TM-9-2320-260-34-2
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 2 OF 2
JULY 1994
TM-9-2320-260-34-2 - Page 391 of 863
15-89. AC MANUAL STARTER SWITCHES REPLACEMENT
THIS TASK COVERS:
a. Removal
b. Installation
INITIAL SETUP
APPLICABLE MODELS
M820, M820A2
TEST EQUIPMENT
Multimeter (Appendix B, Item 115)
TOOLS
General mechanic’s tool kit
(Appendix B, Item 1)
Toolkit, electrical (Appendix B, Item 106)
MATERIALS/PARTS
Twelve insulated wire splices
(Appendix C, Item 49)
REFERENCES (TM)
TM 9-2320-260-10
TM 9-2320-260-20
TM 9-2320-260-34P-2
EQUIPMENT CONDITION
●
External power source disconnected
(TM 9-2320-260-10).
●
Battery ground cable disconnected
(TM 9-2320-260-20).
Tag wires, cables, and leads for installation.
1. Remove covers (5) and (6) from AC manual starter switches (9) and (8).
2. Disconnect six wires (2) and wires (1) from six insulated wire splices (4). Discard insulated wire
splices (4).
3. Disconnect six wires (3) and wires (7) from six insulated wire splices (4). Discard insulated wire
splices (4).
4. Remove two nuts (17) from two nipples (16).
CAUTION
Use care when removing AC manual starter switches. Excessive
snagging or pulling on wiring harnesses may result in damage to
wiring harnesses.
5. Remove four screws (18) and AC manual starter switch (8) from van body (19).
6. Remove two nuts (15) and nipples (16) from AC manual starter switch (9).
7. Remove two nuts (14) from two nipples (12).
8. Remove four screws (13) and AC manual starter switch (9) from van body (19).
1.
2.
3.
4.
5.
6.
7.
8.
Position AC manual starter switch (9) on two nipples (12) and install on van body (19)
with four screws (13). Ensure wiring harnesses (10) and (11) are routed through AC manual starter
switch (9).
Install two nuts (14) on two nipples (12).
Install two nipples (16) on AC manual starter switch (9) with two nuts (15).
Position AC manual starter switch (8) on two nipples (16) and install on van body (19) with four
screws (18). Ensure wiring harnesses (10) and (11) are routed through two nipples (16).
Install two nuts (17) on two nipples (16).
Connect six wires (2) and wires (1) to six new insulated wire splices (4).
Connect six wires (3) and wires (7) to six new insulated wire splices (4).
Install covers (5) and (6) on AC manual starter switches (9) and (8).
15-330
TM 9-2320-260-34-2
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