TM-9-2320-260-34-1

TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)

TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 1 OF 2

JULY 1994
TM-9-2320-260-34-1

  TM-9-2320-260-34-1 - Page 28 of 657

TM 9-2320-260-34-1
Table 2-1. Mechanical Troubleshooting (Contd).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
COOLING SYSTEM
WARNIN G
Hot coolant is under pressure. Care should be used when
removing coolant filler cap or inspecting hot engine coolant
leaks. Steam or hot coolant under pressure may cause severe
injury to personnel.
Wear hand protection at all times when working with heated
parts. Failure to do so may result in injury to personnel
27. LOSS OF COOLANT
Pressure test warm engine cooling system (TM 750-254). Observe pressure tester reading.
a. If pressure tester reading declines and there are no indications of external leaks, coolant
is leaking internally into engine or combustion chambers. Check engine oil for presence of
coolant. Remove oil dipstick. Coolant in oil requires inspection of engine crankshaft main
and connecting rod bearings (paras. 3-47 and 3-48).
b. If coolant is present on oil dipstick, remove cylinder heads (para. 3-18). Inspect cylinder
heads and gaskets, engine block, and cylinder liners for cracks or warpage.
(1) Replace or repair cylinder head(s) if cracked, warped, or damaged
(para. 3-18 or 3-51).
(2) Replace cylinder liners if cracked (para. 3-50).
(3) Replace engine if block is cracked (para. 3-24).
END OF TESTING!
28. ENGINE COOLANT TEMPERATURE GAGE ABOVE 230°F (11O°C)
Step 1. Check coolant flow at surge tank.
Replace water pump if there is no evidence of coolant flow (para. 6-4).
Step 2. Perform troubleshooting (malfunction 27).
END OF TESTING!
CLUTCH
29. VEHICLE WILL NOT MOVE WITH CLUTCH ENGAGED
Check clutch operation. Place transfer case in neutral and transmission in first gear. Engage clutch.
a. Remove transmission if transmission-to-transfer propeller shaft will not turn (para. 8-4).
Check pressure plate and clutch disc for defects. Replace pressure plate and clutch disc
if defective (para. 4-2).
b. Remove pressure plate and clutch disc from flywheel (para. 4-2). Verify flywheel
condition. Repair flywheel if flywheel is burned or damaged and damaged area removal
permits flywheel to remain within specifications, otherwise replace flywheel (para. 3-21).
END OF TESTING!
2-14


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