MCS Cab Wiring Harness Replacement

TM 9-2320-363-34-1 · Chapter 4 — Electrical System Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Applicable   Configuration:                            References:

M917A1 w/MCS                                           TM 9-2320-363-20

Tools and Special Equipment:                           Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31                      Reference          Condition Description
Tool Kit, SC 5180-90-CL-N26
                                                       TM 9-2320-363-20   Batteries Disconnected

                                               NOTE
   l   Wiring harness and leads are secured in place by wire ties, cushion clamps, and screw
       terminals.
   l   Only remove hardware securing harness or lead to be removed.

   DISCONNECT AND REMOVE MCS CAB WIRING HARNESS USING ILLUSTRATION AND TABLE
   AS A GUIDE.

   Use general cleaning methods to clean all parts (page 2-30).

   Inspect all parts for wear or damage.

                                                NOTE

   l   Wiring harness and leads are secured in place by wire ties, cushion clamps, and screw
       terminals.

   l   Make sure harness is secure and all hardware is tight.

   INSTALL AND CONNECT MCS CAB WIRING HARNESS USING ILLUSTRATION AND TABLE AS
   A GUIDE.

                                              NOTE
                                     Follow-on Maintenance:
   Connect batteries (TM 9-2320-363-20).

TABLE QTY

1 2-Pin Male Connector 1 2 2-Pin Male Connector 1 3 Ring Terminal 1 4 Fuse/Relay Block 1

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STARTER SOLENOID REPLACEMENT This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                            References:

Shop Equipment, SC 4910-95-CL-A31                       TM 9-2320-363-20
Tool Kit, SC 5180-90-CL-N05
                                                        Equipment Condition:
Materials/Parts:
                                                        Reference              Condition Description
Washer, Lock              P/N Z0930-78423
                                                        TM 9-2320-363-20       Starter Removed
Adhesive-Sealant          Appendix B, Item 3

1.   REMOVE NUT (1), LOCK WASHER (2), AND WIRE (3) FROM STARTER SOLENOID (4). DISCARD
     LOCK WASHER.

                                        CAUTION
         Preheating may be required to remove nut without damaging plastic base.

2.     REMOVE NUT (5) FROM STARTER SOLENOID (4).

3.   HOLD NUT (6) ON STARTER MOTOR (7) AND REMOVE NUT (8) AND JUMPER (9) FROM STUD
     (10).
4.     REMOVE TWO SCREWS (11).

5.     PULL STARTER SOLENOID (4) AWAY FROM HOUSING (12) AND ROTATE SO MOUNTING
       BRACKET (13) FACES AWAY FROM STARTER MOTOR (7).

6.     REMOVE SPOOL (14) FROM SHIFT FORK (15).

                                            NOTE
        It may be necessary to use soft-jawed vise to hold solenoid plunger for removal
        of spool.

7.     REMOVE SPOOL (14) AND BOOT (16) FROM SOLENOID PLUNGER (17).

       Use general cleaning methods to clean all parts (page 2-30).

Inspect all pads for wear or damage.

1. INSTALL BOOT (16) AND SPOOL (14) ON SOLENOID PLUNGER (17).

2. ROTATE STARTER SOLENOID (4) SO MOUNTING BRACKET (13) FACES AWAY FROM STARTER MOTOR (7).

3. INSTALL SPOOL (14) IN SHIFT FORK (15).

4. ROTATE STARTER SOLENOID (4) TO MOUNTING POSITION AND PRESS FLUSH WITH HOUSING (12).

5. APPLY ADHESIVE-SEALANT TO THREADS AND INSTALL TWO SCREWS (11).

6. INSTALL JUMPER (9) ON STUD (10).

7. APPLY ADHESIVE-SEALANT TO LAST 1/4 IN. OF THREADS ON STUD (10), HOLD NUT (6) AND INSTALL NUT (8). TIGHTEN NUT (8) TO 21-29 LB-FT (28-39 N.m).

8. INSTALL NUT (5) ON STARTER SOLENOID (4). TIGHTEN NUT TO 18-22 LB-FT (24-30 N.m).

9. INSTALL WIRE (3), NEW LOCK WASHER (2), AND NUT (1) ON STARTER SOLENOID (4).

Install starter (TM 9-2320-363-20).