLY REPLACEMENT/REPAIR

7-240

Change 1

7-1