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Direct Support Mechanical Troubleshooting.
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/.5ton/TM-9-2320-386-24-1-2 Extended Service Program (ESP) for 2-1/2-Ton 6x6 M44A3 Series Trucks (Diesel) Manual
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Direct Support Mechanical Troubleshooting - continued - TM-9-2320-386-24-1-20026
TM 9-2320-386-24-1-2
0293 00
Direct Support Mechanical Troubleshooting (Contd).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
c. Remove gear-driven accessories and turn drive gear by hand. If drive gear does not turn,
replace defective component (WP 0169 00, WP 0313 00, or WP 0326 00).
Step 4. Remove transmission (WP 0335 00) and turn engine crankshaft by hand. If crankshaft
turns freely, replace transmission (WP 0335 00).
Step 5. Replace engine (WP 0295 00).
END OF TESTING!
2.
ENGINE CRANKS BUT WILL NOT START
Step 1. Remove exhaust and air intake tubes from turbocharger and check for presence of water. If
water is present on fins of turbocharger, remove and drain exhaust and air intake systems
(WP 0066 00 and WP 0038 00). Replace turbocharger (WP 0325 00).
Step 2. Check fuel injection timing (WP 0322 00).
Adjust fuel injection timing, if necessary (WP 0322 00).
Step 3. Check intake and exhaust valve clearance adjustment (WP 0311 00).
Step 4. Check fuel injector rack control linkage for proper operation.
Replace fuel injector rack control linkage if bent or binding (WP 0320 00).
Step 5. Replace governor (WP 0326 00). If condition continues, replace engine (WP 0295 00).
END OF TESTING!
3.
ENGINE STARTS BUT STOPS WHEN ACCELERATOR IS OPERATED
Step 1. Perform malfunction 2, steps 2 through 4.
Step 2. Check height of fuel injectors for any seizure.
Replace fuel injector(s) if seized (WP 0319 00).
Step 3. Check for bent or broken push rods.
Replace push rod(s) if bent or broken (WP 0309 00).
Step 4. Check surge tank for evidence of blown head gasket before taking cylinder head off.
Step 5. Check cylinder head and cylinder walls for wear and damage.
a. Remove cylinder head (WP 0302 00). Inspect cylinder head and head gasket surface for
cracks. Replace cylinder head if cracked (WP 0302 00).
b. Check intake and exhaust valves for chips, wear, burrs, cracks, and pits. Notify GS
maintenance if exhaust valves are chipped, worn, burred, cracked, or pitted
c. Check cylinder walls for cracks, burrs, chafing, and wear. Replace engine (WP 0295 00).
END OF TESTING!
4.
ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION
Perform malfunction 2.
END OF TESTING!
5.
POOR ACCELERATION AND/OR LACK OF POWER
Step 1. Check turbocharger, air intake, and exhaust system for leaks and restrictions.
a. Tighten any loose connections. Replace any missing hardware.
b. Replace turbocharger if defective (WP 0325 00).
c. If malfunction continues after test run, perform step 2.
Step 2. Check transmission for proper operation.
Replace and repair transmission if operating improperly (WP 0335 00).
Step 3. Perform malfunction 2.
END OF TESTING!

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