Attachment__0007_-_CBT_TM_9-2320-425-10.pdf

*TM 9-2320-425-10

TECHNICAL MANUAL

OPERATOR'S MANUAL

FOR

TRUCK, COMMON BRIDGE TRANSPORT

(CBT), 8X8

M1977A2 W/WINCH

NSN 2320-01-492-8219 (EIC DW5)

M1977A2 W/O WINCH

NSN 2320-01-492-8218 (EIC DW2)

*SUPERSEDURE NOTICE - TM 5-4210-249-13&P-1, TM 5-4210-249-13&P-2, TM 5-4210-249-13&P-3 and TM 5-4210-249-13&P-4 dated 20 Feb 09; EM 0289, TM 9-2320-325-14&P, TM 9-2320-347-10, TM 9-2320-348-10, TM 9-2320-349-10, TM 9-2320-420-10, TM 9-2320-421-10-1, TM 9-2320-421-10-2, TM 9-2320-422-10, TM 9-2320-423-10, TM 9-2320-424-10, TM 9-2320-425-10, TM 9-2320-325-10-HR dated 15 May 2009, Supersedes EM 0232, TM 9-2320-315-14&P, TM 9-2320-315-10, TM 9-2320-315-20 TM 9-2320-315-34, TM 9-2320-315-24P dated 15 Oct 04.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

MAY 2009

WARNING SUMMARY

GENERAL SAFETY CAUTION/WARNING SUMMARY

• This list summarizes critical warnings. They are repeated here to let you know how important they are.

• Study these warnings carefully.

• They can save your life and the lives of personnel you work with.

• If there is any doubt about handling tools, materials, equipment, and procedures, see TB 43-0216, Safety and Hazard Warnings for Operation and Maintenance of TACOM Equipment.

Table 1. Warning Icons Used In This Manual.

WARNING ICON DESCRIPTION

AIR PRESSURE - human hand blocking air gun shows the need to reduce air pressure before use, or debris may injure user and/ or damage equipment.

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - drops of liquid on hand show that the material will cause burns or irritation to human skin or tissue.

CRYOGENIC - hand in block of ice shows that the material is extremely cold and can injure human skin and tissue.

TM 9-2320-425-10

a

Table 1. Warning Icons Used In This Manual. - Continued

WARNING ICON DESCRIPTION

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

EXPLOSION - rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition, or high pressure.

EXTREMELY COLD SURFACE - hand touching object with ice formed on both shows that surface is extremely cold and can damage human tissue.

EYE PROTECTION - person with goggles shows that the material will injure the eyes.

FIRE - flame shows that material may ignite and cause burns.

b

Table 1. Warning Icons Used In This Manual. - Continued

FIRE EXTINGUISHER - fire extinguisher shows that material may ignite and a fire extinguisher should be within easy reach.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential for improper lifting technique, and/ or aid of assistant(s) and/or lifting device (as required).

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - foot with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - moving heavy object pinning human figure against stationary object shows that heavy, moving parts/objects present a danger to life or limb.

c

Table 1. Warning Icons Used In This Manual.

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or limb.

HOT AREA - hand over object radiating heats shows that part is hot and can burn.

MOVING PARTS - hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.

PRESSURE/TENSION HAZARD - human body being impacted by rotating projectile shows that equipment is under pressure or tension presenting a danger to life or limb if pressure or tension is not carefully released.

PROJECTILE HAZARD - human body with object passing through it shows that a projectile hazard exists.

d

RADIATION - three circular wedges show that the material emits radioactive energy and can injure human tissue.

ROLLOVER HAZARD - vehicle indicating direction of human figure shows that vehicle may roll over if conditions are not avoided, presenting a danger to life or limb.

RUN OVER HAZARD - vehicle running over human body shows hazard.

SHARP OBJECT - pointed object in hand shows that a sharp object presents a danger to life or limb.

SKIN IRRITATION - hand radiating shows that material can cause skin irritation.

e

SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger of falling.

STEAM HAZARD - human engulfed in steam cloud shows steam hazard exists that could injure/burn human tissue.

TIRE BLOWOUT - tire with hole shows that an over or under inflated tire may rupture, presenting a danger to life or limb.

VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.

WARNING/CAUTION - triangle with exclamation point within shows that a WARNING or CAUTION is present that indicates a potential hazard, which may cause injury or death to personnel (warning), or damage to equipment (caution).

f

WIRE CABLE/ROPE - human hand with frayed wire cable/rope running across shows injury to unprotected (bare) hands may result.

EAR PROTECTION - headphones over ears show that noise level will harm ears.

FOR INFORMATION ON FIRST AID:

Reference FM 4-25.11. (WP 0164)

WARNING

MODIFICATION HAZARD

• Unauthorized modifications to, alterations to, or installations on this equipment are prohibited and are in violation of AR 750-10.

• Failure to comply may result in injury or death to personnel or damage to equipment.

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WARNING

HIGH-PRESSURE HYDRAULIC SYSTEM

• Hydraulic systems can cause serious injuries if high-pressure lines or equipment fails.

• Never work on hydraulic systems or equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment and can give first aid.

• Never disconnect any hydraulic hose or part while the engine is running. Allow several minutes to elapse after shutting off engine, to allow pressure to relieve itself, before attempting to remove hoses.

Failure to comply may result in injury to personnel.

• The HEMTT vehicles contain hydraulic systems operating at oil pressures up to 3,000 psi (20 685 kPa) and 3,200 psi (22 064 kPa).

Never disconnect any hydraulic line or fitting without first dropping the pressure to zero. Failure to comply may result in serious injury or death to personnel.

WARNING

ELECTRICAL SYSTEM

• Remove all jewelry, such as rings, ID tags, bracelets, etc. If jewelry or tools contact electrical circuits, a direct short may result. Failure to comply may result in serious injury or death to personnel.

• Do not smoke, use open flame, make sparks or other ignition sources around batteries. A battery giving off gas could explode. Failure to comply may result in serious injury or death to personnel.

• Be careful when working on or with electrical equipment. Do not be misled by the term "low voltage". Voltages as low as 50 volts can cause death. For artificial respiration, refer to FM 4-25.11.

• When working inside the vehicle with power off, be sure to ground every capacitor likely to hold a dangerous voltage potential.

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• Never work on electronic equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment.

WARNING

SOLVENT CLEANING COMPOUND

• Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid of skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact:

flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.

• The flashpoint for Type II solvent cleaning compound is 141 to 198°F (61 to 92°C), and Type III is 200 to 241°F (93 to 116°C).

• Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment.

• Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to follow this warning may result in injury or death.

• Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to follow this warning may result in injury.

• Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury.

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POLYURETHANE COATING (CARC)

• Eye and hearing protection must be worn at all times when using power tools for grinding, cutting, sawing, and drilling. Failure to do so may result in injury to personnel. Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating to skin and respiratory system. High concentrations of isocyanate can produce symptoms of itching and reddening of skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain during respiration, increased sputum production, and chest tightness. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing.

Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention.

• The following precautions must be taken whenever using CARC paint:

• Protective equipment (gloves, goggles, ventilation mask) must be worn when using CARC paint.

• NEVER cut CARC-coated materials without high-efficiency, air-purifying respirators in use.

• DO NOT grind or sand painted equipment without high-efficiency, air-purifying respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after initial exposure. Seek medical help immediately if symptoms are detected.

• Use only in well-ventilated area. Check with local environmental office for methods and locations approved for painting in accordance with local and state environmental regulations.

• Always 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.

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ADHESIVE

• Adhesive, solvents and sealing compounds can burn easily and are harmful causing immediate bonding on contact with eyes, skin, or clothing and gives off harmful vapors.

• If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

• If adhesive gets in your eyes, try to keep them open; flush them with water for 15 minutes and get immediate medical attention.

• Wear protective goggles and use in a well-ventilated area.

• Keep away from open fire and use in well-ventilated area to avoid injury or death.

WARNING

FLAMMABLE LIQUID AND COMBUSTIBLE VAPOR

• Gasoline, fuel oil, lubricating oil, grease, paint, paint thinner, cleaning solvents, and other combustible liquids present a serious fire hazard.

• Combustible liquids must ALWAYS be stored in their approved containers and designated compartments or deck storage locations.

• Ensure exhaust and ventilation fans are operating while using cleaning solvents or paint products.

• Never store or charge batteries in a confined space without ventilation or near electrical equipment.

• 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.

k

• When working with fuel, post signs that read NO SMOKING WITHIN

50 FEET OF VEHICLE.

• 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

LIFTING OPERATIONS This section is applicable to all lifting operations regardless of lifting equipment (crane, LHS, etc.) used.

• All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury or death to personnel.

• Never crawl under equipment when performing maintenance unless equipment is securely blocked. Failure to comply may cause injury or death to personnel.

• Keep clear of equipment when it is being raised or lowered. Failure to comply may cause injury or death to personnel.

• Do not work on any item supported only by lift jacks or hoist. Always use blocks or proper stands to support the item prior to any work.

Failure to comply may result in injury or death to personnel.

• Do not lift a load greater than the rated load capacity of the crane or materiel handling equipment. Failure to comply may result in injury or death to personnel or damage to equipment.

• Do not allow heavy components to swing while hanging by lifting device. Failure to comply may cause injury or death to personnel.

• Any part or component that weighs between 50 lbs (23 kg) and 75 lbs (34 kg) must be removed with the aid of an assistant. Any part or component that weighs over 75 lbs (34 kg) must be removed with the aid of an assistant and a lifting device. Failure to comply may cause injury or death to personnel.

• Ensure all chains, hooks, and slings are in good condition and are of correct capacity. Ensure hooks are positioned correctly. Failure to comply may result in injury or death to personnel.

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MOVING MACHINERY

• Use extreme care when operating or working near moving machinery including running engine, rotating shafts, and other moving parts.

Failure to comply may result in injury or death to personnel.

• Use extreme care when measuring voltage while engine is running around rotating fan blade and hot engine parts. Failure to comply may result in injury or death to personnel.

WARNING

LHS and CBT OPERATION

• Check for overhead power lines, ground condition for firmness, and other obstructions before attempting LHS operation.

• LHS hook maximum lifting height is 17 ft. 2 in. (5.23 m). Failure to comply can result in injury or death to personnel.

WARNING

PARTS UNDER PRESSURE

• Wear safety goggles and use caution when removing or installing springs, snap rings, retaining rings, and other parts under spring tension. These parts can act as projectiles. Failure to comply may result in injury or death to personnel.

• 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.

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• During pressure tests, ensure air pressure is drained to 0 psi (0 kPa) before taking off any components. If pressure is not released, plates or line could blow off and harm personnel. Do not drain air from tank with any part of body in air spray path. Skin embolisms and/or debris in eyes can occur from released pressure.

• High air pressure may be released from valve stem when valve core is removed. Stay clear of valve stem after core is removed. Ensure all personnel wear suitable eye protection. Failure to comply may result in injury to personnel.

• Stand clear of trajectory area during deflation or personal injury or death may result.

• Lock-ring is under tension. If lock-ring breaks loose it could cause injury to personnel. Keep hands and fingers away from lock-ring when removing.

• Never adjust relief valve so that personnel must stand on strongback to operate latch.

• If there is any residual pressure in tank when relief valve is open, personnel may lose their balance and fall. Failure to comply may result in injury or death to personnel.

• 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.

• 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. Eye protection is required during all grinding operations. Failure to comply may result in serious injury to personnel.

• Failure to relieve tank pressure may result in sudden, unexpected loss of pressure. Failure to comply may result in personal injury or death.

• Do not remove the radiator cap when the engine is hot, as steam and hot coolant can escape. Failure to comply may result in personal injury or death.

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HEAVY PARTS

Any part or component that weigh over 50 lbs (23 kg) must be removed with the aid of an assistant and a lifting device. Failure to comply may result in personal injury or death.

WARNING

CRANE SYSTEM

• Always refer to the range diagram BEFORE making any lift. It is extremely important that the crane is properly leveled to prevent overstressing.

• Do not operate crane unless outriggers are set up. Always chock front wheels when using outriggers. Failure to comply may result in injury or death to personnel.

• When using crane on any vehicle, park vehicle clear of all overhead powerlines. If operating crane under power lines, do not allow vehicle to contact high-voltage connections. Failure to comply will result in death to personnel.

• Do not stand under crane. Failure to comply may result in injury or death to personnel.

• Refuse to work with worn, frayed, or damaged wire rope. 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. Failure to comply may result in injury or death to personnel.

• When using crane on any vehicle, park vehicle clear of all overhead power lines. Do not operate crane near overhead power lines. Failure to comply may result in injury or death to personnel.

• Boom has a 370 degree rotation and is mechanically stopped at five degrees on either side of the left outrigger beam. Swing operations must be slowed no later than 15 degrees prior to contacting the stop.

o

• Keep boom clear of electrical powerlines and other obstacles. Do not operate crane near overhead powerlines. Failure to comply will result in death to personnel.

• 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.

• If possible, keep one hand away from equipment to reduce the hazard of current flowing through vital organs of the body.

• Keep fingers clear of top of lift-hook. Failure to comply could result in personnel injury.

WARNING

CARBON MONOXIDE (EXHAUST GAS) CAN CAUSE DEATH

• Carbon monoxide does not have color or smell and 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 is in 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 personnel heater or engine of any vehicle is operated for any purpose. Failure to comply may result in injury or death to personnel.

• DO NOT operate vehicle engine in a closed place unless the place has proper ventilation. Failure to comply may result in injury or death to personnel.

• DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment covers removed unless necessary for maintenance purposes. Failure to comply may result in injury or death to personnel.

• BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms. If either odor or exposure symptoms are present, IMMEDIATELY VENTILATE personnel compartments. If symptoms continue, remove affected crew to fresh air and keep p warm. DO NOT PERMIT PHYSICAL EXERCISE. If necessary, give artificial respiration and get immediate medical attention. For artificial respiration, refer to FM 4-25.11 . Failure to comply may result in injury or death to personnel.

• 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.

WARNING

EXTREME HEAT

If required to remain inside the vehicle during extreme heat, occupants should follow the water intake, work/rest cycle, and other heat stress preventive medicine measures contained in FM 21-10, Field Hygiene and Sanitation.

WARNING

CABLES

• Always wear heavy gloves when handling winch cables; never let cable run through hands. Frayed cables can cut. Failure to comply may result in injury or death to personnel.

• Never operate winch with less than five wraps of cable on winch drum. Frayed cables can cut. Failure to comply may result in injury or death to personnel.

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LEAD-ACID BATTERIES

• Wear proper eye protection when working around batteries. Failure to comply may result in injury or death to personnel.

• Use extreme care not to short out battery terminals. Remove all jewelry such as rings, ID tags, bracelets, etc. prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.

• Batteries produce explosive gases. Do not smoke or use open flame near batteries. Do not allow hot, sparking, or glowing objects near batteries. If batteries are giving off gases, presence of a heat, flame, or spark may cause fire and/or explosion. Failure to comply may result in injury or death to personnel.

• Battery electrolyte is harmful to skin, and eyes. Avoid battery electrolyte contact with skin, eyes, or clothing. If battery electrolyte spills, take immediate action to stop burning effects:

WARNING

NBC

• NBC-contaminated air filters must be handled and disposed of only by authorized and trained personnel.

• The unit commander or senior officer in charge of maintenance personnel must ensure that prescribed protective clothing (FM r

3-11.4) is used, and prescribed safety measures and decontamination procedures (FM 3-11.5) are followed.

• The local unit SOP is responsible for final disposal of contaminated air filters. Failure to comply may cause severe injury or death to personnel.

WARNING

TIRE OPERATION

• Operating a vehicle with a tire in an overinflated or underinflated condition, or with a questionable defect, may lead to premature tire failure. Ensure tire has proper tire pressure. Failure to comply may result in injury or death to personnel.

• When inflating tires mounted on the vehicle, all personnel must remain out of trajectory of the side ring and lock-ring as shown by the areas indicated. Failure to follow proper procedures may result in serious injury or death to personnel.

• Cracked, broken, bent or otherwise damaged rim components shall not be reworked, welded, brazed, or otherwise heated or damage or personal injury or death may result.

• No heat shall be applied to a multi-piece wheel or wheel component or damage or injury or death may result.

• Failure to place wheel/tire assembly in safety cage prior to initial inflation could result in serious injury or death to personnel.

• When a wheel/tire is in a restraining device, do not rest or lean any part of body or equipment on or against the restraining device, or injury or death could result.

• While changing tires or while performing tire maintenance, stay out of the trajectory path. Failure to comply may result in injury or death to personnel.

• Always use an inflation hose with an in-line gauge and a clip-on chuck when inflating tires. The gauge and valve must be mounted a minimum of 10 feet (3.10 m) away from air chuck.

• High air pressure may be released from valve stem when valve core is removed. Stay clear of valve stem after core is removed. Ensure s all personnel wear suitable eye protection. Failure to comply may result in injury to personnel.

• Tire is heavy. Brace tire to ensure tire will not fall over on you or on others.

WARNING

VEHICLE OPERATION

• Speed limits posted on curves reflect speeds that are considered safe for automobiles. Heavy trucks with a high center of gravity can roll over at these speed limits. Use caution and reduce your speed below the posted limit before entering a curve. Failure to comply may result in vehicle crash and injury to personnel.

• Use caution and reduce your speed below the posted limit before entering a curve. Failure to comply may result in vehicle crash and injury to personnel.

• Always use seatbelts when operating vehicle. Failure to use seatbelt can result in serious injury or death in case of accident.

• Operation at speeds over 15 mph (24 kph) on paved roads can be achieved when the operator determines that the vehicle being towed and the terrain allow safe operation.

• Under no condition can speeds over 35 mph (55 kph) on paved road and 15 mph (24 kph) off-road be allowed. Loss of control can cause serious injury or death. Excessive speed can cause damage to vehicle being towed.

WARNING

BRAKES

• Ensure all personnel are clear from front of truck before performing brake stall check. Be ready to apply service brake. Operator must remain in cab while performing this check. Failure to comply could result in personnel injury.

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• Never use parking brake for normal braking or wheels will lock up causing severe skid. Skidding vehicle may result in serious personal injury or death.

• Engine must be shut OFF and parking brake set before performing PMCS walkaround. Failure to comply may result in injury or death to personnel.

WARNING

BURNS

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 exhaust pipe or muffler. Exhaust system parts can become hot enough to cause serious burns.

WARNING

HEARING PROTECTION

• Excessive noise levels are present any time the heavy-duty winch or crane is operating.

• Wear single hearing protection (earplugs or equivalent) while working around equipment while it is running. Failure to do so could result in damage to your hearing.

• Seek medical aid should you suspect a hearing problem.

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COMPRESSED AIR

• 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.

• 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.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE:

This manual supersedes TM 9-2320-315-14&P, dated 15 October 2004.

Zero in the "Change No." column indicates an original page or work package.

Date of issue for the original manual is:

Original 15 May 2009

TOTAL NUMBER OF PAGES FOR FRONT AND REAR

MATTER IS 82 AND TOTAL NUMBER OF WORK PACKAGES

IS 167, CONSISTING OF THE FOLLOWING:

Page/WP No.

Change No.

Front Cover 0 Warning Summary 0 i-xlviii 0 Chp 1 - General Information, Equipment Description and Theory of Operation 0 WP 0001 (10 pages) 0 WP 0002 (10 pages) 0 WP 0003 (2 pages) 0 WP 0004 (4 pages) 0 WP 0005 (2 pages) 0 WP 0006 (12 pages) 0 WP 0007 (2 pages) 0 WP 0008 (4 pages) 0 WP 0009 (4 pages) 0 WP 0010 (2 pages) 0 WP 0011 (2 pages) 0 WP 0012 (14 pages) 0 WP 0013 (6 pages) 0 WP 0014 (2 pages) 0 WP 0015 (2 pages) 0 WP 0016 (4 pages) 0 Chp 2 - Operator Instructions 0 WP 0017 (2 pages) 0 WP 0018 (4 pages) 0 WP 0019 (2 pages) 0 WP 0020 (12 pages) 0 WP 0021 (8 pages) 0

Page/WP No.

Change No.

WP 0022 (8 pages) 0 WP 0023 (2 pages) 0 WP 0024 (2 pages) 0 WP 0025 (2 pages) 0 WP 0026 (4 pages) 0 WP 0027 (4 pages) 0 WP 0028 (4 pages) 0 WP 0029 (2 pages) 0 WP 0030 (4 pages) 0 WP 0031 (2 pages) 0 WP 0032 (4 pages) 0 WP 0033 (2 pages) 0 WP 0034 (4 pages) 0 WP 0035 (6 pages) 0 WP 0036 (4 pages) 0 WP 0037 (4 pages) 0 WP 0038 (4 pages) 0 WP 0039 (2 pages) 0 WP 0040 (14 pages) 0 WP 0041 (14 pages) 0 WP 0042 (16 pages) 0 WP 0043 (20 pages) 0 WP 0044 (8 pages) 0 WP 0045 (6 pages) 0 WP 0046 (16 pages) 0 WP 0047 (16 pages) 0 WP 0048 (6 pages) 0 WP 0049 (10 pages) 0

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Page/WP No.

Change No.

WP 0050 (2 pages) 0 WP 0051 (2 pages) 0 WP 0052 (2 pages) 0 WP 0053 (8 pages) 0 WP 0054 (2 pages) 0 WP 0055 (2 pages) 0 WP 0056 (4 pages) 0 WP 0057 (6 pages) 0 WP 0058 (2 pages) 0 WP 0059 (4 pages) 0 WP 0060 (4 pages) 0 WP 0061 (2 pages) 0 WP 0062 (2 pages) 0 WP 0063 (2 pages) 0 WP 0064 (2 pages) 0 WP 0065 (4 pages) 0 WP 0066 (8 pages) 0 WP 0067 (4 pages) 0 WP 0068 (2 pages) 0 WP 0069 (2 pages) 0 WP 0070 (2 pages) 0 WP 0071 (2 pages) 0 WP 0072 (4 pages) 0 WP 0073 (2 pages) 0 WP 0074 (4 pages) 0 WP 0075 (4 pages) 0 WP 0076 (4 pages) 0 WP 0077 (2 pages) 0 WP 0078 (2 pages) 0 WP 0079 (2 pages) 0 WP 0080 (2 pages) 0 WP 0081 (4 pages) 0 WP 0082 (6 pages) 0 WP 0083 (4 pages) 0 WP 0084 (4 pages) 0 WP 0085 (2 pages) 0 WP 0086 (2 pages) 0 WP 0087 (2 pages) 0 WP 0088 (4 pages) 0 WP 0089 (2 pages) 0 WP 0090 (16 pages) 0 WP 0091 (4 pages) 0 WP 0092 (8 pages) 0 WP 0093 (4 pages) 0

Page/WP No.

Change No.

WP 0094 (2 pages) 0 WP 0095 (40 pages) 0 WP 0096 (2 pages) 0 WP 0097 (4 pages) 0 WP 0098 (2 pages) 0 WP 0099 (18 pages) 0 WP 0100 (4 pages) 0 WP 0101 (2 pages) 0 WP 0102 (4 pages) 0 WP 0103 (2 pages) 0 WP 0104 (6 pages) 0 WP 0105 (2 pages) 0 WP 0106 (2 pages) 0 WP 0107 (2 pages) 0 WP 0108 (22 pages) 0 WP 0109 (26 pages) 0 WP 0110 (26 pages) 0 WP 0111 (22 pages) 0 WP 0112 (4 pages) 0 WP 0113 (10 pages) 0 WP 0114 (10 pages) 0 WP 0115 (8 pages) 0 WP 0116 (6 pages) 0 WP 0117 (6 pages) 0 WP 0118 (4 pages) 0 WP 0119 (8 pages) 0 WP 0120 (2 pages) 0 WP 0121 (4 pages) 0 WP 0122 (8 pages) 0 Chp 3 - Troubleshooting Procedures 0 WP 0123 (12 pages) 0 WP 0124 (8 pages) 0 WP 0125 (8 pages) 0 WP 0126 (4 pages) 0 WP 0127 (6 pages) 0 WP 0128 (6 pages) 0 WP 0129 (4 pages) 0 WP 0130 (4 pages) 0 WP 0131 (8 pages) 0 WP 0132 (8 pages) 0 WP 0133 (6 pages) 0 WP 0134 (4 pages) 0 WP 0135 (4 pages) 0

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Page/WP No.

Change No.

WP 0136 (4 pages) 0 WP 0137 (4 pages) 0 WP 0138 (2 pages) 0 WP 0139 (4 pages) 0 WP 0140 (6 pages) 0 WP 0141 (2 pages) 0 WP 0142 (2 pages) 0 WP 0143 (6 pages) 0 WP 0144 (4 pages) 0 WP 0145 (4 pages) 0 WP 0146 (2 pages) 0 Chp 4 - Preventive Maintenance Checks and Services (PMCS) 0 WP 0147 (4 pages) 0 WP 0148 (42 pages) 0 WP 0149 (14 pages) 0 WP 0150 (22 pages) 0 WP 0151 (30 pages) 0 WP 0152 (22 pages) 0

Page/WP No.

Change No.

WP 0153 (14 pages) 0 Chp 5 - Maintenance Instructions 0 WP 0154 (14 pages) 0 WP 0155 (4 pages) 0 WP 0156 (6 pages) 0 WP 0157 (2 pages) 0 WP 0158 (20 pages) 0 WP 0159 (2 pages) 0 WP 0160 (6 pages) 0 WP 0161 (8 pages) 0 WP 0162 (6 pages) 0 WP 0163 (4 pages) 0 Chp 6 - Supporting Information 0 WP 0164 (8 pages) 0 WP 0165 (18 pages) 0 WP 0166 (6 pages) 0 WP 0167 (8 pages) 0

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HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 15 MAY 2009

TECHNICAL MANUAL

OPERATOR'S MANUAL

TRUCK, COMMON BRIDGE TRANSPORT (CBT), 8X8

M1977A2, W/WINCH (NSN 2320-01-492-8219)

M1977A2, W/O WINCH (NSN 2320-01-492-8218)

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TABLE OF CONTENTS

WP Sequence No.

Page No.

Warning Summary

How to Use this Manual

Chapter 1 - General Information, Equipment Description and Theory of Operation

INTRODUCTION.......................................................................................... WP 0001

Table 1. Overview.............................................................. 0001-1

Figure 1. ............................................................................. 0001-1

Table 2. Common Nomenclature........................................ 0001-3

Table 3. Common Abbreviations......................................... 0001-4

Table 4. Significant Hazard And Safety Recommendations............................................................... 0001-10

WARRANTY PROGRAM............................................................................. WP 0002

Table 1. Vehicle Information.............................................. 0002-3

Table 2. Vehicle Information.............................................. 0002-4

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES..... WP 0003

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS................... WP 0004

Table 1. HEMTT Series Vehicle Common Component Location............................................................ 0004-1

Figure 1. ............................................................................. 0004-1

Table 2. M1977A2 CBT Vehicle Component Location........ 0004-3

Figure 2. ............................................................................. 0004-3

DIFFERENCES BETWEEN MODELS......................................................... WP 0005

Table 1. Differences Between HEMTT A2 Models.............. 0005-1 iii

TABLE OF CONTENTS - Continued

Page No.

Table 2. Notes..................................................................... 0005-2

EQUIPMENT DATA..................................................................................... WP 0006

Table 1. Vehicle Operation................................................. 0006-1

Table 2. M1977A2 CBT Cargo Vehicle Dimensions........... 0006-1

Table 3. M1977A2 CBT Cargo Vehicle Weight................... 0006-1

Table 4. M1977A2 CBT Cargo Vehicle Weight................... 0006-2

Table 5. M1977A2 CBT Cargo Vehicle Weight Distribution........................................................................... 0006-2

Table 6. M1977A2 CBT Cargo Vehicle Weight Distribution........................................................................... 0006-2

Table 7. Vehicle Performance............................................. 0006-2

Table 8. Fluid Capacities.................................................... 0006-3

Table 9. Engine................................................................... 0006-3

Table 10. Fuel System........................................................ 0006-4

Table 11. Electrical System................................................. 0006-4

Table 12. Cooling System................................................... 0006-5

Table 13. Transmission....................................................... 0006-5

Table 14. Transfer Case..................................................... 0006-6

Table 15. Front Tandem Axles............................................ 0006-6

Table 16. Rear Tandem Axles............................................ 0006-6

Table 17. Brake System...................................................... 0006-6

Table 18. Wheels................................................................ 0006-7

Table 19. Tires.................................................................... 0006-7 iv

Page No.

Table 20. Steering System.................................................. 0006-7

Table 21. Towing Eyes....................................................... 0006-7

Table 22. Pintle Hook.......................................................... 0006-7

Table 23. Pintle Hook With Self-Guiding Coupler............... 0006-8

Table 24. Cab..................................................................... 0006-8

Table 25. Self-Recovery Winch........................................... 0006-8

Table 26. Load Handling System........................................ 0006-8

Table 27. Auxiliary Equipment............................................ 0006-9

Table 28. M1977A2 CBT Cargo Vehicle Load Classification........................................................................ 0006-9

Table 29. Tire Pressures..................................................... 0006-10

Table 30. Operating Speeds............................................... 0006-11

SELF-RECOVERY WINCH.......................................................................... WP 0007

Figure 1. ............................................................................. 0007-1

ELECTRICAL SYSTEM............................................................................... WP 0008

Figure 1. ............................................................................. 0008-2

Figure 2. ............................................................................. 0008-3

AIR SYSTEM................................................................................................ WP 0009

Figure 1. ............................................................................. 0009-2

MAIN HYDRAULIC SYSTEM....................................................................... WP 0010

Figure 1. ............................................................................. 0010-1

Figure 2. ............................................................................. 0010-2 v

Page No.

STEERING SYSTEM................................................................................... WP 0011

Figure 1. ............................................................................. 0011-1

POWER TRAIN............................................................................................ WP 0012

Figure 1. ............................................................................. 0012-2

Figure 2. ............................................................................. 0012-4

Figure 3. ............................................................................. 0012-6

Figure 4. ............................................................................. 0012-8

Figure 5. ............................................................................. 0012-10

Figure 6. ............................................................................. 0012-12

Figure 7. ............................................................................. 0012-13

Figure 8. ............................................................................. 0012-13

Figure 9. ............................................................................. 0012-14

ENGINE SYSTEMS..................................................................................... WP 0013

Figure 1. ............................................................................. 0013-1

Figure 2. ............................................................................. 0013-3

Figure 3. ............................................................................. 0013-4

Figure 4. ............................................................................. 0013-5

Figure 5. ............................................................................. 0013-6

CAB.............................................................................................................. WP 0014

Figure 1. ............................................................................. 0014-1

WHEELS AND TIRES.................................................................................. WP 0015

Figure 1. ............................................................................. 0015-1 vi

Page No.

COMMON BRIDGE TRANSPORT (CBT) AND BRIDGE ADAPTER

PALLET (BAP)............................................................................................. WP 0016

Figure 1. ............................................................................. 0016-1

Chapter 2 - Operator Instructions

CAB-MOUNTED FOOT CONTROLS........................................................... WP 0017

Table 1. Cab-Mounted Foot Controls.................................. 0017-1

Figure 1. ............................................................................. 0017-1

CAB-MOUNTED HAND CONTROLS.......................................................... WP 0018

Table 1. Cab-Mounted Hand Controls................................ 0018-2

Figure 1. ............................................................................. 0018-2

STEERING COLUMN MOUNTED CONTROLS.......................................... WP 0019

Table 1. Steering Column Mounted Controls...................... 0019-1

Figure 1. ............................................................................. 0019-1

TUNNEL PANEL CONTROLS AND INDICATORS..................................... WP 0020

Table 1. Tunnel panel controls and indicators.................... 0020-2

Figure 1. ............................................................................. 0020-2

Figure 2. ............................................................................. 0020-6

Table 2. Tunnel panel controls and indicators.................... 0020-7

Figure 3. ............................................................................. 0020-7

Figure 4. ............................................................................. 0020-10

INSTRUMENT PANEL CONTROLS AND INDICATORS............................ WP 0021

Table 1. Instrument Panel Controls and Indicators............. 0021-2 vii

Page No.

Figure 1. ............................................................................. 0021-2

Figure 2. ............................................................................. 0021-4

Figure 3. ............................................................................. 0021-6

HEATER COMPARTMENT CONTROLS AND INDICATORS..................... WP 0022

Table 1. Heater Compartment Controls and Indicators....... 0022-1

Figure 1. ............................................................................. 0022-1

Figure 2. ............................................................................. 0022-4

Figure 3. ............................................................................. 0022-6

OPERATOR AND CREW FOUR-POINT SEATBELT/AIR-RIDE SEAT

ADJUSTMENT CONTROLS........................................................................ WP 0023

Table 1. Operator and Crew Four-Point Seatbelt/ Air-Ride Seat Adjustment Controls...................................... 0023-1

Figure 1. ............................................................................. 0023-1

24V BATTERY DISCONNECT SWITCH..................................................... WP 0024

Table 1. 24V Battery Disconnect Switch............................. 0024-1

Figure 1. ............................................................................. 0024-1

HYDRAULIC SELECTOR VALVE CONTROL............................................. WP 0025

Table 1. Hydraulic Selector Valve Control.......................... 0025-1

Figure 1. ............................................................................. 0025-1

LOAD HANDLING SYSTEM (LHS) REMOTE-CONTROL UNIT................. WP 0026

Table 1. Load Handling System (LHS) Remote- Control Unit.......................................................................... 0026-2

Figure 1. ............................................................................. 0026-2 viii

Page No.

LOAD HANDLING SYSTEM (LHS) MAIN HYDRAULIC MANIFOLD........... WP 0027

Table 1. Load Handling System (LHS) Main Hydraulic Manifold............................................................... 0027-2

Figure 1. ............................................................................. 0027-2

Figure 2. ............................................................................. 0027-3

RIFLE STOWAGE MOUNT.......................................................................... WP 0028

Table 1. Rifle Stowage Mount............................................. 0028-2

Figure 1. ............................................................................. 0028-2

ARCTIC ENGINE HEATER CONTROLS AND INDICATORS..................... WP 0029

Table 1. Arctic Engine Heater Controls And Indicators....... 0029-1

Figure 1. ............................................................................. 0029-1

GAS PARTICULATE FILTER UNIT (GPFU) CONTROLS AND

INDICATORS .............................................................................................. WP 0030

Table 1. Gas Particulate Filter Unit (GPFU) Controls And Indicators...................................................................... 0030-2

Figure 1. ............................................................................. 0030-2

MACHINE GUN MOUNT.............................................................................. WP 0031

Table 1. Machine Gun Mount.............................................. 0031-2

Figure 1. ............................................................................. 0031-2

M-8 CHEMICAL ALARM CONTROLS AND INDICATORS......................... WP 0032

Table 1. M-8 Chemical Alarm Controls And Indicators....... 0032-2

Figure 1. ............................................................................. 0032-2

M-13 DECONTAMINATION KIT.................................................................. WP 0033 ix

Page No.

Table 1. M-13 Decontamination Kit..................................... 0033-2

Figure 1. ............................................................................. 0033-2

RADIO INSTALLATION HARDWARE......................................................... WP 0034

Table 1. Radio Installation Hardware.................................. 0034-2

Figure 1. ............................................................................. 0034-2

OPERATE WINDSHIELD WIPERS/WASHER............................................. WP 0035

Figure 1. ............................................................................. 0035-2

Figure 2. ............................................................................. 0035-3

Figure 3. ............................................................................. 0035-4

Figure 4. ............................................................................. 0035-5

OPERATE CAB TEMPERATURE CONTROLS........................................... WP 0036

Figure 1. ............................................................................. 0036-2

Figure 2. ............................................................................. 0036-3

OPERATE FIRE EXTINGUISHER............................................................... WP 0037

Figure 1. ............................................................................. 0037-2

Figure 2. ............................................................................. 0037-3

Figure 3. ............................................................................. 0037-4

OPERATE ACCESS LADDER..................................................................... WP 0038

Figure 1. ............................................................................. 0038-1

Figure 2. ............................................................................. 0038-2

Figure 3. ............................................................................. 0038-3

OPERATE DRAIN PLUG............................................................................. WP 0039 x

Page No.

Figure 1. ............................................................................. 0039-1

Figure 2. ............................................................................. 0039-2

LOADING BRIDGE ADAPTER PALLET (BAP) FROM GROUND............... WP 0040

Figure 1. ............................................................................. 0040-3

Figure 2. ............................................................................. 0040-4

Figure 3. ............................................................................. 0040-5

Figure 4. ............................................................................. 0040-6

Figure 5. ............................................................................. 0040-6

Figure 6. ............................................................................. 0040-7

Figure 7. ............................................................................. 0040-8

Figure 8. ............................................................................. 0040-9

Figure 9. ............................................................................. 0040-11

Figure 10. ........................................................................... 0040-14

UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND....... WP 0041

Figur…