Section IV. MAINTENANCE PROCEDURES
2-8. GENERAL MAINTENANCE INSTRUCTIONS. General maintenance instructions for systems
and components of the vehicle, except engine and transmission, and cranes on M984 and M985E1, are
covered in this section. Refer to TM 9-2815-224-34&P for engine general maintenance procedures. Refer to
Chapter 7 for transmission general maintenance procedures. Read all CAUTIONS and WARNINGS that
apply to all maintenance procedures. Refer to TM 9-2320-279-20 for additional general maintenance
procedures that may also apply. Refer to TM 9-2320-354-24&P or TM 9-2320-355-24&P for maintenance
instructions that apply to cranes on M984 and M985E1 vehicles.
Follow these maintenance practices when working on vehicle.
Do not use paint scrapers, knives, or other metal tools on aluminum parts and
machined surfaces. Aluminum is easily gouged and machined surfaces easily
scratched by steel tools.
(1) Handle all parts and subassemblies carefully to prevent nicking, scratching, and denting.
(2) Handle parts carefully to protect from damage and contamination during removal, cleaning and
inspection, installation, and while stored in containers before installation.
(3) When unpacking new parts, remove all packing material, barrier paper, tape, plastic bags,
protective caps, and protective grease coating.
(4) Do not unwrap parts until ready for use to protect from contamination and damage.
Do not use tape to close off fuel or oil openings. Sticky surface of tape can mix
with fuel and oil and cause equipment malfunctions.
(5) As soon as parts are removed, cap or cover open tubes, hoses, fittings, and openings in
equipment to keep dust, dirt, and other objects out of internal parts. Use suitable containers to
catch coolant, oil, or fuel spills.
W A R N I NG
Be careful when working on or with electrical equipment. Voltage as low as
50 volts can cause injury or death. Always disconnect batteries when working on
electrical equipment. For artificial respiration, refer to FM 21-11.
(6) When repairing wire harness, remove wrap tape from wire harness, exposing wires for
inspection. Lay new wires alongside wire harness and cut new wires 1-1/2 in. (38 mm) longer
than wires being replaced. Cutting wires longer will allow organizational maintenance to replace
damaged pins and sockets later without replacing wires.
(7) When removing parts, inspect for breaks, dents, cracks, surface defects, and other visible
(8) When fastener tightening requirements are not given in maintenance task, tighten screws and
nuts in accordance with Appendix D, TORQUE LIMITS.
(9) The M977 series vehicles have a self bleeding hydraulic system. When the following steps are
completed, air from the hydraulic system should be purged to the hydraulic reservoir.
(a) Operate crane (TM 9-2320-279-10) and hold each crane or winch control lever (except for hoist
motor lever) completely in and then completely out for 30 seconds. Do this five times for each
(b) Operate hoist motor control lever and run hoist cable out 10 ft (3 m) and then back on the
winding drum. Do this three times.
(10) Replace all gaskets, packings, and seals.
(11) Replace lockwire, lockwashers, cotter pins, and plastic cable ties.
(12) Lubricate packings with oil, Stretch packings and place in position, pressing packings evenly in