Italeri M977 Series User manual

TABLE OF CONTENTS
PAGE ii
INTRODUCTION
PAGE 1-1
MAINTENANCE
INSTRUCTIONS
PAGE 2-1
TRANSMISSION
MAINTENANCE
PAGE 7-1
MAINTENANCE PROCEDURES
PAGE 2-145
TRANSFER CASE
MAINTENANCE
PAGE 8-1
AXLES NO. 1 AND NO. 2
MAINTENANCE
PAGE 9-1
ALPHABETICAL
INDEX
PAGE INDEX 1
TROUBLESHOOTING
PAGE 2-2
ENGINE MAINTENANCE
PAGE 3-1
COOLING SYSTEM
MAINTENANCE
PAGE 5-1
ELECTRICAL SYSTEM
MAINTENANCE
PAGE 6-1
FUEL SYSTEM
MAINTENANCE
PAGE 4-1
TM 9-2320-279-34-1
JUNE 1987
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977SERIES8x8HEAVY
EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL NSN
TRUCK, CARGO, WITH WINCH, M977 2320-01-097-0260
TRUCK, CARGO, WITH WINCH, M977A2 2320-01-493-3774
TRUCK, CARGO, WITH WINCH, M977A2R1 2320-01-493-3782
TRUCK, CARGO, WITHOUT WINCH, M977 2320-01-099-6426
TRUCK, CARGO, WITHOUT WINCH, M977A2 2320-01-493-3779
TRUCK, CARGO, WITHOUT WINCH, M977A2R1 2320-01-493-3785
TRUCK, TANK, FUEL, WITH WINCH, M978 2320-01-097-0249
TRUCK, TANK, FUEL, WITH WINCH, M978A2 2320-01-492-8216
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1 2320-01-492-8226
TRUCK, TANK, FUEL, WITHOUT WINCH, M978 2320-01-100-7672
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2 2320-01-492-8215
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1 2320-01-492-8225
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983 2320-01-097-0247
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2 2320-01-492-8223
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1 2320-01-492-8231
TRUCK, TRACTOR, WITH WINCH,
WITH CRANE, M983 2320-01-099-6421
TRUCK, WRECKER-RECOVERY, M984 2320-01-097-0248
TRUCK, WRECKER-RECOVERY, M984A1 2320-01-195-7641
TRUCK, WRECKER-RECOVERY, M984A2 2320-01-492-8224
TRUCK, WRECKER-RECOVERY, M984A2R1 2320-01-492-8233
TRUCK, CARGO, WITH WINCH, M985 2320-01-097-0261
TRUCK, CARGO, WITH WINCH, M985A2 2320-01-492-8214
TRUCK, CARGO, WITH WINCH, M985A2R1 2320-01-493-3787
TRUCK, CARGO, WITHOUT WINCH, M985 2320-01-100-7673
TRUCK, CARGO, WITHOUT WINCH, M985A2 2320-01-492-8201
TRUCK, CARGO, WITHOUT WINCH, M985A2R1 2320-01-493-3789
TRUCK, CARGO, WITH WINCH, M985E1 2320-01-194-7032
TRUCK, CARGO, WITH WINCH, M985E1A2 2320-01-493-3790
TRUCK, CARGO, WITH WINCH, M985E1A2R1 2320-01-493-3792
Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY

WARNING
TM 9-2320-279-34-1
CARBON MONOXIDE (EXHAUST GAS) CAN CAUSE DEATH.
Carbon monoxide is without color or smell, but can cause death. Breathing air
with carbon monoxide produces symptoms of headache, dizziness, loss of
muscular control, a sleepy feeling, and coma. Brain damage or death can result
from heavy exposure. Carbon monoxide occurs in the exhaust fumes of
fuel-burning heaters and internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of no ventilation.
Precautions must be followed to ensure crew safety when the arctic engine
heater or engine of any vehicle is operated for any purpose.
1.
2.
3.
4.
DO NOT operate arctic engine heater or engine of vehicle in a closed place
without proper ventilation.
DO NOT drive any vehicle with inspection plates, cover plates, or engine
compartment covers removed unless necessary for maintenance purposes.
BE ALERT at all times during vehicle operation for exhaust odors and
exposure symptoms. If either are present, IMMEDIATELY VENTILATE
personnel compartments. If symptoms persist, remove affected crew to fresh
air and keep warm. DO NOT PERMIT PHYSICAL EXERCISE. If necessary, give
artificial respiration and get immediate medical attention. For artificial
respiration, refer to FM 21-11.
BE AWARE that the gas particulate filter unit or the field protection mask for
nuclear-biological-chemical protection WILL NOT offer safety from carbon
monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD
VENTILATION.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, 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.
WARNING
Never use the parking brake for normal braking or wheels will lock up causing
severe skid. Skidding vehicle could result in serious injury or death.
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of vehicle.
WARNING
a
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before
working around vehicle. Jewelry can catch on equipment and cause injury, or
may short across an electrical circuit and cause severe burns or electrical shock.

TM 9-2320-279-34-1
WARNING
The radiator is very hot and pressurized during vehicle operation. Let radiator
cool before removing cap. Failure to do so can result in serious burns.
WARNING
The exhaust pipe and muffler can become very hot during vehicle operation. Be
careful not to touch these parts with bare hands, or allow body to come in
contact with pipe or muffler. Exhaust system parts can become hot enough to
cause serious burns.
WARNING
Do not use trailer brakes as parking brake. Trailer brakes may not hold a loaded
vehicle and trailer on a grade. A runaway vehicle may cause severe personal
injury or death.
WARNING
Always use seatbelts when operating vehicle. Failure to use seatbelt can result in
serious injury in case of accident.
WARNING
Avoid quick, jerking, winch operation. Keep other personnel well away from
vehicles involved in winching operations. A snapped cable or shifting load can
cause serious injury or death.
WARNING
Always wear heavy gloves when handling winch cables. Never let cable run
through hands; frayed cables can cut. Never operate winch with less than five
wraps of cable on winch drum.
WARNING
If operating crane under powerlines, do not allow vehicle to contact high-voltage
connections. Death on contact can result. If possible, keep one hand away from
equipment to reduce the hazard of current flowing through vital organs of the
body.
WARNING
When working inside the vehicle with power off, be sure to ground every
capacitor likely to hold a dangerous voltage potential.
WARNING
Never work on electronic equipment unless there is another person nearby who
is familiar with the operation and hazards of the equipment.
WARNING
Be careful when working on or with electrical equipment. Do not be misled by
the term “low voltage”. Voltages as low as 50 volts may cause death. For
artificial respiration, refer to FM 21-11.
b

TM 9-2320-279-34-1
Change 7 c
WARNING
Be careful not to short out battery terminals. Do not smoke or use open flame
near batteries. Batteries may explode from a spark. Battery acid is harmful to
skin and eyes.
WARNING
Brake shoes may be coated with dust. Breathing this dust may be harmful to your health.
Do not use compressed air to clean brake shoes. Wear a filter mask approved for use
against brake dust. Failure to comply may result in injury or death to personnel.
WARNING
Starting fluid is toxic and flammable. Do not store in cab and do not breathe
fumes. Do not puncture or burn containers. Dispose of container following
manufacturer’s recommendations on the container.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
WARNING
After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters
shall be handled with extreme caution. Unprotected personnel can experience
injury or death if residual toxic agents or radioactive material are present. If
vehicle is exposed to chemical or biological agents, servicing personnel shall wear
protective mask, hood, protective overgarments, and chemical protective gloves
and boots in accordance with TM 10-277. All contaminated air filters shall be
placed in double-lined plastic bags and moved swiftly to a segregation area away
from the worksite. The same procedure applies for radioactive dust
contamination. The Company NBC team should measure the radiation prior to
filter removal to determine the extent of safety procedures required per the NBC
Annex to the unit Standard Operating Procedures (SOP). The segregation area in
which the contaminated air filters are temporarily stored shall be marked with
appropriate NBC placards. Final disposal of contaminated air filters shall be in
accordance with local SOP. Decontamination operation shall be in accordance
with FM 3-5 and local SOP.
WARNING
DO NOT grind or sand painted equipment without high-efficiency air purifying
respirators in use.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, 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.
WARNING
Use extreme care when removing or installing spring retainers. Spring retainers
are under tension and can act as projectiles when released suddenly. Ensure
proper eye protection is worn to prevent injury to personnel.
WARNING
Use extreme care when removing or installing springs. Springs are under tension
and can act as projectiles when released. Ensure proper eye protection is worn to
prevent injury to personnel.

TM 9-2320-279-34-1
d Change 7
WARNING
CARC paint contains isocyanate (HDI) which is highly irritating to skin and
respiratory system. High concentrations of HDI can produce symptoms of itching
and reddening of skin, a burning sensation in throat and nose, and watering of
the eyes. In extreme concentrations, HDI can cause cough, shortness of breath,
pain during respiration, increased sputum production, and chest tightness. The
following precautions must be taken whenever using CARC paint:
SALWAYS use air-line respirators when using CARC paint unless air sampling
shows exposure to be below standards. Use chemical cartridge respirator if air
sampling is below standards.
SDO NOT let skin or eyes come in contact with CARC paint. Always wear
protective equipment (gloves, ventilation mask, safety goggles, etc.).
SDO NOT use CARC paint without adequate ventilation.
SNEVER weld or cut CARC coated materials.
SDO NOT grind or sand painted equipment without high-efficiency, air-purifying
respirators in use.
SBE AWARE of CARC paint exposure symptoms: symptoms can occur a few days
after initial exposure. Seek medical help immediately if symptoms are detected.
WARNING
SEye protection is required during all grinding operations. Failure to comply
may result in serious injury to personnel.
STake all necessary precautions to confine grinding sparks so they cannot
contact flammable or combustible materials or vapors. Failure to comply may
result in serious injury or death to personnel.
SWhen grinding, avoid creating excess heat on CARC painted surfaces near
grinding area. CARC paint can ignite if heated. Failure to comply may result
in serious injury or death to personnel.
WARNING
CHEMICAL AGENT RESISTANT COATING (CARC)
Unusable CARC mixtures are considered hazardous waste and will require
disposal in accordance with Federal, state, Department of Defense, Department of
the Army, and local installation hazardous waste regulations. Consult the
installation environmental office for proper disposal guidance. Mixed CARC is
extremely flammable. Use only in well-ventilated areas. Keep away from open
flames, sparks, and other ignition sources.
CARC paint contains isocyanate (HDI), which is highly irritating to skin and
respiratory system. High concentrations of HDI can produce symptoms of itching
and reddening of skin, a burning sensation in throat and nose, and watering of
the eyes. In extreme concentrations, HDI can cause cough, shortness of breath,
pain during respiration, increased sputum production, and chest tightness. The
following precautions must be taken whenever using CARC paint:
SALWAYS use air-line respirators when using CARC paint unless air sampling
shows exposure to be below standards. Use chemical cartridge respirator if air
sampling is below standards.
SDO NOT use CARC paint without adequate ventilation.
SNEVER weld or cut CARC coated materials.
SDO NOT grind or sand painted equipment without high-efficiency, air-purifying
respirators in use.
SBE AWARE of CARC paint exposure symptoms: symptoms can occur a few days
after initial exposure. Seek medical help immediately if symptoms are detected.

TM 9-2320-279-34-1
C7
1of2
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO.7WASHINGTON,D.C.,1July,2005
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL NSN
TRUCK, CARGO, WITH WINCH, M977 2320-01-097-0260
TRUCK, CARGO, WITH WINCH, M977A2 2320-01-493-3774
TRUCK, CARGO, WITH WINCH, M977A2R1 2320-01-493-3782
TRUCK, CARGO, WITHOUT WINCH, M977 2320-01-099-6426
TRUCK, CARGO, WITHOUT WINCH, M977A2 2320-01-493-3779
TRUCK, CARGO, WITHOUT WINCH, M977A2R1 2320-01-493-3785
TRUCK, TANK, FUEL, WITH WINCH, M978 2320-01-097-0249
TRUCK, TANK, FUEL, WITH WINCH, M978A2 2320-01-492-8216
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1 2320-01-492-8226
TRUCK, TANK, FUEL, WITHOUT WINCH, M978 2320-01-100-7672
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2 2320-01-492-8215
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1 2320-01-492-8225
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983 2320-01-097-0247
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2 2320-01-492-8223
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1 2320-01-492-8231
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983 2320-01-099-6421
TRUCK, WRECKER-RECOVERY, M984 2320-01-097-0248
TRUCK, WRECKER-RECOVERY, M984A1 2320-01-195-7641
TRUCK, WRECKER-RECOVERY, M984A2 2320-01-492-8224
TRUCK, WRECKER-RECOVERY, M984A2R1 2320-01-492-8233
TRUCK, CARGO, WITH WINCH, M985 2320-01-097-0261
TRUCK, CARGO, WITH WINCH, M985A2 2320-01-492-8214
TRUCK, CARGO, WITH WINCH, M985A2R1 2320-01-493-3787
TRUCK, CARGO, WITHOUT WINCH, M985 2320-01-100-7673
TRUCK, CARGO, WITHOUT WINCH, M985A2 2320-01-492-8201
TRUCK, CARGO, WITHOUT WINCH, M985A2R1 2320-01-493-3789
TRUCK, CARGO, WITH WINCH, M985E1 2320-01-194-7032
TRUCK, CARGO, WITH WINCH, M985E1A2 2320-01-493-3790
TRUCK, CARGO, WITH WINCH, M985E1A2R1 2320-01-493-3792
Approved for public release; distribution is unlimited.

By Order of the Secretary of the Army:
PETER J. SCHOOMAKER
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
TM 9-2320-279-34-2
C1
2of2
TM 9-2320-279-34-1, June 1987, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Minor changes to illustrations are indicated by a miniature pointing hand.
4. Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages Insert Pages
A thru C/(D blank) A thru C/(D blank)
c/(d blank) c and d
1-1 and 1-2 1-1 and 1-2
6-73 and 6-74 6-73 and 6-74
6-83 and 6-84 6-83 and 6-84
none 6-84.1/(6-84.2 blank)
9-13 and 9-14 9-13 and 9-14
none 9-14.1/(9-14.2 blank)
9-15 and 9-16 9-15 and 9-16
9-89 and 9-90 9-89 and 9-90
Cover Cover
File this change sheet in front of the publication for reference purposes.
0422207
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number IDN: 380653, requirements
for TM 9-2320-279-34-1.

TM 9-2320-279-34-1
C6
1of2
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 6 WASHINGTON, D.C., 15 December, 2003
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL NSN
TRUCK, CARGO, WITH WINCH, M977 2320-01-097-0260
TRUCK, CARGO, WITH WINCH, M977A2 2320-01-493-3774
TRUCK, CARGO, WITH WINCH, M977A2R1 2320-01-493-3782
TRUCK, CARGO, WITHOUT WINCH, M977 2320-01-099-6426
TRUCK, CARGO, WITHOUT WINCH, M977A2 2320-01-493-3779
TRUCK, CARGO, WITHOUT WINCH, M977A2R1 2320-01-493-3785
TRUCK, TANK, FUEL, WITH WINCH, M978 2320-01-097-0249
TRUCK, TANK, FUEL, WITH WINCH, M978A2 2320-01-492-8216
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1 2320-01-492-8226
TRUCK, TANK, FUEL, WITHOUT WINCH, M978 2320-01-100-7672
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2 2320-01-492-8215
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1 2320-01-492-8225
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983 2320-01-097-0247
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2 2320-01-492-8223
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1 2320-01-492-8231
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983 2320-01-099-6421
TRUCK, WRECKER-RECOVERY, M984 2320-01-097-0248
TRUCK, WRECKER-RECOVERY, M984A1 2320-01-195-7641
TRUCK, WRECKER-RECOVERY, M984A2 2320-01-492-8224
TRUCK, WRECKER-RECOVERY, M984A2R1 2320-01-492-8233
TRUCK, CARGO, WITH WINCH, M985 2320-01-097-0261
TRUCK, CARGO, WITH WINCH, M985A2 2320-01-492-8214
TRUCK, CARGO, WITH WINCH, M985A2R1 2320-01-493-3787
TRUCK, CARGO, WITHOUT WINCH, M985 2320-01-100-7673
TRUCK, CARGO, WITHOUT WINCH, M985A2 2320-01-492-8201
TRUCK, CARGO, WITHOUT WINCH, M985A2R1 2320-01-493-3789
TRUCK, CARGO, WITH WINCH, M985E1 2320-01-194-7032
TRUCK, CARGO, WITH WINCH, M985E1A2 2320-01-493-3790
TRUCK, CARGO, WITH WINCH, M985E1A2R1 2320-01-493-3792
Approved for public release; distribution is unlimited.

By Order of the Secretary of the Army:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
JOHN M KEANE
General, United States Army
Chief of Staff
Official:
TM 9-2320-279-34-2
C1
2of2
TM 9-2320-279-34-1, June 1987, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Minor changes to illustrations are indicated by a miniature pointing hand.
4. Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages Insert Pages
A thru C/(D blank) A thru C/(D blank)
iandii iandii
none ii.1/(ii.2 blank)
2-5 thru 2-8 2-5 thru 2-8
2-127 thru 2-136 2-127 thru 2-136
none 2-136.1 thru 2-136.8
Index 1 thru Index 4 Index 1 thru Index 4
Cover Cover
File this change sheet in front of the publication for reference purposes.
0318303
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number IDN: 380653, requirements
for TM 9-2320-279-34-1.
PETER J. SCHOOMAKER