Home

TM 5-3805-264-14&P - Liberated Manuals

1. Hydraulic Hoses and Fittings Hydraulic Reservoir Replacement Hydraulic Reservoir Hydraulic Oil Filter Element Hydraulic Oil Filter Service Indicator Gage Replacement 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT This task covers a Removal b Installation Initial Setup Equipment Conditions Materials Parts CTIS electronic control unit ECU removed TM Marker tags Item 20 Appendix 9 2320 363 20 or TM 9 2320 302 20 Six MCS control unit removed 917 1 5 paragraph 4 42 References Tools Test Equipment TM 9 2320 363 10 General mechanic s tool kit Item 8 Appendix TM 9 2320 302 10 NOTE Although slightly different in shape M917A1 and M917A2 shift towers are similar M917A1 shift tower is illustrated Perform only those steps that apply to your model a REMOVAL NOTE Wires and cables should be tagged before removal paragraph 4 17 4 117 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t 1 Remove six screws 2 and rear access panel 3 from shift tower 1 2 Repeat step 1 for front access panel 3 To keep
2. Data Plate Shovel Bracket Spill Shield 4 64 CARGO COVER REPLACEMENT This task covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Item 8 Two locknuts a REMOVAL 1 Extend cargo cover 2 over dump body paragraph 2 14 Release control handle and manually unwind cargo cover to access screws 3 2 Remove six screws 3 holding cargo cover 2 to roll up bar 1 336 008 4 101 TM 5 3805 264 14 amp P 4 64 CARGO COVER REPLACEMENT Con t Uncrimp and remove centering springs 7 from eye bolts 8 and from grommets in cargo cover 2 Remove two locknuts 5 and eye bolts 8 from cross arm 6 and connecting arms 4 Discard locknuts Remove cross arm 6 from connecting arms 4 Slide cross arm from cargo cover 2 Remove cargo cover INSTALLATION 4 102 Install cross arm 6 through pocket in cargo cover 2 Install cross arm 6 into each connecting arm 4 and secure with two eye bolts 8 and new locknuts 5 Attach two centering springs 7 to eye bolts 8 and to grommets in cargo cover 2 Crimp spring ends
3. STOCK NUMBER FIG ITE STOCK NUMBER FIG 5935 01 518 3692 3 8 2510 01 518 4549 24 1 6220 01 518 6827 3 1 6240 01 518 6843 3 4 5310 01 518 7454 12 15 4720 01 518 9183 21 3 4730 01 518 9184 14 39 4730 01 518 9540 21 8 4720 01 519 0924 21 7 4730 01 519 1777 21 4 4730 01 519 1782 21 4 5930 01 520 4456 2 2 SECTION IV CAGEC 81343 64678 64678 70318 81346 64678 72764 72764 02249 02249 02249 80204 80204 80204 80204 80204 80204 80204 80204 80204 80204 80204 80204 12662 12662 02249 5 050 72764 52793 72764 79470 5 752 81348 64678 60827 60827 9 737 5 3805 264 14 amp P C1 CROSS REFERENCE INDEXES PART NUMBER IN PART NUMBER AS15003 1 A06 24606 276 A06 30769 101 A1BMW6024G 7335 6 BCI 231E BNT220 BNT22002 12071 0300 12071 0400 12071 0500 1821 025 075 w 1821 025 125 1821 025 250 1821 031 100 1821 038 075 1821 038 100 UJ 1821B B1821B 038C150 050C200 B1821B 050C325 B1821BH063C200 B1821BH063C300N B1821BH075C400N B490A B490R B9971 00550 CMG 400892 10 CW7435 57C C21PA03 C3109X8X6 ECT 13 CRY FFW92 FLD 45884 0072 FT 1215 ZP 150 2 150 4130 6150 5930 5305 4130 09995 5930 3040 3040 3040 5305 5305 5305 5306 2305 5305 5305 5305 5305 5305
4. E T Gee L 5 A bey _ 5 E um 4m m cmt 4 40 5 3805 264 14 4 42 MCS CONTROL UNIT MAINTENANCE M917A1 W MCS M917A2W MCS Con t 5 Position switch 14 on shift tower cover 16 6 Apply slight downward pressure on switch 14 until two tangs 15 snap into place _ Z 7 Connect wire lead on switch e dH NEUE SE LE S 16 371 206 8 Install rear panel 13 with six screws 12 371 202 FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 917 1 and M917A1 w MCS e Check operation of MCS control unit paragraph 2 1 4 41 TM 5 3805 264 14 amp P 4 43 MCS REMOTE CONTROL REPAIR M917A1 W MCS AND M917A2 W MCS This task covers a Disassembly c Assembly b Cleaning and Inspection Initial Setup Equipment Conditions Materials Parts MCS remote control disconnected from MCS tail Marker tags Item 20 Appendix F gate paragraph 2 13 One gasket Tools Test Equipment General mechanic s tool kit Item 8 a DISASSEMBLY NOTE
5. 2 7 2 27 Preservation of Parts 4 10 4 5 Procedures for Common Components and Miscellaneous Items 4 83 4 152 R Rainy or Snowy Weather Operation 2 17 2 41 Reflector Replacement 4 68 4 113 Remote Control Repair MCS 917 1 w MCS M917A2 w MCS 4 43 4 42 Removal of Equipment from Administrative Storage 4 84 4 152 Repair Parts 120 suisque oe eed eres dere ue eo eut ous 4 3 4 1 Reporting Equipment Improvement Recommendations EIRS 1 6 1 2 Index 5 5 3805 264 14 amp P INDEX Con t Subject Safety Care and Service Replacement Parts and Servicing Instructions Shield Cab Replacement Shovel Bracket Soldering ER relie bee eee ten eed Special Tools TMDE and Support Equipment Spill Shield Spreading Controlled M917A1 w MCS and M917A2 w MCS Stabilizer and Dump Body Standard To
6. 4 12 4 6 Instructions Cleaning nett aan deputata 4 9 4 4 Disassembly Assembly 4 13 4 6 4 12 4 6 EUBNGATION 5 o ct ad a ed ats uM aa 4 14 4 6 2 le a 4 6 4 2 Index 3 5 3805 264 14 amp P INDEX Con t Subject Paragraph Page L Lights Replacement Marker Clearance 4 41 4 37 STEAM 4 40 4 36 Lights Wiring Harness Maintenance 4 46 4 52 Les and Ponse ssec Wee ees ap ee ved Uie IR 4 21 4 10 Load Dumping ein eere ERR RU ee 2 10 2 29 Load Transporting uei deu wale teda eeu ecu 2 9 2 28 Loading Dump Body 24 p bibe epe RR eS s 2 8 2 28 Location and Contents of Decals and Stencils 1 12 1 7 Description of Major Components 1 5 Lubrication Data iust tu EN ed p pape duda CAI ea ur et ee 4 33 4 17 6 2425 52 pipet cas aban 4 14 4 6 Procedures General 4 30 4 14 M Maintenance Forms Records and Reports 1 2 1 1 Majo
7. 371 046 371 011 M917A2 DS 2 9 IG 2 34 5 3805 264 14 amp P 2 10 DUMPING LOAD Con t 2 Return hydraulic control lever 6 to N Neutral position 25550 M917A2 371 031 d After Dumping CAUTION Always disengage PTO when hydraulic power is no longer needed If PTO is engaged while dump truck is transporting a load severe damage to hydraulic pump PTO or transmission will result 1 Disengage PTO TM 9 2320 363 10 or 9 2320 302 10 2 Turn off main light switch 5 3 Slide tailgate release control E 1 2 valve lever 4 right to LOCK position 4 As required release mud flaps 1 from stowed position on hooks 2 2 35 5 3805 264 14 amp P 2 11 ADJUSTING TAILGATE OPENING WARNING Use extreme caution when adjusting tailgate opening NEVER adjust tailgate open ing when tailgate is open Failure to follow this warning could result in injury to per sonnel CAUTION Adjustment chains are intended for use only during spreading operations If used when stockpiling damage to chains or tailgate may result NOTE To reduce interference between tailgate chain and tailgate locking linkage chain must pass through chain latch from the outside inward a In preparation for dumping load with tailgate closed lift chain out of
8. PTO LOCKOUT 4 62 5 3805 264 14 amp P 4 49 WIRING DIAGRAMS Con t 1 1 CHASSIS WIRING 8 titch 29 300646 47 974 FUSE AT 1 ELEC BLOCK POSITION G4 CAB CTRL OISABLE RELAY SHIFT 049 GNO PANEL LAVP HEATER MATL MATL CDL R MATL MATL CTRL SWITCH SWITCH EOF CONTROLS CLOSED UPON SWITCHBOX PLUG IN MCS GATE SOLENOID VALVES ENERGIZE TO OPEN GATE PLUG INTERFACE i GATE LOCATED HAND HELD i SWITCHBOX SWITCHES m Mer WE LH LH LH CTR RH CTR RH RH MATL CTRL MATL CTRL MATL CTRL MATL CTRL SWITCH SWITCH SWITCH SWITCH MCS M917A1 W MCS AND M917A2 W MCS 4 63 5 3805 264 14 amp P 4 49 WIRING DIAGRAMS Con t BODY UP SWITCH ON TRUCK CHASSIS WIRING HARNESS Ex dec lt TRANSPORT LOCK SWITCH R GREEN D 2 BLUE BROWN BL BLACK BODY UP AND TRANSPORT LOCK SWITCHES ON TRUCK BK CHASSIS lt A gt BEACON WIRING RE HARNESS LIS WH LIGHT BLACK WHITE BEACON WARNING LIGHT 4 64 5 3805 264 14 amp P 4 49 WIRING DIAGRAMS Con t MARKER CLEARANCE LIGHT LIGHT CLUSTER BR BROWN GREEN WHITE ON TRUCK CHASSIS WIRING HARNESS YELLOW DUMP BODY TAILLIGHTS AND MARKER CLEARANCE LIGHTS 4 65 TM 5 3805 264 14 amp P Section VII DUMP BODY MAI
9. G 2 TAILGATE RELEASE AIR CYLINDER TUBES a Fabricate from bulk Part Number NT10006 79470 3 8 in OD nonmetallic tubing b Cut to 36 in long to make Part Number 245786X36 Cut to 38 in long to make Part Number 245787 38 G 3 MCS AIR CYLINDER TUBE a Fabricate from bulk Part Number 020003 7 79146 3 8 in OD copper tubing b Cut to approximately 12 in long then cut to fit and flare ends to make Part Number 010029X12 Two required per each MCS air cylinder G 4 MCS TAILGATE AIR TUBES a Fabricate from bulk Part Number NT10006 79470 3 8 in OD nonmetallic tubing b Cut to 66 in long to make Part Number 245538X66 Cut to 21 in long to make Part Number 245539 21 d Cut to 17 in long to make Part Number 245540X17 Cut to 8 in long to make Part Number 245541 8 f Cut to 31 in long to make Part Number 245542X31 g Cut to 9 in long to make Part Number 245543 9 h Cut to 144 in long to make Part Number 245544X144 G 5 DUMP BODY SIDE BOARD a Fabricate from bulk Part Number MILL2037 81349 2 0 in x 8 0 in rough sawn hardwood b Cut to fit 148 75 in long to make Part Number 403345X148 75 Two required per dump body G 6 HYDRAULIC RESERVOIR SIGHT TUBE a Fabricate from bulk Part Number PT 24006NA 79470 3 8 in OD clear tubing b Cut to 1 50 ft long to make Part Number 239635X1 50 5 3805 264 14 amp P G 7 HYDRAULIC CYLINDER DISASSEMBLY TOOL 1 00 in 2
10. NO 4 229 0 X 148 75 IN MILL2037 81349 5 3805 264 14 amp P SECTION II 2 15 Figure 12 MCS Tailgate Assembly SECTION II 1 NO 10 11 12 13 14 15 2 SMR CODE PDOOO PDOOO XDOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ PFOZZ PAOZZ XDOZZ PFOZZ PAOZZ PAOZZ PAOZZ PFOZZ 3 NSN 2510014738251 2510014738250 5310004883889 5305000712071 4710014975644 5306002264827 5340014978124 5305000712076 3040014970345 5310008206653 5305007247228 5315015070537 5310015187454 CAGEC 5X050 5X050 5X050 96906 80204 5X050 5X050 80204 5X050 80204 5X050 5X050 52793 80204 50620 5X050 TM 5 3805 264 14 amp P 5 PART NUMBER 140409 140410 129652 MS51943 39 1821 050 200 239974 239973 1821 031 100 129653 1821 050 325 129528 239963 CW7435 57C 1821 063 300 38 22LP CMG 400892 DESCRIPTION AND USABLE ON CODES UOC 6 GROUP 1810 CARGO BODY FIG 12 MCS TAILGATE ASSEMBLY MCS TAILGATE GREEN MCS TYPE UOC 7E1 7E2 MCS TAILGATE TAN MCS TYPE TAN UOC 7E1 7E2 TAILGATE BARE MCS UOC 7E1 7E2 NUT SELF LOCKING HE Af Da oa ws UOC 7E1 7E2 SCREW CAP HEXAGON H 1 2 13X2 00
11. Pull cargo cover 2 to roll up bar 1 Pass cover UNDER roll up bar and secure to roll up bar with six screws 3 Fully retract cargo cover 2 paragraph 2 14 336 039 5 3805 264 14 amp P 4 65 CARGO COVER CRANK ASSEMBLY MAINTENANCE This task covers a Removal b Disassembly c Cleaning and Inspection Initial Setup Equipment Conditions Cargo cover extended and crank handle removed paragraph 2 14 Tools Test Equipment General mechanic s tool kit Item 8 a REMOVAL Remove chain from sprockets paragraph 4 66 d Assembly e Installation Materials Parts One locknut Two pushnuts 2 Remove two nuts 1 washers 2 screws 5 and crank assembly baseplate 25 from dump body b DISASSEMBLY 1 Remove pushnut 9 from crank assembly baseplate stud 4 Remove brake band spring 8 and discard pushnut 2 Remove pushnut 15 from brake pawl 10 Discard pushnut 5 4 103 TM 5 3805 264 14 amp P 4 65 CARGO COVER CRANK ASSEMBLY MAINTENANCE Con t 3 Remove retaining ring 20 from control handle 21 Remove brake pawl spring 16 Discard retaining ring if damaged 4 Remove retaining ring 18 and brake pawl 10 from pivot shaft 23 Discard retaining ring if damaged 5 Remove control handle 21 and brake band 7 from crank assembly baseplate 25 Remove locknut 19 and screw 22 fr
12. 4 31 Dump Body Lowers With Hydraulic Control Lever the Neutral Position and PTO din e bana deine daa Dump Body Raises and Lowers 5 Dump Body Raises With Hydraulic Control Lever in the Neutral Position and PTO Engaged Dump Body Will Not Raise and or emen MCS M917A1 w MCS and M917A2 w MCS MCS Gate Will Not MCS Gate Will Not Operate With Driver s 5 MCS Gate Will Not Operate With Remote Control MCS Gates Open or Close When Remote Control Is Connected One or More MCS Gates Will Not Open or Close Properly 2 TAILGATE Tailgate Assembly Lock Will Not 4 30 4 27 TM 5 3805 264 14 amp P Table 4 3 Unit Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION MCS M917A1 W MCS AND M917A2 W MCS 1 MCS GATE WILL NOT OPERATE Step 1 Check for air leaks throughout vehicle chassis air system Tighten or replace leaking or damaged air system components TM 9 2320 363 20 or TM 9 2320 302 20 Step 2 Check for leaking air hoses fittings or valves on MCS tailgate Tighten or replace leaking or damaged air hoses and fit
13. BRAKE Pane Industrles Inc DISTANCE 1992039032 Figure 17 Decals SECTION II 1 NO WD 10 11 2 SMR CODE PCOZZ PCOZZ PCOZZ PCOZZ PCOZZ PCOZZ PCOZZ PAOZZ PFOZZ PCOZZ PCOZZ 3 NSN 7690014458976 7690014459903 7690014459933 7690014459897 7690014458961 7690014458967 7690014458973 9905014988178 9905014499632 7690014491470 7690014491447 CAGEC 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5B752 5B752 TM 5 3805 264 14 amp P 403375 403374 403377 401577 403492 403378 403376 403514 403541 0920 5 0920 5 5 6 PART NUMBER DESCRIPTION AND USABLE ON CODES UOC GROUP 2210 DATA PLATES AND INSTRUCTION HOLDERS FIG T DECALS MARKER IDENTIFICATI CAUTION BODY re PT MARKER IDENTIFICATI DANGER MARKER IDENTIFICATI CAUTION MARKER IDENTIFICATI DANGER MARKER IDENTIFICATI OIL LEVEL MARKER IDENTIFICATI CAUTION MARKER IDENTIFICATI CAUTION BODY PROD ae rue serie SEM EET PLATE INSTRUCTION DANGER GATE OPENING 8 90324 DECAT RO 90325 END FIGURE 17 1 7 NO PrP PN SECTION II TM 5 3805 264 14 amp P Figure 18 Hydraulic Pump Assembly SECTION II 5 3805 264 14 a
14. 1 END FIGURE 22 1 5 3805 264 14 amp P SECTION II 3 7 2 17 Figure 23 Hydraulic Reservoir Assembly SECTION II 1 NO d 0 IN PRP M P 17 18 19 20 21 22 23 24 25 26 27 28 28 29 2 SMR CODE PGOOZ PFOZZ PAOZZ PAOZZ XAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ MOOZZ 3 NSN 2590014470748 2940014463570 5306012719425 5331014474034 5331014474040 5331014473098 5305000680510 4730002041272 6685014471188 4730009213624 2590014461903 5305009931848 4730000686616 4730002783888 4730002892357 5310000614650 5305000680509 5310004883889 5310005847888 5310008098533 5310012671684 5305000712071 CAGEC 5X050 5X050 60827 60827 60827 60827 60827 80204 30780 5X050 81346 5X050 5X050 70318 79470 5 050 30780 30780 5X050 64678 45152 5X050 5X050 80204 96906 5X050 96906 96906 96906 80204 TM 5 3805 264 14 amp P 5 PART NUMBER 126615 403365 PS 0001 251 70 BN TR 1200 01 246 70 BN TS 355 70 BN 1821 038 100 2102 2 2 403367 A733S 6CFG 403368 403246 A1BMW6024G 6 9X6 239635X1 50 0102 12 8 2102 8 8 401288 23 09130 003 114356A 403678 403677 1821 025 125 551943 39 237379 MS35338 51 MS27183 23 MS51412 10 1821 050 200 6 DESCRIPTION AND USA
15. Dry cleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protec tive gloves and goggles is suggested Use in well ventilated area Keep away from open flame and other sources of ignition 2 Clean mounting hardware ground cable terminal lugs and ground point with cleaning sol vent Item 5 Appendix and scrub brush Item 3 Appendix 3 Remove any rust with wire brush Item 4 Appendix 4 Look for cracks loose terminal lugs and stripped threads Replace any defective parts 5 Install hardware connecting ground cable terminal lug to ground point Ensure that all hard ware is tight TM 5 3805 264 14 amp P 4 21 LINES AND PORTS To keep dirt from contaminating fluid systems when removing and installing lines perform the following steps 1 Clean fittings and surrounding area before disconnecting lines 2 Cover cap plug or tape lines and ports after disconnecting lines Use cap and plug set Item 1 Appendix 1 pn hydraulic lines When these are not available use hand carved wooden plugs clean rags Item 16 Appendix duct tape Item 22 Appendix F or other similar materials to prevent dirt from entering sys tem 3 Ensure that new and used parts are clean before installing 4 Wait to remove cover cap plug or tape from lines and ports until just before installing lines
16. CRYSTEEL MFG O W 5 3805 264 14 amp P 1 12 LOCATION AND CONTENTS OF PLATES DECALS AND STENCILS Con t OIL LEVEL WITH BODY DOWN e FULL ADD 2 QTS ADD 1 GAL KEEPHANDS AWAY FROM GATE OPENINGS OPENING AT ALL TIMES 5 3805 264 14 amp P 1 12 LOCATION AND CONTENTS OF PLATES DECALS AND STENCILS Con t NP AE DANGER DO NOT GO UNDER RAISED BODY IT MAY DROP AND KILL YOU OPERATE HOIST CONTROLS ONLY FROM INSIDE TRU CAB P N 403374 M917A2 THIS VEHICLE IS EQUIPPED WITH A BACK UP ALARM WHEN BACKING THE ALARM MUST SOUND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE BODY MUST BRACED BEFORE SERVICING HOIST OR WORKING IN AREA WITH BODY IN RAISED POSITION TRUCK MUST BE LEVEL FOR DUMPING NOT OVERLOAD P N 403378 CRYSTEEL MFG ne UY THIS VEHICLE 16 EQUIPPED WITH A BACK UP ALARM WHEN BACKING THE MUST SOUND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE 371 072 5 3805 264 14 amp P 1 13 DIFFERENCES BETWEEN MODELS a b 917 1 and M917A1 w MCS the same except for tailgate configuration The 917 2 and M917A2 w MCS are the same except for tailgate configuration The M917A1 and M917A
17. 2320 302 10 Check filter service indicator gage 22 If gage needle is in RED zone hydraulic oil filter ele ment needs replacing Notify your supervisor 22 PnP 40694 Oe Ce Ce CS 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Item No Location Interval Item To Check Service Procedure Not Fully Mission Capable If 14 After MCS Tailgate M917A1 w MCS and M917A2 w MCS a Remove locking pins 24 from top hole in adjustment tubes 25 and place in bottom hole 2 18 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 14 After MCS Operate MCS control unit 2 inside b MCS control unit does not Con t Tailgate cab paragraph 2 1 Check that open or close gates and is M917A1 appropriate MCS gate 26 opens required for mission w MCS and and closes as each toggle switch is M917A2 operated w MCS M917A2 371 031 M917A1 2 19 5 3805 264 14 amp P control activat
18. 1 10 1 4 GIGANING up exe Ec AUR Rp deu Rue iot 3 5 3 9 Cleaning Instructions 4 9 4 4 Cold Weather 2 18 2 43 Common Components and Miscellaneous Items Procedures for 4 83 4 152 Index 1 5 3805 264 14 amp P INDEX Con t Subject C Con t Common Tools and Compression Fittings Tubes and Controlled Spreading M917A1 w MCS and M917A2 w MCS Controls and Indicators Gab Motunhted un 54 58 i Rete assa A chavs eet E Exteimalo zb che cnet ket Corrosion Prevention and Control Cylinder Support Frame Replacement Data Plate Data Equipment nice vei Saee IR ur TR CREDE RA cR E bBrication ee ae ake re Decals and Stencils Location and Contents Destruction of Army Materiel to Prevent Enemy Use Differences Between Models Disassembly and Assembly Du
19. 4 22 2 TAPE CAUTION e DO NOT use antiseize tape on air lines Damage to air valves may result if anti seize tape is used e Apply antiseize tape only to pipe threads of male fittings of hydraulic system When connecting hydraulic lines and fittings without compression sleeves or packings antiseize tape Item 21 Appendix F may be used to keep connections from leaking Use as follows 1 Ensure that threads are clean and dry 2 Start antiseize tape one or two threads from small or leading edge of fitting joining tape together with an overlap of about 1 8 in 3 18 mm for fittings with fine threads For fittings with coarse threads tape should be wrapped around threads two or three times 3 Tightly wrap antiseize tape in same direction as you would tighten a nut Tape must be pressed into threads without cutting or ripping Antiseize Tape CAUTION DO NOT exceed specified torque or use power tools to tighten fittings taped with antiseize tape Over tightening could damage fitting threads and cause connection to leak 4 Using hand tools tighten fittings to specified torque 4 10 5 3805 264 14 amp P 4 23 TUBES AND COMPRESSION FITTINGS a Tubes with inverted nuts and compression fittings are designed for one time assembly Once assembled they must be replaced as a unit if any parts are found defective Used parts may not seal properly when
20. WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment NOTE Use antiseize tape on all pipe threads paragraph 4 22 Attach a nylon sling and suitable lifting device to hydraulic reservoir 15 Take up slack in sling Position hydraulic reservoir 15 on cylinder support frame 14 Install four screws 5 washers 6 new lock washers 7 spacers 8 and new locknuts 9 Torque locknuts to 100 110 lb ft 136 149 Nem Remove nylon sling Install elbow 13 and hose barb 12 to hydraulic reservoir 15 Connect suction hose 11 to hose barb 12 and tighten clamp 10 Install tee 2 with oil sampling valve 3 to filter housing 1 Connect hydraulic return hose 4 to tee 2 FOLLOW ON TASKS 4 142 hydraulic reservoir Chapter 3 Section 1 Remove body props and lower dump paragraph 2 15 5 3805 264 14 amp P 4 76 HYDRAULIC RESERVOIR REPAIR This task covers a Disassembly b Cleaning and Inspection Initial Setup Tools Test Equipment General mechanic s tool kit Item 8 Appendix Cap and plug set Item 1 Appendix Materials Parts Lubricating oil Item 13 or 14 Appendix F a
21. In some cases part may be damaged during removal If the part appears to be good and other parts behind it are not defective leave it in place and continue with the procedure Here are a few simple rules 1 Do not remove dowel pins or studs unless loose bent broken or otherwise damaged 2 Do not remove bearings or bushings unless damaged If you need to remove them to access parts behind carefully pull out bearings and bushings 3 Replace all gaskets lockwashers self locking nuts seals cotter pins and preformed packings 4 3 TM 5 3805 264 14 amp P 47 GENERAL Con t d The following Initial Setup information applies to all maintenance procedures 1 Resources are not listed unless they apply to the procedure 2 Personnel Required is listed only if more than one mechanic is required to complete the procedure e All tags and forms attached to the equipment must be checked to learn the reason for removal of equipment from service Modification Work Orders MWOs and Technical Bulletins TBs must also be checked for equipment changes and updates 4 8 WORK SAFETY a Before beginning a procedure think about the safety risks and hazards to yourself and to others Wear protective gear such as safety goggles or lenses safety shoes rubber apron or gloves b Before beginning a procedure ensure that the following conditions have been observed unless otherwise specified 1 Vehicle
22. 5 3805 264 14 TABLE CONTENTS Con t GROUP 18 BODY CAB HOOD AND HULL CARGO BODY cmo CYLINDER SUPPORT FRAME AND BRACKETS STABILIZER AND DUMP BODY ASSEMBLY uci nieto MCS TAILGATE ASSEMBLY AIR CYLINDER ASSEMBLY erbe deed ones Mtt 13 1 AIR TANK LINES AND FITTINGS GROUP 22 BODY CHASSIS AND HULL ACCESSORY ITEMS 2201 CANVAS RUBBER OR PLASTIC ITEMS 15 1 CARGO COVER AND COMPONENT PARTS SHOVEL MOUNTING batiment idet 16 1 2210 DATA PLATES AND INSTRUCTIONS HOLDERS 17 1 DECAES N 17 1 GROUP 24 HYDRAULIC AND FLUID SYSTEMS 2401 PUMP AND MOTOR ttt ttti HYDRAULIC PUMP tette 2403 HYDRAULIC CONTROLS AND OR MANUAL 5 DUMP CONTROL AND CABLE 2406 STRAINERS FILTERS LINES AND FITTINGS ETC 20 FILTER ELEMENT HYDRAULIC 0 HYDRAULIC HOSES AND 8 12 4 2022 0 2 200 0 00 21 2407 HYDRAULIC 8
23. 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t 7 Install transfer case control cable pivot pin 16 in bracket 24 and secure with retaining pin 15 8 10 4 124 Install spacer 19 cable 17 clamp 20 two screws 18 new lockwashers 21 and nuts 22 to bracket 23 With transmission selector lever in D Drive position install transmission control cable pivot pin 6 in bracket 14 and secure with retaining pin 5 Install spacer 9 cable 7 clamp 10 two screws 8 new lockwashers 11 and nuts 12 to bracket 13 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t TA 019 11 Place transmission selector lever Neutral position TM 9 2320 363 10 or TM 9 2320 302 10 12 Connect six connectors 4 to shift tower jumper harness connectors 13 Remove two top and two bottom screws 2 on front and rear of shift tower 1 4 125 TM 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t 14 Install rear access panel 3 and six screws 2 15 Repeat step 14 for front access panel FOLLOW ON TASKS Install MCS control unit M917A1 w MCS paragraph 4 42 e Install CTIS electronic control unit ECU TM 9 2320 363 20 or TM 9 2320 302 20 4 126 5 38
24. ENGINE BRAKE 2 n d 5 E TAILGATE B B RELEASE 371 046 DANGER f TRAILER YF 5 3805 264 14 amp P 2 10 DUMPING LOAD Con t unlatched 2 32 WARNING NEVER unlock tailgate or operate MCS gates or operate hydraulic control lever in cab without first ensuring that all personnel are clear of dump body Failure to fol low this warning may result in injury to personnel CAUTION Ensure that tailgate latches are fully opened before raising dump body Failure to follow this caution could result in damage to equipment 10 Slide tailgate release control valve lever 4 left to UNLOCK position Check that tailgate is TAILGATE 371 046 TRAILER YF 371 011 Raising Dump Body WARNING e NEVER raise dump body more than half way with tailgate or MCS tailgate closed If dump body is raised fully without opening tailgate dump truck center of gravity will shift rearward Dump truck could tip causing injury to personnel or damage to equipment e NEVER raise dump body without first checking for overhead obstructions such as trees and power lines Ensure that overhead clearance is sufficient Failure to follow this
25. 5 3805 264 14 amp P OPERATOR S UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LISTS FOR TRUCK DUMP HEAVY BODY M917A1 NSN 3805 01 431 1165 EIC E5C M917A2 NSN 3805 01 488 7442 EIC BPB AND M917A1 W MCS MATERIAL CONTROL SYSTEM NSN 3805 01 432 8249 EIC E5D M917A2 W MCS MATERIAL CONTROL SYSTEM NSN 3805 01 488 6963 EIC BA4 This manual supersedes TM 5 3805 264 14 amp P dated December 1997 Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY DECEMBER 2005 5 3805 264 14 amp P HEADQUARTERS No 1 DEPARTMENT OF THE ARMY WASHINGTON D C 14 February 2011 TECHNICAL MANUAL OPERATOR S UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LISTS FOR TRUCK DUMP HEAVY BODY M917A1 NSN 3805 01 431 1165 EIC E5C M917A2 NSN 3805 01 488 7442 EIC BPB AND M917A1 W MCS MATERIAL CONTROL SYSTEM NSN 3805 01 432 8249 EIC E5D M917A2 W MCS MATERIAL CONTROL SYSTEM NSN 3805 01 488 6963 4 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 5 3805 264 14 amp P dated 30 December 2005 is changed as follows 1 File this sheet in front of the publication for reference purposes 2 New or updated material is indicated by an asterisk in the outer margin of the page 3 Remove old pages a
26. 6 When the item is not used with all serial numbers of the same model the effective serial numbers are shown on the last line s of the description before UOC Not Applicable 7 The Usable On Code when applicable see paragraph 5 Special Information 8 In the Special Tools List section the Basis of Issue BOI appears as the last line s in the entry for each special tool special TMDE and other special support equipment When density of equipment sup ported exceeds density spread indicated in the Basis of Issue the total authorization is increased proportionately 9 The statement END OF FIGURE appears just below the last item description in Column 6 for a given figure in both Section and Section 1 QTY Column 7 The QTY quantity per figure column indicates the quantity of the item used in the breakout shown on the illustration figure which is prepared for a functional group subfunctional group group or an assembly A V appearing in this column in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application C 4 EXPLANATION OF COLUMNS SECTION IV a National Stock Number NSN Index 1 STOCK NUMBER Column This column lists the NSN by National Item Identification Num ber NIIN sequence The NIIN consists of the last nine digits of the NSN i e NSN 5305 01 674 1467 When using this column to locate an item ignore the first four dig
27. Step 1 Check MCS remote control switches for voltage and continuity Replace damaged switches paragraph 4 43 Replace damaged remote control 4 29 TM 5 3805 264 14 amp P Table 4 3 Unit Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2 Check MCS remote control cable for voltage and continuity Replace damaged remote control cable paragraph 4 43 Step 3 Check MCS tailgate wiring harness and MCS air cylinder solenoids for voltage and continu ity Repair or replace damaged MCS tailgate wiring harness paragraph 4 48 Replace damaged MCS air cylinder solenoids paragraph 4 57 5 ONE OR MORE MCS GATES WILL NOT OPEN OR CLOSE PROPERLY Step 1 Check MCS tailgate for leaking or damaged air system components Tighten or replace leaking or damaged components paragraphs 4 55 thru 4 59 Step 2 Check MCS tailgate for damaged gates Replace damaged gate paragraph 4 54 Step 3 Check MCS tailgate for damaged gate adjustment tubes and locking pins Replace damaged adjustment tube paragraph 4 60 TAILGATE 6 TAILGATE ASSEMBLY LOCK WILL NOT RELEASE Step 1 Check for air leaks throughout vehicle chassis air system Tighten or replace leaking or damaged air system components TM 9 2320 363 20 or TM 9 2320 302 20 Step 2 Check for damaged or leaking tailgate release air cylinder Repair or replace tailgate release air cylinder paragraph 4 51 or 4 58 Step 3 Check f
28. UOC 7E1 7E2 UOC 7E1 7E2 BOLT MACHINE UOC 7E1 7E2 QJCOVER ACCESS wish Lees sand UOC 7E1 7E2 SCREW CAP HEXAGON H UOC 7E1 7E2 GATE MCS UOC 7E1 7E2 UOC 7E1 7E2 WASHER LOCK ele se Sete eae UOC 7E1 7E2 SCREW CAP HEXAGON 5 8 11 3 00 UOC 7E1 7E2 PIN STRAIGHT HEADED 3 8 X 2 1 2 IN SQ 2 25 44 5 WASHER FLAT 7 1 7 2 END FIGURE 12 1 GREEN 7 10 16 16 SECTION II TM 5 3805 264 14 amp P 3 20 4 39 32 39 3 Figure 13 Air Cylinder Assembly SECTION II 5 3805 264 14 amp P 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 1810 CARGO BODY FIG 18 AIR CYLINDER ASSEMBLY 1 XDOZZ 5X050 404932 PIN STRAIGHT HEADED 493 OD X 1 1 97 kde x ORE SR EG IR 1 XDOZZ 5X050 404934 PIN STRAIGHT HEADED 50 OD X 1 50 1 Dre 1 PAOZZ 5315014469177 79146 019070 PIN STRAIGHT HEADED 1 2 X 2 INCH 1 INCLUDES SPRING PIN 2 XDOZZ 5X050 404933 125 X 2 359 es PAOOO 3040014472738 5X050 403607 CYLINDER ASSEMBLY A OTY 1 7A1 7A2 OTY 5 7E1 7E2 PLAIN CYLINDER ASSY INCLUDES ITEMS 4 THROUGH 41 3 PAOZZ 3040015157916 5X050 13141 CYLINDER ACTUATING ITEMS 4 4 THROUGH 41 4 4 e
29. 5305 5305 6220 6220 5325 5310 5310 5930 4130 2540 5310 4130 4130 4130 1 5 DEX NSN 0 050 4208 1 466 9174 1 520 4456 0 993 1848 0 921 3624 1 466 5398 1 507 6990 1 446 6274 1 446 6277 1 446 4665 0 068 0508 0 068 0509 0 071 2513 0 226 4827 0 543 4372 0 068 0510 0 725 2317 0 071 2071 0 071 2076 0 724 7222 0 724 7228 0 947 4358 1 445 9978 1 445 9981 1 446 9182 1 518 7454 0 820 6653 1 497 0704 0 044 4035 1 449 5775 0 003 9174 1 446 2112 1 446 3255 1 446 2107 EIG 10 8 2 23 23 1 1 1 22 22 22 7 7 23 15 12 15 14 23 17 12 23 9 2 2 9 10 11 12 10 22 12 12 14 15 11 19 21 21 21 14 5 13 13 14 15 12 10 1 3 10 13 11 SECTION IV CAGEC 81349 80205 96906 96906 96906 96906 96906 96906 96906 96906 96906 96906 80205 80205 96906 96906 96906 96906 00624 96906 96906 96906 96906 96906 80205 13829 96906 81349 81349 80205 60827 79470 80756 60827 60827 93061 93061 72764 72764 5 3805 264 14 amp P CROSS REFERENCE INDEXES PART NUMBER IN PART NUMBER 1112037 516562 51 516624 1050 516624 1100 527183 10 527183 14 527183 15 527183 23 527183 9 535191 306 535206 281 535207 263 535333 40 535338 46 535338 51 551412 10 51525A12 16 51527 A12 551527 8 551849 100 551943 35 551943 39 551943 45
30. ELBOW PIPE TO TUBE HOSE 55 UOC 7A1 7E1 HOSE ASSEMBLY NONME 1 5 16 JIC X 105 SE SE 90D xt UOC 7A2 7E2 ELBOW BIPE 249 SER UOC 7A1 7E1 ELBOW PIPE UOC 7E2 NIPPLE PIPE UOC 7A2 ELBOW TUBE TO 55 ELBOW TUBE TO BOSS eiee anea ROG HOSE 55 UOC 7A1 7E1 HOSE ASSEMBLY NONME 57 SF SF UOC 7A2 7E2 HOSE 55 UOC 7A1 7E1 HOSE ASSEMBLY NONME 3 4 JIC X 57 90Ls s eR SIE Oe BO UOC 7A2 7E2 5 ADAPTER STRAIGHT PDs sises cea eas as 1 1 2 450 1 1 2 56 Dd 1 1 16 JIC X LAMP HOSE 1 91 2 22 INCH HOSE NONMETALLIC 1 50 ID X 24 00 INCH perea END OF FIGURE 7 QTY PMP H SECTIONI TM 5 3805 264 148 Figure 22 Cylinder Assembly Hoist SECTION II 5 3805 264 14 amp P 1 2 3 4 5 6 7 SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 2407 HYDRAULIC CYLINDERS 22 CYLINDER ASSEMBLY HOIST 1 PFFFF 3040014463620 5 050 403236 CYLINDER ASSEMBLY A 1 2 PAFZA 5330014471113 02249 034 55008 53118 PARTS KIT SEAL REPL INCLUDES ALL 1 WEAR RINGS GUIDE RINGS RET RINGS WIPERS RET WIPERS U CUP SEALS 3 PAFZZ 3
31. ES ete Hydraulic Control Valve LP mL ctl Localo Relief Valve 0 2 2 Hydraulic Cylinder ag artem e oe wee ande Operating Press re etx edt Re tae alae PER GE D jer qp Inside cab control unit or remote control Electro pneumatic Four 4 PTO driven 12 75 gal 48 2 1 Lubricating oil OE HDO 10 MIL L 2104 or OEA MIL L 46167 Gear 2500 psi 17 238 kPa 10 micron cartridge element Service indicator gage Mounted on reservoir Single spool three 3 ports Integral with hydraulic pump 2500 psi 17 238 kPa 400 Ib 181 6 kg 2500 psi 17 238 kPa 124 in 315 Three 3 double acting stages TM 5 3805 264 14 amp P Section Ill PRINCIPLES OF OPERATION Paragraph Page Number Paragraph Title Number 1 15 Electrical System 5 24 rM EE ES umso Pang Are UE RU 1 1 1 16 Dump Body xi ede taz br Pede OG GIC e br ee BSE en 1 13 11 17 Hydraulic 1 16 1 15 ELECTRICAL SYSTEM a The dump body electrical system consists of wiring harnesses that connect to the vehicle s chassis wiring harnesses b The dump body harnesses connect to
32. Install crank assembly baseplate 25 on dump body with two screws 5 washers 2 and nuts 1 Do not tighten screws Install chain to sprockets and tighten screws 5 paragraph 4 66 FOLLOW ON TASKS e Check operation of cargo cover paragraph 2 14 Fully retract cargo cover paragraph 2 14 4 105 TM 5 3805 264 14 amp P 4 66 CARGO COVER CHAIN AND SPROCKETS REPLACEMENT This task covers a Removal c Installation b Cleaning and Inspection Initial Setup Equipment Conditions Materials Parts Cargo cover extended and crank handle Corrosion preventive Item 8 Appendix F removed paragraph 2 14 Four starwashers Tools Test Equipment General mechanic s tool kit Item 8 a REMOVAL NOTE Perform steps 1 2 3 and 5 to remove chain from sprockets 1 Remove four screws 4 starwashers 3 and crank assembly cover 5 Discard starwash ers 2 Remove four screws 1 and chain cover 2 336 010 4 106 5 3805 264 14 amp P 4 66 CARGO COVER CHAIN AND SPROCKETS REPLACEMENT Con t 3 Loosen crank assembly baseplate mounting screws 6 Raise crank assembly baseplate 11 and remove chain 7 from sprocket 10 4 Remove retaining ring 9 and sprocket 10 from crankshaft 8 Discard retaining ring if damaged 336 011 Remove chain 7 from sprocket 16 6 Loosen set screw 15 and remove sprocket 16 with sprocket alinemen
33. 1 Lights Taillights and marker clearance lights one on each side of dump body and three in light cluster at rear hinge are located on dump body Beacon warning light is located on cab shield 2 Instrument Panel Indicator Warning Lights and Related Switches Body Up and Body Transport Lock indicator lights are located on instrument panel in cab Body Up and Transport Lock switches are located on cylinder support frame 3 MCS Tailgate M917A1 w MCS and M917A2 w MCS Solenoid controlled air cylinders open and close MCS gates 1 16 DUMP BODY a Dump Body Assembly 1 The dump body is a welded assembly of heavy gage steel with bolt on assemblies and components It is 13 5 ft 411 cm long with 14 cu yd 10 7 m 18 5 ton 16 8 metric ton capacity 2 The dump body is attached to the truck frame at the rear hinge Other attachment points are at the stabilizer and the hydraulic cylinder 3 An abrasion resistant steel bed resists wear and denting 4 A bolt on cab shield protects the cab The beacon warning light is mounted on the cab shield 5 Wooden side boards along the top on both sides of the dump body add height to help pre vent spillage when hauling material 6 The dump body has an interlocking under structure b Stabilizer 1 A hinged stabilizer mounted between the truck frame and the dump body adds stability as the dump body is raised 2 Five grease fittings on the stabilizer allow for lub
34. 14 Tag hydraulic control cable 27 15 Remove two nuts 28 lockwashers 29 screws 32 clamp 30 and spacer 31 from bracket 34 Dis card lockwashers 16 Remove retaining pin 26 from pivot pin 25 and pivot pin from bracket 33 4 121 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t 17 Remove two top screws 2 from front and rear of shift tower 1 18 Lift handle assemblies 35 from shift tower 1 19 Separate hydraulic control lever 37 from transfer case selector lever 38 by removing two bolts 36 flatwashers 40 and nuts 39 4 122 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t b INSTALLATION 1 Install hydraulic control lever 37 to transfer case selector lever 38 with two bolts 36 flatwashers 40 and nuts 39 Position handle assemblies 35 on shift tower 1 3 To keep shift tower 1 rigid install two top screws 2 on front and rear of shift tower 4 With hydraulic control lever in DOWN position install hydraulic control cable pivot pin 25 in bracket 33 and secure with retaining pin 26 5 Install spacer 31 cable 27 clamp 30 two screws 32 new lockwashers 29 and nuts 28 to bracket 34 6 Place hydraulic control lever in N Neutral position paragraph 2 1 4 123
35. 21 8 23 12 BULK 16 14 14 23 14 23 2 4 10 18 9 12 23 15 15 15 3 5 14 7 11 11 19 45 21 2 11 4 9 21 24 STOCK NUMBER 5310 00 584 7888 5310 00 637 9541 5315 00 721 8370 5305 00 724 7222 5305 00 724 7228 5305 00 725 2317 5310 00 732 0558 5340 00 753 3741 5325 00 768 8563 5325 00 803 7301 5330 00 809 1052 5310 00 809 4058 5310 00 809 4061 5310 00 809 8533 5315 00 809 8786 5310 00 814 0672 5310 00 820 6653 4730 00 822 5609 5310 00 823 8804 5935 00 833 8561 5970 00 833 8562 5310 00 833 8567 5935 00 856 3513 4730 00 921 3624 4720 00 925 4955 5310 00 935 9021 5305 00 947 4358 5306 00 957 7531 5305 00 984 7353 5305 00 988 1725 5305 00 989 7434 5305 00 993 1848 4730 01 011 7736 4730 01 028 5540 5340 01 032 8448 4730 01 046 4034 4730 01 048 5260 4730 01 048 7873 FIG 23 15 10 10 11 12 11 15 16 18 15 18 15 16 23 11 16 21 BBA AY 23 BULK 11 14 10 15 15 15 15 23 21 21 16 21 14 14 14 14 14 14 14 14 SECTION IV STOCK NUMBER 4730 01 056 4990 4730 01 062 2570 5305 01 075 0957 6220 01 086 5691 6220 01 095 0011 4730 01 096 9128 4730 01 134 3571 5305 01 162 2358 5325 01 163 6558 2540 01 175 7257 5330 01 212 2222 5935 01 214 4163 5935 01 214 5259 5365 01 217 4133 5975 01 226 8078 5975 01 230 4370 5330 01 236 0469 5365 01 236 0717 4730 01 244 3552 3110 01 260 2561 5310 01 267 1684 530
36. 3 DO NOT operate engine in enclosed areas DO NOT idle engine for long periods without maintaining adequate ventilation in cab DO NOT drive dump truck with inspection plates or cover plates removed BE ALERT at all times for exhaust poisoning symptoms They are Headache Dizziness Sleepiness Loss of muscular control If you see another person with exhaust poisoning symptoms Remove person from area Expose to fresh air Keep person warm Do not permit physical exercise Administer cardiopulmonary resuscitation CPR if necessary Notify a medic BE AWARE The field protective mask for nuclear biological chemical NBC protection will not protect you from carbon monoxide poisoning THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION 5 3805 264 14 amp P WARNING CARGO COVER OPERATION Observe the following safety regulations when operating cargo cover e Never operate cargo cover under obstructions such as trees and power lines Ensure that all personnel are clear of rear of dump body and the immediate area of the cover Ensure that chain cover is in place Keep all clothing away from moving parts DO NOT cover load with crank handle installed e DO NOT use cargo cover frame as a grabhandle Failure to follow this warning may result in death or injury to personnel WARNING CLEANING AGENTS e Dry cleaning solvent MIL PRF 68
37. 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 18 Remove four screws 37 and shift tower 1 from cab floor 19 Remove transmission tunnel access cover TM Y 9 2320 363 20 or TM 9 2320 302 20 E o M X 822 37 20 At hydraulic pump turn jam nut 38 over entire length of threads on cable 36 21 Remove two screws 40 flatwashers 42 and lockwashers 41 from flange clamp 43 Discard lock washers 22 Slide flange clamp 43 away from bonnet 39 23 Unscrew bonnet 39 and slide spacer 44 along cable 36 until cable bracket 46 can be accessed 24 Remove cotter pin 47 and clevis pin 45 from hydraulic pump actuator 48 Discard cotter pin 4 131 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 25 Remove nut 49 and cable bracket 46 26 Count number of threads from end of cable 36 to nut 50 27 Remove nut 50 b INSTALLATION 1 Install nut 50 onto cable 36 same number of threads as removal 2 Slide cable bracket 46 onto cable 36 and install nut 49 3 Position cable bracket 46 onto hydraulic pump actuator 48 and install clevis pin 45 and new cotter pin 47 4 Slide spacer 44 screw bonnet 39 and slide flange clamp 43 over cable bracket 46 5 Install two screws 40 flatwashers 42 and new lockwashers 41 to flange clamp 43 6 Slide jam nut 38 onto cable 36 7 Tighten jam nut 38
38. 5975 01 310 5011 FIG 15 TS BoP PPP Pe U E N E Ur dO US 13 37 SECTION IV CAGEC 77060 77060 77060 77060 77060 77060 77060 77060 77060 77060 77060 77060 77060 77060 77060 19207 19207 19207 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 TM 5 3805 264 14 amp P CROSS R PART NUMBER INDEX PART NUMB 12015344 12015792 1202 0116 1204 7938 1204 8086 12045773 12047933 12048074 12048159 12052924 12066304 12084673 12085036 12124582 12129493 12302814 12387349 43 12420936 126426 126427 126615 126617 127170 127373 127838 127852 127892 128125 128126 128129 128130 128131 128214 129305 129306 129528 129568 129652 129653 129732 129871 13141 ER EFERENCE INDEXES NSN 5935 01 518 0417 5935 01 214 5259 5940 01 340 0587 2530 01 464 9916 5999 01 364 1237 5940 01 366 1563 5940 01 462 1717 5325 01 446 8320 5999 01 406 4110 5940 01 469 7988 2540 01 175 7257 5310 00 061 4651 5999 01 422 9740 2590 01 447 0748 5315 01 4 5340 01 4 5340 01 4 2510 01 4 5340 01 4 5340 01 4 3040 01 4 5340 01 4 5340 01 4 5930 01 4 147 0480 169 6693 146 5137 146 1842 145 9486 1
39. Connect wiring harness connector 11 to chassis wiring harness connector 10 3 Route wiring harness 3 along inner surface of right side dump body frame rail 8 and through grommet 7 at front of right side dump body 9 4 Route wiring harness 3 up dump body 9 and cab shield 2 Secure with clamps 5 and new locknuts 4 on welded studs 6 5 Secure wiring harness 3 along inner surface of right side dump body frame rail 8 with clamps 5 and new locknuts 4 on welded studs 6 6 Install wiring harness 3 through cab shield grommet 1 Install new tie wraps FOLLOW ON TASKS e Connect batteries 9 2320 363 20 M917A1 and M917A1 w MCS e Remove body props and lower dump body paragraph 2 15 e Check operation of beacon warning light TM 9 2320 363 10 or TM 9 2320 302 10 4 51 TM 5 3805 264 14 amp P 4 46 LIGHTS WIRING HARNESS MAINTENANCE This task covers a Removal b Repair Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS Tools Test Equipment General mechanic s tool kit Item 8 c Installation Materials Parts Marker tags Item 20 Appendix e Tie wraps Item 19 Appendix F References TM 9 2320 363 20 TM 9 2320 302 20 General Safety Instructions
40. MCS adjustment tube removed paragraph 4 60 MCS air cylinder removed paragraph 4 56 c Installation Tools Test Equipment General mechanic s tool kit Item 8 Appendix 1 Materials Parts Four lockwashers Personnel Required Two a REMOVAL 1 Remove four screws 3 lockwashers 2 MCS gate 4 and two brackets 1 from tailgate 5 Discard lockwashers 2 Remove two brackets 1 from MCS gate 4 3 UNE E E Tel ES ND a n 1 zug js Qi AL ub HN EN 3 ci XM al 5 b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions 4 75 TM 5 3805 264 14 amp P 4 54 MCS GATE REPLACEMENT M917A1 W MCS AND M917A2 W MCS Con t c INSTALLATION 1 Position two brackets 1 on MCS gate 4 2 Install two brackets 1 and MCS gate 4 to tailgate 5 with four new lockwashers 2 and screws 3 A A ER 8 IA il FOLLOW ON TASKS Install MCS adjustment tube paragraph 4 60 Install MCS air cylinder paragraph 4 56 4 76 5 3805 264 14 amp P 4 55 MCS AIR RESERVOIR REPLACEMENT M917A1 W MCS AND M917A2 W MCS This task covers a Removal Initial Setup Equipment Conditions Chassis air system drained
41. assembled e Assemble hydraulic cylinder starting with the largest diameter sleeve and work ing inward 1 If removed install two bushings 35 to barrel 25 and bushing 34 to plunger 1 NOTE Perform steps 2 thru 7 to install largest diameter sleeve 2 With hydraulic cylinder components in horizontal position install two piston rings 33 and new wear ring 32 to sleeve 14 3 Install sleeve 14 to barrel 25 and install bot tom retaining ring 31 to barrel using 5 in seal installation tool 31 14 25 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 4 Install new bottom guide ring 30 and new spi ral retaining ring 29 5 Install new seal 28 Install new wiper 26 to new wiper retainer 27 and install wiper retainer 7 Install retaining ring 24 24 26 27 28 NOTE Perform steps 8 thru 13 to install next sleeve 8 Install two piston rings 23 piston ring 22 and new wear ring 21 to sleeve 3 21 22 23 3 5 32 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 9 Install sleeve 3 to sleeve 14 and install bot tom retaining ring 20 to sleeve 14 using 4 in seal installation tool 20 10 Install new bottom guide ring 19 and new spi 13 ral retaining ring 18 11 Install new seal 17 12 Install new wiper 15 to new wiper retainer 15 16 and install wiper retainer 13 Install retaining ri
42. e Wires should be tagged and wire color noted before disconnecting paragraph 4 17 e Perform steps 1 thru to disassemble plug in connector 1 Remove screw 4 screw 1 and clamp 2 from connector housing 3 2 Pull connector 5 outward and remove seven screws 6 to remove connector and connector housing 3 from wires of cable 8 3 Remove jumper wire 7 4 42 5 3805 264 14 amp P 4 43 MCS REMOTE CONTROL REPAIR M917A1 W MCS AND M917A2 W MCS Con t NOTE Perform steps 4 thru 10 to disassemble control box 4 Loosen four twist lock screws 11 and remove cover 12 from control box 9 5 Remove gasket 10 from cover 12 Discard gasket NOTE Perform steps 6 thru 8 for each of four switches 6 Loosen two screws 14 and disconnect two wires 13 from switch 15 NOTE Note position of switch and retainer for assembly T Remove switch 15 and retainer 16 from switch housing 19 8 Remove ring 17 switch housing 19 and data plate 18 from cover 12 12 4 43 TM 5 3805 264 14 amp P 4 43 MCS REMOTE CONTROL REPAIR M917A1 W MCS AND M917A2 W MCS Con t 9 Remove locking plug 20 grommet 21 and cable 8 from control box 9 10 Remove nut 22 and bushing 23 b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions ASSEMBLY NOTE Perf
43. tion of hydraulic system paragraph 4 21 NOTE e Hoses should be tagged before removal paragraph 4 17 suitable container should be used to catch any draining hydraulic fluid Ensure that all spills are cleaned up 1 At lower end of hydraulic cylinder 1 disconnect hose assemblies 6 from elbows 5 Remove elbows 5 20 5 3805 264 14 amp P 5 6 HYDRAULIC CYLINDER REPLACEMENT Con t WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 2 Install lifting sling through loop in hydraulic cyl inder 1 and attach lifting sling to lifting device 3 Remove locknut 8 screw 10 and pivot pin 9 from cylinder support frame 7 and hydrau lic cylinder 1 Discard locknut 4 While holding hydraulic cylinder 1 securely remove six locknuts 2 screws 4 and left qu and right mounting brackets 3 and 11 from 8 33 Pd 5 5 dump body 12 Discard locknuts Lx gt Ki m 5 Remove left and right mounting brackets 3 and 11 from hydraulic cylinder 1 WARNING e Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitabl
44. 11 with pin 12 and new retaining pin 10 4 80 5 3805 264 14 amp P 4 56 MCS AIR CYLINDER REPLACEMENT M917A1 W MCS AND M917A2 W MCS Con t 3 If removed install elbow 2 to air cylinder sole noid 3 Connect air line 1 to elbow 4 Connect solenoid connector 5 to MCS tail gate wiring harness connector 4 336 023 5 Install new tie wraps as required FOLLOW ON TASKS Start engine and pressurize air systems TM 9 2320 363 10 or TM 9 2320 302 10 Check for leaks e Check operation of MCS tailgate paragraph 2 13 Install MCS tailgate cover paragraph 4 53 TM 5 3805 264 14 amp P 4 57 MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE M917A1 W MCS AND M917A2 W MCS This task covers a Removal d Assembly b Disassembly e Installation c Cleaning and Inspection Initial Setup Equipment Conditions Materials Parts MCS air cylinder removed paragraph 4 56 Pipe sealing compound Item 7 Appendix F Tools Test Equipment i Ball bearing grease Item 12 General mechanic s tool kit Item 8 Appendix One solenoid repair kit a REMOVAL NOTE Note position of elbows tubes and solenoid assembly to aid in installation 1 Disconnect tube 1 from fitting 3 on solenoid assembly 2 2 Remove solenoid assembly 2 from air cylinder 4 2 B 336 024 4 b DISASSEMBLY Remove two filters 6 and elbow
45. 259 599 473 473 622 622 532 473 531 473 CROSS REFERENCE INDEXES INDEX NSN 0 011 502 2940 0 01 498 1887 0 01 498 1885 0 01 519 0924 0 01 518 9540 0 01 518 9183 0 01 519 1782 0 01 519 1777 0 01 445 7883 0 01 442 7238 9 00 057 2929 0 01 048 5260 0 01 048 5260 0 01 518 6827 0 01 086 5691 5 01 163 6558 0 01 048 7873 5 01 447 0479 0 01 056 4990 4130 01 062 2570 4130 01 096 9128 5930 01 332 0680 4130 00 068 6616 5340 00 753 3741 5340 01 032 8448 5935 00 833 8561 5970 00 833 8562 5940 00 399 6676 5975 01 230 4370 T3 FIG WWW WwW 5 5 N PN BP P BD gt A A FP FS ITEM 20 26 27 SECTION IV CAGEC 19207 13445 01276 01276 13548 13548 TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES PART NUMBER IN PART NUMBER 8338567 8486 900598 125 900598 85 93745 94706 5310 5930 5365 5365 5935 5935 DEX NSN 0 833 8567 1 336 0919 1 340 3898 1 217 4133 1 518 3692 1 518 3690 FIG ITEM 4 6 5 2 22 9 22 11 3 8 3 9 5 3805 264 14 amp P APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS Section l INTRODUCTION D 1 SCOPE a This appendix lists Components of End Item and Basic Issue Items BII for the M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body to help you inventory items required for safe and ef
46. 5510002559269 4720009254955 4720013958773 4720011829067 CAGEC 77060 81349 79470 79470 61424 TM 5 3805 264 14 amp P 5 PART NUMBER 68240R MILL2037 PT24006NA NT10006 PFT 6B BLK 100 6 7 DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 95 GENERAL USE STANDARDIZED PARTS GROUP 9501 HARDWARE SUPPLIES AND BULK MATERIEL COMMON FIG BULK CONDUIT V LUMBER HARDWOOD 4x49 V TUBING NONMETALLIC 3 8 OD V TUBING NONMETALLIC ess V TUBING NONMETALLIC eese V END OF FIGURE BULK 1 SECTION IV STOCK NUMBER 5310 00 003 9174 4730 00 044 4035 4730 00 050 4208 5999 00 057 2929 4730 00 057 5555 5310 00 061 4650 5310 00 061 4651 5305 00 068 0508 5305 00 068 0509 5305 00 068 0510 4730 00 068 6616 5305 00 071 2071 5305 00 071 2076 5305 00 071 2513 5310 00 080 6004 5310 00 088 1251 4730 00 137 7875 5935 00 153 4397 4730 00 173 1881 5325 00 174 9341 4730 00 204 1272 5306 00 226 4827 5510 00 255 9269 5305 00 269 2803 4730 00 277 8289 4730 00 278 3888 4730 00 289 2357 5310 00 347 0021 5940 00 399 6676 5310 00 409 3333 4820 00 435 4391 5310 00 488 3889 5325 00 530 7968 5305 00 543 4372 5310 00 550 1130 TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX FIG TT 14 10 4 14 15 23 10 11 23 14 23 23 12 23 12 15 14 24 15 13
47. 551967 8 590726 60 1391 45912 3 6FG8C 45913 1 4CG5C 81940 2 1 AS561 8 48 PS 0001 PT24006NA RRT206 TR 1200 01 5 355 70 5209 8 4 VS269NTA 6 4 11 415 11 416 5510 5315 5325 5325 5310 5310 5310 5310 5310 5305 5305 5305 5310 5310 2310 2 5310 4730 4730 4730 5305 5310 5310 5310 5310 5305 4820 5310 5310 4820 5315 5306 4720 5325 5331 4130 4130 9905 9905 1 6 DEX NS 0 255 9269 0 809 8786 0 803 7301 0 530 7968 0 809 4058 0 080 6004 0 809 4061 0 809 8533 0 823 8804 0 984 7353 0 988 1725 0 989 7434 0 550 1130 0 637 9541 0 584 7888 1 267 1684 0 173 1881 1 011 7736 0 822 5609 1 075 0957 0 935 9021 0 488 3889 0 409 3333 0 732 0558 0 269 2803 0 435 4391 0 814 0672 0 088 1251 1 298 8416 0 721 8370 1 271 9425 0 925 4955 0 768 8563 1 447 3098 1 345 6065 1 244 3552 1 498 7858 1 498 7857 FIG BULK 11 15 15 15 14 24 16 23 7 7 15 15 1 5 5 15 15 23 23 21 21 21 4 5 11 14 9 12 23 10 1 5 16 18 16 15 21 10 23 BULK 18 23 23 13 14 ITEM 1 18 43 30 48 13 28 10 20 32 29 28 27 28 14 41 17 14 10 25 12 SECTION IV TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX CAGEC PART NUMBER NSN FIG ITEM 73764 WE11H417E 9905 01 498 7860 1 9
48. ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 The E mail address is tacomlcmc daform2028 us army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 SUPERSEDURE NOTICE This manual supersedes TM 5 3805 264 14 amp P dated December 1997 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TABLE OF CONTENTS Page ere How Use This CHAPTER 1 INTRODUCTION 1 1 Section General 1 1 Section Equipment Description and 1 5 Section Ill Principles of i Change 1 TM 5 3805 264 14 amp P TABLE OF CONTENTS Con t Illus Fig Page CHAPTER 2 OPERATING 5 2 1 Section Description and Use of Operator s Controls and Indicators 2 1 Section Il Operator Preventive Maintenance Checks and Services PMCS 2 7 Section Operation Under Usual Section IV Operation Under Unusual 2 43 CHAPTER 3 OPERATOR MAINTENANCE Section Lubricat
49. Appendix F on all metal surfaces Use detergent Item 9 Appendix F and water when you clean rubber or plastic 2 Deterioration Rust and Corrosion a Be alert for deterioration of plastic and rubber materials Report it to your supervisor b Check metal parts of vehicle for rust and corrosion If any bare metal or corrosion exists clean and apply a light coat of oil 15 Appendix Report it to your supervisor 3 Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool of course but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose report it to your supervisor 4 Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to your supervisor 5 Electric Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and ensure that the wires are in good condition 2 8 5 3805 264 14 amp P 2 5 GENERAL PMCS PROCEDURES Con t 6 Hoses and Fluid Lines Look for wear damage and signs of leaks Ensure that clamps and fittings are tight Wet spots indicate leaks of course but a stain around a fitting or connector can also mean a leak If a leak comes from a loose fitting or connector tighten it If something is broken or worn out repo
50. DISASSEMBLY CAUTION Ports in reservoir should be plugged to pre vent contamination of hydraulic system paragraph 4 21 1 Remove hydraulic oil filter service indicator gage paragraph 4 79 2 Remove hydraulic oil filter element paragraph 4 78 3 Remove four screws 1 and filter housing 13 from hydraulic reservoir 11 4 Remove pipe 12 from filter housing 13 5 Remove seal 14 from filter housing mounting flange Discard seal 6 Separate filter housing 13 and remove pre formed packing 15 Discard preformed pack ing 7 Remove fill 2 six screws 3 strainer 4 8 Remove sight tube 6 and two elbows 5 9 Remove drain plug 10 elbow 7 hose 8 and cap 9 b CLEANING AND INSPECTION Clean and inspect components dance with Chapter 4 Section General Mainte nance Instructions c Assembly Materials Parts Con t Rags 16 Appendix Antiseize tape Item 21 Appendix One preformed packing One seal e 336 049 4 143 TM 5 3805 264 14 amp P 4 76 HYDRAULIC RESERVOIR REPAIR Con t ASSEMBLY NOTE Use antiseize tape on all pipe threads paragraph 4 22 1 Install drain plug 10 elbow 7 hose 8 and cap 9 NOTE For information on manufacturing sight tube refer to Appendix Illustrated List of Manufactured Items 2 Install tw
51. In an XB item is not available from salvage order it using the CAGEC and part number given Installation drawing diagram instruction sheet or field service drawing that is identified by manufacturer s part number XD Des dades Item is not stocked Order an XD coded item through normal supply channels using the CAGEC and part number given if no NSN is avail able 2 Maintenance Code Maintenance codes tell you the level s of maintenance authorized to use and repair support items The maintenance codes are entered in the third and fourth positions of the SMR code as follows a The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove replace and use an item The maintenance code entered in the third position will indi cate authorization to one of the following levels of maintenance Code Application Explanation eap Operator or Crew Maintenance done within Unit Maintenance or aviation unit maintenance o E Unit Maintenance or aviation unit can remove replace and use the item RE ROO Direct Support Maintenance or aviation intermediate maintenance can remove replace and use the item n ADU SEV General Support Maintenance can remove replace and use the item Specialized Repair Activity SRA remove replace and use the item D coco du REPAS Depot Maintenance can remove replace and use the item NOTE Some limited repair ma
52. Install lower end of hydraulic cylinder 1 to cyl inder support frame 7 with pivot pin 9 screw 10 and new locknut 8 6 Remove lifting sling from lifting device and hydraulic cylinder 1 T Install two elbows 5 to lower end of hydraulic cylinder 1 Connect two hose assemblies 6 to elbows FOLLOW ON TASKS Fill hydraulic reservoir Chapter 3 Section 1 Remove body props and lower dump body paragraph 2 15 e Install cab shield paragraph 4 62 5 22 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR This task covers a Disassembly b Cleaning and Inspection Initial Setup Equipment Conditions Hydraulic cylinder removed paragraph 5 6 Tools Test Equipment General mechanic s tool kit Item 8 Appendix 1 Pliers retaining ring Item 5 Appendix Nylon sling Item 6 Appendix 1 Seal installer 3 in Item 4 Seal installer 4 in Item 5 Appendix Seal installer 5 in Item 6 Appendix Hydraulic cylinder disassembly tool Suitable lifting device a DISASSEMBLY c Assembly Materials Parts Lubricating oil Item 14 Appendix Rags Item 16 Appendix Marker tags Item 20 Appendix Masking tape Item 23 Appendix One parts kit Personnel Required Two General Safety Instructions Use extreme caution when handling heavy parts Hydraulic cylinder sleeves may extend down ward as hydra
53. Keep away from open flame and other sources of ignition e If any exterior parts are coated with rust preventive compound remove with cleaning solvent Item 5 Appendix F and rags Item 16 Appendix d Inspect the equipment for any damage incurred during shipment Also check to see if the equip ment has been modified e Check the equipment against the packing slip to ensure that the shipment is complete Report any discrepancies 4 6 SERVICING INSTRUCTIONS a Perform all Unit maintenance PMCS Schedule the next PMCS on DD Form 314 b Perform all lubrication regardless of interval as described in Lubrication Instructions Chapter 3 Section C Report any problems on DA Form 2404 5 3805 264 14 Section GENERAL MAINTENANCE INSTRUCTIONS Paragraph Page Number Paragraph Title Number 4 7 Eum cs esate Ba gees 4 3 Work Safety a dd ae ae 4 4 4 4 4 10 Preservation of Parts 2 22 4 5 xj PE 4 5 4 12 Inspection Instructions 4 6 Disassembly and Assembly Instructions 4 6 Lubrication INSIMICHONS ose popa Ee PIIQR MESSER 4 6 4 15 Application of Adhesives 4 7 Sta
54. NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel a REMOVAL NOTE e Wires should be tagged before disconnecting paragraph 4 17 e Note location of tie wraps and routing of wiring harness prior to removal to aid in installation Remove two wiring harness terminal leads from backup alarm TM 9 2320 363 20 or TM 9 2320 302 20 2 Remove taillight from each side of dump body and disconnect wiring harness paragraph 4 40 3 Remove marker clearance light from each side of dump body and disconnect wiring harness paragraph 4 41 Disconnect wiring harness leads 2 from three marker clearance lights 3 at rear hinge light bracket 7 5 Disconnect wiring harness connector 5 from chassis wiring harness connector 6 and remove wiring har ness 4 from dump body 1 b REPAIR NOTE Wiring harness need not be removed from vehicle to make repairs Repair wiring harness in accordance with instructions in Chapter 4j Section General Maintenance Instructions 4 52 5 3805 264 14 amp P 4 46 LIGHTS WIRING HARNESS MAINTENANCE Con t 3 6 7 INSTALLATION 1 Positi
55. NOTE e Hoses should be tagged before removal paragraph 4 17 Use a suitable container to catch any draining hydraulic fluid Ensure that all spills are cleaned up 1 Disconnect hydraulic return hose 4 from tee 2 4 140 5 3805 264 14 amp P 4 75 HYDRAULIC RESERVOIR REPLACEMENT Con t 2 Remove tee 2 with oil sampling valve 3 from filter housing 1 3 Loosen clamp 10 and disconnect suction hose 11 from hose barb 12 4 Remove hose barb 12 and elbow 13 from hydraulic reservoir 15 5 Attach a nylon sling and suitable lifting device to hydraulic reservoir 15 Take up slack in sling 6 Remove four locknuts 9 spacers 8 lock washers 7 washers 6 and screws 5 Dis card locknuts and lockwashers WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 7 Remove hydraulic reservoir 15 from cylinder support frame 14 b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions 4 141 TM 5 3805 264 14 amp P 4 75 HYDRAULIC RESERVOIR REPLACEMENT Con t INSTALLATION
56. and nipple 3 from filter housing cover 4 4 147 TM 5 3805 264 14 amp P 4 78 HYDRAULIC OIL FILTER SERVICE INDICATOR GAGE REPLACEMENT Con t b CLEANING AND INSPECTION Clean and inspect components in accor dance with Chapter 4 Section Ill General Mainte nance Instructions c INSTALLATION NOTE Use antiseize tape on all pipe threads paragraph 4 22 1 Apply antiseize tape to pipe threads of nipple 3 and install nipple and elbow 2 to filter housing cover 4 2 Install gage 1 to elbow 2 FOLLOW ON TASKS e Remove body props and lower dump body paragraph 2 15 4 148 5 3805 264 14 Section X PREPARATION FOR STORAGE OR SHIPMENT Paragraph Page Number Paragraph Title Number General Definition of Administrative Storage Preparation of Equipment for Administrative Care of Equipment in Administrative Exercise Procedures for Common Components and Miscellaneous 5 Removal of Equipment from Administrative Storage Preparation of Equipment for 4 79 GENERAL a This chapter c
57. paragraph 4 22 e Install hose support clamps and new tie wraps as necessary e Perform steps 1 thru 4 to install two hydraulic cylinder hoses and fittings Install elbow 5 and elbow 7 to hydraulic cylinder 6 Install elbow 10 and adapter 11 to hydraulic pump 12 Install hose 9 to elbow 7 and elbow 10 Install hose 8 to adapter 11 and elbow 5 Dot NUI 4 138 5 3805 264 14 amp P 4 74 HYDRAULIC HOSES AND FITTINGS REPLACEMENT Con t NOTE Perform steps 5 thru 7 to install suction hose 5 Install elbow 17 and hose barb 16 to bottom of hydraulic reservoir 4 Install adapter 13 to hydraulic pump 12 Install suction hose 15 and two clamps 14 to adapter 13 and hose barb 16 Tighten clamps NOTE Perform steps 8 thru 11 to install return hose and fittings 8 Install tee 2 on filter housing 3 9 Install oil sampling valve 1 on tee 2 10 Install adapter 18 to hydraulic pump 12 11 Install return hose 19 to adapter 18 and tee 2 FOLLOW ON TASKS Install transmission tunnel access cover TM 9 2320 363 20 or TM 9 2320 302 20 hydraulic reservoir Chapter 3 Section 1 Remove body props and lower dump body paragraph 2 15 4 139 TM 5 3805 264 14 amp P 4 75 HYDRAULIC RESERVOIR REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Dump body raised
58. 01 4 7690 01 4 9905 01 4 9905 01 4 3040 01 4 4730 01 4 4730 01 4 5220 01 4 5310 01 4 197 5582 146 1729 146 1541 146 1481 146 1508 197 4886 145 8961 198 8178 149 9632 147 2738 173 9699 173 9667 174 8432 181 4919 5330 01 482 8766 5330 01 4 5365 01 4 5330 01 4 173 2903 175 2277 174 2447 5325 01 502 5209 I 12 FIG 17 17 17 14 21 21 21 21 17 17 17 13 14 14 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 23 23 13 13 S oo WwW abo 9 PRP PN NUON 43 23 16 21 13 14 17 42 11 31 36 35 34 33 32 23 22 24 25 SECTION IV CAGEC 5 050 5 050 5 050 5 050 5 050 5 050 93061 5 050 5 050 5 050 5 050 5 050 5 050 5 050 64670 60602 60602 19204 93061 93061 13548 13548 13548 93061 OPXJ7 93061 93061 93061 93061 64678 77060 79470 19200 19200 19207 19207 19207 5A910 TM 5 3805 264 14 amp P C1 PART NUMBER PART NUMBER 404929 404930 404931 404932 404933 404934 404938 404939 404940 406340 406341 406342 406355 406356 407023 45884 48 55940 4 572929 60 6 60 6 60085R 60202R 60700 61NTA 6 63 04 63NTA 6 68NTA 6 4 68NTA 6 6 68PMT 6 4 681 545 07 22 68240R 276 69X6 7550233 1 7550233 2 8338561 8338562 8338564 8338566 531 304 304 472 473 472 473 473 259
59. 017 11 Install tie rods 4 on top end plate 3 12 Position cylinder sleeve with piston on top end plate 13 Slide bottom end plate 6 on piston shaft 5 14 Install four lockwashers 10 and four retaining nuts 9 on tie rods 4 15 Install nut 7 and clevis 8 on piston shaft 5 in same position as removal 16 Install mounting bracket 2 and four screws 1 on top end plate 3 17 Install elbow 12 on top end plate 3 18 Install tube 11 on elbow 12 336 016 FOLLOW ON TASKS e Install MCS air cylinder solenoid assembly paragraph 4 57 Install tailgate release MCS air cylinde or 4 56 4 90 5 3805 264 14 4 59 TAILGATE RELEASE MCS AIR LINES AND FITTINGS REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Chassis air system drained TM 9 2320 363 10 or TM 9 2320 302 10 MCS air system drained Chapter 4 Section Il Operator PMCS MCS tailgate cover removed if replacing MCS air lines paragraph 4 53 a REMOVAL c Installation Tools Test Equipment General mechanic s tool kit Item 8 Appendix Materials Parts Marker tags Item 20 Appendix F Tie wraps Item 19 Appendix F General Safety Instructions DO NOT disconnect air lines while air system is pressurized WARNING DO NOT disconnect air lines while air system is pressurized Air sy
60. 129305 129306 128126 5561 8 48 239693 12387349 43 239694 1821 063 200 AS15003 1 127838 6 7 DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 1810 CARGO BODY FIG 1 STABILIZER AND REAR HINGE PIN STRAIGHT HEADED 2 HINGE 55 2 2 222252 42 2 SCREW CAP HEXAGON 3 4 10X4 00 2 SELF LOCKING HE 3 4 10 2 HINGE ASSY LOWER o 1 PIVOT ASSY LhH cgi seg sepa eka EE 1 PIVOT ASSY RH seed ec reod ins 1 PROP BODY 2 SS 2 PIN SPRING 1 4 3 00 2 BRACKET SUPPORT se scg 24 2 NUT SELF LOCKING HE 5 8 11 12 BRACKET ANGLE 5 2 tR 2 SCREW CAP HEXAGON H 5 8 11 2 00 12 FITTING LUBRICATION 1 8 NPT STABILIZER 55 25222 6554 4 1 END FIGURE 10 1 SECTION II TM 5 3805 264 14 amp P 16 15 Figure 11 Dump Body Assembly SECTION II 1 ITEM NO a fF WN H O 12 13 14 16 17 18 19 20 2 SMR CODE XDOZZ PAOZZ PAOZZ PAOZZ XDFFF XDFFF XDFFF PFOZZ PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ 0022 NSN 5305007247222 531 531 534 530 531 531 534 534 530 534 531 231 304 0000039174 0000614651 0014696693 5011622358 5014470479 5014470481 0014465137 0014464927 5007252317 001446094
61. 2 Beacon Warning Light Rotating amber strobe light alerts other vehicles of presence of dump truck 3 Dump Body Bed constructed of steel used for hauling aggregate hot mix asphalt and other materials 4 Side Boards Wooden boards add height to sides of dump body to help prevent spillage when hauling material 5 Tailgate Double acting tailgate opened at top or bottom with chains to adjust opening 6 Cable Guides Vehicle lifting cables pass through guides to maintain correct center of balance and to protect dump body from damage 7 Cargo Cover Controls Consist of crank handle and control handle Extend and retract cargo cover 8 Shovel Bracket Provides exterior storage for shovel 9 Bumper Extensions Provide adjustable attachment point for slings 917 2 and M917A2 w MCS 10 Lift Tie Down Shackles Provide lift and tie down points for dump truck 1 5 TM 5 3805 264 14 amp P 1 11 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Con t Key Component Description 11 Marker Clearance Lights Indicate presence of dump body 12 Cargo Cover Prevents spillage of dump body contents 13 Reflectors Mark outline of dump body 14 Stabilizer Maintains stability of raised dump body 15 Hydraulic Cylinder Hydraulic cylinder raises and lowers dump body 16 Hydraulic Reservoir Contains hydraulic fluid 17 Body Props Support raised EMPTY dump body for inspection and maintenance 18 Lifting Eyes Provide lift points for dump truck 19
62. 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V3 00 Change 1 TO Forward direct to addressee listed in publication U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 FROM Activity and location Include ZIP Code DATE PART 11 REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS TITLE M9T7AT M917A1 w MCS PUBLICATION NUMBER DATE TM 5 3805 264 14 amp P 30 December 2005 M917A2 and M917A2 w MCS TOTAL NO PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR NO NO NO NUMBER NO NO NO ITEMS RECOMMENDED ACTION SUPPORTED PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS EXTENSION SIGNATURE Change 1 USAPPC V3 00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form see AR 25 30 the proponent agency is ODISC4 Use Part Il reverse for Repair Parts and Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM DATE TO Forward to proponent of publication or form Include ZIP Code U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E
63. 5 3805 264 14 amp P gt iv S 1 ns quA 2 49 9 49 SECTION II 28 48 Figure 15 Cargo Cover and Component Parts Sheet 1 of 2 Figure 15 Cargo Cover and Component Parts Sheet 2 of 2 SECTION II 1 NO UF HS 0 NO N20 FP RP pp Ob E E ANA UNF WNP WAI AHF A 2 SMR CODE PFOZZ PAOZZ PAOZZ PAOZZ PFOZZ PFOZZ PAOZZ PFOZZ PFOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOOZ PFOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZA PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ PFOZA 3 NSN 5340014746455 3020014466412 5315014466724 3020014466409 5340014746462 5342014459481 5305009881725 5342014495475 3130014749064 5305005434372 5310006379541 5310007320558 2540014495775 5360014463122 3040014463790 5305000712513 5342014752802 5310013336436 3040014463793 5360014467903 5306009577531 5342014460902 5360014463194 5315014475712 5305014468972 5340014927615 5340014746449 5310005501130 5305009881725 5325005307968 3020014466405 5305009847353 3020014732738 2530014463340 5310000881251 5360014464054 3040014464689 5315014488804 CAGEC 5B752 5B752 5B752 5B752 5B752 5B752 96906 5B752 5B752 80204 80205 96906 5B752
64. 5B752 5B752 80204 5B752 64678 5B752 5B752 10266 5B752 5B752 5B752 5B752 5B752 5B752 80205 96906 96906 5B752 96906 5B752 5B752 11862 81349 5B752 5B752 5B752 TM 5 3805 264 14 amp P 5 PART NUMBER 0311 961402 0720 603557 0840 618512 0750 619594 0311 961401 0311 961273 MS35206 281 0311 961267 0710 602155 1821 038 075 535338 46 551967 8 ECT 13 CRY 0311 960238 0311 961280 1821 025 250 0311 861590 23 10340 125 0311 861591 0715 619601 213 1 4 20 2 1 2 0311 861589 0311 960237 0835 691616 0825 670460 0311 961356 0311 861596 535333 40 535206 281 516624 1100 0750 619592 535191 306 0311 862406 0311 960739 0815 660451 M45913 1 4CG5C 0715 619800 0311 860730 0840 618513 15 1 DESCRIPTION AND USABLE ON CODES UOC 6 GROUP 22 BODY CHASSIS AND HULL ACCESSORY ITEMS GROUP 2201 CANVAS ITEMS FIG 1 PARTS RUBBER OR PLASTIC CARGO COVER AND COMPONENT ACCESO exp CHAIN ROLLER 40 X 168 IN KEY WOODRUFF SPROCKET WHEEL PLATE MOUNTING 1 4 1 1 2 IN LEFT SIDE CONTROL ROD LEFT SIDE SCREW MACHINE 1 4 20X0 75 CONTROL ROD RIGHT SIDE HOUSING BEARING UNI SCREW CAP HEXAGON H 3 8 NUT PLAIN HEXAGON TARPAULIN SPRING SPIRAL TORSI WASHER LOCK SHAFT SHOULDERED SCREW CAP HEXAGON CONTROL ROD RIGHT SIDE NUT SELF LOCKING
65. 7 from valve body 5 4 82 5 3805 264 14 amp P 4 57 MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 336 025 Remove fitting 13 from valve body 5 Remove fitting 14 from elbow 15 Remove two screws 17 and solenoid 16 from filter housing 12 Remove plunger 10 and spring 9 from solenoid 16 Remove pin 11 from plunger 10 Remove gasket 8 from filter housing 12 Remove elbow 15 from valve body 5 336 026 5 3805 264 14 amp P 4 57 MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 9 Remove two screws 18 filter housing 12 and metal gasket 20 from valve body 5 10 Remove gasket 19 from filter housing 12 11 Remove gasket 21 from valve body 5 336 027 12 Remove two screws 23 and end cap 22 from valve body 5 13 Remove gasket 24 and plastic insert 25 from end cap 22 14 Remove valve 26 from valve body 5 336 028 4 84 5 3805 264 14 amp P 4 57 MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t CLEANING AND INSPECTION tions Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc d ASSEMBLY 9 ODN gt 12 13 14 Apply a light coat of grease to valve 26
66. 72764 WE11H418E 9905 01 498 7859 1 9 02249 002 55074 04844 22 6 04710 01 5000 35 4820 01 446 8874 19 3 30780 O1HP 6 4730 00 057 5555 14 11 79146 010029X11 13 7 30780 0102 12 8 4730 00 278 3888 14 8 23 17 79146 012037 13 30 79146 016964 4730 01 446 2108 13 8 79146 019067 5315 01 446 9174 13 44 79146 019070 5315 01 446 9177 13 1 79146 020003 7 4710 01 466 4881 BULK 2 02249 0263914 3040 01 446 6280 22 5 02249 0263984 22 5 79146 030084 13 40 5B752 0311 860730 3040 01 446 4689 15 37 5B752 0311 860732 3040 01 446 3782 15 40 5B752 0311 861589 5342 01 446 0902 15 22 5B752 0311 861590 5342 01 475 2802 15 17 5B752 0311 861591 3040 01 446 3793 15 19 5B752 0311 861596 5340 01 474 6449 15 27 5B752 0311 862406 3020 01 473 2738 15 33 5B752 0311 960237 5360 01 446 3194 15 23 5B752 0311 960238 5360 01 446 3122 15 14 5B752 0311 960739 2530 01 446 3340 15 34 5B752 0311 961267 5342 01 449 5475 15 8 5B752 0311 961273 5342 01 445 9481 1 5 6 5B752 0311 961280 3040 01 446 3790 15 15 5B752 0311 961356 5340 01 492 7615 26 5B752 0311 961401 5340 01 474 6462 15 5 5B752 0311 961402 5340 01 474 6455 15 1 5B752 0311 962125 15 29 5B752 0311 962128 3040 01 473 2741 15 44 5B752 0311 962132 5340 01 474 6446 15 42 79146 032135 4820 01 418 4232 14 12 02249 034 55008 53118 5330 01 447 1113 22 2 02249 035 17002 00225 5365 01 446 4322 22 12 79146 035055 14 10 30780 0503 12 8 4730 01 046 4034 21 9 64678 06 22309 048 6220 01 469 5480 2 6 64678 06 24618 000 2 1 02249
67. 77060 12085036 CONNECTOR 1 6 PAOZZ 5940014621717 77060 12048159 SUTERMINAL LUG 2ee8999 3 RR tis 4 END OF FIGURE SECTION II TM 5 3805 264 14 amp P 2 8 3 18 TERME eT ee 6 Figure 7 MCS Gate Harness and MCS Power Harness SECTION II 1 NO 10 11 12 13 14 15 16 qu 18 19 20 21 2 SMR CODE PAOOA PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOOA PAOZZ PAOZZ XDOZZ PFOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ 3 NSN 6150014974886 5935008563513 5975013556985 5935001534397 5975013105011 5999014229740 5935012145259 5305000680508 5310008238804 5310000614650 6150014974879 5935001534397 5975013556985 2530014649916 5940013661563 5310000614650 5310008238804 5305000680508 CAGEC 5X050 77326 77326 77326 77326 77060 19207 77060 80204 96906 45152 5 050 77326 77326 77060 77060 77060 77060 45152 96906 80204 5 3805 264 14 amp P 5 PART NUMBER 403484 11 700 11 763 11 761 11 720 12015323 12420936 12015792 1821 025 075 527183 9 114356 403248 11 720 11 761 12066304 1204 8086 12048074 1204 7938 114356 527183 9 1821 025 075 6 DESCRIPTION AND USABLE ON CODES UOC
68. 95 CL A74 3 F H Shop Equipment Automotive Main 4910 00 754 0705 T24660 tenance and Repair Field Mainte nance Basic Less Power SC 4910 95 A31 SPECIAL TOOLS 4 F Installer Seal 3 Inch J42381 5 F Installer Seal 4 Inch J42382 6 F Installer Seal 5 Inch J42383 Section REMARKS None 5 3805 264 14 amp P APPENDIX REPAIR PARTS AND SPECIAL TOOLS LISTS RPSTL Section l INTRODUCTION C 1 SCOPE This Repair Parts and Special Tools Lists RPSTL lists and authorizes spares and repair parts special tools special test measurement and diagnostic equipment TMDE and other special support equipment required for performance of Unit Direct Support and General Support Maintenance of the M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Bogy It authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by the Source Maintenance and Recoverability SMR codes C 2 GENERAL In addition to Section Introduction this RPSTL is divided into the following sections a Section Repair Parts List A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance The list also includes parts which must be removed for replacement of the autho rized parts Parts lists are composed of functional groups in ascending alphanumeric sequence with the parts in each group listed in ascending
69. ALLOCATION CHART 1 2 3 4 5 6 Maintenance Level FIELD SUSTAINMENT Unit DS GS Depot Tools and Group Component Maintenance Equipment Number Assembly Function F H D Ref Code Remarks 06 Electrical System 0608 Miscellaneous Items Control Unit MCS Inspect 0 1 Replace 0 5 1 Repair 1 0 1 0609 Lights Taillight Inspect 0 1 Replace 0 3 1 Marker Clearance Inspect 0 1 Light Replace 0 3 1 0610 Sending Units Replace 0 3 1 Warning Switches 0613 Hull or Chassis Wir ing Harness Harness Lights Replace 1 0 1 Repair 0 3 1 2 Harnesses MCS Replace 0 5 1 Repair 0 5 1 2 Harness Body Up Replace 0 3 1 Transport Lock Repair 0 3 1 2 18 Body Cab Hood and Hull 1810 Cargo Body Dump Body Assem 4 0 1 3 bly Repair 1 0 1 3 Cylinder Support Replace 1 0 1 3 Frame 5 3805 264 14 amp P Section Il MAINTENANCE ALLOCATION CHART Con t 1 2 3 4 5 6 Maintenance Level FIELD SUSTAINMENT Unit DS GS Depot Tools and Group Component Maintenance Equipment Number Assembly Function F H D Ref Code Remarks 1810 Cargo Body Tailgate MCS Inspect 0 1 Replace 1 0 1 2 Repair 0 5 1 2 Air Cylinder Tailgate Replace 0 5 1 Release Repair 0 8 1 Air Cylinder MCS Replace 0 5 1 Repair 1 0 1 Air Lines Hoses Replace 0 5 1 22 Body Chassis and Hull Accessory Items 2201 Canvas Rubber or Plastic Items Cargo Cover Inspect 0 1
70. AS SHAFT STRAIGHT SPRING HELICAL 1 4 20X2 50 BOLT EYE ARM HAND CRANK EXTE 4 LEFT SIDE SPRING SPIRAL TORSI KEY MACHINE SCREW TAPPING WASHER LOCK SCREW MACHINE RING RETAINING SPROCKET WHEEL SCREW MACHINE RATCHET WHEEL 1 4 X 1 5 8 IN H14 X 1 00 IN 1 4 IN 1 4 20X0 75 3 8 16 X 3 4 1 4 20X2 50 1 IN EXTERNAL BRAKE BAND AND LINI NUT NUT 1 4 IN NYLOCK NUT SELF LOCKING HE 1 4 20 SPRING HELICAL COMP 7 12 PP Bp RPP PDO SECTION II TM 5 3805 264 14 amp P 1 2 3 4 5 6 C7 ITEM SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY 39 XAOZZ 5B752 0311 962125 BASE CRANK ce wei cgt po ewa 9 Be 1 40 PFOZZ 3040014463782 5B752 0311 860732 SHAFT SHOULDERED 41 PAOZZ 5305010750957 96906 551849 100 SCREW MACHINE 1 4 20 1 50 1 42 PFOZZ 5340014746446 5B752 0311 962132 HANDLE MANUAL 1 43 PAOZZ 5325008037301 96906 MS16624 1050 RING RETAINING 1 2 IN EXTERNAL 2 44 PFOZZ 3040014732741 5B752 0311 962128 PAWL a dosh or SS E Sg IE EIS 1 45 PAOZZ 5310000614650 45152 114356A NUT SELF LOCKING HE 1 4 20 1 46 PAOZZ 5340014457778 5B752 0765 618830 JGREIPZHANDL
71. Char Appendix B If not authorized notify your supervisor 7 Fluid Leakage It is necessary for you to know how fluid leakage affects the status of your dump truck The following are definitions of the types classes of leakage you need to know to be able to determine the status of your equipment Learn and be familiar with them and remember when in doubt notify your supervi sor 4 15 TM 5 3805 264 14 amp P 4 31 GENERAL PMCS PROCEDURES Con t Leakage Definitions for Unit PMCS Class Leakage indicated by wetness or discoloration but not great enough to form drops Class 11 Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class 111 Leakage great enough to form drops that fall from the item being checked inspected CAUTION Operation is allowable with Class and Class leakage WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with Class or Class leaks check fluid lev els more frequently Class leaks must be reported immediately to your supervi sor Failure to do this will result in damage to vehicle and or components 4 32 PMCS INITIAL SETUP a General 1 This paragraph lists tools materials and personnel required for PMCS and lubrication 2 Mandatory replacement parts for PMCS and lubrication are listed paragraph 4 34 b Tools 1 Drain pan Item 4 Appendix I 2 General mechanic s to
72. Equipment Conditions Materials Parts Con t Hydraulic pump removed paragraph 5 4 Lubricating oil Item 14 Appendix Rags Item 16 Appendix Tools Test Equipment One lip seal General mechanic s tool kit Item 8 Appendix One retaining ring Machinist s vise Item 9 Two check assemblies Two gasket seals Two ring seals Four roller bearings Twelve pocket seals Torque wrench Item 12 Appendix I Socket wrench set Item 13 Appendix I Deep well socket 7 8 x 3 4 in drive Materials Parts General Safety Instructions Grease Item 11 Appendix F Use extreme caution when handling heavy parts a DISASSEMBLY WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment CAUTION Remove dirt from outside of hydraulic pump Perform repair in a clean work area to prevent contaminants from causing equipment failure NOTE Mark castings of pump to aid in assembly 1 Remove retaining ring 1 spacer 2 and seal retainer 3 from drive shaft 4 Discard retain ing ring 5 14 5 3805 264 14 amp P 5 5 HYDRAULIC PUMP REPAIR Con t 2 Secure hydraulic pump in vise and remove three screws
73. Forward to proponent of publication or form Include ZIP Code U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 FROM Activity and location Include ZIP Code PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER TM 5 3805 264 14 amp P DATE 30 December 2005 M917A2 w MCS TITLE M917A1 M917A1 w MCS M917A2 and ITEM NO PAGE NO PARA GRAPH LINE NO FIGURE NO TABLE NO RECOMMENDED CHANGES AND REASON Provide exact wording of recommended changes if possible Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS SIGNATURE EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V3 00 Change 1 TO Forward direct to addressee listed publication U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 FROM Activity and location Include ZIP Code DATE PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER 5 3805 264 14 amp P DATE 30 December 2005 TITLE M917A1 M917A1 w MCS M917A2 and M917A2 w MCS PAGE NO COLM LINE NATIONAL STOCK NO NO NUMBER REFEREN
74. GROUP 0613 HULL OR CHASSIS WIRING HARNESS FIG MCS GATE HARNESS AND MCS POWER HARNESS WIRING HARNESS BRAN UOC 7E1 7E2 CONNECTOR PLUG ELEC UOC 7E1 7E2 SPRING HELICAL COMP UOC 7E1 7E2 BOOT DUST AND MOIST UOC 7E1 7E2 CONNECTOR RECEPTACL UOC 7E1 7E2 BOOT DUST AND MOIST UOC 7E1 7E2 CONTACT ELECTRICAL UOC 7E1 7E2 CONNECTOR BODY PLUG UOC 7E1 7E2 SCREW CAP HEXAGON H UOC 7A1 7E1 7E2 WASHER FLAT UOC 7A1 7E1 7E2 NUT SELF LOCKING HE UOC 7A1 7E1 7E2 CABLE ASSEMBLY SPEC UOC 7A1 7E1 7E2 CONNECTOR RECEPTACL UOC 7A1 7E1 7E2 BOOT DUST AND MOIST UOC 7A1 7E1 7E2 CONNECTOR LOCKING UOC 7A1 7E1 7E2 BOOT VEHICULAR COMP UOC 7A1 7E1 7E2 TERMINAL QUICK DISC UOC 7A1 7E1 7E2 CONNECTOR PLUG ELEC UOC 7A1 7E1 7E2 NUT SELF LOCKING HE UOC 7A1 7E1 7E2 WASHER FLAT UOC 7A1 7E1 7E2 SCREW CAP HEXAGON UOC 7A1 7E1 7E2 END OF FIGURE 7 1 1 4 20X0 75 7 5 3805 264 14 amp P SECTION II Figure 8 Bodyup Transport Lock Harness and Material Control Chassis Harness SECTION II 1 NO FW 10 11 12 13 2 SMR CODE PAOZZ PAOZZ PAOZZ PAOZZ PFOOO XDOZZ PAOZZ MOOZZ PAOZZ PAOZZ XDOZZ PAOZZ PFOZZ 3 NSN 6150014466344 5975012268078 5999014229740 5935013088599 6150014669174 5940013400587 5325014468320 59990136412
75. IN 68PMT 6 4 ADAPTER STRAIGHT PI 403645 VALVE REGULATING FL PART OF KIT P N 404940 suede ded Fem hi E n 403650 se GASKET ai eque ei ska ie 403649 SOSBACER PLATE 2 4 e mme 403648 sSGASKETT etae UTE 403647 VALVE PILOT ASSY PART OF KIT P N 4049405 aS Sas Sec ore 403646 SCREW SOCKET HEAD 0 50 X 25 4MM 12015323 BOOT DUST AND 15 12124582 CONTACT ELECTRICAL 12010973 CONNECTOR BODY PLUG 030084 FILTER ELEMENT AIR 404938 ELBOW PIPE TO TUBE 1 2 NPT 403642 NUT JAM 5 8 18 5 403634 5 ROD END OS 019067 PIN STRAIGHT HEADED 1 2 X 1 11 32 IN INCLUDES SPRING PIN 1 8 X 2 1 4 END OF FIGURE 13 2 13 3 Blank C7 OTY oA SECTION II 5 3805 264 14 amp P 1 16 20 26 2 4 7 1 9 1 23 b7 29 21 22 23 25 Hog d ip od LL S puce Figure 14 Air Tank Lines and Fittings SECTION II 1 10 11 12 13 14 16 T7 18 19 20 21 22 23 24 2 SMR CODE PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PFOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ MOOZZ PAOZZ PAOZZ PAOZZ PAOZZ P
76. INSPECTION CORRECTIVE ACTION 3 MCS GATE WILL NOT OPERATE WITH REMOTE CONTROL Step 1 Check for air leaks throughout vehicle chassis air system Tighten or replace leaking or damaged air system components TM 9 2320 363 20 or TM 9 2320 302 20 Step 2 Check MCS tailgate for leaking or damaged air system components Tighten or replace leaking or damaged components paragraphs 4 55 thru 4 59 NOTE For assistance in troubleshooting an MCS electrical malfunction refer to wiring dia grams paragraph 4 49 Step 3 Check MCS fuse for continuity Replace damaged fuse TM 9 2320 363 20 or TM 9 2320 302 20 Step 4 Check MCS remote control switches for voltage and continuity Replace damaged switched paragraph 4 43 Replace damaged remote control Step 5 Check MCS remote control cable for voltage and continuity Replace damaged remote control cable paragraph 4 43 Step 6 Check truck to MCS tailgate wiring harness for voltage and continuity Repair or replace damaged truck to MCS tailgate wiring harness paragraph 4 47 Step 7 Check MCS tailgate wiring harness and MCS air cylinder solenoids for voltage and continu ity Repair or replace damaged MCS tailgate wiring harness paragraph 4 48 Replace damaged MCS air cylinder solenoids paragraph 4 57 4 MCS GATES OPEN OR CLOSE WHEN REMOTE CONTROL IS CONNECTED NOTE For assistance in troubleshooting an MCS electrical malfunction refer to wiring diagrams paragraph 4 49
77. Install valve 26 in valve body 5 Install gasket 24 and plastic insert 25 on end cap 22 Position end cap 22 on valve body 5 and install two screws 23 Install gasket 21 on valve body 5 Install gasket 19 on filter housing 12 Position metal gasket 20 and filter housing 12 on valve body 5 and install two screws 18 Apply pipe sealing compound to elbow 15 and install elbow on valve body 5 Install gasket 8 on filter housing 12 Install pin 11 in plunger 10 Position plunger 10 and spring 9 on solenoid 16 Position solenoid 16 on filter housing 12 and install two screws 17 Apply pipe sealing compound to fitting 14 and install fitting on elbow 15 Apply pipe sealing compound to fitting 13 and install fitting on valve body 5 336 026 4 85 TM 5 3805 264 14 amp P 4 57 MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 15 Apply pipe sealing compound to elbow 7 and install elbow on valve body 5 16 Install two filters 6 on valve body 5 6 336 025 e INSTALLATION 1 Install solenoid assembly 2 to air cylinder 4 2 Connect tube 1 to fitting 3 on solenoid assembly 2 2 d 4 336 024 FOLLOW ON TASKS Install MCS air cylinder paragraph 4 56 4 86 5 3805 264 14 amp P 4 58 TAILGATE RELEASE MCS AIR CYLINDER REPAIR This task covers a Disassembl
78. PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protec tive gloves and goggles is suggested Use in well ventilated area Keep away from open flame and other sources of ignition 1 Clean inner and outer surfaces with cleaning solvent Item Appendix F and dry with clean rags Item 16 Appendix 2 Remove grease and accumulated deposits with a scrub brush Item 3 Appendix F WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to personnel 3 Clear all threaded holes with compressed air to remove dirt and cleaning fluids CAUTION DO NOT wash oil seals electrical cables and flexible hoses with dry cleaning sol vent or mineral spirits Serious damage or destruction of material will result Seals Electrical Cables and Flexible Hoses Wash oil seals electrical cables and flexible hoses with a solution of detergent Item 9 Appendix and water and wipe dry with a clean rag Item 16 Appen dix F d General Cleaning Covered by Other Manuals Refer to TM 9 247 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including Chemicals 4 10 PRESERVATION OF PARTS
79. Paragraph Page Number Paragraph Title Number rol MP Maintenance Forms Records Destruction of Army Materiel to Prevent Enemy Preparation for Storage or Official Nomenclature Names Designations and Abbreviations Reporting Equipment Improvement Recommendations Warranty Information Safety Care and 0 Corrosion Prevention and Control 1 1 SCOPE NOTE e Refer to TM 9 2320 363 10 TM 9 2320 363 20 TM 9 2320 363 34 and TM 9 2320 363 24P for operation maintenance and repair parts and special tools list for the M917A1 and M917A1 w MCS chassis e Refer to TM 9 2320 302 10 TM 9 2320 302 20 TM 9 2320 302 34 and TM 9 2320 302 24P for operation maintenance and repair parts and special tools list for the M917A2 and M917A2 w MCS chassis a Type of Manual Operator s Unit Direct Support and General Support Maintenance Manual with Repair Parts and Special Tools Lists b Equipment Name and Model Number Truck Dump Heavy Body 6 x 6 14 Cu Yd On Off High way M917A1 M917A1 w MCS M917A2 and M917A2 w MCS C Purpose of Equipment Us
80. TM 5 3805 264 14 amp P 5 PART NUMBER 245542X31 264NTA 6 63NTA 6 60NTA 6 61NTA 6 245543 9 245540 17 245539 21 245541 8 245786 36 245787 38 216 4 403620 403621 401332 403381 6 7 DESCRIPTION AND USABLE CODES UOC TUBE NYLON 31 IN MAKE FROM BULK 2 PN NT10006 79470 UOC 7E1 7E2 IEEZDUBEIG 1249 43 fuu 3 UOC 7E1 7E2 INSERT TUBE 1 UOC 7A1 7E1 7E2 SLEEVE 5 1 UOC 7A1 7E1 7E2 TUBE COUPLING 1 UOC 7A1 7E1 7E2 TUBE NYLON 9 IN MAKE FROM BULK PN 2 710006 77 84 70 REIS UOC 7E1 7E2 TUBE NYLON 17 IN MAKE FROM BULK 1 2 110006 079470 2 UOC 7E1 7E2 TUBE NYLON 21 IN MAKE FROM BULK 1 PN NITOO06 794209205 x Ru RE UOC 7E1 7E2 TUBE NYLON 8 IN MAKE FROM BULK PN 1 N TI0006 79470 Imm UOC 7E1 7E2 TUBE NYLON 36 IN MAKE FROM BULK 1 NTT10006 79470 i2 lv TUBE NYLON 38 IN MAKE FROM BULK 1 BN 1210006 79470 2 ee NIPPLE PIPE 1 4 X 1 375 al UOC 7A1 7E1 QUICK COUPLING 1 UOC 7A1 7E1 7E2 QUICK COUPLING cis ss hoe 9 4 1 UOC 7A1 7E1 7E2 ADAPTER STRAIGHT PI MALE 3 8 X 1 4 1 UOC 7E1 7E2 BUSHING BLANK 1 2 1 4 2 END OF FIGURE 14 2 10 14 11 12 an E s TM
81. UOC 7E1 7E2 TANK PRESSURE totes ei alk mi eae aed aye UOC 7E1 7E2 PLUG PIPE UOC 7E1 7E2 COCK POPPET DRAIN UOC 7E1 7E2 WASHER FLAT UOC 7E1 7E2 NUT SELF LOCKING HE UOC 7E1 7E2 TUBE NYLON PN NT10006 UOC 7E1 7E2 ADAPTER STRAIGHT PI UOC 7E1 7E2 INSERT TUBE EITTING 9 ses wes UOC 7E1 7E2 SLEEVE COMPRESSION UOC 7E1 7E2 TUBE COUPDING UOC 7E1 7E2 ELBOW PIPE TO TUBE 2 7A1 7A2 OTYIT TEL TEZ UOC 7A1 7A2 7E1 7E2 INSERT TUBE FITTING SLEEVE COMPRESSION NUT TUBE 524 2 94 e Rn TUBE NYLON 144 IN MAKE FROM BULK PN NT10006 79470 UOC 7E1 7E2 3 8 16X1 00 S4 B 3 8 16 22200 66 IN MAKE FROM BULK 79470 7 PPP PR PRP SECTION II 1 ITEM NO 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 SMR CODE MOOZZ PAOZZ PAOZZ PAOZZ PAOZZ MOOZZ MOOZZ MOOZZ MOOZZ MOOZZ MOOZZ PAOZZ PAOZZ PAOZZ PFOZA PFOZZ 3 NSN 4730011343571 4730010564990 4730010485260 4730010487873 4730002778289 4730014739699 4730014739667 4730015189184 5365015182872 4 CAGEC 5X050 30780 93061 93061 93061 5X050 5X050 5X050 5X050 5X050 5X050 93061 5X050 5X050 5X050 5X050
82. Unit Maintenance of any leaks HYDRAULIC SYSTEM NOTE To prevent overfilling hydraulic reservoir DO NOT add hydraulic fluid when dump body is raised 6 DUMP BODY WILL NOT RAISE WHEN HYDRAULIC CONTROL LEVER IS PLACED IN UP POSITION Step 1 Check position of main light switch Place main light switch in SER DRIVE or STOP LIGHT position TM 9 2320 363 10 or TM 9 2320 302 10 Step 2 Check if PTO is engaged Engage PTO TM 9 2320 363 10 or TM 9 2320 302 10 3 6 5 3805 264 14 amp P Table 3 1 Operator Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3 Check the hydraulic oil level in sight tube on reservoir Add hydraulic oil if necessary Section I Step 4 Check position of dump body transport lock Place transport lock in UNLOCKED position paragraph 2 2 Step 5 Dump body still will not raise Notify Unit Maintenance 7 DUMP BODY RAISES AND LOWERS SLUGGISHLY Step 1 Check the hydraulic oil level in sight tube on reservoir Add hydraulic oil if necessary Section I Step 2 Check hydraulic oil filter service indicator gage Notify Unit Maintenance if gage is in the RED zone Step 3 Check hydraulic system for leaks Notify Unit Maintenance if a leak is present Step 4 Check for binding and inadequate lubrication at dump body hydraulic cylinder and stabilizer pivot points Lubricate pivot points Chapter 3 Section Step 5 Dump body still raises and lowers sluggi
83. Unpainted metal parts that will not be installed immediately after cleaning should be covered with a thin coat of lubricating Item 15 Appendix 4 11 PAINTING On painted areas where paint has been removed paint in accordance with procedures outlined in TM 43 0139 and TB 43 0209 4 5 TM 5 3805 264 14 amp P 4 12 INSPECTION INSTRUCTIONS NOTE All damaged areas should be marked for repair or replacement All components and parts must be carefully checked to determine if they are serviceable for use can be repaired or must be scrapped a b C tors d age e Inspect drilled and tapped threaded holes for the following 1 Wear distortion cracks and any other damage in or around holes 2 Threaded areas for wear distortion stretching and evidence of cross threading Inspect metal lines flexible lines or hoses and metal fittings and connectors for the following 1 Metal lines for sharp kinks cracks bad bends and dents 2 Flexible lines or hoses for fraying evidence of leakage and loose metal fittings or connec 3 Metal fittings and connectors for thread damage and worn or rounded hex heads Inspect castings forging and machined metal parts for the following 1 Machined surfaces for nicks burrs scoring grooves raised metal wear and other dam 2 Inner and outer surfaces for breaks and cracks Inspect bearings in accordance with TM 9 214 4 13 DISASSEMBL
84. a REMOVAL c Installation Materials Parts Fourteen locknuts Tools Test Equipment General mechanic s tool kit Item 8 Appendix Lifting slings three Item 6 Appendix Torque wrench Item 11 Suitable lifting device 1 At center of cab shield 1 remove six locknuts 9 12 washers 8 and six screws 7 Discard locknuts 2 Remove body props and lower dump body paragraph 2 15 4 96 5 3805 264 14 amp P 4 62 CAB SHIELD REPLACEMENT Con t WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 3 Attach lifting slings 2 to cab shield 1 and remove slack from lifting slings 4 Remove six locknuts 9 12 washers 8 and six screws 7 from outside edges of cab shield 1 and dump body 6 Discard locknuts 5 Remove two locknuts 5 four washers 4 and two screws 3 from top of cab shield 1 and dump body 6 Discard locknuts 6 Lift cab shield 1 from dump body 6 and place cab shield in a safe work area b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions INSTALLATION W
85. accordance with Chapter Section Gen eral Maintenance Instructions Install fill cap WARNING DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are discon nected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to per sonnel c Inspect all hydraulic lines fittings and components for signs of leaks Tighten any connections that are loose Ensure that hydraulic lines are supported Replace any dam aged component Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 6 Semi Body Props Inspect body props for binding or annual damage Replace if damaged para graph 4 61 WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel 7 Semi Hydraulic a Raise dump body and support with annual Reservoir body props paragraph 2 15 Fill Cap Vent WARNING 4 22 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 M917A2 w MCS Dump Truck Body Con t Item No Interval Location Item To Check Service Procedure Not Fully Mission Capable If 10 S
86. against flange clamp 43 8 Install transmission tunnel access cover 9 2320 363 20 or 9 2320 302 20 X lt 48 N 49 9 Install four screws 37 securing shift tower 1 4 132 to cab floor 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 10 Install spacer 33 hydraulic control lever cable 36 clamp 32 two screws 34 new lockwashers 30 and nuts 31 to bracket 35 11 Place hydraulic control lever in DOWN position paragraph 2 1 12 By hand push end of cable 36 in as far as it will go and install pivot pin 28 in same hole in bracket 27 as removed If this cannot be achieved perform step 14 13 Release hand pressure from cable 36 Force of hydraulic pump actuator will cause hydraulic control lever to N Neutral position 14 Loosen nut at pivot pin 28 and rotate pivot pin in desired direction Tighten nut 15 Repeat steps 12 thru 14 until pivot pin 28 can be installed in same hole in bracket 27 as removed with cable 36 pushed in all the way Install retaining pin 29 4 133 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 16 With transfer case selector lever in N Neutral position install pivot pin 18 in bracket 26 and secure with retaining pin 17 Remove tag from cable 25 17 Install spacer 20 cable 25 clamp 21 two screws 19 ne
87. and supported on body props paragraph 2 15 Hydraulic oil drained Chapter 3 Section 1 Tools Test Equipment General mechanic s tool kit Item 8 Appendix I Cap and plug set Item 1 Appendix 1 Nylon sling Item 6 Appendix 1 Adjustable wrench Item 10 Appendix 1 Torque wrench Item 11 Appendix 1 Suitable lifting device c Installation Materials Parts Rags Item 16 Appendix Antiseize ne eS T Four locknuts Four lockwashers Personnel Required Two General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY DO NOT disconnect hydraulic lines while engine is running Use extreme caution when handling heavy parts WARNING e NEVER work under a raised dump body unless it is secured in the raised posi tion with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel e DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel a REMOVAL CAUTION Hoses and ports in hydraulic components should be plugged to prevent contamina tion of hydraulic system paragraph 4 21
88. b INSTALLATION WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 1 Attach slings to cylinder support frame 2 and attach slings to lifting device Take up slack in slings with lift Lift cylinder support frame 2 and position on vehicle chassis 5 Install right angle bracket 6 and left angle bracket 3 to vehicle chassis 5 and cylinder support frame 2 with 24 screws 1 and new locknuts 4 4 Torque locknuts 4 to 200 Ib ft 271 FOLLOW ON TASKS 5 8 e Install hydraulic cylinder paragraph 5 6 e Install hydraulic reservoir paragraph 4 75 Install body up switch paragraph 4 38 5 3805 264 14 amp P Section Il DUMP BODY ACCESSORY ITEMS MAINTENANCE 5 3 CARGO COVER REPAIR Repair cargo cover in accordance with FM 10 16 General Fabric Repair 5 3805 264 14 amp P Section HYDRAULIC SYSTEM MAINTENANCE Paragraph Page Number Paragraph Title Number Hydraulic Pump Replacement 5 10 5 5 Hydraulic Pump ERR ERR RR 5 6 Hydraulic Cylinder Replacement 5 20 Hydraulic Cyli
89. body is Failure to follow this warning may result in death or injury to personnel a REMOVAL NOTE e Wires should be tagged before disconnecting paragraph 4 17 e Note location of tie wraps and routing of wiring harness prior to removal to aid in installation 1 At beacon warning light disconnect two wiring harness connectors from beacon warning light connectors 4 49 5 3805 264 14 amp P 4 45 BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE Con t Remove wiring harness 3 from cab shield grommet 1 Remove locknuts 4 and clamps 5 securing wiring harness 3 to welded studs 6 on cab shield 2 and dump body 9 Discard locknuts 4 Remove wiring harness 3 from grommet 7 at front right side of dump body 9 5 Repeat step 3 to release wiring harness 3 from welded studs on inner surface of right side dump body frame rail 8 Discard locknuts 6 Disconnect wiring harness connector 11 from chassis wiring harness connector 10 7 Remove wiring harness 3 4 50 5 3805 264 14 amp P 4 45 BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE Con t b REPAIR NOTE Wiring harness need not be removed from vehicle to make repairs Repair wiring harness in accordance with instructions in Chapter 4 Section 111 General Maintenance Instructions c INSTALLATION Position wiring harness 3 between points of connection
90. brackets from hydraulic cylinder pivots 14 Discard locknuts 5 Disengage PTO TM 9 2320 363 10 or TM 9 2320 302 10 Lower hydraulic cylinder 9 by placing hydraulic control lever in cab in DOWN position paragraph 241 With hydraulic cylin der lowered place wooden blocks between base of cylinder and cylinder support frame 13 to provide support 5 3805 264 14 amp P 5 1 DUMP BODY AND STABILIZER REPLACEMENT Con t Using suitable lift and chains lower front of dump body 4 Attach suitable lift and chains at four corners of dump body 4 Take up slack in chains with lift Remove two locknuts 18 and screws 17 from rear hinge 15 and hinge pins 19 Discard locknuts Remove left and right hinge pins 19 from rear hinge 15 WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment NOTE Before removing dump body from vehicle chassis perform a trial lift to ensure body is balanced and will lift straight and level from vehicle chassis 10 Remove dump body 4 from vehicle chassis 7 Place dump body on suitable supports and remove lifting device and chains WARNING Provide adeq
91. by Unit Maintenance annually The Lubrication Chart shows lubrication points items to be lubricated the required lubricants and recommended intervals for lubrication Any special lubrication instructions required for specific compo nents are contained in the NOTES section of the chart d The KEY provides information needed to select the proper lubricant for various temperature ranges and uses and identifies the capacities and intervals e Recommended intervals are based on normal conditions of operation temperature and humid ity When operating under extreme conditions lubricants should always be changed more frequently When in doubt notify your supervisor J 2 SPECIFIC LUBRICATION INSTRUCTIONS a Keep all lubricants in a closed container and store in a clean dry place away from extreme heat Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep lubrication equipment clean and ready for use b Maintain a record of lubrication performed and report any problems noted during lubrication Refer to DA Pam 738 750 for maintenance forms and procedures to record and report any findings C Keep all external parts of equipment not requiring lubrication free of lubricants After lubrication wipe off excess lubricant to prevent accumulation of foreign matter d Refer to FM 9 207 for lubrication instructions in cold weather J 1 5 3805 264 14 amp P LUBRI
92. components in accordance witl Chapter 4 Section General Maintenance Instructions c INSTALLATION 1 Install left mounting bracket 15 on roll up bar 14 Position roll up bar on dump body and through right mounting bracket 21 2 Install three screws 18 new lockwashers 17 and nuts 16 to left mounting bracket 15 and dump body 3 Loosen set screw 19 at each end of roll up bar 14 and center bar between left and right mounting brack ets 15 and 21 Tighten set screws 4 Install sprocket alinement key 12 and sprocket 20 on roll up bar 14 Tighten set screw 13 4 111 TM 5 3805 264 14 amp P 4 67 CARGO COVER SUPPORT FRAME AND ROLL UP BAR REPLACEMENT Con t 5 Install spring assembly 7 on dump body and through welded shaft support bar and tube 1 with two screws 8 new lockwashers 9 and nuts 10 6 Connect swing arm 5 and connecting arm 3 with eyebolt 4 and nut 2 Install swing arm 5 on spring assembly shaft 6 Install new spring pin 11 through shaft 8 Install one end of rubber strap on connecting arm 3 eyebolt and opposite end on swing arm 5 eyebolt 336 013 FOLLOW ON TASKS Install cargo cover chain Install cargo cover paragraph 4 64 e Check operation of cargo cover paragraph 2 14 Fully retract cargo cover paragraph 2 14 4 112 5 3805 264 14 amp P 4 68 REFLECTOR REPLACEMENT This
93. disassembly tools equally spaced between bottom retain ing ring and sleeve NOTE Hydraulic cylinder disassembly tools will fall free as sleeve with bottom retaining ring is removed from larger sleeve 17 Remove sleeve 3 from sleeve 14 Remove bottom retaining ring 20 from sleeve 3 18 Remove wear ring 21 piston ring 22 and two piston rings 23 from other end of sleeve 3 Discard wear ring NOTE Perform steps 19 thru 26 to remove next sleeve 24 19 Remove retaining ring 24 from barrel 25 25 5 28 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t NOTE Wiper retainer and seal should come out as sleeve is extended a few inches If not apply a three inch strip of tape at a 45 degree angle to a cleaned section of sleeve Retract and again extend sleeve to remove wiper retainer and seal 20 Extend sleeve 14 to expose wiper retainer 27 and seal 28 Remove wiper retainer and seal from sleeve Remove wiper 26 from wiper retainer Discard wiper wiper retainer and seal Remove tape from sleeve if used 21 Retract sleeve 14 Remove spiral retaining ring 29 from barrel 25 Discard spiral retain ing ring 22 Extend sleeve 14 a few inches and apply tape to a cleaned section of sleeve 23 Retract and extend sleeve 14 to expose bot tom guide ring 30 Remove and discard bot tom guide ring 5 29 5 3805 264 14 amp P 5 7 HYDR
94. dump body is to be loaded using a hopper check clearance before pulling under hopper Position dump truck with hopper above center of dump body 2 27 5 3805 264 14 amp P 2 7 PREPARING TO LOAD DUMP BODY Con t WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment Dump body side boards weigh approximately 65 Ib 30 kg each Two personnel are required to install or remove side boards Failure to follow this warning may cause injury to personnel NOTE Dump truck operator should get assistance from loading vehicle operator to remove dump body side boards 3 Remove dump body side boards if necessary WARNING Ensure that parking brake is set before loading dump truck TM 9 2320 363 10 or TM 9 2320 302 10 If parking brake is not set dump truck could roll or shift position Failure to follow this warning may result in death or injury to personnel or damage to equipment Set parking brake 9 2320 363 10 9 2320 302 10 f Disengage PTO if engaged TM 9 2320 363 10 or TM 9 2320 302 10 2 8 LOADING DUMP BODY 2 28 WARNING Stand clear of dump body during loading operation Material being l
95. in place Keep all clothing away from moving parts DO NOT cover load with crank handle installed DO NOT use cargo cover frame as a grabhandle Failure to follow this warning may result in death or injury to personnel CAUTION DO NOT attempt to uncover load without first removing any snow or water that has accumulated on cargo cover Cargo cover may be damaged if this caution is not fol lowed Uncovering Load 1 Unfasten rubber strap 1 from dump body weldment 2 and fasten to eyebolt 3 336 006 5 3805 264 14 amp P 2 14 OPERATING CARGO COVER Con t 2 Remove crank handle 4 from storage pouch box 3 Install crank handle 4 on crank shaft 5 Turn handle clockwise to roll up cargo cover Stop at any time and mechanism will hold cover in place 4 Stop cranking when cargo cover is completely rolled up 5 Remove crank handle 4 and stow 336 007 b Covering Load WARNING DO NOT cover load with crank handle installed Failure to follow this warning may result in injury to personnel 1 Ensure that crank handle 4 is NOT installed 2 Quickly move cargo cover control handle 6 to farthest down BRAKE position CAUTION DO NOT let go of cargo cover control handle until cargo cover is fully over load Handle provides braking action for cargo cover swing If you let go of handle before
96. ing leaks or damaged components c Remove body props and lower dump body paragraph 2 15 N m m 31 2 22 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel 18 Monthly Body Props Raise dump body and support on a Body props are damaged or body props paragraph 2 15 b Apply grease Item 11 Appendix to grease fitting 32 on each body prop 14 cannot be installed to safely support dump body 2 23 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 19 Monthly Stabilizer Apply grease Item 11 Appendix H to five grease fittings 33 on stabilizer 34 There are two grease fittings at top and bottom crosses and one grease fitting at center hinge 20 Monthly Tran
97. of water to clean dump body Failure to follow this warning may result in injury to personnel 2 Use a high pressure stream of water to clean the interior and outer sides 3 Use a stiff broom or brush and detergent Item 9 Appendix F to remove remaining dirt from interior and outer sides 4 Raise dump body and support it with body props paragraph 2 18 Rinse inside of box Clean underside of dump body with a high pressure stream of water 5 Use stiff broom or brush and detergent Item 9 Appendix F to remove remaining dirt from underside of dump body 6 Leave dump body raised until it is thoroughly dry 7 When dry lower dump body Close and secure tailgate b Cargo cover may be cleaned as required using a high pressure stream of water 3 9 3 10 Blank TM 5 3805 264 14 amp P CHAPTER 4 UNIT MAINTENANCE Section l REPAIR PARTS SPECIAL TOOLS TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT TMDE AND SUPPORT EQUIPMENT Paragraph Page Number Paragraph Title Number 4 1 Common Tools and Equipment 4 1 4 2 Special Tools TMDE and Support 4 1 4 3 Repair Parts dea b cee EE ERA Aq XR RE RU A deal ey 4 1 4 1 COMMON TOOLS AND EQUIPMENT For authorized common tools and equipment refer to Appendix Tool Identification List and to the Mod ified Table of Organization and Equipment MTOE
98. per Gallon Kilometers per Liter 0 425 Kilometers per Liter Miles per Gallon 2 354 Miles per Hour Kilometers per Hour 1 609 Kilometers per Hour Miles per Hour 0 621 076098 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
99. shift tower 1 rigid reinstall two top and two bottom screws 2 on front and rear of shift tower 1 4 Disconnect six connectors 4 from shift tower jumper harness connectors 4 118 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t NOTE To ease installation note mounting position of cable pivot pins and hold down clamps prior to disconnecting cables 5 Place transmission selector lever in D Drive position TM 9 2320 363 10 or TM 9 2320 302 10 6 Tag transmission shift cable 7 T Remove two nuts 12 lockwashers 11 screws 8 clamp 10 and spacer 9 from bracket 13 Discard lockwashers 8 Remove retaining pin 5 from pivot pin 6 and pivot pin from bracket 14 4 119 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t 9 Place transfer case selector lever in N Neutral position TM 9 2320 363 10 or TM 9 2320 302 10 10 Tag transfer case shift cable 17 11 Remove two nuts 22 lockwashers 21 screws 18 clamp 20 and spacer 19 from bracket 23 Dis card lockwashers 12 Remove retaining pin 15 from pivot pin 16 and pivot pin from bracket 24 4 120 5 3805 264 14 amp P 4 72 HYDRAULIC CONTROL LEVER REPLACEMENT Con t 13 Place hydraulic control lever in DOWN position paragraph 2 1
100. should be even with FULL mark on oil level decal 20 If level is low remove fill cap 19 Remove any debris from strainer with a clean rag Add oil Item 13 or 14 Appendix through fill cap opening until level is even with FULL mark on decal Install fill cap Chapter 3 Section 1 Table 2 1 Operator Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 12 After Tailgate Con t Release 6 ads Lever A 225 DANGER M917A2 Panel Shown WARNING To prevent burns use caution when removing fill cap of hydraulic reser voir when hydraulic fluid is hot Avoid contact with hot hydraulic oil Use extreme care when filling hydraulic reservoir Failure to follow this warn ing may result in injury to personnel 13 After Hydraulic a With engine off and dump body low Reservoir ered check sight tube 18 to deter 2 16 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 13 After Hydraulic Run engine at idle speed and engage Con t Reservoir TM 9 2320 363 10 or 9
101. should be parked on level ground with parking brake set 2 Transmission must be in N Neutral 3 Engine must be off and unless otherwise indicated cool 4 Components must be at operating temperature to be tested Immediately clean up spilled fluids to avoid slipping d When lifting heavy parts have someone help you Ensure that lifting equipment or jack is working properly that it meets weight requirement of part being lifted and that it is securely fastened to part Always use power tools carefully 4 9 CLEANING INSTRUCTIONS WARNING Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment To prevent this refer to TM 9 247 for further instructions a General Cleaning instructions will be the same for the majority of parts and components which make up the equipment The following applies to all cleaning operations 1 Clean all parts before inspection after repair and before assembly 2 Keep hands free of grease which can collect dust dirt and grit 3 After cleaning all parts should be covered or wrapped to protect them from dust and dirt Parts that are subject to rust should be lightly oiled after cleaning paragraph 4 10 4 4 5 3805 264 14 amp P 4 9 CLEANING INSTRUCTIONS Con t b Castings Forgings and Machined Metal Parts WARNING Dry cleaning solvent MIL
102. slot 2 of chain latch 1 NOTE Adjustment must be made equally on both sides of tailgate b Lengthen or shorten chain length by pulling links through chain latch 1 Secure adjustment by sliding chain into slot 2 2 36 5 3805 264 14 amp P 2 12 ADJUSTING MCS GATE OPENINGS M917A1 W MCS AND M917A2 W MCS WARNING e Use extreme caution when adjusting MCS gate openings NEVER adjust gate openings when gates are open Failure to follow this warning could result in injury to personnel e Keep hands and feet away from gate openings at all times Failure to follow this warning could result in injury to personnel NOTE Adjust MCS gate openings with engine on and MCS air system pressurized a When dump truck is transporting a load or when it is parked MCS gates must be kept locked Gates are locked by placing locking pins 2 in top hole in adjustment tubes 1 b In preparation for controlled spreading with dump body down and MCS gates closed remove locking pins 2 from top hole in adjustment tubes 1 CAUTION Outer right and outer left side adjustment tube locking pins must be installed with pin heads to outside If incorrectly installed end of pins will protrude and become bent NOTE To achieve desired spreading pattern each gate opening can be adjusted individu ally Install locking pin 2 desired hole adjustment tube 1 The lowe
103. the cab is dumping the load When plugged in the remote control overrides the control unit inside the cab e The MCS tailgate can also operate as a conventional tailgate opening from the bot tom 5 3805 264 14 amp P 1 17 HYDRAULIC SYSTEM a The hydraulic system powers the hydraulic cylinder which raises and lowers the dump body b Major components of the hydraulic system are 1 Hydraulic Pump a The gear pump is mounted directly to the vehicle PTO It supplies the system with a working pressure of 2500 psi 17 238 kPa with approximately 1200 rpm input speed from the PTO b There is one port at the rear of the pump It is connected to the bottom of the reservoir and receives through a suction hose hydraulic fluid from the reservoir 2 Control Valve a The control valve is an integral part of the hydraulic pump It is a single spool type with the control spool linked mechanically to the hydraulic control lever in the cab b When the hydraulic control lever is pulled back the control valve routes hydraulic fluid through port B to the hydraulic cylinder This extends the cylinder and raises the dump body c When the hydraulic control lever is pushed forward the control valve routes hydraulic fluid through port A to the hydraulic cylinder This retracts the hydraulic cylinder and lowers the dump body d A third control valve port returns hydraulic fluid through the filter and into the reservoir
104. the inside back cover An alphabetical index is provided at the end of the manual to assist locating information not readily found in the Table of Contents Numbers located at lower right corner of art e g 336 003 371 029 etc are art control numbers and are used for tracking purposes Disregard these numbers FOLLOW THESE GUIDELINES WHEN YOU USE THIS MANUAL Read through this manual and become familiar with its contents before attempting to operate or maintain the dump truck body warning summary is provided at the beginning of this manual should be read before attempting to operate or maintain the dump truck body Within chapter or section headings are used to help group the material to assist in quickly find ing tasks Read all preliminary information found at the beginning of each task After completing a task ALWAYS perform the follow on maintenance at the end of the task 1 5 3805 264 14 amp P Material Control System MCS Tailgate Beacon Cab Warning Light Shield Cargo Cover Controls Side Board Tailgate Dump 336 002 Body M917A1 M917A2 Cargo gt g Cover orem 7 A Stabilizer Hydraulic Reservoir n ANE p Hydraulic e Cylinder Tool Body Storage Box Prop 336 029 M917A1 W MCS M917A2 W MCS 1 0 5 3805 264 14 amp P 1 INTRODUCTION Section l GENERAL INFORMATION
105. while dumping If dump body leans or shifts to one side lower it immediately and check for one of the following underinflated or flat tires tires sinking in soft soil e load shifting to one side of body high or gusty wind e weak or broken leaf spring If one of these or any other problems are found do not continue dumping until the problem is corrected Failure to follow this warning may result in death or injury to personnel or damage to equipment DO NOT try to loosen a sticky load by pulling forward or backward and braking abruptly Injury to personnel or damage to equipment may result WARNING HAZARDOUS WASTE DISPOSAL When servicing this vehicle performing maintenance or disposing of materials such as engine coolant transmis sion fluid lubricants battery acids or batteries and CARC paint consult your Unit Local Hazardous Waste Dis posal Center or safety office for local regulatory guidance If further information is needed please contact the Army Environmental Hotline at 1 800 872 3845 WARNING HEAVY COMPONENTS Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condi tion and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment e Dump body side boards weigh approximately 65 Ib 30 kg ea
106. 0 01 445 9897 17 4 5X050 402038 24 5X050 403236 3040 01 446 3620 22 5X050 403246 2590 01 446 1903 23 13 5X050 403248 6150 01 497 4879 7 12 5X050 403254 6150 01 446 6345 6 5X050 403255 6150 01 445 9130 4 5X050 403256 6150 01 446 6344 8 5X050 403345X148 75 11 20 5X050 403365 2940 01 446 3570 23 5 050 403366 4330 01 446 3337 20 5 050 403367 6685 01 447 1188 23 10 5 050 403368 23 12 5 050 403374 7690 01 445 9903 17 2 5 050 403375 7690 01 445 8976 17 I 11 SECTION IV CAGEC 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 5X050 TM 5 3805 264 14 amp P CROSS R PART PART NUMBER 036 10364 10364 10364 10364 103650 103677 103678 104927 104928 103376 103377 103378 103381 103412 103456 103457 103458 103459 103484 103492 103514 103541 103607 103620 103621 103626 103627 103628 103629 103630 103631 103632 103633 103634 103635 103636 103637 103638 103639 10364 10364 10364 10364 10364 0 1 2 3 4 5 6 7 8 9 NUMBER INDEX EFERENCE INDEXES NSN 7690 01 4 7690 01 4 7690 01 4 145 8973 145 9933 145 8967 5365 01 518 2872 6150 01 4 4720 01 4 4720 01 4 4720 01 4 4720 01 4 6150
107. 0 Type III is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protective gloves and goggles is suggested Use in well ven tilated area Keep away from open flame and other sources of ignition Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment To prevent this refer to TM 9 247 for further instructions WARNING COMPRESSED AIR Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to personnel WARNING DUMP BODY OPERATION Hearing protection is required when performing loading or dumping operations Failure to follow this warning may result in injury to personnel Ensure that parking brake is set before loading dump truck TM 9 2320 363 10 or TM 9 2320 302 10 If park ing brake is not set dump truck could roll or shift position Failure to follow this warning may result in death or injury to personnel or damage to equipment Stand clear of dump body during loading operation Material being loaded could fall on personnel standing too close Failure to follow this warning may result in death or injury to personnel NEVER unlock tailgate or operate MCS tailgate or gates or operate hydraulic con
108. 01 446 8320 8 9 5340 01 474 6462 15 4820 01 446 8874 19 3 5220 01 474 8432 13 5305 01 446 8972 15 25 3130 01 474 9064 15 5315 01 446 9174 13 44 5340 01 474 9576 15 5315 01 446 9177 13 1 5365 01 475 2277 13 5325 01 446 9182 22 14 5342 01 475 2802 15 5325 01 446 9204 22 14 5310 01 481 4919 13 5325 01 446 9210 22 14 5330 01 482 8766 13 5315 01 447 0479 11 8 5340 01 492 7615 15 5315 01 447 0480 10 1 3040 01 497 0345 12 5315 01 447 0481 11 9 5930 01 497 0704 1 2590 01 447 0748 23 1 6150 01 497 4879 7 5330 01 447 1113 22 2 6150 01 497 4886 7 6685 01 447 1188 23 10 6150 01 497 5582 1 5305 01 447 1330 18 17 4710 01 497 5644 12 3040 01 447 2738 13 3 5340 01 497 8124 12 5331 01 447 3098 23 7 3040 01 498 1885 KITS 5331 01 447 4034 23 4 3040 01 498 1887 5 5331 01 447 4040 23 6 9905 01 498 7857 1 5315 01 447 5712 15 24 9905 01 498 7858 1 5315 01 448 8804 15 38 9905 01 498 7859 1 7690 01 449 1447 17 11 9905 01 498 7860 1 7690 01 449 1470 17 10 9905 01 498 8178 17 5340 01 449 5470 9 11 5925 01 499 3416 iu 5342 01 449 5475 15 8 5310 01 502 2940 153 2540 01 449 5775 15 13 5325 01 502 5209 13 9905 01 449 9632 17 9 5315 01 507 0537 12 4320 01 451 0045 18 1 5930 01 507 6990 1 3040 01 459 5141 1 1 3040 01 515 7916 123 5940 01 462 1717 6 6 5935 01 518 0417 8 5940 01 462 1718 4 Il 5365 01 518 2872 14 2530 01 464 9916 7 16 5935 01 518 3690 3 SECTION IV TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX
109. 040014464665 02249 B12071 0500 RING PESTON 5 INCH 5 3s 2 4 22 3040014466277 02249 12071 0400 RING PISTON 4 INCH 1 4 22 3040014466274 02249 12071 0300 RING PESTON 3 2 1 5 PAFZZ 3040014466280 02249 0263914 sRING PISTON 3 5 2 225522 4 1 5 XDFZZ 02249 0263984 RING BISTON 4 5 2 52 2 6 XDFZZ 02249 002 55074 04844 BARREL ASSEMBLY T 7 XDFZZ 02249 062 50049 04752 SLEEVE ASSY 5 INCH 1 8 XDFZZ 02249 062 40044 04689 SLEEVE ASSY 4 INCH 1 9 PAFZZ 5365013403898 01276 900598 125 PLUG MACHINE THREAD 1 1 16 12 1 WITH O RING shad 10 XDFZZ 02249 063 30135 04992 PLUNGER ASSY 3 INCH 1 11 PAFZZ 5365012174133 01276 900598 8S PLUG MACHINE THREAD 3 4 16 WITH 1 OF RING we 25223 56 ae eS 12 PAFZZ 5365014464322 02249 035 17002 00225 5 3 13 PAFZZ 5325014464051 02249 083 10005 00562 RING RETAINING 5 INCH 1 13 PAFZZ 5325014464052 02249 083 50003 00462 RING RETAINING 4 INCH 1 13 PAFZZ 5325014464053 02249 083 50003 00362 RING RETAINING 3 INCH 1 14 22 5325014469182 02249 9971 00550 RING RETAINING 5 INCH 1 14 PAFZZ 5325014469204 02249 083 50002 00450 RING RETAINING 4 INCH T 14 PAFZZ 5325014469210 02249 083 50002 00350 RING RETAINING 3 INCH
110. 05 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT This task covers a Removal Initial Setup Equipment Conditions Wheels blocked TM 9 2320 363 10 or TM 9 2320 302 10 CTIS electronic control unit ECU removed 9 2320 363 20 or TM 9 2320 302 20 e MCS control unit removed M917A1 w MCS paragraph 4 42 Tools Test Equipment General mechanic s tool kit Item 8 b Installation Materials Parts Marker tags Item 20 Appendix F One cotter pin Eight lockwashers References TM 9 2320 363 10 TM 9 2320 302 10 TM 9 2320 363 20 TM 9 2320 302 20 NOTE Although slighty different in shape M917A1 and M917A2 shift towers are similar M917A1 shift tower is shown Perform only those steps that apply to your model a REMOVAL 1 Remove six screws 2 and rear access panel 3 from shift tower 1 2 Repeat step 1 to remove front access panel from shift tower 3 To keep shift tower rigid reinstall two top and two bottom screws 2 on front and rear of shift tower 1 4 127 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 16 15 4 128 Tag and disconnect shift tower jumper harness power and ground connectors 13 from cab harness power and ground connectors 12 Remove grommet 11 and cab harness power and ground connectors 12 from shift tower 1 NOTE To ease
111. 050 239974 12 5 64678 24 00783 000 2 5X050 245352 11 16 5X050 245538 66 14 15 5 050 245539 21 14 32 5 050 245540 17 14 31 5X050 245541 8 14 33 5X050 245542 31 14 25 5 050 245543 9 14 30 5X050 245544 144 14 24 5X050 245786 36 14 34 SECTION IV TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX CAGEC PART NUMBER NSN FIG ITEM 5X050 245787X38 14 35 60827 246 70 5331 01 447 4040 23 60827 251 70 BN 5331 01 447 4034 23 4 38335 25316 5330 01 212 2222 18 30780 264NTA 6 4730 01 134 3571 14 26 70485 2872 5325 00 174 9341 8 12 13829 308 5030 201 18 6 13829 308 8020 901 18 14 13829 308 9310 156 4320 01 451 0045 18 1 13829 308 9414 024 18 15 13829 312 2920 130 3040 01 446 2408 18 12 79146 320001 14 6 99321 3507 5310 00 347 0021 2 5 50620 38 22LP 5315 01 507 0537 12 14 13829 391 1401 382 5305 01 447 1330 18 1 7 13829 391 1425 437 5307 01 446 7531 18 19 13829 391 1451 115 5310 01 340 8088 18 18 13829 391 2882 051 5330 00 809 1052 18 10 82338 391 2883 119 5330 01 236 0469 18 5 13829 391 2884 019 5330 01 340 8159 18 13 13829 391 3283 052 5365 01 446 0280 18 20 13829 391 3381 040 5365 01 236 0717 18 4 13829 391 3383 069 5365 01 361 4609 18 13829 391 3782 146 5310 01 340 8353 18 16 13829 391 0381 906 3110 01 260 2561 18 13829 391 2185 913 3120 01 328 4294 18 11 5 050 400121 24 5 5X050 401288 23 19 5X050 401332 4730 01 518 9184 14 39 5X050 401540 21 15 5X050 401577 769
112. 050 403637 SEAL PLAIN PART OF KIT P N 404939 2 22 KFOZZ 5X050 403629 BEARING PISTON ROD PART OF KIT P N 1 4049365 seat A Es 23 XDOZZ 5X050 403635 ARM WINDSHIELD WIPE PART OF KIT P N 1 404939 Se A Se 24 XDOZZ 5X050 404927 WASHER FLAT SPECIAL 1 130 ID X 1 1 750 OD X 064 25 PFOZZ 5325015025209 5X050 404928 RING RETAINING 1 942 OD X 062 1 INTERNAL 2458 26 XDOZZ 5X050 404930 NUT PLAIN BARREL 1 2 200 4 13 1 SECTION II 1 ITEM NO 27 28 29 30 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 SMR CODE PFOZZ PAOZZ PAOZZ XDOZZ PAOZZ KFOOO PAOZA PAOZZ PAOZA KFOZZ XDOZZ PAOZZ PAOZA PAOZZ XDOZZ XDOZZ XDOZZ XDOZZ PAOZZ 3 NSN 5310015022940 4730013456065 4730001377875 4730014551068 5330014742447 5365014752277 5330014732903 5975013105011 5999014064110 5935012144163 5315014469174 CAGEC 5X050 93061 30780 79146 93061 5X050 5X050 5X050 5X050 5X050 5X050 77060 77060 22785 79146 93061 5X050 5X050 79146 TM 5 3805 264 14 amp P 5 6 PART NUMBER DESCRIPTION AND USABLE ON CODES UOC 404931 WASHER HOCK VS209P 8 4 BUSHING PIPE 1 2 14 X 1 4 18 NPTF 1 FOR CYLINDER PN 131341 2 FOR CYLINDER PN 403607 2101 4 4C BBBOW PIPE 0 25 IN me 012037 ADAPTER STRAIGHT PI 3 8 1 4
113. 062 40044 04689 22 8 02249 062 50049 04752 22 7 02249 063 30135 04992 22 10 SECTION IV CAGEC 5B752 5B752 5B752 5B752 5B752 5B752 5B752 5B752 11862 5B752 02249 02249 02249 02249 02249 5B752 5B752 5B752 5B752 5B752 30780 13548 13548 77326 77326 77326 77326 5X050 45152 5X050 77060 77060 77060 22785 77060 77060 TM 5 3805 264 14 amp P CROSS R PART NUMBER 0710 602155 0715 619601 0715 619602 0715 619800 0720 603557 0750 619592 0750 619594 0765 618830 0815 660451 0825 670460 083 10005 00562 083 50002 00350 083 50002 00450 083 50003 00362 083 50003 00462 0835 691616 0840 618512 0840 618513 0920 590324 0920 590325 1 1 2 CDS 10004R 10250R 11 700 11 720 11 761 11 763 110543 114356A 117122 1201 0300 1201 5797 12010293 12010973 12015199 12015323 EFER ENCE INDEXES PART NUMBER INDEX NSN 3130 01 474 9064 5360 01 446 7903 5360 01 446 3190 5360 01 446 4054 3020 01 446 6412 3020 01 446 6405 3020 01 446 6409 5340 01 445 7778 5305 01 446 8972 5325 01 446 4051 5325 01 446 9210 5325 01 446 9204 5325 01 446 4053 5325 01 446 4052 5315 01 447 5712 5315 01 446 6724 5315 01 448 8804 7690 01 449 1470 7690 01 449 1447 4730 01 028 5540 6220 01 095 0011 6240 01 518 6843 5935 00 856 3513 5935 00 153 4397 5975 01 355 6985 5310 00 061 4650 5315 01 447 0481 5935 01 339 9574 5935 01 308 8599 5975 01 226 8078 5935 01 214 4163
114. 10 TM 5 3805 264 14 amp P 5 4 HYDRAULIC PUMP REPLACEMENT Con t WN e Hoses should be tagged before remova paragraph 4 17 A suitable container should be used to catch any draining hydraulic fluid Ensure that all spills are cleaned up Loosen clamp 11 and disconnect suction hose 12 from adapter 13 Remove adapter 13 from hydraulic pump 5 Disconnect hose 19 from adapter 20 Disconnect hose 18 from adapter 17 Remove adapters 17 and 20 from control valve 4 Disconnect hose 15 from elbow 16 Remove elbow 16 from control valve 4 Remove nut 9 and washer 8 from stud 6 of hydraulic pump 5 Remove two screws 10 and support bracket 7 from transmission housing 14 WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment Remove four nuts 3 lockwashers 2 screws 1 and hydraulic pump 5 from PTO 21 Discard lock washers TM 5 3805 264 14 amp P 5 4 HYDRAULIC PUMP REPLACEMENT Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc
115. 11 2 Install adapter 8 to air reservoir 11 3 Install reducer 9 elbow 7 check valve 6 bushing 5 and adapter 3 to air reservoir 11 4 Install air reservoir 11 to welded brackets 1 with four screws 10 flatwashers 15 and new locknuts 14 5 Connect air hose 4 to adapter 8 6 Connect air supply hose 2 to adapter 3 s Ti T AX 9 e ae 14 COSS 5 FOLLOW ON TASKS Start engine and pressurize air systems TM 9 2320 363 10 or TM 9 2320 302 10 e Check for leaks e Check operation of MCS tailgate paragraph 2 13 Install MCS tailgate cover paragraph 4 53 4 78 5 3805 264 14 amp P 4 56 MCS AIR CYLINDER REPLACEMENT M917A1 W MCS AND 917 2 W MCS This task covers a Removal c Installation b Cleaning and Inspection Initial Setup Equipment Conditions Materials Parts Chassis air system drained TM 9 2320 363 10 Item 19 or TM 9 2320 302 10 le wraps Item 19 Appendix F MCS air system drained Chapter 2 Section ll Personnel Required Two Operator PMCS e MCS tailgate cover removed paragraph 4 53 General Safety Instructions Tools Test Equipment DO NOT disconnect air lines while air system is General mechanic s tool kit Item 8 Appendix pressurized a REMOVAL WARNING DO NOT disconnect air lines while
116. 11 General Maintenance Instructions c INSTALLATION 1 Position wiring harness 7 on MCS tailgate 6 between points of connection 2 On each side of MCS tailgate 6 position wiring harness receptacle 10 on tailgate weldment 11 and secure with two screws 9 and new self locking nuts 8 4 60 5 3805 264 14 amp P 4 48 MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 3 Connect wiring harness connector 4 to each air cylinder solenoid connector 5 4 Connect wiring harness connector 3 to truck to MCS tailgate wiring harness receptacle 2 at left dump body pillar 1 5 Install new tie wraps FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 917 1 and M917A1 w MCS Start vehicle and pressurize air system TM 9 2320 363 10 TM 9 2320 302 10 e Check operation of MCS tailgate using cab mounted MCS control unit and remote control and 2 2 e Install MCS tailgate cover paragraph 4 53 4 61 5 3805 264 14 amp P WIRING DIAGRAMS 4 49 5 X907 GAVEL NAOHS AS HILIMS 201 TRAVEL ro rde 009 M NMOHS AS HILIMS 2009 1703901 019 d ONI NI Houmas 10 99 5 o 4 NHYH 892 NIYH H LOXYd NON AZI 01 y 9 aut ONS SSN 8Y3 nna
117. 11 Mile Road Warren MI 48397 5000 FROM Activity and location Include ZIP Code PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER TM 5 3805 264 14 amp P DATE 30 December 2005 M917A2 w MCS TITLE M917A1 M917A1 w MCS M917A2 and ITEM NO PAGE NO PARA GRAPH LINE NO FIGURE NO TABLE NO RECOMMENDED CHANGES AND REASON Provide exact wording of recommended changes if possible Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS SIGNATURE EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V3 00 Change 1 TO Forward direct to addressee listed publication U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 FROM Activity and location Include ZIP Code DATE PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER 5 3805 264 14 amp P DATE 30 December 2005 TITLE M917A1 M917A1 w MCS M917A2 and M917A2 w MCS PAGE NO COLM LINE NATIONAL STOCK NO NO NUMBER REFERENCE NO FIGURE NO ITEM NO TOTAL NO OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART 11 REMARKS A
118. 13829 391 3782 146 WASHER ELAT 2522225 9 6 SH ee RR 5 17 PAFZZ 5305014471330 13829 391 1401 382 SCREW CAP SOCKET 2 IN 3 18 PAFZZ 5310013408088 13829 391 1451 115 NUT PLAIN HEXAGON ees 2 19 22 5307014467531 13829 391 1425 437 SJSTUD PLAIN sa secon oe Sie 1 20 22 5365014460280 13829 391 3283 052 1 END FIGURE 18 1 5 3805 264 14 amp P SECTION II A As 2 Figure 19 Dump Control Cable SECTION II 1 1 2 2 3 SMR CODE NSN PAOZZ 2590014427238 PFOZZ 2590014457883 PFOZZ 2590015287521 PAOZZ 4820014468874 TM 5 3805 264 14 amp P 4 5 6 7 PART CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 2403 HYDRAULIC CONTROLS AND OR MANUAL CONTROLS FIG 9 DUMP CONTROL AND CABLE 60602 55940 4 CONTROL ASSEMBLY PU 60602 45884 48 CONTROL ASSEMBLY PU UOC 7A1 7E1 64678 FLD 45884 0072 CONTROL ASSEMBLY PU 1 UOC 7A2 7E2 04710 01 5000 35 PARTS KIT VALVE seses sedatie 1 END FIGURE 19 1 5 3805 264 14 amp P SECTION II Figure 20 Filter Element Hydraulic SECTION II 5 3805 264 14 amp P 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND U
119. 17A2 WIMCS Con t b REPAIR NOTE Wiring harness need not be removed from vehicle to make repairs Repair wiring harness in accordance with instructions in Chapter 4 Section General Maintenance Instructions c INSTALLATION 1 Position truck to MCS tailgate wiring harness 9 between points of connection 2 Connect truck to MCS tailgate wiring harness 9 to chassis wiring harness 8 3 Position truck to MCS tailgate wiring harness receptacle 2 against cover plate 5 Secure with two screws 6 and new self locking nuts 4 4 Install cover plate 5 to dump body pillar 1 with four screws 7 4 56 5 3805 264 14 amp P 4 47 TRUCK TO MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 5 Connect MCS tailgate wiring harness connector 3 to truck to MCS tailgate wiring harness receptacle 2 6 Install new tie wraps FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 917 1 and M917A1 w MCS Remove body props and lower dump paragraph 2 15 e Check operation of MCS tailgate using cab mounted MCS control unit and remote control and 2 2 4 57 TM 5 3805 264 14 amp P 4 48 M917A2 W MCS MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND This task covers a Removal b Repair Initial Setup Equipment Conditions Batteries disconnected TM 9 2320 3
120. 19207 11655784 5340 01 445 9357 Tarp Crank Handle TAA in tool pouch storage box TA2 7E2 5B752 0311 960301 D 3 D 4 Blank 5 3805 264 14 amp P APPENDIX ADDITIONAL AUTHORIZATION LIST Refer to TM 9 2320 363 10 or TM 9 2320 302 10 E 1 E 2 Blank 5 3805 264 14 amp P APPENDIX EXPENDABLE AND DURABLE ITEMS LIST Section l INTRODUCTION F 1 SCOPE This appendix lists expendable and durable items you will need to operate and maintain the M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body This listing is for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Depart ment Expendable Durable Items F 2 EXPLANATION OF COLUMNS a Column 1 Item Number This number is assigned to the entry in the listing and is referenced in the Initial Setup of maintenance paragraphs or narrative instructions to identify the material needed e g Dry cleaning solvent Item 5 Appendix b Column 2 Level This column identifies the lowest level of maintenance that requires the listed item C Operator Crew O Unit Maintenance F Direct Support Maintenance H General Support Maintenance Column 3 National Stock Number This is the National Sto
121. 2 To order this NBC decal use National Stock Number NSN 7690 01 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 e f Blank 5 3805 264 14 amp P LIST EFFECTIVE PAGES WORK PACKAGES Dates of issue for original and change pages are Original 30 December 2005 Change 1 14 February 2011 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 412 CONSISTING OF THE FOLLOWING Page Change Page Change No No No No Cover Back Blank a thru e f Blank i thru 1 0 1 1 thru 1 3 1 4 Blank 1 5 thru 1 13 1 14 Blank 1 15 thru 1 19 1 20 Blank 2 1 thru 2 5 2 6 Blank 2 7 thru 2 25 2 26 Blank 2 27 thru 2 42 2 43 2 44 Blank 3 1 3 2 Blank 3 3 thru 3 7 3 8 Blank 3 9 3 10 Blank 4 1 thru 4 152 5 1 thru 5 35 5 36 Blank 6 1 6 2 Blank A 1 thru A 2 B 1 thru B 8 C 1 thru C 7 Figure 1 thru Figure 11 11 1 gt Figure 12 thru Figure 24 BULK 1 KITS 1 1 and 2 3 1 4 1 5 1 6 thru 1 12 I 13 1 14 D 1 thru D 3 D 4 Blank E 1 E 2 Blank F 1 thru F 4 G 1 thru G 3 G 4 Blank H 1 thru H 2 1 1 thru 1 2 J 1 thru J 8 Index 1 thru Index 7 Index 8 Blank Sample DA Form 2028 Blank DA Form 2028 2 Three copies Metric Conversion Chart Back Cover Zero in this column indicates an original page or work package A B Blank oor 0 000 0 5 3
122. 2 tailgate opens from the bottom for normal dumping Adjustment chains allow for adjustment of tailgate opening d The M917A1 w MCS and M917A2 w MCS tailgate has four electro pneumatically operated gates controlled by a control unit mounted on the shift tower inside the cab or by a hand held remote control that plugs into a receptacle on either side of the MCS tailgate This allows controlled spreading of material The MCS tailgate also operates as a standard tailgate opening at the bottom 1 14 EQUIPMENT DATA VEHICLE DIMENSIONS Overall Length M917A1 M917A2 M917A1 w MCS M917A2 Overall Height M917A1 and 917 1 85 Overall Height M917A2 917 2 85 Overall Width M917A1 and M917A1 w MCS Overall Width M917A2 and M917A2 w MCS Wheelbase M917A1 and 917 1 Wheelbase M917A2 and 917 2 Ground Turning Diameter RI eU ear MERE da ged bee oda ig tabes VEHICLE WEIGHTS Curb Weight M917A1 eor vibe M917A1 w MCS Empty cs keen eR emp Iq xS Ran M917A2 Empty cat needed bow eter M917A2 w MCS DUMP
123. 22 042 0 00 22 1 CYLINDER ASSEMBLY 8 2408 LIQUID TANKS OR 22 410000 HYDRAULIC RESERVOIR ASSEMBLY 23 1 GROUP 33 SPECIAL PURPOSE KITS 3307 SPECIAL PURPOSE 8 222 24 1 SPILL SHIELD 24 1 GROUP 94 REPAIR KITS 9401 REPAIR 1st rite nett aeeie KITS _KITS 1 GROUP 95 GENERAL USE STANDARDIZED PARTS HARDWARE SUPPLIES AND BULK MATERIEL COMMON BULK 1 ote a alu BULK _BULK 1 Section Cross Reference Indexes NATIONAL STOCK NUMBER PART NUMBER INDEX ttp ote e a anie 1 5 APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS APPENDIX E ADDITIONAL AUTHORIZATION 5 E 1 APPENDIX F EXPENDABLE AND DURABLE ITEMS 8 F 1 APPENDIX G ILLUSTRATED LIST OF MANUFACTURED 5 G 1 iii Change 1 TM 5 3805 264 14 amp P TABLE OF CONTENTS Con t APPENDIX TORQUE LIMITS APPENDIX TOOL IDENTIFICATION LIST APPENDIX LUBRICATION INSTRUCTIONS Chang
124. 28 ER CPP Ded d Sade eim 4 13 Explanation of Table 4 30 General Lubrication 4 14 General PMCS Procedures PMCS Initial Set p iot wv Draw wo ue ET E Pen 4 33 Lubrication 4 17 Table 4 1 Lubrication 4 34 Mandatory Replacement 4 18 Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck 4 19 4 28 GENERAL NOTE Refer to TM 9 2320 363 20 or TM 9 2320 302 20 for Unit PMCS for the dump truck chassis To ensure that the dump truck body is ready for operation at all times it must be lubricated and inspected on a regular basis so that defects may be found before they result in serious damage equipment failure or injury to personne Table 4 1 lists the types amounts and temperature ranges of the lubricants required for specified inter vals Table 4 2 contains systematic instructions on lubrications inspections adjustments and corrections to be performed by Unit Maintenance to keep your equipment in good operating condition and ready for its
125. 3040 01 446 3620 4 3040 01 446 3782 14 3040 01 446 3790 3 3040 01 446 3793 10 5325 01 446 4051 17 5325 01 446 4052 38 5325 01 446 4053 1 2 14 19 15 19 17 17 17 17 15 17 17 17 18 15 11 21 21 21 21 10 23 21 1 3 21 21 18 11 15 15 15 21 20 15 23 22 15 15 15 22 22 22 12 m NDN ds wk DUN w PNA RB Pon wwwono SECTION IV TM 5 3805 264 14 amp P C1 CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG ITE STOCK NUMBER FIG 5360 01 446 4054 15 36 4710 01 466 4881 BULK 5365 01 446 4322 22 12 5999 01 466 5398 2 3040 01 446 4665 22 3 5305 01 466 7940 2 3040 01 446 4689 15 37 6150 01 466 9174 8 5340 01 446 4927 11 12 6220 01 469 5480 2 5340 01 446 5137 11 11 5340 01 469 6693 TY 3040 01 446 6274 22 4 5940 01 469 7988 4 3040 01 446 6277 22 4 3020 01 473 2738 15 3040 01 446 6280 22 5 3040 01 473 2741 5 6150 01 446 6344 8 1 5330 01 473 2903 13 6150 01 446 6345 6 1 2510 01 473 8250 12 3020 01 446 6405 15 31 2510 01 473 8251 12 3020 01 446 6409 15 4 4130 01 473 9667 14 3020 01 446 6412 15 2 4130 01 473 9699 14 5315 01 446 6724 15 3 5330 01 474 2447 13 5340 01 474 6446 15 5307 01 446 7531 18 19 5340 01 474 6449 15 5360 01 446 7903 15 20 5340 01 474 6455 15 5325
126. 37 5325001749341 5935015180417 CAGEC 5X050 777060 19207 77060 64678 77060 77060 77060 77060 77060 77060 70485 77060 5 3805 264 14 amp P 5 PART NUMBER 403256 12010293 12420936 1201 5797 A06 24606 276 12015199 1202 0116 68240R 276 12052924 12045773 12047933 2872 12015344 6 DESCRIPTION AND USABLE ON CODES UOC GROUP 0613 HULL OR CHASSIS WIRING HARNESS BODYUP TRANSPORT LOCK HARNESS AND MATERIAL CONTROL CHASSIS HARNESS LEAD ASSEMBLY ELECT BOOT DUST AND 15 CONNECTOR BODY PLUG WIRING 55 UOC 7E1 7E2 PLUG CONNECTOR ELEC UOC 7E1 7E2 TERMINAL QUICK DISC UOC 7E1 7E2 CONDUIT MAKE FROM BULK PN UOC 7E1 7E2 GROMMET UOC 7E1 7E2 CONTACT BELECTIRICAL 2 nn UOC 7E1 7E2 HOUSING 8 UOC 7E1 7E2 GROMMET NONMETALLIC UOC 7E1 7E2 CONNECTOR PLUG ELEC UOC 7E1 7E2 68240R END OF FIGURE 7 5 3805 264 14 amp P SECTION II Figure 9 Cylinder Support Frame and Brackets SECTION II 1 AN HDA UF WN 2 SMR CODE XDFZZ PAFZZ PFFZZ PAFZZ XDFZ
127. 4 amp P 2 1 CAB MOUNTED CONTROLS AND INDICATORS Con t ENGINE BRAKE 2 4 5 TAILGATE D RELEASE f TRAILER YF 371 046 371 011 Key Control or Indicators Function 4 Reduce MPH Indicator Red light comes on when vehicle is traveling too fast for tire pressure Light selected on CTIS 5 Body Up Indicator Light Red light comes on when dump body is raised Turns off when dump body is down and in contact with truck frame 6 Body Transport Lock Red light comes on when dump body is locked to truck frame in preparation Indicator Light for dump truck transport Alerts driver that dump body will not raise 7 Tailgate Release Control Air activated lever controls tailgate release air cylinder to unlock and lock Valve Lever tailgate Left position is UNLOCK right position is LOCK 8 PTO Switch Engages PTO when turned ON PTO will not operate unless main light switch is in SER DRIVE or STOP LIGHT position Light in switch comes on when PTO is ON 5 3805 264 14 amp P 2 2 EXTERNAL CONTROLS AND INDICATORS Control or Indicators Function 1 Hydraulic Reservoir Sight Sight tube shows level of hydraulic fluid in reservoir Oil level decal is marked Tube and Oil Level Decal FULL ADD 2 QTS and ADD 1 GAL 2 Hydr
128. 49 5470 159 5141 197 8124 146 0947 146 0980 3040 01 515 7916 1 9 B 0 H OY ITEM 13 18 16 10 11 17 15 w VW N RP H H e Ul d SECTION IV TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX CAGEC PART NUMBER NSN FIG ITEM 45152 1354190 5305 01 162 2358 11 4 5X050 140409 2510 01 473 8251 12 1 5X050 140410 2510 01 473 8250 12 1 12662 142 18 5325 01 283 3513 3 3 5X050 142607 2510 01 518 4549 24 1 5X050 143893 11 5 050 150380 24 4 77060 15300014 5940 01 462 1718 4 11 77060 15300027 5935 01 308 7866 4 2 58752 1545 619860 5340 01 474 9576 15 49 5X050 201834 12 1 5X050 208047 5315 01 446 3121 9 8 30780 2101 4 4C 4730 00 137 7875 13 29 30780 2102 2 2 4730 00 204 1272 23 9 30780 2102 8 8 4730 00 289 2357 14 7 23 18 10266 213 1 4 20 2 1 2 5306 00 957 7531 15 21 93061 216 4 4730 00 277 8289 14 36 64678 23 09130 003 23 20 64678 23 10340 125 5310 01 333 6436 15 18 64678 23 10864 706 5305 01 466 7940 2 4 72764 23 10 5925 01 499 3416 1 6 5X050 237379 23 26 5X050 237386 9 5X050 237387 9 5X050 237409 5340 01 446 4927 11 12 5 050 237410 3040 01 446 2413 11 19 5 050 238021 5340 01 445 7781 3 7 5 050 239635 1 50 23 16 5X050 239693 10 10 5X050 239694 10 12 5X050 239932 4730 01 446 2110 21 2 5X050 239963 3040 01 497 0345 12 11 5X050 239973 4710 01 497 5644 12 5X
129. 5 two nuts 8 and five wash ers 6 securing pump housings NOTE Note stud location for assembly 3 Remove stud 7 CAUTION Internal surfaces and parts of hydraulic pump are machined to strict manufacturing tolerances Care must be taken not to damage machined surfaces NOTE Drive shaft and gearshaft may slide out with end housing Place hydraulic pump on clean flat surface and separate end housing 11 from gear housing 13 Remove drive shaft 4 and gearshaft 9 from end housing 11 Remove thrust plate 10 from end housing 11 Remove six pocket seals 12 from thrust plate Discard pocket seals 5 15 5 3805 264 14 amp P 5 5 HYDRAULIC PUMP REPAIR Con t 7 Remove two check assemblies 17 from end housing 11 Discard check assemblies 16 8 Remove two roller bearings 14 ring seals 15 and lip seal 16 from end housing 11 Discard roller bearings ring seals and lip seal 15 14 gt AX 17 9 Remove gear housing 13 from pump housing 19 Remove two gasket seals 18 from gear housing Discard gasket seals 10 Remove thrust plate 20 and six pocket seals 21 from pump housing 19 Discard pocket seals 11 Remove two roller bearings 22 Discard roller bearings 5 16 5 3805 264 14 amp P 5 5 HYDRAULIC PUMP REPAIR Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Secti
130. 5 4 mm 3 00 in 76 2 mm 020 in 50 in 51 mm 12 7 mm 1 Fabricate from 020 in shim stock 2 All dimensions are approximate 3 Four required G 3 G 4 Blank 5 3805 264 14 amp P APPENDIX TORQUE LIMITS H 1 SCOPE This appendix lists standard torque values as shown in Table H 1 and provides general information for applying torque Special torque values and tightening sequences are indicated in the maintenance procedures for applicable components H 2 GENERAL a Always use the torque values listed in Table H 1 when the maintenance procedure does not give a specific torque value b Unless otherwise indicated standard torque tolerance shall be 10 Torque values listed are based on clean dry threads Reduce torque by 10 when engine oil is used as a lubricant Reduce torque by 20 if new plated capscrews are used d Capscrews threaded into aluminum may require reductions in torque of 30 or more of Grade 5 capscrew torque Capscrew threaded into aluminum must also attain two capscrew diameters of thread engage ment CAUTION If replacement capscrews are of higher grade than originally supplied use torque specifications for the original This will prevent equipment damage due to over torquing H 1 5 3805 264 14 amp P Table H 1 Torque Limits Current Usage Much Used Much
131. 507 06 22309 048 6 DESCRIPTION AND USABLE CODES UOC GROUP 0608 MISCELLANEOUS ITEMS FIG 2 CONTROL SWITCHES MCS BRACKET SWITCH UOC 7A1 7E1 SWITCH TOGGDBE 2 Iq UE ERIS UOC 7A1 7E1 SWITCH TOGGBE iae ap UOC 7E2 4X MAT L CTRL UOC 7A1 7E1 SCREW MACHINE 1 4 20 0 75 IN UOC 7A1 7E1 WASHER FLAT 1 4 UOC 7A1 7E1 LIGHT INDICATOR MATERIAL CONTROL UOC 7A1 7E1 7E2 END OF FIGURE 7 SECTION II TM 5 3805 264 14 amp P Figure 3 Taillights Marker Lights and Reflectors SECTION II 1 SMR CODE PAOZZ PAOZA PAOZZ PAOZZ PAOZA PAOZZ PAOZZ PAOZZ PFOZZ PAOZZ PAOZZ 3 NSN 6220010865691 6220015186827 5325011636558 5325012833513 6240015186843 6220010950011 6220014459978 6220014459981 5340014457781 5935015183692 5935015183690 CAGEC 13548 13548 13548 12662 13548 13548 12662 12662 5X050 13548 13548 TM 5 3805 264 14 amp P 5 PART NUMBER 60202R 60085R 60700 142 18 10250R 10004R B490A B490R 238021 93745 94706 6 DESCRIPTION AND USABLE ON CODES UOC GROUP 0609 LIGHTS FIG 3 TAILLIGHTS MARKER LIGHTS AND REFLECTORS STOP LIGHT TAILLIGH LIGHT ASSY UOC 7A1 7E1 LAMP UNIT VEHICULAR UO
132. 6 01 271 9425 5325 01 283 3513 4820 01 298 8416 5935 01 308 7866 5935 01 308 8599 5975 01 310 5011 3120 01 328 4294 5930 01 332 0680 5310 01 333 6436 5930 01 336 0919 5935 01 339 9574 5940 01 340 0587 5365 01 340 3898 5310 01 340 8088 5330 01 340 8159 5310 01 340 8353 4730 01 345 6065 5975 01 355 6985 5365 01 361 4609 5999 01 364 1237 5940 01 366 1563 5999 01 406 4110 TM 5 3805 264 14 amp P CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX FIG 14 14 14 14 14 15 3 3 14 14 11 3 16 18 13 7 22 4 8 4 18 18 14 18 23 23 22 18 18 18 13 18 13 ITEM STOCK NUMBER 2 4820 01 418 4232 17 5999 01 422 9740 21 27 2590 01 442 7238 16 5340 01 445 7778 41 5340 01 445 7781 2590 01 445 7883 4 7690 01 445 8961 7690 01 445 8967 26 7690 01 445 8973 7 7690 01 445 8976 2 6150 01 445 9130 1 5342 01 445 9481 8 5340 01 445 9486 39 7690 01 445 9897 8 7690 01 445 9903 11 7690 01 445 9933 4 6220 01 445 9978 2 6220 01 445 9981 5 5365 01 446 0280 5 5342 01 446 0902 4 5340 01 446 0947 20 5930 01 446 0980 9 4720 01 446 1481 28 4720 01 446 1508 3 4720 01 446 1541 3 4720 01 446 1729 1 2510 01 446 1842 2 2590 01 446 1903 4 4730 01 446 2107 3 4730 01 446 2108 6 4730 01 446 2110 37 4730 01 446 2112 11 3040 01 446 2408 3040 01 446 2413 18 5315 01 446 3121 2 5360 01 446 3122 4 5360 01 446 3190 7 5360 01 446 3194 9 4730 01 446 3255 18 4330 01 446 3337 13 2530 01 446 3340 16 2940 01 446 3570 28
133. 63 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS e MCS tailgate cover removed paragraph 4 53 a REMOVAL c Installation Tools Test Equipment General mechanic s tool kit Item 8 Appendix Materials Parts Marker tags Item 20 Four self locking nuts Tie wraps Item 19 Appendix F NOTE Wires should be tagged before disconnecting paragraph 4 17 Note location of tie wraps and routing of wiring harness prior to removal to aid in installation 1 Disconnect wiring harness connector 3 from truck to MCS tailgate wiring harness receptacle 2 at left dump body pillar 1 4 58 5 3805 264 14 amp P 4 48 MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 2 Disconnect wiring harness connector 4 from each air cylinder solenoid connector 5 3 On each side of MCS tailgate 6 remove two self locking nuts 8 and screws 9 securing wiring harness receptacle 10 to tailgate weldment 11 Discard self locking nuts 4 Remove wiring harness 7 from MCS tailgate 6 TM 5 3805 264 14 amp P 4 48 MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND M917A2 W MCS Con t b REPAIR NOTE Wiring harness need not be removed from vehicle to make repairs Repair wiring harness in accordance with instructions in Chapter 4 Section 1
134. 7 0009359021 5008098786 0014462413 TM 5 3805 264 14 amp P C1 CAGEC 5X 80 81 19 5X 5X 5X 5X 45 050 204 348 207 050 050 050 050 152 OPXJ7 5X 5X 5X 5X 80 5X 64 5X 96 80 5X 5X 050 050 050 050 204 050 670 050 906 205 050 050 5 PART NUMBER 129568 B1821BH063C200N FFW92 12387349 43 126426 143893 126427 127373 1354190 63 04 117122 127892 127852 237409 1821 038 150 129732 407023 245352 551943 35 516562 51 237410 403345 148 75 6 ESCRIPTION AND U 7 SABLE ON CODES UOC GROUP 1810 CARGO BODY 11 DUMP BODY CABSHIELD ASSE SCREW CAP HEXAGON WASHER FLAT 5 8 SELF LOCKING H 5 8 11 ASSEMBLY DUMP BOX W S UOC 7A1 7A2 D GATE DUMP BOX W S D GATE DU UOC 7E1 7E2 COVER ACCESS SCREW TAPPING COTTE P BOX W MCS GATE gt as X Q Q D d Gl H PIN SHOULDE TAILGATE UOC 7A1 PLATE PLA SCREW C PLATE GUARD SPLASH VEHIC PLATE ANCHOR FLAP NUT SELF PIN SPRING 3 16X1 SHAFT STRAIGHT SIDEBOARD 2 0 X 8 AKE FROM BULK PN Til END OF FIGURE In HE 3 8 16 1 50
135. 805 264 14 amp P TECHNICAL MANUAL HEADQUARTERS 5 3805 264 14 amp P DEPARTMENT OF THE ARMY WASHINGTON D C 30 December 2005 OPERATOR S UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LISTS FOR TRUCK DUMP HEAVY BODY M917A1 NSN 3805 01 431 1165 EIC E5C M917A2 NSN 3805 01 488 7442 EIC BPB AND M917A1 W MCS MATERIAL CONTROL SYSTEM NSN 3805 01 432 8249 EIC E5D M917A2 W MCS MATERIAL CONTROL SYSTEM NSN 3805 01 488 6963 EIC BA4 Current as of 5 July 2005 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any errors or if you would like to recommend any improvements to the procedures in this publication please let us know The preferred method is to submit your DA Form 2028 Recommended Changes to Publications and Blank Forms through the Internet on the Army Electronic Product Support AEPS website The Internet address is https aeps ria army mil The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program You may also mail E mail or fax your com ments or DA Form 2028 directly to the U S Army TACOM Life Cycle Management Command The postal mail address is U S Army TACOM Life Cycle Management Command
136. 9 207 for lubrication instructions cold weather f Refer to AR 70 12 for use of standardized lubricants g Hydraulic oil filter element will be changed when it is known to be contaminated or clogged h Hydraulic oil must be sampled initially at 90 days of operation as prescribed by DA Pam 738 750 4 14 5 3805 264 14 amp P 4 31 GENERAL PMCS PROCEDURES a Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If any deficiency is discovered perform the appropriate troubleshooting task in Section V of this chapter If any component or system is not serviceable or if the given service does not correct the deficiency notify your supervisor b Before performing preventive maintenance read all the checks required for the applicable interval and prepare all tools needed to make all checks Have several clean rags Item 16 Appendix handy Perform ALL inspections at the applicable interval WARNING Dry cleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protec tive gloves and goggles is suggested Use in well ventilated area Keep away from open flame and other sources of ignition 1 Keep It Clean Dirt grease oil and debris get in the way and may cover up a serious prob lem Clean as you work and as neede
137. 917A1 w MCS 917 2 8 Index 6 Paragraph 1 8 4 25 4 6 4 62 4 70 4 18 4 2 4 71 2 49 5 1 4 16 1 4 4 82 4 81 4 84 4 38 4 39 Table 3 1 Table 4 3 4 47 1 2 4 12 4 2 4 96 4 115 4 1 4 116 2 38 5 1 4 7 1 2 4 151 4 149 4 152 4 33 4 35 4 13 4 8 2 36 4 66 4 73 4 70 4 68 4 66 4 36 4 35 2 29 3 4 4 28 3 5 4 29 4 54 5 3805 264 14 amp P INDEX Con t Subject Paragraph Page T Con t Tubes and Compression Fittings 4 23 4 11 Tubing Heat Shrinkable 4 19 4 8 U Unit PMCS PC C M Table 4 2 4 19 Troubleshooting eb xx eb bro HER EP E Table 4 3 4 29 Troubleshooting Symptom Index 4 37 4 28 Warranty Information 1 7 1 2 Welding 52 1 Poly eta edd iu Tw 4 26 4 12 Windy Weather Operation 2 16 2 43 Wires Hoses Tagging 4 17 4 8 Wiring Diagrams 5 24 2 o8 Rog kde Pea nd 4 49 4 62 Wiring Harness Maintenance Beacon Warning 4 45 4 49 Body Up and Transport Lock 5 4 44 4 47 neret OMEN rts AT rt
138. ABS ECU CTIS ECU Datalogger and batteries TM 9 2320 363 20 or TM 9 2320 302 20 Failure to follow this caution may damage electronic components 12 If removed install stabilizer Refer to TM 9 237 Operator s Manual for Welding Theory and Application for instructions on welding compo nents 13 Secure lower half 6 of stabilizer to upper half 5 and to dump body 4 using a suitable chain or nylon strap NOTE Before lifting dump body perform a trial lift to ensure body is balanced and will lift straight and level 14 Attach suitable lift and chains at four corners of dump body 4 Take up slack in chains with lift NOTE When positioning dump body on vehicle chassis pay close attention to hydraulic cylinder positioning and rear hinge assembly alinement 15 Lift dump body 4 and position over vehicle chassis 7 Lower body until rear hinge 15 and hinge pads 16 are alined and hydraulic cylinder is properly positioned in recess at front of dump body 5 3805 264 14 amp P 5 1 DUMP BODY AND STABILIZER REPLACEMENT Con t 16 Install left and right hinge pins 19 in rear hinge 15 17 Install two screws 17 and new locknuts 18 in rear hinge 15 and hinge pins 19 18 Lower dump body 4 onto vehicle chassis 7 Remove lifting chains from rear of dump body 16 19 Working from underside of vehicle release lower half 6 and upper half 5 of stabilizer from bottom of dump body 4 NOTE
139. AOZZ PAOZZ PAOZZ PAOZZ MOOZZ 3 NSN 4730010969128 4730010564990 4730010485260 4730010487873 4730000444035 4730002892357 4730002783888 5305000680510 4730000575555 4820014184232 5310000806004 5310009359021 4730010622570 4730010564990 4730010485260 4730010487873 4730012443552 4730010564990 4730010485260 4730010487873 CAGEC 93061 93061 93061 93061 79470 79146 30780 30780 80204 79146 30780 79146 96906 96906 5X050 93061 93061 93061 93061 93061 93061 93061 93061 5X050 TM 5 3805 264 14 amp P 5 PART NUMBER 68NTA 6 6 63NTA 6 60NTA6 61NTA 6 C3109X8X6 320001 2102 8 8 0102 12 8 B1821BH038C100N 035055 01 6 032135 527183 14 551943 35 245538 66 68NTA 6 4 63NTA 6 60NTA 6 61NTA 6 VS269NTA 6 4 63NTA 6 60NTA 6 61NTA 6 245544 144 14 1 6 DESCRIPTION AND USABLE ON CODES UOC GROUP 1810 CARGO BODY AIR TANK LINES AND FITTINGS ADAPTER STRAIGHT PI QTY 2 7A1 7A2 QTY 4 1 7 2 5 55 eye So eee INSERT TUBE FITTING e3 SLEEVE COMPRESSION sNUT TUBE COUPLING i2 s n es BUSHING PIPE eaa UOC 7E1 7E2 VAIN EG CHECK gt NEP eh Se Roe as UOC 7E1 7E2 ELBOW PIPE UOC 7E1 7E2 REDUCER sert eee ab 9 R UOC 7E1 7E2 SCREW CAP HEXAGON H
140. ARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 1 Raise cab shield 1 to dump body 6 2 Install two screws 3 four washers 4 and two new locknuts 5 to top of cab shield 1 and dump body 6 3 Install six screws 7 12 washers 8 and six new locknuts 9 to outside edges of cab shield 1 and dump body 6 4 Remove lifting slings 2 from cab shield 1 5 Raise and support dump body on body props paragraph 2 15 6 Install six screws 7 12 washers 8 and six new locknuts 9 to center of cab shield 1 and dump body 6 4 97 TM 5 3805 264 14 amp P 4 62 CAB SHIELD REPLACEMENT Con t 7 Torque 12 locknuts 9 and two locknuts 5 to 150 ft Ib 203 FOLLOW ON TASKS Install beacon warning light wiring harness to cab shield paragraph 4 45 Remove body props and lower dump body paragraph 2 15 install beacon warning light TM 9 2320 363 10 or TM 9 2320 302 10 4 98 5 3805 264 14 amp P 4 63 MUD FLAP REPLACEMENT This task covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Item 8 Appendix Two spring pins Six locknu
141. AULIC CYLINDER REPAIR Con t 24 25 26 27 5 30 Using two small screwdrivers remove bottom retaining ring 31 from groove of barrel 25 Position four hydraulic cylinder disassembly tools equally spaced between bottom retain ing ring and barrel NOTE Hydraulic cylinder disassembly tools will fall free as sleeve with bottom retaining ring is removed from barrel Remove sleeve 14 from barrel 25 Remove bottom retaining ring 31 from sleeve 31 Remove wear ring 32 and two piston rings 33 from other end of sleeve 14 Discard wear ring 32 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions ASSEMBLY WARNING e Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment e Hydraulic cylinder sleeves may extend downward as hydraulic cylinder is lifted Expect sleeve movement any time hydraulic cylinder is handled Failure to do so may result in serious injury to personnel NOTE e Apply a light coat of lubricating oil to surfaces of components as they
142. BLE ON CODES UOC GROUP 2408 RESERVOIRS LIQUID TANKS OR FIG 2b HYDRAULIC RESERVOIR ASSEMBLY TANK OIL HYDRAULIC e re sss teera mistas tx BOLT MACHINE 5 16 18 1 00 INCH O RING SCREW HEXAGON 3 8 16X1 00 BhBOW PIPE 25 o RR GAGE PRESSURE DIAL NIPPLE PIPE 1 8NPT X 1 50 PIPE SPECIAL 1 50 X 18 75 INCH CAP FILLER SCREW MACHINE 10 32 0 75 ELBOW PIPE TO TUBE 299 xx c TUBE SIGHT 3 8 OD X 1 50 FT MAKE FROM BULK PT24006NA 79470 REDUCER PIPE 3 4 M X 1 2 F ELBOW PIPE 1 2 HOSE ASSY 1 2 X 20 SPACER PLATE 252 NUT SELF LOCKING HE ChAMP HOSE SST AP PIPE 1 2 NPT v 2 0 cR RS SCREW CAP HEXAGON SPACER cscs oip Eaa a e WASHER LOCK 3 4 WASHER FLAT 3 4 UOC 7A1 7E1 WASHER FLAT 1 2 SCREW CAP HEXAGON 1 2 13 2 00 END OF FIGURE 23 1 7 PP RPP Boe PP 5 3805 264 14 amp P SECTION II 2 6 Figure 24 Spill Shield SECTION II 5 3805 264 14 amp P 1 2 3 4 5 6 7 ITEM S
143. BODY Capacity Pe Ri EPA EAR er e Ra Load SIDES Cargo Cover Model Operation 303 8 in 771 7 cm 316 8 in 804 7 cm 143 in 363 cm 135 5 in 344 cm 102 in 259 cm 103 8 in 364 cm 174 in 442 cm 179 in 455 cm 9 in 22 9 cm 38 9 ft 11 9 m 68 000 Ib 30 872 kg 29 454 Ib 31 472 Ib 30 600 Ib 32 618 Ib 13 372 kg 14 288 kg 13 892 kg 14 809 kg 14 cu yd 10 7 m 18 5 tons 16 8 metric tons 13 5 ft 411 cm 87 in 221 cm 96 in 244 cm 40 in 102 cm 62 in 157 cm 48 in 122 cm 400 AERO side mount Crank handle 5 3805 264 14 amp P 1 14 EQUIPMENT DATA MCS TAILGATE M917A1 w MCS and M917A2 w MCS Operations ar edid eus deut a Are qul ae see uti HYDRAULIC SYSTEM Operation c he ee RI ae afe a goa tet AP a Mens Reservoir Ede aue Lite sc Eu ases etd due net Hydraulic Fl id gt Ee er Hydraulic Pump ev cde SUI Operating Hydraulic Filter TYPO 345 Service Indicator x3 RA ve LOCATION io uere o eee
144. Body Props ue be d NERO NO RN ERE AS ea ea nie 2 15 2 42 Cargo COVER 2 14 2 40 Cold Weathers bep xw AU te nats 2 18 2 43 Rainy or Snowy Weather 2 17 2 43 Windy Weather sinc ter veretur prete pdt etras 2 16 2 43 Operator Preventive Maintenance Checks and Services PMCS Table 2 1 2 10 Troubleshooting oc xke x REDE Ies Soe dota centers Table 3 1 3 5 Troubleshooting Symptom Index 3 3 3 4 P Faning aang E aote x RA ge eere epe ed ae ates VM 4 11 4 5 Parts and Kits Service Replacement 4 25 4 12 PMGS Initial S t p 22 s eei ea a aa 4 32 4 16 PMCS Procedures General Operator Pudet gore eb td deb do obe gri durs 2 5 2 8 Unit cuu dot ine et eeu Qu ded iacu Me i 4 31 4 15 PMCS Operator 2 22 nel Reds mhi er Ee dee ees Table 2 1 2 10 LL Se ae Ce Table 4 2 4 19 Ports Eines and o2 eU Wo v eaux Be D ees 4 21 4 10 Preparation for Storage or 1 4 1 2 Preparation of Equipment for Administrative Storage 4 81 4 149 Preparation of Equipment for Shipment 4 85 4 152 Preparing to Load Dump Body
145. C 7A2 7E2 GROMMET NONMETALLIC GROMMET 22 be he EP RIO 5 UOC 7A2 7E2 LIGHT MARKER CLEARA UOC 7A1 7E1 REFLECTOR LIGHT AMBER REFLECTOR LIGHT BRACKET ANGLE s 23555 84 93 x9 es CONNECTOR ASSEMBLY UOC 7A2 7E2 CONNECTOR ASSEMBLY UOC 7A2 7E2 STOP TURN TAIL END OF FIGURE 7 SECTION II TM 5 3805 264 14 amp P 2 11 Figure 4 Wiring Harness Beacon Light SECTION II 1 NO UU amp WN 10 11 2 SMR CODE PAOOO PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZA PAOZZ PAOZZ PAOZZ PAOZZ 3 NSN 6150014459130 5935013087866 5940014697988 5975012268078 5975012304370 5310008338567 5999000572929 5940003996676 5970008338562 5935008338561 5940014621718 CAGEC 5X050 77060 77060 77060 5A910 19207 19204 19207 19207 19207 77060 TM 5 3805 264 14 amp P 5 PART NUMBER 403255 15300027 12129493 12010293 8338566 8338567 572929 8338564 8338562 8338561 15300014 DESCRIPTION AND USABLE ON CODES UOC GROUP FIG BR WIRING HARNESS BEACON LIGHT 6 0609 LIGHTS WIRING HARNESS BRAN BEACON LIGHT CONNECTOR BODY PLUG TERMINAL STUD BOOT DUST AND MOIST CABLE NIPPLE ELECTR WASHER SLOTTED CONTACT ELECTRICAL NO GAGE TERMINAL SET QU
146. CATION CHART TRUCK DUMP HEAVY BODY M917A1 NSN 3805 01 431 1165 M917A1 W MCS NSN 3805 01 432 8249 M917A2 NSN 3805 01 448 7442 M917A2 W MCS NSN 3805 01 448 6963 This Lubrication Chart is for operator crew C and Unit Maintenance O Lubrication intervals on con dition or hard time are based on normal operation Lubricate more during constant use and less during inactive periods Use correct grade of lubricant for seasonal temperature expected For equipment under manufacturer s warranty hard time oil service intervals shall be followed Intervals shall be shortened if lubricants are known to be con taminated or if operation is under adverse condi tions e g longer than usual operating hours extended idling periods extreme dust etc WARNING Dry cleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin The use of protective gloves and goggles is suggested Use in well ventilated area Keep away from open flame and other sources of igni tion Clean area around lubrication points with dry clean ing solvent Item 5 Appendix F or equivalent before lubricating equipment After lubrication wipe off excess lubricant to prevent accumulation of for eign matter Before you start your lubrication service ALWAYS Clean area around lubrication point before lubricating Use the Lubrication
147. CE NO FIGURE NO ITEM NO TOTAL NO OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART 11 REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS EXTENSION SIGNATURE Change 1 USAPPC V3 00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form see AR 25 30 the proponent agency is ODISC4 Use Part Il reverse for Repair Parts and DATE Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 FROM Activity and location Include ZIP Code PUBLICATION FORM NUMBER TM 5 3805 264 14 amp P DATE 30 December 2005 TITLE M917A1 M917A1 w MCS M917A2 and M917A2 w MCS ITEM NO PAGE NO PARA GRAPH LINE NO FIGURE NO TABLE NO Provide exact wording of recommended changes if possible RECOMMENDED CHANGES AND REASON Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS SIGNATURE EXTENSION DA FORM
148. Chart as your guide NEVER Use wrong type grade lubricant Use too much lubricant M917A1 M917A1 W MCS M917A2 AND M917A2 W MCS LUBRICANT INTERVAL Cargo Cover Chain Oil Can Point Note 1a O Transport Lock Linkage 4 Fittings View A and Note 2 Hydraulic Reser voir Check Level and Fill View B and Note 3a C Hydraulic Reser voir Drain and Refill View B and Note 3b O Stabilizer Bottom Cross 2 Fittings View C and Note 4 C TM 5 3805 264 14 amp P LUBRICANT Cargo Cover Roller Shaft Bearings Cil Can Point View D and Note 1b O Stabilizer Top Cross 2 Fittings View C and Note 4 C Tailgate Hinge Pins 1 Fitting Each View E and Note 5 C Tailgate Locking Linkage 1 Fit ting View F and Note 6 C Stabilizer Center Hinge 1 Fitting View C and Note 4 C Body Props 1 Fitting Each View G and Note 7 C J 3 5 3805 264 14 amp P KEY Lubricant Component Refill Capacity Expected Temperatures 6 F to 122 F 4 F to 50 F 14 C to 50 C 20 C to 10 C 67 F to 32 F 55 C to 0 C Intervals OE HDO MIL L 2104 Lubricating Oil ICE Tactical OEA MIL L 46167 Lubricating Oil ICE Arctic e Hydraulic Reser voir 12 75 gal 48 21 OE HDO 10 OE HDO 10 OEA GAA MIL G 10924 Grease Automotive and Artillery
149. E 1 UOC 7E1 7E2 77326 11 700 CONNECTOR PLUG ELEC 1 UOC 7E1 7E2 7J764 BNT22002 SWITCH ASSEMBLY 236206800508 m 9 tis 1 UOC 7E1 7E2 73764 BNT220 a COVER ACCES S 1 UOC 7E1 7E2 73764 23E10 CERCULT BREAKER cueing wee he 4 UOC 7E1 7E2 64678 BCI 231E SSCDIP ELECTRICAL atas 4 UOC 7E1 7E2 72764 CM10P NUT GLAND ELECTRICA 4 UOC 7E1 7E2 72764 WE11H415E PLATE IDENTIFICATIO OPEN CLOSED 1 LEFT cees wih Cece see porum mum ERU RU UOC 7E1 7E 72764 11 416 PLATE IDENTIFICATIO OPEN CLOSED 1 LEFT CENTER UOC 7E1 7E2 72764 WE11H417E PLATE IDENTIFICATIO OPEN CLOSED 1 RIGHT CENTER nmm ees UOC 7E1 7E2 72764 11 418 PLATE IDENTIFICATIO OPEN CLOSED 1 RIGET e eee UOC 7E1 7E2 72764 C21PA03 s SWITCH TOGGLE o sie ane ese 3 9 9 4 UOC 7E1 7E2 END OF FIGURE 5 3805 264 14 amp P SECTION II Figure 2 Control Switches MCS SECTION II 1 2 ITEM SMR NO CODE 1 XDOZZ 2 PAOZA 2 PFOZZ 3 XDOZZ 4 PFOZZ 5 PAOZZ 6 PAOZA 3 NSN 5930013320680 5930015204456 5305014667940 5310003470021 6220014695480 CAGEC 64678 64678 64678 64678 64678 99321 64678 TM 5 3805 264 14 amp P 5 PART NUMBER 06 24618 000 681 545 07 22 106 30769 101 24 00783 000 23 10864 706 3
150. E soa Sie eels Ree EY eT 1 47 PAOZZ 5360014463190 5B752 0715 619602 SPRING HELICAL 1 48 PAOZZ 5310008094058 96906 MS27183 10 WASHER FLAT 1 4 8 49 PAOZZ 5340014749576 5B752 1545 619860 STRAP ELASTIC 15 2 END OF FIGURE 15 2 15 3 Blank SECTION II TM 5 3805 264 14 amp P Figure 16 Shovel Mounting SECTION II 1 NO SMR CODE PAOOZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 3 NSN 2540011757257 5305002692803 5310008094061 5310008140672 5340007533741 5340010328448 TM 5 3805 264 14 amp P 4 5 6 7 PART CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 2201 CANVAS RUBBER OR PLASTIC ITEMS FIG SHOVEL MOUNTING 19207 12302814 MOUNTING KIT TOOL 9 5 1 80205 MS90726 60 SCREW CAP HEXAGON 3 8 24 1 INCLUDED IN MOUNTING 96906 MS27183 15 FLAT 3 8 INCLUDED IN 8 MOUNTING ET se dtd Bier GE 96906 M45912 3 6FG8C NUT SELF LOCKING HE 3 8 24 4 INCLUDED IN MOUNTING 19200 7550233 1 STRAP WEBBING 14 1 19200 7550233 2 STRAP WEBBING 20 INCH 1 END FIGURE 16 1 SECTION II TM 5 3805 264 14 amp P DANGER DO NOT GO UNDER RAISED BODY IT MAY DROP AND KILL YOU OPERATE HOIST v 1 Raise body to full height and shut off all power 2 Raise prop to upr
151. Equipment Batteries disconnected TM 9 2320 363 20 General mechanic s tool kit Item 8 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS a REMOVAL Remove taillight 4 from grommet 3 Disconnect lights wiring harness connector 2 from taillight 4 Remove taillight Remove grommet 3 from dump body 1 e AM 9 4 Sd 29 PAD QUO PENN qu S b INSTALLATION SS 1 Install grommet 3 dump body 1 2 Connect lights wiring harness connector 2 to taillight 4 3 Install taillight 4 in grommet 3 FOLLOW ON TASKS e Connect batteries TM 9 2320 363 20 M917A1 and M917A1 w MCS e Check operation of taillight TM 9 2320 363 10 or TM 9 2320 302 10 4 36 5 3805 264 14 amp P 4 41 MARKER CLEARANCE LIGHT REPLACEMENT This task covers a Removal b Installation Initial Setup Equipment Conditions Tools Test Equipment Batteries disconnected 9 2320 363 20 General mechanic s tool kit Item 8 Appendix 1 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS NOTE There is a marker clearance light on each side of dump body and a cluster of three marker clearance lights on bracket at rear hinge Replacement of a dump body marker clearance light is shown a REMOVAL Remove mar
152. G NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel a REMOVAL NOTE Note location of tie wraps prior to removal to aid in installation Disconnect transport lock switch connector 2 from wiring harness connector 1 2 Remove button 7 nut 6 and transport lock switch 3 from chassis mount 5 1 4 34 5 3805 264 14 amp P 4 39 TRANSPORT LOCK SWITCH REPLACEMENT Con t NOTE To ensure proper installation note position of jamnut on transport lock switch 3 Remove jamnut 4 from transport lock switch 3 b INSTALLATION Install jamnut 4 on transport lock switch 3 in same position as noted during removal Position transport lock switch 3 through hole in chassis mount 5 and install nut 6 and button 7 Connect transport lock switch connector 2 to wiring harness connector 1 BOORD Install new tie wraps as required FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 M917A1 and M917A1 w MCS e Remove body props and lower dump paragraph 2 15 e Check operation of transport lock switch paragraph 2 1 4 35 TM 5 3805 264 14 amp P 4 40 TAILLIGHT REPLACEMENT This task covers a Removal b Installation Initial Setup Equipment Conditions Tools Test
153. ICK INSULATOR BUSHING SHELL ELECTRICAL CO TERMINAL LUG END OF FIGURE 14 WIRE 7 SECTION II TM 5 3805 264 14 amp P Figure 5 Bodyup and Transport Lock Switches SECTION II 5 3805 264 14 amp P 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 0610 SENDING UNITS AND WARNING SWITCHES FIG BODYUP AND TRANSPORT LOCK SWITCHES 1 PAOZZ 5305009897434 96906 MS35207 263 SCREW MACHINE 10 32 0 50 2 PAOZA 5930013360919 13445 8486 SWITCH LEVER ig ede 3 PAOZZ 5930014460980 5X050 129871 SWITCH PUSH PULL TRAVEL LOCK SWITCH 1 END OF FIGURE SECTION II TM 5 3805 264 14 amp P 2 6 uu 4 55 Figure 6 Wiring Harness Dump Body Lights SECTION II 5 3805 264 14 amp P 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 0613 HULL OR CHASSIS WIRING HARNESS FIG WIRING HARNESS DUMP BODY LIGHTS 1 PAOZZ 6150014466345 5X050 403254 CABLE ASSEMBLY SPEC DUMP BODY 1 LIGHT Ses de gee ep ee 2 XDOZZ 77060 12084673 LOCK SECONDARY KEEA 1 3 PAOZZ 5975013105011 77060 12015323 BOOT DUST AND 15 4 4 PAOZZ 5935013399574 77060 1201 0300 PLUG END SEAL ELECT 1 5 XDOZZ
154. IGNATURE Your Name Your Signature DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED USAPPC V3 00 Change 1 Forward direct to addressee listed publication U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS 6501 E 11 Mile Road Warren MI 48397 5000 Your address FROM Activity and location Include ZIP Code DATE Date you filled out this form PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER TM 5 3805 264 14 amp P DATE 30 December 2005 TITLE M917A1 M917A1 w MCS M917A2 and M917A2 w MCS NO NO NO COLM LINE NATIONAL STOCK NUMBER REFERENCE NO FIGURE NO ITEM NO TOTAL NO OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed Your Name TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS EXTENSION SIGNATURE Your Signature Change 1 USAPPC V3 00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form see AR 25 30 the proponent agency is ODISC4 Use Part Il reverse for Repair Parts and Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM DATE TO
155. It may be necessary to raise front of dump body to aline stabilizer with chassis mounting holes 20 Raise front of dump body 4 and position wooden blocks between dump body frame rails 8 and vehicle chassis 7 21 Aline lower half of stabilizer mounting surface 1 to angle brackets 3 Install six screws 1 and new locknuts 2 in left and right angle brack ets Torque locknuts to 150 Ib ft 203 22 Lift front of dump body 4 remove wooden blocks position body props in raised position and lower body onto props paragraph 2 15 5 5 TM 5 3805 264 14 amp P 5 1 DUMP BODY AND STABILIZER REPLACEMENT Con t 23 Install left and right mounting brackets 11 on cylinder pivots 14 NOTE It may be necessary to raise and or lower front of dump body to aline mounting brackets to dump body 24 Aline mounting brackets 11 with mounting surface of dump body 4 25 Install six screws 12 and new locknuts 10 to secure mounting brackets 11 to dump body 4 Torque locknuts to 150 Ib ft 203 26 Remove dump body 4 from body props and lower body paragraph 2 15 27 Remove lifting device and chains from dump body 4 FOLLOW ON TASKS Connect chassis to dump body air lines paragraph 4 59 Connect chassis to dump body electrical harnesses paragraphs 4 44 thru 4 47 Install mud flaps paragraph 4 63 5 6 5 3805 264 14 amp P 5 2 CYLINDE
156. MR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 33 SPECIAL PURPOSE KITS GROUP 3307 SPECIAL PURPOSE KITS FIG 24 SPILL SHIELD 1 PAOZZ 2510015184549 5 050 142607 SPILL SHARD oh eared las cults iia Rye eds RIS s 1 2 PAOZZ 5 050 402038 HEX LOCKNUT 3 8 8 3 PAOZZ 5310000806004 96906 MS27183 14 SWASHER FhAT 2 8 4 XAOZZ 5X050 150380 B20 sg iab tee 1 5 22 5 050 400121 5 3 8 X 1 8 6 XDOZZ 5 050 201834 SPILL SHIELD 2 END FIGURE 24 1 24 2 Blank SECTION II TM 5 3805 264 14 amp P 1 2 3 4 ITEM SMR NO CODE NSN CAGEC PAOZZ 3040014981887 5X050 404939 PAOZZ 3040014981885 5X050 404940 5 PART NUMBER 6 DESCRIPTION AND USABLE ON CODES UOC GROUP 94 REPAIR KITS GROUP 9401 REPAIR KITS FIG KITS PARTS KIT LINEAR AC UOC 7A1 7E1 ARM WINDSHIELD WIPE BEARING PISTON ROD PACKING PREFORMED PACKING PREFORMED PREFORMED PACKING SEAL PLAIN SEAL PLAIN STRIP METAL PARTS KIT LINEAR AC UOC 7A1 7E1 VALVE PILOT ASSY 1 VALVE REGULATING FL 1 END OF FIGURE KITS 1 13 23 13 22 13 9 13 16 13 20 13 21 13 13 13 14 13 35 13 31 7 SECTION II 1 ITEM NO amp WN 2 SMR CODE XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ NSN
157. Mud Flaps Prevent dirt and mud from tires from spraying passers by or other vehicles 20 Taillights Include tail stop and turn signal lights Backup lights are located only in chassis mounted taillights TM 9 2320 363 10 9 2320 302 10 21 MCS Tailgate 917 1 Has four electro pneumatically controlled gates which allow for controlled w MCS M917A2 w spreading of material Can also operate like a standard tailgate MCS 5 3805 264 14 amp P 1 12 LOCATION AND CONTENTS OF PLATES DECALS AND STENCILS a Plates CAUTION 2 BODY BE BRACED BEFORE 2 2 SERVICING HOIST OR WORKING 2 AREA WITH BODY IN RAISED POSITION TRUCK MUST BE LEVEL FOR DUMPING 7 00 NOT OVERLOAD 2 2 P N 403378 CRYSTEEL MFG 2222777722222222222777722222222222222222222222722227 DANGER DO NOT GO UNDER RAISED BODY MAY DROP AND KILL YOU OPERATE HOIST CONTROLS E ONLY FROM INSIDE TRUCK CAB PIN 403374 2222222222222222222222222222222222222222222222222222222 SS A NS SSSSSSSSSSSSSSSSSSSSSSSSSSNSSSSO Manufactured by Crysteel Mfg Inc LUBRICATION DATA 917 1 amp M917A1MCS Lake Crystal MN IEEE DAILY 5 HOIST OIL RESERVOIR e MONTHLY 1 TAILGATE HINGE PIN 1 2 GAA 2 GAA L 4 GAA L 5 GAA MONTHLY 2 BODY PR
158. NTENANCE Paragraph Number Paragraph Title Tailgate Replacement M917A1 and 917 2 Tailgate Release Air Cylinder MCS Tailgate Replacement M917A1 w MCS M917A2 5 MCS Tailgate Cover Replacement M917A1 w MCS M917A2 w MCS MCS Gate Replacement M917A1 w MCS and M917A2 5 MCS Air Reservoir Replacement M917A1 w MCS and M917A2 w MCS MCS Air Cylinder Replacement M917A1 w MCS and 917 2 w MCS MCS Air Cylinder Solenoid Assembly Maintenance M917A1 w MCS and M917A2 w MCS Tailgate Release MCS Air Cylinder Tailgate Release MCS Air Lines and Fittings MCS Adjustment Tube Replacement M917A1 w MCS and M917A2 w MCS Body Prop Cab Shield Replacement Mud Flap Replacement e IE 63 4 50 TAILGATE REPLACEMENT 917 1 AND 917 2 This task covers a Removal c Installation b Cleaning and Inspection Initial Setup Equipment Conditions Tailgate release control valve lever UNLOCKED position paragraph 2 1 Tailgate c
159. Nylon 2835 01 078 2081 91796 4 8FTX2IN 7 Soldering Gun 3439 00 618 6623 58536 A A 59307 SC 4910 95 CL A74 1A1B 8 Tool Kit General 5180 00 177 7033 50980 SC 5180 90 CL N26 Mechanic s Automotive SC 5180 90 CL N26 5 3805 264 14 amp P Section Il TOOL IDENTIFICATION LIST Con t 1 2 3 4 5 3 4 in drive Item Item National CAGEC No Name Stock Number Part Number Reference 9 Vise Machinist s 5120 00 293 1439 79416 504M2 SC 4910 95 CL A74 10 Wrench Adjustable 5120 00 264 3793 24617 2117080 SC 4910 95 CL A74 0 3 5 8 in jaw opening 11 Wrench Torque 5120 00 640 6364 58635 A A 2411 SC 4910 95 CL A74 1 2 in drive 0 175 Ib ft capacity 12 Wrench Torque 5120 01 355 1773 55719 TE602A SC 4910 95 CL A72 3 4 in drive 0 600 Ib ft capacity 13 Wrench Set Socket 5120 00 204 1999 81348 GGG W 641 SC 4910 95 CL A72 5 3805 264 14 amp P APPENDIX J LUBRICATION INSTRUCTIONS J 1 GENERAL NOTE e These instructions are mandatory Lubrication of M917A1 M917A1 w MCS M917A2 and M917A2 w MCS chassis is in TM 9 2320 363 10 or TM 9 2320 302 10 and TM 9 2320 363 20 or TM 9 2320 302 20 a The M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body must receive lubrication with approved lubricants at recommended intervals in order to be mission ready at all times b Hydraulic oil filter are changed
160. OLLOW ON TASKS 4 146 e Remove body props and lower dump paragraph 2 15 Fill hydraulic reservoir as necessary Chapter 3 Section I 5 3805 264 14 amp P 4 78 HYDRAULIC OIL FILTER SERVICE INDICATOR GAGE REPLACEMENT This task covers a Removal c Installation b Cleaning and Inspection Initial Setup Equipment Conditions Materials Parts Dump body raised and supported on body props Rags 16 Appendix paragraph 2 15 Antiseize tape Item 21 Appendix Tools Test Equipment General Safety Instructions General mechanic s tool kit Item 8j Appendix NEVER work under a raised dump body unless it Cap and plug set Item 1 Appendix I is secured in the raised position with body props WARNING e NEVER work under a raised dump body unless it is secured in the raised posi tion with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel e DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel a REMOVAL CAUTION Ports and hoses in reservoir should be plugged to prevent contamination of hydraulic system paragraph 4 21 1 Remove gage 1 from elbow 2 2 Remove elbow 2
161. OP MONTHLY 3 TRAVELLOCK MONTHLY 4 STABILIZER LUBRICATION KEY c CHECK F FILL L LUBRICATE CH CHANGE B BOTH SIDES LUBRICATING OIL INTERNAL COMBUSTION TACTICAL SERVICE MIL L 2104 GAA GREASE AUTOMOTIVE ARTILLERY MIL G 10924 oc ON CONDITION SEE OPERATORS MANUAL lhl OPERATION BODY PROP 1 Raise body to full height and shut off all power 2 Raise prop to upright position 3 Lower body slowly until body bracket contacts prop 4 DO NOT POWER HOIST DOWN O P N 403375 2 SMM SS Y gp LL ETE Y 2 A BT A UNLOAD BODY BEFORE USING BODY PROP 9 USIN SSNS SS 5 3805 264 14 amp P 1 12 LOCATION AND CONTENTS OF PLATES DECALS AND STENCILS Con t b Decals TRAVEL LOCK OPERATION Li UNLOCKE LOCKED D gt EASY COVER AERO INDUSTRIES INC 1 800 535 9545 0920 590324 336 047 DANGER DO NOT GO UNDER RAISED BODY IT MAY DROP AND KILL YOU OPERATE HOIST CONTROLS ONLY __ FROM INSIDE TRUCK CAB 2 2 BODY MUST BRACED BEFORE SERVICING HOIST OR WORKING IN AREA WITH BODY IN RAISED POSITION TRUCK MUST BE LEVEL FOR DUMPING V DO NOT OVERLOAD ltl AaAA q qnuq NN
162. PLACEMENT M917A1 W MCS AND 917 2 WIMCS This task covers a Removal b Installation Initial Setup Equipment Conditions Tools Test Equipment MCS gates closed paragraph 2 12 General mechanic s tool kit Item 8 Chassis air system drained TM 9 2320 363 10 Appendix or 9 2320 302 10 Materials Parts MCS air system drained Chapter 2 Section Operator PMCS Two locknuts e MCS tailgate cover removed paragraph 4 53 a REMOVAL 1 Remove locking pin 9 from adjustment tube 3 2 Remove locknut 6 screw 5 and adjustment tube 3 from MCS gate 7 Discard locknut 3 Remove locknut 8 screw 4 and upper tube 2 from MCS tailgate 1 Discard locknut 9 8 4 93 TM 5 3805 264 14 amp P 4 60 MCS ADJUSTMENT TUBE REPLACEMENT M917A1 W MCS AND M917A2 WI MCS Con t b INSTALLATION 1 Install upper tube 2 to MCS tailgate 1 with screw 4 and new locknut 8 2 Position adjustment tube 3 over upper tube 2 Install adjustment tube to MCS gate 7 with screw 5 and new locknut 6 CAUTION Outer right and outer left side adjustment tube locking pins must be installed with pin heads to outside If incorrectly installed end of pins will protrude and become bent 3 Install locking pin 9 to adjustment tube 3 FOLLOW ON TASKS e Check operation of MCS adjustment tube paragraph 2 12 Ins
163. PTO disengaged Failure to fol low this caution may damage body props hydraulic cylinder or dump body 5 Turn off main light switch and disengage PTO TM 9 2320 363 10 or TM 9 2320 302 10 Operate hydraulic control lever to lower dump body 1 until body props 4 firmly engage V brackets 2 b Stowing Body Props 1 Start engine place main light switch in SER DRIVE or STOP LIGHT position and engage PTO TM 9 2320 363 10 or TM 9 2320 302 10 2 Raise dump body 1 until body props 4 are clear of V brackets 2 3 Swing body props 4 down to stowed position in stowage brackets 6 4 With engine at idle speed lower dump body 1 5 Turn off main light switch disengage PTO and shut down engine TM 9 2320 363 10 or TM 9 2320 302 10 2 42 5 3805 264 14 amp P Section OPERATION UNDER UNUSUAL CONDITIONS Paragraph Page Number Paragraph Title Number 2 16 Operation in Windy 2 17 Operation in Rainy or Snowy 2 43 Operation in Cold 2 16 OPERATION IN WINDY WEATHER WARNING DO NOT attempt to dump in high wind High winds may disperse aggregate caus ing injury to personnel or damage to equipment High winds may also cause dump truck to roll over when bed is raised Fail
164. Props e Stabilizer e Transport Lock Linkage e Tailgate Hinge Pins Tailgate Locking Linkage As Required ALL TEMPERATURES WD 40 Corrosion Preventive e Cargo Cover Chain e Cargo Cover Roller Shaft Bear ings As Required ALL TEMPERATURES D Daily M Monthly S Semi annual OC On Condition For arctic operation refer to FM 9 207 TRANSPORT LOCK LINKAGE TM 5 3805 264 14 amp P HYDRAULIC RESERVOIR OIL FILTER HOUSING OIL FILTER ELEMENT FILL CAP OE HDO OR OEA OIL LEVEL WITH BODY DOWN FULL wma ADD 2 QTS ADD 1 GAL DRAIN TUBE AND CAP J 5 5 3805 264 14 amp P STABILIZER CENTER HINGE FITTING GAA TOP CROSS FITTINGS GAA BOTTOM CROSS FITTINGS GAA CARGO COVER ROLLER SHAFT BEARINGS WD 40 J 6 TAILGATE HINGE PINS TM 5 3805 264 14 amp P F TAILGATE LOCKING LINKAGE G BODY PROPS 5 3805 264 14 amp P CARGO COVER a Semiannually remove chain cover Clean chain as required and lubricate sparingly with corro sion preventive Install chain cover paragraph 4 66 b Semiannually lubricate roller shaft bearings at roll up bar mounting brackets Apply corrosion preventive sparingly 2 TRANSPORT LOCK LINKAGE a Monthly raise dump body and support on body props paragraph 2 15 Apply GAA to four lubri cati
165. R SUPPORT FRAME REPLACEMENT This task covers a Removal b Installation Initial Setup Equipment Conditions Tools Test Equipment Con t Body up switch removed paragraph 4 38 Torque wrench Item 12j Appendix I Suitable lifting device Materials Parts Twenty four locknuts Hydraulic reservoir removed paragraph 4 75 Hydraulic cylinder removed paragraph 5 6 Tools Test Equipment Personnel Required Three General mechanic s tool kit Item 8 Appendix I General Safety Instructions Nylon slings Item 6 Use extreme caution when handling heavy parts a REMOVAL WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 1 Attach slings to cylinder support frame 2 and attach slings to lifting device Take up slack in slings with lift 5 7 TM 5 3805 264 14 amp P 5 2 CYLINDER SUPPORT FRAME REPLACEMENT Con t 2 Remove 24 locknuts 4 screws 1 left angle bracket 3 and right angle bracket 6 from cylinder support frame 2 and vehicle chassis 5 Discard locknuts 3 Remove cylinder support frame 2 from vehicle chassis 5 and move frame to safe work area Remove slings
166. Recoverability Code XXxxx XXXXx XXXXX 1st two positions 3d position 4th position 5th position How you get an item Who can install replace or Who can do complete Who determines disposition use the item repair on the item action on an unserviceable item Complete Repair Maintenance capacity capability and authority to perform all corrective maintenance tasks of the Repair function in a use user environment in order to restore serviceability to a failed item C 1 5 3805 264 14 amp P C 3 EXPLANATION OF COLUMNS SECTIONS AND III Con t 1 Source Code The source code tells you how to get an item needed for maintenance repair or overhaul of an end item equipment Explanations of source codes follow Code Application Explanation PA Stocked items use the applicable NSN to request requisition items with these PB source codes They are authorized to the maintenance category indicated by PC the code entered in the third position of the SMR code PD PE PF Items coded PC are subject to deterioration PG Items with these codes are not to be requested requisitioned individually They KD are part of a kit which is authorized to the maintenance category indicated in KF the third position of the SMR code The complete kit must be requisitioned and KB applied MO Made at UM AVUM Items with these codes are not to be requested requisitioned individually They Level must be made from bulk materiel which is identi
167. Replace 0 5 1 Repair 0 5 3 Support Frame Roll Replace 0 7 1 ers Repair 0 7 1 Crank Assembly Replace 0 7 1 Repair 1 0 1 2210 Data Plates and Replace 0 3 1 Instruction Holders 5 3805 264 14 amp P Section Il MAINTENANCE ALLOCATION CHART Con t 1 2 3 4 5 6 Maintenance Level FIELD SUSTAINMENT Unit DS GS Depot Tools and Group Component Maintenance Equipment Number Assembly Function F H D Ref Code Remarks 24 Hydraulic and Fluid Systems 2401 Pump and Motor Hydraulic Pump Replace 1 0 1 3 Assembly Repair 1 0 1 3 2403 Hydraulic Controls and or Manual Con trols Dump Control Replace 0 5 1 Assembly Repair 0 1 1 2406 Strainers Filters Lines and Fittings Filter Assembly Service 0 3 1 Replace 0 5 1 Repair 0 3 1 Hoses Fittings Replace 0 3 1 2 2407 Hydraulic Cylinders Cylinder Assembly Replace 2 0 1 3 Repair 2 0 1 3 4 5 6 2408 Liquid Tanks or Res ervoirs Reservoir Assembly Replace 0 5 1 2 Repair 0 5 1 5 3805 264 14 amp P Section TOOLS AND TEST EQUIPMENT REQUIREMENTS Tool or Test Equipment Reference Maintenance National Stock Code Level Nomenclature Number Tool Number 1 O F H Tool Kit General 5 Auto 5180 00 177 7033 33004 motive SC 5180 90 CL N26 2 Shop Equipment Automotive Main 4910 00 754 0654 32593 tenance Repair Common No 1 Less Power SC 4910
168. SABLE ON CODES UOC QTY GROUP 2406 STRAINERS FILTERS LINES AND FITTINGS ETC FIG 29 FILTER ELEMENT HYDRAULIC 1 PAOZZ 4330014463337 5X050 403366 FILTER ELEMENT FLUI 10 MICRON 1 END OF FIGURE 20 1 5 3805 264 14 amp P SECTION II Figure 21 Hydraulic Hoses and Fittings SECTION II 1 NO 10 11 12 13 14 15 2 SMR CODE PAFZZ PAOZZ PAOZZ PFOZA PAOZZ PFOZZ PAOZZ PAOZZ PAOZZ PAOZZ PFOZZ PAOZZ PFOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PFOZZ 3 NSN 4820012988416 4730014462110 4720014461508 4720015189183 4730010285540 4730015191782 4730015191777 4730010117736 4730008225609 4720014461481 4720015190924 4720014461541 4730015189540 4730010464034 4730014462112 4730014462107 4720014461729 4730014463255 4730001731881 CAGEC 81349 5X050 5X050 5X050 30780 5X050 5X050 96906 00624 5X050 5X050 5X050 5X050 30780 60827 9 737 5 050 60827 96906 5X050 TM 5 3805 264 14 amp P 5 PART NUMBER M81940 2 1 239932 403459 406342 1 1 2 CDS 406355 406356 MS51527 A12 MS51527A8 403458 406340 403457 406341 0503 12 8 FT 1215 ZP HC150 403456 FT 150 ZP MS51525A12 16 401540 21 1 6 DESCRIPTION AND USABLE ON CODES UOC GROUP 2406 STRAINERS AND FITTINGS ETC FILTERS LINES FIG 2 HYDRAULIC HOSES AND FITTINGS VALVE BLEEDER HYDRA
169. TM 9 2320 363 10 or TM 9 2320 302 10 MCS air system drained Chapter 2 Section Operator PMCS MCS tailgate cover removed paragraph 4 53 Tools Test Equipment General mechanic s tool kit Item 8 Appendix a REMOVAL b Installation Materials Parts Marker tags Item 20 Four locknuts Personnel Required Two General Safety Instructions DO NOT disconnect air lines while air system is pressurized WARNING DO NOT disconnect air lines while air system is pressurized Air system pressure must be released before air lines are disconnected A line disconnected under pres sure may cause personnel injury NOTE Hoses should be tagged before removal paragraph 4 17 1 Disconnect air supply hose 2 from adapter 3 TM 5 3805 264 14 amp P 4 55 MCS AIR RESERVOIR REPLACEMENT M917A1 W MCS AND 917 2 W MCS Con t 2 Disconnect air hose 4 from adapter 8 3 Remove four locknuts 14 flatwashers 15 screws 10 and air reservoir 11 from welded brackets 1 Discard locknuts 4 Remove adapter 3 bushing 5 check valve 6 elbow 7 and reducer 9 from air reservoir 11 5 Remove adapter 8 from air reservoir 11 6 Remove draincock with lanyard 13 and plug 12 from air reservoir 11 b INSTALLATION 1 Install draincock with lanyard 13 and plug 12 to air reservoir
170. TRODUCTION B 1 THE ARMY MAINTENANCE SYSTEM MAINTENANCE ALLOCATION CHART MAC a This introduction Section provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two Level Maintenance system concept b The Maintenance Allocation Chart MAC in Section II designates overall authority and responsibil ity for the performance of maintenance functions on the identified end item or component The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance levels which are shown on the MAC in column 4 as Field includes subcolumns C Operator Crew O Unit F Direct Support Sustainment includes subcolumns H General Support D Depot C Section III lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from Section d Section IV contains supplemental instructions and explanatory notes for a particular maintenance function B 2 MAINTENANCE FUNCTIONS Maintenance functions are limited to and defined as follows a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel b Test To verify serviceability by measuring th
171. Used Used at Times Used at Times Quality of Indeterminate Minimum Medium Best Material Commercial Commercial Commercial SAE Grade Number 1or2 5 6 or 7 8 Capscrew Head Markings S Manufacturer s Alm marks may vary E These are all Q SAE Grade 5 3 line Capscrew Body Size Torque Torque Torque Torque Inches Thread Ib ft Ib ft Ib ft lb ft 1 4 20 5 7 8 11 10 14 12 16 28 6 8 10 14 14 19 5 16 18 11 15 17 23 19 26 24 33 24 13 18 19 26 27 37 3 8 16 18 24 31 42 34 46 44 60 24 20 27 35 47 49 66 7 16 14 28 38 49 66 55 75 70 95 20 30 41 55 75 78 106 1 2 13 39 53 75 102 85 115 105 142 20 41 56 85 115 120 163 9 16 12 51 69 110 149 120 163 155 210 18 55 75 120 163 170 231 5 8 11 83 113 150 203 167 226 210 285 18 95 129 170 231 240 325 3 4 10 105 142 270 366 280 380 375 508 16 115 156 295 400 420 569 7 8 9 160 217 395 536 440 597 605 820 14 175 237 435 590 675 915 1 8 235 319 590 800 660 895 910 1234 14 250 339 660 895 990 1342 APPENDIX TOOL IDENTIFICATION LIST Section INTRODUCTION 5 3805 264 14 amp P 1 1 GENERAL This appendix lists tools you will need to maintain the dump truck body This listing is for informational purposes only and is not authority to requisition the tools Common tools are f
172. Y AND ASSEMBLY INSTRUCTIONS Follow these general practices when performing disassembly and assembly procedures tion loss 1 Keep major components together whenever possible and practical 2 Tag hoses electrical wires cables and harnesses to identify them and aid during installa 3 Keep related parts together for identification purposes 4 Temporarily install attaching hardware such as screws bolts washers and nuts to prevent 5 Only disassemble to the point of the problem 6 Ensure that parts are clean and lubricated before assembly 4 14 LUBRICATION INSTRUCTIONS Refer to Chapter 3 Section for detailed illustrated instructions on proper lubrication Some general practices to remember 4 6 1 Use the correct lubricant 2 3 Clean all fittings prior to lubrication 4 Lubricate clean disassembled and new parts to prevent rusti paragraph 4 10 Keep lubricants clean TM 5 3805 264 14 amp P 4 15 APPLICATION OF ADHESIVES a General Adhesives are recommended in some tasks to ensure and strengthen seals The follow ing information describes their correct use and application b Silicone Sealant Silicone sealant Item 17 Appendix F is used to seal parts against moisture Use the following instructions when applying 1 Anytime a seal is broken the part must be thoroughly cleaned to remove any remaining sealing compound and dirt 2 Thoroughly clean surface befo
173. Z XDFZZ XDFZZ PFFZZ PAFZZ PAFZZ PFFZZ 3 NSN 5310000614651 5340014459486 5305007247222 5315014463121 5305000712076 5310004883889 5340014495470 CAGEC 5X050 19207 5X050 80204 5X050 5X050 5X050 5X050 80204 96906 5X050 TM 5 3805 264 14 amp P 5 PART NUMBER 128129 12387349 43 128130 B1821BH063C200N 126617 237386 237387 208047 B1821BH050C325N MS51943 39 128131 6 DESCRIPTION AND USABLE ON CODES UOC GROUP 18 BODY CAB HOOD AND HULL GROUP 1810 CARGO BODY p CYLINDER SUPPORT FRAME AND BRACKETS COVER ASSY UPPER NUT SELF LOCKING HE BRACKET MOUNTING L H SCREW CAP HEXAGON H CRADLE ASSEMBLY SCREW CAP HEXAGON H NUT SELF LOCKING HE BRACKET MOUNTING R H END OF FIGURE 1 2 13X3 25 1 2913 4 5 2 7 5 3805 264 14 amp P SECTION II Figure 10 Stabilizer and Rear Hinge SECTION II 1 2 SMR NO CODE 1 22 2 XDFZZ 3 22 4 PAFZZ 5 XDFZZ 6 XDOZZ 7 XDOZZ 8 PGOZZ 9 PAOZZ 10 XDOZZ 11 PAFZZ 12 XDFZZ 13 PAFZZ 14 PAOZZ 15 XDFZZ 3 NSN 5315014470480 5305009474358 5310004093333 2510014461842 5315007218370 5310000614651 5305007247222 4730000504208 CAGEC 5X050 5X050 80204 96906 5X050 5X050 5X050 5X050 80205 5X050 19207 5X050 80204 81343 5X050 TM 5 3805 264 14 amp P 5 PART NUMBER 127170 110543 1821 075 400 551943 45 128125
174. a US des Rig dette 4 46 4 52 MCS Tailgate 917 1 w MCS and 917 2 w MCS 4 48 4 58 Truck to MCS Tailgate M917A1 w MCS and M917A2 w MCS 4 47 4 54 Work Safety cgo Ue Re R T O e 4 8 4 4 Index 7 Index 8 Blank RECOMMENDED CHANGES TO PUBLICATIONS Use Part Il reverse for Repair Parts and DATE AND BLANK FORMS Special Tool Lists RPSTL and Supply Date you filled out For use of this form see AR 25 30 the proponent agency is ODISC4 Catalogs Supply Manuals SC SM this form TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code U S Army TACOM Life Cycle Management Command ATTN AMSTA LCL MPP TECH PUBS Your mailing address 6501 E 11 Mile Road Warren MI 48397 5000 PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE Title Operator s Unit DS amp GS Maintenance Manual TM 5 3805 264 14 amp P Manual w RPSTL for M917A1 M917A1 w MCS 30 December 2005 947 A2 and M917A2 w MCS ITEM PAGE NO NO PARA GRAPH LINE FIGURE NO TABLE RECOMMENDED CHANGES AND REASON Provide exact wording of recommended changes if possible Reference to line numbers within the paragraph or subparagraph TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS EXTENSION S
175. abrasion resistant floor Wooden side boards along the top on both sides of the dump body add height to help prevent spill age when hauling material d The dump body is equipped with a cargo cover that is easily operated by one person operator s instrument panel inside the vehicle has a Body Up Body Transport Lock indicator light These lights allow monitoring of the dump body s status without leaving the cab f The chassis has limited off road capabilities with a CTIS TM 9 2320 363 10 for M917A1 and M917A1 w MCS or 9 2320 302 10 for M917A2 917 2 w MCS This provides a wide variety of terrain in which the dump truck can operate g The 917 1 917 1 w MCS 917 2 M917A2 w MCS are the same except for the tailgate configuration 1 The M917A1 and M917A2 have a double acting tailgate which opens at the top or bottom with chains to adjust the tailgate opening The tailgate is unlocked and locked by operating the tailgate release con trol valve lever on the instrument panel inside the cab 2 The M917A1 w MCS and M917A2 w MCS have a tailgate with dual function capability It is equipped with an MCS with four independently controlled gates If can also be operated as a top hinged tailgate 5 3805 264 14 amp P 1 11 LOCATION AND DESCRIPTION MAJOR COMPONENTS 371 039 Key Component Description 1 Cab Shield Protects cab during loading operations
176. adjusting lubricating etc at the user level 3 Recoverability Code Recoverability codes are assigned to items to indicate the disposi tion action on unserviceable items The recoverability code is entered in the fifth position of the SMR code as fol lows Code Application Explanation Nonreparable item When unserviceable condemn and dispose of the item at the level of maintenance shown in the third position of the SMR code o Reparable item When uneconomically reparable condemn and dispose of the item at Unit Maintenance or aviation unit maintenance enis ees Reparable item When uneconomically reparable condemn and dispose of the item at Direct Support Maintenance or aviation intermediate main tenance Histon EG Reparable item When uneconomically reparable condemn and dispose of the item at General Support Maintenance DELI Reparable item When beyond lower level repair capability return to Depot Maintenance Condemnation and disposal of item not authorized below Depot Maintenance Reparable item Condemnation and disposal of item not authorized below Specialized Repair Activity SRA eid es ade a Item requires special handling or condemnation procedures because of specific reasons e g precious metal content high dollar value critical material or hazardous material Refer to appropriate manuals directives for specific instructions NSN Column 3 Lists the Nati
177. air system is pressurized Air system pressure must be released before air lines are disconnected A line disconnected under pres sure may cause personnel injury NOTE Note location of tie wraps prior to removal to aid in installation Disconnect solenoid connector 5 from MCS tailgate wiring harness connector 4 2 Disconnect air line 1 from elbow 2 If damaged remove elbow from air cylinder solenoid 3 336 021 4 79 TM 5 3805 264 14 amp P 4 56 MCS AIR CYLINDER REPLACEMENT M917A1 W MCS AND M917A2 W MCS Con t 3 Remove retaining pin 10 and pin 12 to disconnect air cylinder 9 from MCS gate 11 NOTE Note position of nut at air cylinder piston shaft clevis to ensure proper adjustment of air cylinder on installation 4 Remove retaining pin 8 and pin 6 to disconnect air cylinder 9 from MCS tailgate 7 Me le Nig gt 12 336 022 b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions INSTALLATION NOTE Ensure that position of nut at air cylinder piston shaft clevis is the same as noted during removal to ensure proper adjustment of air cylinder on installation 1 Install air cylinder 9 to MCS tailgate 7 with pin 6 and new retaining pin 8 2 Install air cylinder 9 to MCS gate
178. ake several hard braking stops without skidding While exercising and when it is safe and convenient operate all other functional components and perform all DURING and AFTER operational checks 2 Scheduled Services Scheduled services will include inspection per subparagraph b and will be conducted in accordance with Chapter 4 Section IV Unit Preventive Maintenance Checks and Services PMCS Lubricate in accordance with instructions Chapter 3 Section 3 Corrective Action Immediately take action to correct shortcomings and deficiencies noted Record inspection and exercise results on DA Form 2404 Record and report all maintenance actions on DA Form 2407 After exercising restore the preservation to the original condition Replenish lubricants used during exercising and note the amount on DA Form 2408 Table 4 4 Exercise Schedule Weeks 2 4 6 8 10 12 14 16 18 20 22 24 Scheduled Services X Major Exercise X e Rotation Rotate items in accordance with any rotational plan that will keep the equipment in an operational condition and reduce the maintenance effort 4 151 TM 5 3805 264 14 amp P 4 83 PROCEDURES FOR COMMON COMPONENTS AND MISCELLANEOUS ITEMS a Tires Visually inspect tires during each walkaround inspection This inspection includes checking tires with a tire gage Inflate repair or replace as necessary those found to be low damaged or excessivel
179. al Contamination Avoidance FM 3 3 Field Behavior of NBC Agents Including Smoke and 5 FM 3 6 First Ald Manual EMEN Rd UR S FM 4 25 11 General Fabric FM 10 16 NBG ance ka aed ede ate gata dak e FM 3 5 NBG Protection agin de De edad gu e en FM 3 4 Northern Operations 12 23 ad Ie Pb dee e ree pe FM 31 71 Operation and Maintenance of Ordnance Materiel in Cold Weather 0 F to 65 F FM 9 207 Operational Terms and 5 FM 101 5 1 Railway Operating and Safety FM 55 21 WISUAI SIGN AIS x eee eoe eta ue due RM iS DONT UE FM 21 60 A 1 5 3805 264 14 amp P A 5 TECHNICAL BULLETINS Color Marking and Camouflage Painting of Military Vehicles Construction Equipment and Materiels Handling TB 43 0209 Corrosion Prevention and Control Including Rustproofing Procedures for Tactical Vehicles and TB 43 0213 Equipment Improvement Report and Maintenance Digest U S Series Army Tank Automotive Command Tank Automotiv
180. all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by the listed corrective actions notify your supervisor f When troubleshooting a malfunction 1 Locate the symptom or symptoms in paragraph 4 37 that best describes the malfunction If the appropriate symptom is not listed notify your supervisor 2 Turn to the page Table 443 where the troubleshooting procedures for the malfunction in question are described Headings at the top of each page show how each troubleshooting procedure is organized Malfunction Test or Inspection in step number order and Corrective Action 3 Perform each step in the order listed until the malfunction is corrected and the item being inspected is operational DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so 4 36 EXPLANATION OF COLUMNS The columns in Table 4 3 are defined as follows 1 MALFUNCTION A visual or operational indication that something is wrong with the equip ment 2 TEST OR INSPECTION A procedure to isolate the problem in a system or component 3 CORRECTIVE ACTION A procedure to correct the problem 4 26 5 3805 264 14 amp P 4 37 TROUBLESHOOTING SYMPTOM INDEX Troubleshooting Procedure Page DUMP BODY TROUBLESHOOTING HYDRAULIC SYSTEM Dump Body Lowers With Hydraulic Control Lever in the Neutral Position and PTO Disengaged ied ten ase
181. applicable to your unit 4 2 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT Special tools are listed and illustrated in the Repair Parts and Special Tools List RPSTL TMDE and support equipment are listed the Maintenance Allocation Chart Appendix 4 3 REPAIR PARTS Repair parts are listed and illustrated Appendix O of this manual 4 1 5 3805 264 14 amp P Section Il SERVICE UPON RECEIPT Paragraph Page Number Paragraph Title Number 255 ead ee eee Tees 4 2 4 5 Inspection Instructions 4 2 4 6 Servicing Instructions ada aes 4 4 GENERAL When new used or reconditioned M917A1 917 1 w MCS M917A2 and M917A2 w MCS is first received determine whether it has been properly prepared for service and is in condition to perform its mission Follow the inspection instructions in paragraph 4 5 servicing instructions in paragraph 4 6 4 5 INSPECTION INSTRUCTIONS a Read and follow all instructions on DD Form 1397 b Remove all straps plywood tape seals wrapping or any other shipping material WARNING Dry cleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protec tive gloves and goggles is suggested Use in well ventilated area
182. arning may cause personnel injury When connected MCS remote control overrides cab control unit When remote control is disconnected cab control activates To avoid inadvertent opening or closing of gates ALWAYS check gate positions and position of toggle switches on both cab and remote controls before plugging in or unplugging remote control Toggle Switches should be in CLOSED position Failure to follow this warning may cause personnel injury Care must be exercised when using the Material Control System MCS In the event material fails to flow through gates open gate using open control and clear jam using shovel DO NOT attempt to clear material using your hands or feet Failure to follow this warning may cause injury to personnel WARNING WORK SAFETY Unless otherwise specified perform all maintenance with dump truck on level ground transmission in N Neu tral parking brake set and engine off Failure to follow this warning may result in personnel injury e Wear eye protection when using high pressure stream of water to clean dump body Failure to follow this warn ing may result in injury to personnel NEVER work under raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel Although battery ground cable must be connected in order to test electrical circuit voltage dis
183. aulic Filter Service Indicates serviceability of hydraulic filter Indicator Gage 2 3 5 3805 264 14 amp P 2 2 EXTERNAL CONTROLS AND INDICATORS Con t 336 003 Key Control or Indicators Function 3 Cargo Cover Crank Handle 4 Cargo Cover Control Handle 5 Transport Lock Turn clockwise to retract cargo cover and uncover load When not in use handle is stowed in storage pouch and placed in BII box Provides braking action for cargo cover as it extends to cover load Positions are LOCK RELEASE and BRAKE Locks dump body to truck frame Unlocked during normal operation Locked for transporting of dump truck Unlocked position is at 3 o clock Locked position is at 6 o clock A locking pin holds transport lock in desired position 5 3805 264 14 amp P 2 2 EXTERNAL CONTROLS AND INDICATORS Con t 7 Key Control or Indicators Function 6 MCS Air Reservoir Cable Drains MCS air reservoir when pulled Pull M917A1 w MCS and M917A2 w MCS 7 Adjustment Tube Locking Controls amount of MCS gate opening The lower the pin placement the Pin M917A1 w MCS and larger the gate opening Top pin placement locks gate closed M917A2 w MCS 8 MCS Remote Control Plugs into receptacle at left or right of MCS tailgate Four toggle switches M917A1 w MCS and M917A2 w MCS control LEFT LEFT CENTER RIGHT CENTER and RIGHT MCS gates Move swit
184. ay be a corrosion problem C If a corrosion problem is identified it can be reported using SF 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA Pam 738 750 TM 5 3805 264 14 amp P Section EQUIPMENT DESCRIPTION AND DATA Paragraph Page Number Paragraph Title Number Equipment Characteristics Capabilities and Features Location and Description of Major 5 Location and Contents of Plates Decals and Stencils Differences Between Models Equipment Data 1 10 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES a The M917A1 M917A1 w MCS M917A2 and M917A2 w MCS dump truck body consists of a steel body designed to transport and dump or spread aggregate hot mix asphalt or similar materials A sealed open loop hydraulic system raises and lowers the dump body The hydraulic system operates on pressure supplied by a gear pump that is mounted directly to the transmission s PTO b The dump body has a 14 cubic yard 10 7 m 18 5 ton 16 8 metric ton capacity It is constructed of heavy duty steel with an
185. bers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the next higher assembly b Column 2 Component Assembly Column 2 contains the item names of components assem blies subassemblies and modules for which maintenance is authorized Column 3 Maintenance Function Column 3 lists the functions to be performed on the item listed in Column 2 For detailed explanation of these functions see paragraph B 2 1 Services Inspect test service adjust aline calibrate and or replace 2 Fault location troubleshooting The process of investigating and detecting the cause of equipment malfunctioning the act of iso lating a fault within a system or unit under test UUT 3 Disassembly assembly The step by step breakdown taking apart of a spare function group coded item to the level of its least component that is assigned SMR code for the level or maintenance under consideration i e identified as maintenance signif icant 4 Actions Welding grinding riveting straightening facing machining and or resurfacing 5 3805 264 14 amp P 3 EXPLANATION COLUMNS THE MAC SECTION II Con t NOTE When a complete replace or repair task performed at higher level maintenance includes lower level maintenance tasks equipment condition follow on tasks the lower level work time figures in the MAC must be added to the higher le
186. bes the malfunction If the appropriate symptom is not listed notify your supervisor 2 Turn to the page in Table 311 where the troubleshooting procedures for the malfunction in question are described Headings at the top of each page show how each troubleshooting procedure is organized Malfunction Test or Inspection in step number order and Corrective Action 3 Perform each step in the order listed until the malfunction is corrected and the item being inspected is operational DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so 3 2 EXPLANATION OF COLUMNS The columns in Table 3 1 are defined as follows 1 MALFUNCTION A visual or operational indication that something is wrong with the equip ment 2 TEST OR INSPECTION A procedure to isolate the problem in a system or component 3 CORRECTIVE ACTION A procedure to correct the problem 3 3 TM 5 3805 264 14 amp P 3 3 TROUBLESHOOTING SYMPTOM INDEX Troubleshooting Procedure Page DUMP BODY TROUBLESHOOTING HYDRAULIC SYSTEM Dump Body Raises and Lowers 5 3 7 Dump Body Will Not Lower When Hydraulic Control Lever is Placed DOWN eo a tw cuc id Dump Body Will Not Raise When Hydraulic Control Lever is Placed in NN MCS M917A1 w MCS and M917A2 w MCS MCS Gate Will Not MCS Gate Will No
187. ble in standard sizes as well as various undersized and or oversized sizes Service kits for reconditioning certain parts and service sets which include all parts necessary to complete a procedure are also available 4 26 WELDING WARNING Provide adequate ventilation and personal protective equipment before starting any welding operation Contact your unit local Industrial Hygienist or Safety Officer for assistance Failure to follow this warning may result in injury to personnel CAUTION Before welding the following components must be disconnected DDEC ECU ABS ECU CTIS ECU Datalogger and batteries TM 9 2320 363 20 or TM 9 2320 302 20 If welding on a trailer it must be uncoupled from dump truck Failure to follow this caution may damage electronic components Refer to TM 9 237 Operator s Manual for Welding Theory and Application for instructions on welding components 4 27 ELECTRICAL REPAIR a General Specific electrical system maintenance tasks are covered in Chapter 4 Section VI of this manual b Wiring Harness and Cable Repair Wiring harness and cable repair for the dump truck body is the same as for the dump truck chassis Refer to instructions Chapter 3 of TM 9 2320 363 20 or TM 9 2320 302 20 4 12 TM 5 3805 264 14 amp P Section IV UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS Paragraph Page Number Paragraph Title Number 4
188. brication Procedures 4 30 4 14 General PMCS Procedures Operator i teet Pete dr o eeu alt a Ad eir Bob bep dude 2 5 2 8 Unit celta 4 31 4 15 Ground Points 4 20 4 9 H Heat Shrinkable 4 19 4 8 Hoses Tagging Wires and Po toes eae teet eae ea Re EE RR 4 17 4 8 Hydraulic System Principles of Operation 1 17 1 16 Hydraulic Control Lever Cable Replacement 4 73 4 127 Control Lever Replacement 4 72 4 117 Cylinder Repair s serrr eanne tent pre e a pa Apa aes 5 7 5 23 Cylinder Replacement 5 6 5 20 Hoses and Fittings Replacement 4 74 4 136 Oil Filter Element Replacement 4 77 4 145 Oil Filter Service Indicator Gage Replacement 4 78 4 147 Pump Repair 25k Eee 5 5 5 14 Pump Replacement 5 4 5 10 Reservoir s xui aeg Ae ER e MALA 4 76 4 143 Reservoir Replacement 4 75 4 140 Inspection Instructions
189. cargo cover is over load damage to crank assembly may result 3 Carefully lift cargo cover control handle 6 toward RELEASE position until cargo cover begins to move Keep hand on handle so that cover moves slowly If cargo cover moves too fast move handle down slightly to apply brakes 4 When cargo cover is fully over load release cargo cover control handle 6 Handle will return to top LOCK position 5 Unfasten rubber strap 1 from eyebolt 3 and fasten to dump body weldment 2 2 41 TM 5 3805 264 14 amp P 2 15 OPERATING BODY PROPS WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel NOTE e Use body props to support a raised EMPTY dump body for inspection or main tenance e Refer to paragraph 2 10 for operation of hydraulic control lever to raise and lower dump body a Utilizing Body Props 1 Start engine place main light switch in SER DRIVE or STOP LIGHT position and engage PTO TM 9 2320 363 10 or TM 9 2320 302 10 2 Check that transport lock is unlocked paragraph 2 1 3 Raise dump body 1 TS V TU 4 Raise body prop 4 on each a side of vehicle chassis 3 until prop contacts stop 5 MA gt CAUTION Dump body must be lowered onto body props with
190. ch Two personnel are required to install or remove side boards Failure to follow this warning may cause injury to personnel 5 3805 264 14 amp P WARNING HYDRAULIC SYSTEM e DO disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel e prevent burns use caution when removing fill cap of hydraulic reservoir when hydraulic fluid is hot Avoid contact with hot hydraulic oil Use extreme care when filling sampling or draining hydraulic oil Failure to follow this warning may result in injury to personnel WARNING MATERIAL CONTROL SYSTEM MCS Use extreme caution when adjusting MCS gate openings NEVER adjust gate openings when gates are open Failure to follow this warning could result in injury to personnel e Keep hands and feet away from gate openings at all times Failure to follow this warning could result in injury to personnel DO NOT stand or walk behind dump truck when it is dumping or in raised position When using MCS remote control always walk or stand to side of dump body Failure to follow this warning may result in personnel injury DO NOT connect or disconnect MCS remote control when dump body is being raised or lowered Failure to fol low this w
191. ch es to OPEN or CLOSED positions When not in use remote control is stowed in storage pouch and placed in box 2 5 2 6 Blank 5 3805 264 14 amp P Section Il OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS Paragraph Page Number Paragraph Title Number General 2 oth Ba are act aang eho cae GAs arate Explanation of Table General PMCS Procedures Operator Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS 917 2 and M917A2 w MCS Dump 2 10 2 3 GENERAL NOTE Refer to TM 9 2320 363 10 or TM 9 2320 302 10 for Operator PMCS for the dump truck chassis To ensure that the dump truck is ready for operation at all times it must be inspected on a regular basis so that defects may be found and corrected before they result in serious damage equipment failure or injury to personnel Table 2 1 contains systematic instructions on inspections adjustments and corrections to be performed by the operator crew to keep your equipment in good operating condition and ready for its primary mission 2 4 EXPLANATION OF TABLE ENTRIES a Item Number Item No Column Numbers in this column are for reference When completing DA Form 2404 Equipment Inspection and Maintenance Worksheet include the item number
192. changes or revisions and for new publications relating to material covered in this technical man ual A 3 FORMS Refer to DA Pam 738 750 Functional Users Manual for the Army Maintenance Management System TAMMS for instructions on the use of maintenance forms Equipment Control Record DA Form 2408 9 Equipment Inspection and Maintenance DA Form 2404 Equipment Log Assembly DA Form 2408 Maintenance DA Form 2407 Preventive Maintenance Schedule and Record DD Form 314 Processing and Deprocessing Record for Shipment Storage and Issue of Vehicles and Spare DD Form 1397 Product Quality Deficiency 4 SF Form 368 Recommended Changes to Equipment Technical Publications DA Form 2028 2 Recommended Changes to Publications and Blank Forms DA Form 2028 Report of Discrepancy 1 SF Form 364 A 4 FIELD MANUALS Basic Cold Weather 5 4 FM 31 70 Chemical and Biologic
193. ck Number assigned to the item Use it to request or requisition the item d Column 4 Item Name Description Commercial and Government Entity Code CAGEC Part Number Indicates the Federal Item Name and if required a description to identify the item The last line for each item indicates the Commercial and Government Entity Code CAGEC in parentheses followed by the part number if applicable e Column 5 Unit of Measure U M Unit of Issue This measure is expressed by a two character alphabetical abbreviation e g ea in pr If the unit of measure differs from the unit of issue as shown in the Army Master Data File AMDF requisition the lowest unit of issue that will satisfy your requirements F 1 5 3805 264 14 amp P Section EXPENDABLE AND DURABLE ITEMS LIST 1 2 3 4 5 Item National Item Name Description U M Number Level Stock Number CAGEC Part Number U I 1 O ADHESIVE Loctite Minute Bond 312 05972 31231 8040 01 024 6991 50 Milliliter Bottle ml 2 O BARRIER MATERIAL Greaseproof Waterproofed Flexible 81349 MIL B 121 8135 00 171 0930 100 Yard Roll yd 3 O 7920 00 061 0038 BRUSH Scrub 83421 7920 00 061 0038 ea 4 O 7920 00 900 3577 BRUSH Wire 17987 3577 ea 5 CLEANING COMPOUND Solvent 81349 MIL PRF 680 6850 01 474 2320 5 Gallon Can gl 6850 01 474 2321 50 Gallon Drum gl 6 O COMPOUND Dishwashing Hand 83421 7930 00 899 9534 7930 00 899 9534 5 Gal
194. connect battery ground cable before performing resistance tests or replacing parts This will prevent shock to personnel and damage to parts and equipment DO NOT touch heat shrinkable tubing for at least 30 seconds after heating Heat shrinkable tubing is hot and will burn you 5 3805 264 14 amp P e Hydraulic cylinder sleeves may extend downward as hydraulic cylinder is lifted Expect sleeve movement time hydraulic cylinder is handled Failure to do so may result in serious injury to personnel DO disconnect tailgate release or MCS air lines while chassis or MCS air systems are pressurized Air system pressure must be released before air lines are disconnected A line disconnected under pressure may cause personnel injury Provide adequate ventilation and personal protective equipment before starting any welding operation TM 9 237 Contact your unit local Industrial Hygienist or Safety Officer for assistance Failure to follow this warning may result in injury to personnel WARNING NBC EXPOSURE If NBC exposure is suspected all air filter media should be handled by personnel wearing protective equipment Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures WARNING gt IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PERSONNEL WEARING FULL NBC PROTECTIVE EQUIPMENT SEE OPERA TOR MAINTENANCE MANUAL 7690 01 114 370
195. connector 6 3 Disconnect four wiring harness leads 4 from toggle switches 2 Remove MCS control unit 3 4 38 TM 5 3805 264 14 amp P 4 42 MCS CONTROL UNIT MAINTENANCE M917A1 W MCS and M917A2WI MCS Con t b DISASSEMBLY 1 Remove indicator light 9 from bracket 11 40 2 Remove four nuts 10 and toggle switches 2 from bracket 11 CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions d ASSEMBLY 1 Install four toggle switches 2 to bracket 11 with four nuts 10 2 Install indicator light 9 to bracket 11 INSTALLATION 1 Connect four wiring harness leads 4 to toggle switches 2 2 Connect wiring harness connector 6 to indicator light connector 5 3 Install MCS control unit 3 on shift tower 1 with four washers 8 and screws 7 4 39 5 3805 264 14 amp P 4 42 MCS CONTROL UNIT MAINTENANCE M917A1 W MCS and M917A2WI MCS Con t M917A2 W MCS f MCS SWITCH REPLACEMENT 1 Drain air system TM 9 2320 302 10 2 Remove six screws 12 and rear panel 13 371 202 3 Disconnect wire lead at faulty switch 14 14 15 4 Depress two tangs 15 on switch 14 remove switch through top of shift tower cover B 16 O
196. d Use dry cleaning solvent Item 5 Appendix F all metal surfaces Use dishwashing compound Item 6 Appendix F and water when you clean rubber plastic and painted surfaces 2 Deterioration Rust and Corrosion a Be alert for deterioration of plastic and rubber materials Report it to your supervisor b Check metal parts for rust and corrosion If any bare metal or corrosion exists clean and apply a light coat of lubricating oil Item 15 Appendix Report it to your supervisor 3 Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose tighten it 4 Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to your supervisor 5 Electric Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and ensure that the wires are in good condition 6 Hydraulic Hoses and Lines Look for wear damage and signs of leaks Ensure that clamps and fittings are tight Wet spots indicate leaks but a stain around a fitting or connector can also mean a leak If a leak comes from a loose fitting or connector tighten it If something is broken or worn out correct it if authorized by the Maintenance Allocation
197. deficiencies prior to storage or obtain a deferment from the approving authority e Lubrication Lubricate equipment in accordance with Chapter 8 Section I f General Cleaning Painting and Preservation CAUTION DO NOT direct water under pressure against unsealed electrical systems or any exterior opening Failure to follow this caution may result in damage to equipment 1 Cleaning Clean the equipment of dirt grease and other contaminants but do not use vapor degreasing 2 Painting Remove rust and damaged paint by scraping wire brushing sanding or buffing Sand to a smooth finish and spot paint as necessary TB 43 0209 3 Preservation After cleaning and drying immediately coat unpainted metal surfaces with oil or grease as appropriate NOTE e Place a piece of barrier material Item 2 Appendix between desiccant bags and metal surfaces e Air circulation under draped covers reduces deterioration from moisture or heat 4 Weatherproofing Sunlight heat moisture humidity and dirt tend to accelerate deterio ration Install all covers authorized for the equipment Close and secure all openings except those required for venting and draining Seal openings to prevent the entry of rain snow or dust Insert desiccant when complete seal is required Place equipment and provide blocking or framing to allow for ventilation and water drainage Support cover away from item surfaces which may rust
198. dix Two self locking nuts General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel a REMOVAL NOTE e Wires should be tagged before disconnecting paragraph 4 17 e Note location of tie wraps and routing of wiring harness prior to removal to aid in installation 1 Disconnect MCS tailgate wiring harness connector 3 from truck to MCS tailgate wiring harness recepta cle 2 at left dump body pillar 1 4 54 5 3805 264 14 amp P 4 47 TRUCK TO MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND M917A2 WIMCS Con t 2 Remove four screws 7 and pull cover plate 5 away from dump body pillar 1 3 Remove two self locking nuts 4 and screws 6 securing truck to MCS tailgate wiring har ness receptacle 2 to cover plate 5 Discard self locking nuts 4 Disconnect truck to MCS tailgate wiring harness 9 from chassis wiring harness 8 5 Remove truck to MCS tailgate wiring harness 9 A LIE 4 55 TM 5 3805 264 14 amp P 4 47 TRUCK TO MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS AND M9
199. dling heavy parts One self locking nut WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment a REMOVAL 1 Remove self locking nut screw clamp and release air reservoir draincock lanyard 4 from MCS tailgate cover 2 Discard self locking nut 2 Remove ten self tapping screws 3 and MCS tailgate cover 2 from MCS tailgate 1 3 336 020 4 73 TM 5 3805 264 14 amp P 4 53 MCS TAILGATE COVER REPLACEMENT M917A1 W MCS AND M917A2 W MCS Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions INSTALLATION 1 Aline screw holes on MCS tailgate cover 2 with screw holes on MCS tailgate 1 2 Install and tighten ten self tapping screws 3 3 Secure air reservoir draincock lanyard 4 to MCS tailgate cover 2 with clamp screw and new self lock ing nut 336 020 4 74 5 3805 264 14 amp P 4 54 MCS GATE REPLACEMENT M917A1 W MCS AND M917A2 W MCS This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions
200. e The control valve has a relief valve which is set at 2500 psi 17 238 kPa 3 Hydraulic Cylinder a The hydraulic cylinder is a three stage telescoping cylinder with a 124 in 315 cm stroke b The bottom of the hydraulic cylinder is attached by a pivot pin to the cylinder support frame c The collar of the hydraulic cylinder is attached by pivot pins to the dump body inside the long beam at the front of the dump body d The pivot pins at the top and bottom of the cylinder allow the cylinder to pivot as it is extended and retracted Composite lubrication free bearings at these pivot points ensure smooth maintenance free operation 4 Hydraulic Filter The filter is located on top of the reservoir It filters hydraulic fluid as it returns to the reservoir through the return line from the control valve b The filter element is made of 10 micron synthetic material A filter service indicator gage indicates when the filter needs replacing c The filter has a by pass feature 5 Hydraulic Reservoir a The reservoir is an all steel container with 12 75 gal 48 2 capacity b It is mounted upright bolted to the hydraulic cylinder mount between the hydraulic cylinder and the vehicle cab c The fill cap is also a breather and a strainer It must be kept clean at all times 5 3805 264 14 amp P 1 17 HYDRAULIC SYSTEM Con t d The oil level in the reservoir can be seen through the si
201. e 1 5 3805 264 14 amp P HOW USE THIS MANUAL This manual is designed to help you operate and maintain the M917A1 917 1 w MCS M917A2 and M917A2 w MCS Dump Truck Body FEATURES OF THIS MANUAL A table of contents is provided at the beginning of this manual An index of all paragraphs con tained within a section is found at the beginning of each section WARNINGs CAUTIONs NOTEs subject headings and other important information are high lighted in BOLD print as a visual aid WARNING A WARNING indicates a hazard which can result in death or serious injury CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment NOTE A NOTE is a statement containing information that will make the procedure easier to perform Statements and words of particular importance are printed in CAPITAL LETTERS to create emphasis Instructions are located with illustrations that show the specific task which the operator or mechanic is working Dashed leader lines used in illustrations indicate that called out items are not visible i e they located within the structure Dashed leader lines in the Lubrication Chart indicate that lubrication is required on BOTH sides of the equipment Technical instructions include metric units in addition to standard units A metric conversion chart is provided on
202. e Check for damage to tailgate locking Tailgate locking linkage is dam Locking linkage 13 aged Linkage 2 14 TM 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If REAR AND RIGHT SIDE 10 After Overall View Check under vehicle for evidence of a Class hydraulic fluid leaks hydraulic fluid leakage are evident b Check dump body for obvious dam b Damage that would impair age that would impair operation e g operation is evident missing or damaged marker clear ance lights 11 taillight 17 body prop 14 and adjustment chain 12 at tailgate 11 After Tailgate Check for damage to tailgate locking Tailgate locking linkage is dam Locking linkage 13 aged Linkage NOTE Perform the following After PMCS checks with engine on and air system fully pressurized 12 After Tailgate Operate tailgate release control valve Tailgate will not unlock or lock Release lever inside cab paragraph 2 1 Lever Check that tailgate unlocks and locks properly 2 15 5 3805 264 14 amp P mine level of hydraulic in reservoir 21 Level
203. e Equipment TB 43 0001 39 Series Warranty Program for M915 Family of Vehicles TB 9 2320 363 15 A 6 TECHNICAL MANUALS Direct and General Support Maintenance Manual for M915A2 M916A1 M916A2 917 1 M917A1 wMCS TM 9 2320 363 34 Inspection Care and Maintenance of Antifriction Bearings TM 9 214 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including 5 TM 9 247 Operator s Manual for M915A2 M916A1 M916A2 M917A1 and M917A1 wMCS Chassis TM 9 2320 363 10 Operator s Manual for M915A3 M916A3 M917A2 and M917A2 wMCS Chassis TM 9 2320 302 10 Operator s Manual for Welding Theory and Application TM 9 237 Painting Instructions for Army TM 43 0139 Procedures for Destruction of Equipment to Prevent Enemy Use Mobility Equipment Command TM 750 244 3 Railcar Loading Procedures 242 2 2 2 42 TM 55 601 Storage and Materials Handling TM 743 200 1 Unit Direct Support and General Support Repair Parts and Special Tools Li
204. e capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment e Hydraulic cylinder sleeves may extend downward as hydraulic cylinder is lifted Expect sleeve movement any time hydraulic cylinder is handled Failure to do may result in serious injury to personnel 6 Remove hydraulic cylinder 1 from vehicle Move hydraulic cylinder to a safe work area 5 21 TM 5 3805 264 14 amp P 5 6 HYDRAULIC CYLINDER REPLACEMENT Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions c INSTALLATION WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 1 Install lifting sling through loop in hydraulic cyl inder 1 and attach lifting sling to lifting device Position hydraulic cylinder 1 to vehicle While holding hydraulic cylinder 1 securely position left and right mounting brackets 3 and 11 to hydraulic cylinder 1 4 Install left and right mounting brackets 3 and 11 to dump body 12 with six screws 4 and new locknuts 2 5
205. e mechanical pneumatic hydraulic or electrical char acteristics of an item end item and comparing those characteristics with prescribed standards C Service Operations required periodically to keep an item in proper operating condition 0 to clean includes decontaminate when required to preserve to drain to paint or to replenish fuel lubricants chemical fluids or gases d Adjust To maintain or regulate within prescribed limits by bringing into proper position or by set ting the operating characteristics to specified parameters e Aline To adjust specified variable elements of an item to bring about optimum or desired perfor mance B 1 TM 5 3805 264 14 amp P B 2 MAINTENANCE FUNCTIONS Con t f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipment used in precision measurement Consists of comparisons of two instru ments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared g Remove Install To remove and install the same item when required to perform service or other maintenance functions Install may be the act of emplacing seating or fixing onto position a spare repair part or module component or assembly in a manner to allow the proper functioning of an equipment or system h Replace To remove an unserviceable item a
206. e scribe marks from disassembly to properly assemble pump housings Light tapping with rubber hammer may be required to seat housings in place 8 Install new gasket seal 18 in gear housing 13 and place gear housing on pump housing 19 Install drive shaft 4 and gearshaft 9 into gear housing 13 Check for free turning of gears 10 Install new gasket seal 18 on gear housing 13 Apply light coat of grease to drive shaft 4 11 Place end housing 11 over drive shaft 4 and carefully press housing in place seating gears against thrust plate 10 11 13 NOTE Ensure that stud is installed in correct location as noted in disassembly 12 Install three screws 5 three washers 6 stud 7 washer 6 and nut 8 in place to secure pump housings Tighten screws and stud in crisscross pattern and torque to 200 Ib ft 271 N m Check for free shaft movement by turn ing drive shaft 4 with a wrench 13 Install one washer 6 and nut 8 on stud 7 and tighten by hand 5 18 5 3805 264 14 amp P 5 5 HYDRAULIC PUMP REPAIR Con t 14 Install seal retainer 3 spacer 2 and new retaining ring 1 on drive shaft 4 FOLLOW ON TASKS Install hydraulic pump paragraph 5 4 5 19 TM 5 3805 264 14 amp P 5 6 HYDRAULIC CYLINDER REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Dump body raised and sup
207. ed by engineering and construction units to transport and dump or spread aggregate hot mix asphalt or similar materials 1 2 MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738 750 Functional User s Manual for the Army Maintenance Management System as contained in the Maintenance Management Update 1 3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Refer to TM 750 244 3 for procedures for destruction of Army materiel to prevent enemy use 1 1 TM 5 3805 264 14 amp P 1 4 PREPARATION FOR STORAGE OR SHIPMENT Refer tq Chapter 4 Section X for instructions for preparing the dump truck body for storage or shipment 1 5 OFFICIAL NOMENCLATURE NAMES DESIGNATIONS AND ABBREVIATIONS NOTE Refer to ASME Y14 38 1999 for standard abbreviations Official Name Common Name or Abbreviation Central Tire Inflation CTIS Corrosion Prevention and CPC Material Control 2 2 MCS Power Take Off er pui os RE Ee ee PTO 1 6 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRs If your dump truck needs improvement le
208. ed to the item and will be used for requisitioning purposes C Column 3 Description and Usable On Code Indicates the Federal item name and if required a minimum description in parentheses to identify and locate the item The entry for each item ends with the Commercial and Government Entity Code CAGEC in parentheses followed by the part number Usable On Code indicates the vehicle to which the item is assigned Usable on codes for the M917A1 M917A1 w MCS M917A2 and M917A2 w MCS are Usable On Code Model 1 M917A1 7E1 M917A1 w MCS 7A2 M917A2 7E2 M917A2 w MCS D 1 5 3805 264 14 amp P D 3 EXPLANATION COLUMNS Con t d Column 4 Unit of Issue Indicates how the item is issued for the National Stock Number shown in Column 2 Column 5 Quantity Required Qty Rad Indicates the quantity of the item authorized to be used with the equipment Section Il COMPONENTS OF END ITEM There are currently no assigned 5 3805 264 14 amp P Section Ill BASIC ISSUE ITEMS 1 2 3 4 Illus National Description Usable Number Stock Number CAGEC Part Number On Code 3040 01 459 5141 Control Unit Assembly MCS 7E1 7E2 tool pouch storage box 5X050 128214 5140 00 329 4306 Pouch Mechanics Tool TAA storage box 2 2 80049 50 8016 5120 00 293 3336 Shovel Hand Rd Pt D Hdl 7E1 Short Size 2 2
209. emi annual Semi annual Semi annual Stabilizer Tailgate Release Air Cylinder Lines Tailgate Locking Linkage WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel Inspect stabilizer for loose mounting or damage If damaged notify Direct Support Maintenance WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel With vehicle air system pressurized check air lines fittings and tailgate release air cylinder under dump body for loose mounting leaks or damage A solution of detergent Item 9 Appendix F and water applied to lines and fittings will help locate leaks WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel Inspect tailgate locking linkage for breaks bends cracks corrosion and loose mounting 4 23 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truc
210. es To avoid inadvertent opening or closing of gates ALWAYS check gate positions and position of toggle switches on both cab and remote controls before plugging in or unplugging remote control Toggle switches should be in CLOSED posi tion Failure to follow this warning may cause personnel injury c Plug MCS remote control 28 into receptacle 29 at either side of MCS tailgate 23 Check that appropriate MCS gate 26 opens and closes as each toggle switch 27 is operated d Remove locking pins 24 from bot tom hole and install in top hole of adjustment tubes 25 Table 2 1 Operator Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 14 After MCS Con t Tailgate WARNING M917A1 w MCS and When connected MCS remote control M917A2 overrides cab control unit When w MCS remote control is disconnected cab c MCS remote control does not work and is required for mis sion 2 20 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If WARNING NEVER work under a raised dump body unless
211. eve 3 Remove nylon sling and bottom retaining ring 9 from plunger 10 Remove wear ring 10 piston ring 11 and two piston rings 12 from other end of plunger 1 Discard wear ring NOTE Perform steps 11 thru 18 to remove 13 next sleeve 11 Remove retaining ring 13 from sleeve 14 5 26 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t NOTE Hydraulic cylinder may be posi tioned horizontally and tipped to extend sleeve Wiper retainer and seal should come out as sleeve is extended a few inches If not apply a three inch strip of tape at a 45 degree angle to a cleaned section of sleeve Retract and again extend sleeve to remove wiper retainer and seal Extend sleeve 3 to expose wiper retainer 16 and seal 17 Remove wiper retainer and seal from sleeve Remove wiper 15 from wiper retainer Discard wiper wiper retainer and seal Remove tape from sleeve if used Retract sleeve 3 Remove spiral retaining ring 18 from sleeve 14 Discard spiral retaining ring Extend sleeve 3 a few inches and apply tape to a cleaned section of sleeve Retract and extend sleeve 3 to expose bot tom guide ring 19 Remove and discard bot tom guide ring 5 27 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 16 Using two small screwdrivers remove bottom retaining ring 20 from groove of sleeve 14 Position four hydraulic cylinder
212. ficient operation b Refer to TM 9 2320 363 10 or TM 9 2320 302 10 for and related to the dump truck chas sis D 2 GENERAL The and BII Lists are divided into the following sections a Section Components of End ltem This listing is for informational purposes only and is not authority to requisition replacements These items are part of the end item but are removed and separately pack aged for transportation or shipment As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Illustrations are furnished to assist you in identifying the items b Section Ill Basic Issue Items These are the minimum essential items required to place the truck in operation to operate it and to perform emergency repairs Although shipped separately packaged BII must be with the truck during operation and whenever it is transferred between property accounts The illustrations will assist you with hard to identify items This manual is your authority to request requisition replacement based on TOE MTOE authorization of end item D 3 EXPLANATION OF COLUMNS Below is an explanation of columns found in the tabular listings a Column 1 Illustration Number Number This column indicates the number of the illus tration that shows the item b Column 2 National Stock Number Indicates the National Stock Number NSN assign
213. fied by the part number in the MF Made at DS AVUM DESCRIPTION AND USABLE ON CODE UOC column and listed in the bulk Level materiel group of the repair parts list in this RPSTL If the item is authorized to MH Made at GS Level you by the third position of the SMR code but the source code indicates it is ML Made at Specialized made at a higher level order the item from the higher level of maintenance Repair Activity SRA MD MadeatDepot 2 1 AO Assembled by Items with these codes are not to be requested requisitioned individually The UM AVUM Level parts that make up the assembled item must be requisitioned or fabricated AF Assembled by and assembled at the level of maintenance indicated by the source code If DS AVUM Level the third position code of the SMR code authorizes you to replace the items AH Assembled by GS but the source code indicates that the item is assembled at a higher level Level order the item from the higher level of maintenance AL Assembled by SRA AD Assembled at Depot 5 3805 264 14 amp P C 3 EXPLANATION OF COLUMNS SECTIONS AND III Con t NOTE Cannibalization of controlled exchange when authorized may be used as a source of supply for items with the following source codes except for those source coded XA Code Application Explanation RA up DO NOT requisition an XA coded item Order its next higher assembly XB
214. figure and item number sequence Bulk materials are listed by item name sequence at the end of the section Repair part kits are listed separately in their own functional group within Section Il Repair parts for reparable special tools are also listed in this section Items listed are shown on the associated illustra tion s figure s b Section Ill Special Tools List list of special tools special TMDE and other special support equipment authorized by this RPSTL as indicated by Basis of Issue BOI information in the DESCRIPTION AND USABLE ON CODE UOC column for the performance of maintenance Not applicable Refer to TM 9 2320 363 24P Section IV Cross Reference Indexes list in National Item Identification Number NIIN sequence of all National stock numbered items appearing in the listing followed by a list in alphanumeric sequence of all part numbers appearing in the listings National Stock Numbers NSN and part numbers are cross referenced to each illustration figure and item number appearance C 3 EXPLANATION OF COLUMNS SECTIONS AND III a ITEM NO Column 1 Indicates the number used to identify items called out in the illustration b SMR CODE Column 2 The SMR code is a five position code containing supply requisitioning information maintenance category authorization criteria and disposition instruction as shown in the following breakout Source Code Maintenance Code
215. for the check service indicating a fault Item numbers also appear in the order that you must perform checks and services for the interval listed b Interval Column This column tells you when you must perform the procedure in the procedure column 1 Before procedures must be done before you operate the dump truck 2 During procedures must be done while you are operating the dump truck 3 After procedures must be done immediately after you have operated the dump truck 4 Weekly procedures must be done once each week 5 Monthly procedures must be done once each month C Location Item to Check Service Column This column provides the location and item to be checked or serviced NOTE WARNINGs and CAUTIONs appearing in your PMCS table should always be observed WARNINGs and CAUTIONSs appear before applicable procedures You must observe these WARNINGS to prevent serious injury to yourself and others and CAUTIONSs to prevent your equipment from being damaged d Procedure Column This column gives the procedure you must perform to check or service the item listed in the Item to Check Service column to know if the equipment is ready or available for its intended mis sion or for operation You must perform the procedure at the time stated in the interval column 2 7 TM 5 3805 264 14 amp P 2 4 EXPLANATION OF TABLE ENTRIES Con t e Not Fully Mission Capable If Column Information in this column tells you what fa
216. g alphanumeric sequence paragraph C 4b Both indexes cross reference you to the illustration figure and item number of the item you are looking for 2 Second Turn to the figure and item number verify that the item is the one you re looking for then locate the item number in the repair parts list for the figure C 7 ABBREVIATIONS For standard abbreviations see MIL STD 12D Military Standard Abbreviations for Use on Drawings Specifications Standards and in Technical Documents Abbreviations Explanation MC National Item Identification Number consists of the last 9 digits of the NSN Repair Parts and Special Tools Lists 5 3805 264 14 amp P SECTION II 4 2 10 5 10 1 Figure 1 Control Unit Assembly MCS SECTION II 1 NO 10 2 SMR CODE PAOOZ PAOZA PAOZZ PFOOZ XDOZZ PAOZA PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 3 NSN 3040014595141 6150014975582 5935008563513 5930015076990 5925014993416 5999014665398 9905014987858 9905014987857 9905014987860 9905014987859 5930014970704 TM 5 3805 264 14 amp P 4 5 6 7 PART CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 06 ELECTRICAL SYSTEM GROUP 0608 MISCELLANEOUS ITEMS FIG 1 CONTROL UNIT ASSEMBLY MCS 5X050 128214 CABLE ASSEMBLY CONT 1 UOC 7E1 7E2 5X050 403412 CABLE ASSEMBLY POW
217. ght tube on the outside of the reservoir An oil level decal mounted adjacent to the sight tube is marked FULL ADD 2 QTS and ADD 1 GAL Hydraulic Control Lever Mechanical Linkage Hydraulic Reservoir Hydraulic Cylinder Oil Flow Raise p Lower 1 17 1 18 Blank TM 5 3805 264 14 amp P CHAPTER 2 OPERATING INSTRUCTIONS Section l DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS Paragraph Page Number Paragraph Title Number 2 1 Cab Mounted Controls and Indicators 2 1 External Controls and Indicators 2 3 2 1 CAB MOUNTED CONTROLS AND INDICATORS M917A2 371 031 M917A1 Key Control or Indicator Function 1 Hydraulic Control Lever Raises and lowers dump body Squeeze T handle together and pull lever back to UP position to raise dump body Push lever forward to DOWN position to lower dump body Place in N Neutral detent position to stop dump body movement Lever will not operate to raise dump body if main light switch is in blackout mode 2 MCS Control Unit Four toggle switches control LEFT LEFT CENTER RIGHT CENTER and M917A1 w MCS and RIGHT MCS gates Move switch es forward to OPEN position and rearward M917A2 w MCS to CLOSE position 3 MCS Indicator Light Red light indicates MCS has power M917A1 w MCS and M917A2 w MCS 2 1 5 3805 264 1
218. gs at all times Failure to follow this warning could result in injury to personnel NOTE Operation requires two personnel driver and assistant driver e Follow general dumping instructions in paragraph 2 10 with minor differences Differences will be pointed out as they occur a Follow instructions in paragraph 2 10 to prepare to dump except for the following steps 1 DO NOT unlock tailgate 2 Adjust MCS gate openings paragraph 2 12 b Ensure that toggle switches on MCS control unit inside cab are in CLOSE position paragraph 2 1 Remove MCS remote control 1 from stowage Ensure that toggle switches 5 are CLOSED position Plug remote control into receptacle 2 at right or left side of MCS tailgate 3 d Move toggle switches 5 to OPEN position Depending on desired spreading pattern all gates 4 or selected gates may be opened Raise dump body 2 3 ft 61 91 stop Material should begin to spill out through gates 4 f Have driver pull forward with transmission in first gear TM 9 2320 363 10 or TM 9 2320 302 10 Maintain a steady speed not to exceed 3 mi h 5 km h Have assistant driver check thickness of dumped material to determine if gate openings need adjusting g If adjustment is needed stop dump truck lower dump body close gates 4 place transmission in N Neutral and set parking brake Adjust MCS gate openings paragraph 2 12 h Maintain a steady speed until all mate
219. h or injury to personnel and damage to equipment Raise tailgate 5 to dump body 2 2 Position tailgate 5 so that bottom pins 6 are resting on dump body stops 7 and tailgate hinge pin holes are alined with dump body hinge pin holes 3 Install hinge pins 1 and lynch pins 3 to each side of tailgate 5 4 Remove lifting slings 4 from tailgate 5 FOLLOW ON TASKS e Lubricate tailgate hinge pins Chapter J Section Start engine and pressurize air systems TM 9 2320 363 10 TM 9 2320 302 10 Set tailgate release control valve lever to LOCKED position paragraph 2 1 e Latch tailgate chains paragraph 2 11 4 67 TM 5 3805 264 14 amp P 4 51 TAILGATE RELEASE AIR CYLINDER REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Tailgate release control valve lever UNLOCKED position paragraph 2 1 Dump body raised and supported on body props paragraph 2 15 Chassis air system drained TM 9 2320 363 10 or TM 9 2320 302 10 Tools Test Equipment General mechanic s tool kit Item 8j Appendix I c Installation Materials Parts Marker tags Item 20 Appendix Two cotter pins Personnel Required Two General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY DO NOT disconnect air lines while air system
220. hains released paragraph 2 11 General Safety Instructions Use extreme caution when handling heavy parts Personnel Required Two Tools Test Equipment General mechanic s tool kit Item 8 Appendix Lifting slings three Item 6 Appendix Suitable lifting device a REMOVAL WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment 1 Attach lifting slings 4 to tailgate 5 and remove slack from lifting slings 2 Remove lynch pins 3 and hinge pins 1 from each side of tailgate 5 4 66 5 3805 264 14 amp P 4 50 TAILGATE REPLACEMENT M917A1 AND M917A2 Con t 3 Lift tailgate 5 from dump body 2 and place tailgate in a safe work area b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions c INSTALLATION WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in deat
221. ify Direct Support 10 DUMP BODY LOWERS WITH HYDRAULIC CONTROL LEVER IN THE NEUTRAL POSITION AND PTO DISENGAGED Step 1 Check for damaged or out of adjustment hydraulic control lever cable Adjust hydraulic control lever cable paragraph 4 73 Replace damaged hydraulic control lever cable paragraph 4 73 Step 2 Dump body still will not operate properly Notify Direct Support 11 DUMP BODY RAISES AND LOWERS SLUGGISHLY Step 1 Check hydraulic filter service indicator gage Service hydraulic oil filter paragraph 4 77 Step 2 Check engine idle speed TM 9 2320 363 20 or TM 9 2320 302 20 Step 3 Check for damaged hydraulic hoses Replace damaged hydraulic hoses paragraph 4 74 Step 4 Check for binding bearings at pivot points of dump body hydraulic cylinder and stabilizer Notify Direct Support TM 5 3805 264 14 amp P Section ELECTRICAL SYSTEM MAINTENANCE Paragraph Page Number Paragraph Title Number Body Up Switch Replacement abba d podre dd 4 32 4 39 Transport Lock Switch Replacement 4 34 Taillight Repla ebielib duces de qud Rund 4 36 4 41 Marker Clearance Light Replacement 4 37 MCS Control Unit Maintenance M917A1 w MCS and 917 2 w MCS 4 38 4 43 MCS Remote Control Repair M917A1w MCS M917A2 4 42 B
222. ight position CONTROLS ONLY FROM INSIDE TRUCK CAB 3 Lower body slowly until body bracket contacts prop 4 DO NOT POWER HOIST DOWN 2 403375 DO NOT GO UNDER RAISED BODY 1 IT MAY DROP AND KiLL YOU OPERATE HOIST CONTROLS c 2 f Oo A EXAMEN A BODY MUST BE BRACED BEFORE SERVICING HOIST OR WORKING IN 7 AREA WITH BODY IN RAISED POSITION aes SG o A 2 TRUCK MUST BE LEVEL FOR DUMPING DO NOT OVERLOAD 7 PAIA WITH BODY DOWN FULL ADD 2 5 BODY MUST BRACED BEFORE 2 SERVICING HOIST OR WORKING IN CA U Tl 0 AREA WITH BODY IN RAISED POSITION TRUCK MUST LEVEL FOR DUMPING UNLOAD BODY BEFORE A emma ADD 1 GAL mus USING BODY PROF NOT OVERLOAD DANGER KEEP HANDS s AWAYFROM ATE GATE OPENINGS alae AT ALL TIMES Manvtactuted by LUBRICATION DATA 917 1 amp MO T17ATMCS Lake Crysiat MN HOIST RESERVOIR TAILGATE HINGE PN BOOY PROP TRAVEL LOCK STABUZER LUBRICATION KEY CHECK N rL MER M LUBRICATE EASY COVER 800 AEROINDUSTRIES INC 1 800 535 9545 10 LUBRICATING OIL IHTERNAL COMBUSTION TACTICAL SERVICE MIL 2104 GREASE AUTOMOTIVE amp ARTILLERY MU G 10924 ON CONDITION SEE OPERATORS
223. installation note mounting position of cable pivot pins and hold down clamps prior to disconnecting cables Place transmission selector lever D Down position TM 9 2320 363 10 or 9 2320 302 10 Tag transmission shift cable 15 Remove two nuts 10 lockwashers 9 screws 6 clamp 8 and spacer 7 from bracket 14 Discard lockwashers Remove retaining pin 4 from pivot pin 5 and pivot pin from bracket 16 X 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 10 Place transfer case selector lever in N Neutral position TM 9 2320 363 10 or TM 9 2320 302 10 11 Tag transfer case shift cable 25 12 Remove two nuts 23 lockwashers 22 screws 19 clamp 21 and spacer 20 from bracket 24 Dis card lockwashers 13 Remove retaining pin 17 from pivot pin 18 and pivot pin from bracket 26 ry 26 24 4 129 TM 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 14 Place hydraulic control lever in DOWN position paragraph 2 1 15 Tag hydraulic control lever cable 36 16 Remove two nuts 31 lockwashers 30 screws 34 clamp 32 and spacer 33 from bracket 35 Dis card lockwashers 17 Remove retaining pin 29 from pivot pin 28 and pivot pin from bracket 27 4 130 5 3805 264 14 amp P
224. ion Instructions Section Il Operator Troubleshooting 5 3 3 Section Ill Operator Maintenance 3 9 CHAPTER 4 UNIT MAINTENANCE 4 1 Section Repair Parts Special Tools Test Measurement and Diagnostic Equipment TMDE and Support Section Il Service Upon Section Ill General Maintenance Instructions Section IV Unit Preventive Maintenance Checks and Services PMCS Section V Unit Troubleshooting Section VI Electrical System Maintenance Section VII Dump Body Section VIII Dump Body Accessory Items Maintenance 4 101 Section IX Hydraulic System Maintenance 4 117 Section X Preparation for Storage or Shipment 4 149 CHAPTER 5 DIRECT SUPPORT Section Dump Body Section Il Dump Body Accessory Items 5 9 Section Ill Hydraulic S
225. ional tailgate that opens from the bottom to dump the load Adjustment chains mounted to the tailgate control the tailgate opening for spreading operations b A tailgate release control valve lever located on the instrument panel inside the cab controls the tailgate release air cylinder mounted under the dump body to unlock and lock the tailgate at the bot tom 5 3805 264 14 amp P 1 16 DUMP BODY Con t 2 M917A1 w MCS and M917A2 w MCS Air Lines Air Reservoir Air Cylinder Adjustment Tube Locking Pin COVER REMOVED FOR CLARITY Remote Control a The MCS tailgate has four openings gates that are electro pneumatically controlled by a cab control unit or a hand held remote control Each gate can be opened and closed independently of the other gates b Compressed air plumbed from the chassis air system and stored in an air reservoir mounted on the MCS tailgate opens and closes the gates using solenoid controlled air cylinders c Gate opening adjustments are made at each gate using an adjustment tube with a locking pin that can be moved to different holes in the tube The lower the pin placement the larger the gate open ing The top pin placement locks the gate closed d The remote control has a coiled cable that plugs into a receptacle on the left or right side of the MCS tailgate It is operated by a person walking alongside the dump body while the operator inside
226. is pressurized WARNING e NEVER work under a raised dump body unless it is secured in the raised posi tion with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel e DO NOT disconnect air lines while air system is pressurized Air system pres sure must be released before air lines are disconnected A line disconnected under pressure may cause personnel injury a REMOVAL NOTE Hoses should be tagged before removal paragraph 4 17 1 Disconnect two air lines 4 from two elbows 3 and remove elbows from air cylinder 5 NOTE Note position of nut at air cylinder piston shaft clevis to ensure proper adjustment of air cylinder on installation 2 Remove cotter pin 8 and pin 6 to remove air cylinder 5 from tailgate release lever 7 Discard cotter pin 3 Remove cotter pin 9 and pin 2 to remove air cylinder 5 from dump body 1 Discard cotter pin b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions 4 68 5 3805 264 14 4 51 TAILGATE RELEASE AIR CYLINDER REPLACEMENT Con t 336 019 INSTALLATION Install air cylinder 5 to dump body 1 with pin 2 and new cotter pin 9 NOTE Ensure that position of nut at air cylinder piston shaft clevis is the same as noted during removal to e
227. ised and supported on body props paragraph 2 15 Hydraulic oil drained Appendix J Transmission tunnel access cover removed TM 9 2320 363 20 or 9 2320 302 20 Materials Parts Rags 16 Marker tags Item 20 Appendix F Tie wraps Item 19 c Installation Tools Test Equipment Cap and plug set Item 1 Appendix I General mechanic s tool kit Item 8 Appendix Adjustable wrench Item 10 Appendix I General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY DO NOT disconnect hydraulic lines while engine is running WARNING e NEVER work under a raised dump body unless it is secured in the raised posi tion with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel e DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel a REMOVAL CAUTION Hoses and ports in hydraulic components should be plugged to prevent contamina tion of hydraulic system paragraph 4 21 NOTE e Hoses should be tagged before removal paragraph 4 17 Use a suitable container t
228. it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel 15 After Body Props Raise dump body and support with body Body props are damaged can props paragraph 2 15 Check that body not be installed to safely support props function properly and do not bind dump body NOTE Perform the following After PMCS check with engine off 16 After Air Pull cable pull 30 and drain air reser Reservoir voir Release cable pull when all air has M917A1 drained w MCS and M917A2 w MCS Q i a 2 21 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel 17 Weekly Hydraulic a Raise dump body and support with System body props paragraph 2 15 b Inspect hydraulic cylinder 31 Damage to components or hydraulic reservoir 21 and hydrau Class hydraulic fluid leaks lic lines and fittings for loose mount are evident
229. its of the NSN However the complete NSN should be used when ordering items by stock number 2 FIG Column This column lists the number of the figure where the item is identified located The figures are in numerical order in Section and Section 3 ITEM Column The item number identifies the item associated with the figure listed in the adjacent FIG column This item is also identified by the NSN listed on the same line b Part Number Index Part numbers in this index are listed by part number in ascending alphanu meric sequence i e vertical arrangement of letter and number combination which places the first letter or digit of each group in order A through Z followed by the numbers 0 through 9 and each following letter or digit in like order TM 5 3805 264 14 amp P C 4 EXPLANATION OF COLUMNS SECTION IV Con t 1 CAGEC Column The Commercial and Government Entity CAGE Code C is a five digit alphanumeric code used to identify the manufacturer distributor or Government agency etc that supplies the item 2 PART NUMBER Column Indicates the primary number used by the manufacturer individ ual firm corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items 3 STOCK NUMBER Column This column lists the NSN for the associated part
230. ix to insulate soldered and crimped electrical connec tions as follows 1 Cut desired length of new heat shrinkable tubing twice the length of the connection to be covered 2 Slide the heat shrinkable tubing onto the wire and out of the way before making electrical connection 3 After making electrical connection slide heat shrinkable tubing into place over electrical connection 4 8 5 3805 264 14 amp P 4 19 HEAT SHRINKABLE TUBING Con t WARNING DO NOT touch heat shrinkable tubing for at least 30 seconds after heating Heat shrinkable tubing is hot and will burn you 4 Hold hot air blow gun Item P Appendix l 4 5 in 10 2 12 7 cm away from heat shrinkable tubing and apply heat for approximately 30 seconds Stop applying heat as soon as heat shrinkable tubing forms to the shape of the electrical connection 4 20 ELECTRICAL GROUND POINTS Many electrical problems are the result of poor ground connection You can ensure that ground connec tions are good by performing the following steps WARNING Although battery ground cable must be connected in order to test electrical circuit voltage disconnect battery ground cable before performing resistance tests or replacing parts This will prevent shock to personnel and damage to parts and equipment 1 Remove hardware connecting ground cable terminal lug to ground point WARNING
231. ix locknuts 2 and screws 1 from left and right angle brackets 3 Discard lock nuts b Installation Personnel Required Three References TM 9 2320 363 10 TM 9 2320 302 10 TM 9 2320 363 20 TM 9 2320 302 20 TM 9 237 General Safety Instructions Use extreme caution when handling heavy parts NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY 5 1 TM 5 3805 264 14 amp P 5 1 DUMP BODY AND STABILIZER REPLACEMENT Con t 2 Working from underside of vehicle secure lower half 6 of stabilizer to upper half 5 and to dump body 4 using a suitable chain or nylon strap WARNING 4 5 Use extreme care when han dling heavy parts Lifting cables chains hooks and slings must be in good condi tion and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment e NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel 3 Raise front of dump body 4 and support on body props paragraph 2 15 using a suitable lifting device and chains 4 Remove six locknuts 10 and screws 12 from left and right mounting brackets 11 Remove
232. k Not Fully Mission No Interval Service Procedure Capable If 13 10 000 Hydraulic b Remove fil 5 Remove Con t Miles or Reservoir strainer from reservoir 7 para Annual graph 4 75 Clean strainer and C e reinstall Replace hydraulic oil filter element paragraph 4 76 Clean drain plug and reinstall NOTE Hydraulic reservoir capacity is 12 75 gal 48 2 1 DO NOT overfill Fill reservoir 7 with lubricating oil Item 13 14 Appendix A until level of fluid in sight tube 4 is at FULL mark as indicated on oil level decal 6 Install fill cap 5 4 25 5 3805 264 14 amp P Section V UNIT TROUBLESHOOTING PROCEDURES Paragraph Page Number Paragraph Title Number 4 35 GENERAL a This section provides information for identifying and correcting malfunctions that you may find while operating and maintaining the dump truck body b The Troubleshooting Symptom Index paragraph 4 37 lists common malfunctions which occur and refers you to the proper page in Table 4 3 for a troubleshooting procedure C If you are unaware of the location of an item mentioned in troubleshooting refer to paragraphs 1 11 2 1 or 2 2 d Before performing troubleshooting read and follow all safety instructions found in the warning summary at the front of this manual e This section cannot list all malfunctions that may occur nor
233. k Body Con t Drain hydraulic oil into a suitable container Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to fol low this warning may result in death or injury to personnel 11 Semi Frame Inspect dump body frame and annual Crossmem crossmembers for cracks breaks bers bends weld breaks wear and missing or loose bolts and rivets b Inspect for corrosion in accordance with TM 43 0213 c Remove body props and lower dump body paragraph 2 15 12 Annual Decals all decals and stencils to Stencils ensure legibility WARNING To prevent burns use caution when removing fill cap of hydraulic reservoir when hydraulic fluid is hot Avoid contact with hot hydrau lic oil Use extreme care when draining hydraulic oil Failure to follow this warning may result in injury to personnel 13 110 000 Hydraulic a With dump body down and engine Miles Reservoir off remove magnetic drain plug Annual from underside of reservoir 7 4 24 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 M917A2 w MCS Dump Truck Body Con t Location Item To Item Chec
234. ker clearance light 1 from grommet 2 2 Disconnect lights wiring harness connector 3 from back of marker clearance light 1 Remove marker clearance light 3 Remove grommet 2 from dump body 4 EN 4 F 3 g b INSTALLATION 1 Install grommet 2 in dump body 4 2 Connect lights wiring harness connector 3 to back of marker clearance light 1 3 Install marker clearance light 1 in grommet 2 FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 M917A1 and M917A1 w MCS Check operation of marker clearance lights TM 9 2320 363 10 or TM 9 2320 302 10 TM 5 3805 264 14 amp P 4 42 MCS CONTROL UNIT MAINTENANCE M917A1 W MCS and 917 2 W MCS This task covers M917A1 W MCS a Removal b Disassembly c Cleaning and Inspection Initial Setup Equipment Conditions Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS M917A1 W MCS a REMOVAL d Assembly e Installation M917A2 W MCS f MCS Switch Replacement Tools Test Equipment General mechanic s tool kit Item 8 Materials Parts Marker tags Item 20 NOTE Wires should be tagged before disconnecting paragraph 4 17 Remove four screws 7 washers 8 and MCS control unit 3 from shift tower 1 2 Disconnect indicator light connector 5 from wiring harness
235. l parking brake set and engine off Failure to follow this warning may result in per sonnel injury NOTE e Review all WARNINGs CAUTIONs and NOTEs before performing PMCS and operating the dump truck Perform all PMCS checks if a You are the assigned operator but have not operated the dump truck since the last Weekly inspection b You are operating the dump truck for the first time FRONT AND LEFT SIDE 1 Before Overall View Check under vehicle for evidence of Class hydraulic fluid leaks are hydraulic fluid leakage evident INSIDE CAB 2 Before CargoCover Check that crank handle is stowed in Crank Han storage pouch box dle 2 10 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 3 Before Startup NOTE Dump truck s chassis air system con trols both models tailgate locking mechanism and supplies air to the M917A1 w MCS and M917A2 w MCS tailgate a Start engine and fully pressurize air system TM 9 2320 363 10 or TM 9 2320 302 10 Listen for air leaks on chassis and at b Air leakage is evident rear of dump body 4 During Dump Body Check hydraulic control lever 1 Hydraulic control lever mal Controls MCS control unit 2 and indicator functio
236. l yd 24 5970 00 815 1295 TUBING Heat Shrinkable ft 81343 M23053 5 106 0 F 5 F 6 Blank 5 3805 264 14 amp P APPENDIX ILLUSTRATED LIST OF MANUFACTURED ITEMS Section l INTRODUCTION G 1 SCOPE a This appendix includes complete instructions for making items authorized to be manufactured or fabricated b A part number index in alphanumeric order is provided for cross referencing the part number of the item to be manufactured to the paragraph which covers fabrication criteria C All bulk materials needed for manufacture of an item are listed by Part Number and Cage Code or specification number d Only items requiring complicated manufacturing instructions are illustrated Table G 1 Manufactured Items Part Number Cross Reference Index Part Number Name Paragraph 010029X12 Tube MCS Air Cylinder G 3 239635X1 5 Tube Sight Hyd G 6 Reservoir 245538 66 Tube Air MCS Tailgate G 4 245539X21 Tube Air MCS Tailgate G 4 245540X17 Tube Air MCS Tailgate G 4 245541X8 Tube Air MCS Tailgate G 4 245542X31 Tube Air MCS Tailgate G 4 245543X9 Tube Air MCS Tailgate G 4 245544 144 Tube Air MCS Tailgate G 4 245786X36 Tube Air Tailgate G 2 Release 245787X38 Tube Air Tailgate G 2 Release 403345X148 75 Board Side Dump G 5 Body N A Disassembly Tool G 7 Hydraulic Cylinder G 1 5 3805 264 14 amp P Section Il MANUFACTURING INSTRUCTIONS
237. lon Can gl 7 COMPOUND Sealing Pipe 05972 59231 8030 01 054 0740 50 Cubic Centimeter Tube cc 8 CORROSION PREVENTIVE 09137 WD 40 8030 01 418 9006 Box of 12 Aerosol Cans 9 Ounces Each 07 9 DETERGENT General Purpose Liquid 83421 7930 00 282 9699 7930 00 282 9699 1 Gallon gl 10 O FLUX Soldering TY1 Form A 58536 A A 51145 3439 00 255 9935 1 Pound Can Ib 5 3805 264 14 amp P Section Il EXPENDABLE AND DURABLE ITEMS LIST Con t 1 2 3 4 5 Item National Item Name Description U M Number Level Stock Number CAGEC Part Number U I 11 GREASE Automotive and Artillery GAA 81349 M 10924 B 9150 01 197 7693 14 Ounce Cartridge OZ 9150 01 197 7688 214 Ounce Tube OZ 9150 01 197 7690 1 Pound Can Ib 9150 01 197 7689 6 Pound Can Ib 9150 01 197 7692 35 Pound Pail Ib 9150 01 197 7691 120 Pound Drum Ib 12 GREASE Ball Bearing 73219 9150 00 076 1574 9150 00 076 1574 5 Pound Can Ib 13 OIL Lubricating Internal Combustion Engine Arctic OEA 81349 MIL L 46167 9150 00 402 4478 1 Quart Can qt 9150 00 402 2372 5 Gallon Can gl 9150 00 491 7197 55 Gallon Drum gl 14 OIL Lubricating Internal Combustion Engine OE HDO 10 81349 M2104 1 10W 9150 00 189 6727 1 Quart Can qt 9150 00 186 6668 5 Gallon Can gl 9150 00 191 2772 55 Gallon Drum gl 15 OIL Lubricating Internal Combustion Engine OE HDO 30 81349 M2104 1 30W 9150 00 186 6681 1 Quart Can qt 9150 00 188 9858 5 Gallo
238. m Check Not Fully Mission No Interval Service Procedure Capable If 6 After Overall View b Check dump body for obvious dam b Damage that would impair Con t age that would impair operation e g operation is evident missing or damaged cargo cover controls 10 marker clearance light 11 body prop 14 and adjustment chain 12 at tailgate 7 After Transport Check that transport lock 15 is at 3 Lock o clock UNLOCKED position If locked remove pin 16 move transport lock counterclockwise to 3 o clock position and reinstall pin 2 13 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 7 After Transport Con t Lock 336 003 8 After Cargo Cover Operate cargo cover controls 10 Cargo cover does not extend and check for smooth operation or retract properly paragraph 2 14 b Inspect cargo cover for looseness of b Cargo cover mounting is loose mounting to support frame 9 and or cover is cut or torn Support cuts or tears to cover Inspect support frame is damaged frame for damage c After operating cargo cover controls 10 ensure that crank handle is stowed in storage pouch box 9 After Tailgat
239. mp Body and Stabilizer Dump Body L oadifnig alin entes Preparing to Principles of Operation Dumping Loads 22 e iste ett Electrical System Principles of Operation Electrical Equipment Characteristics Capabilities and Features Common Tools and ue los DEP En E utem idonei od d pastu t ee o amu T E Es SUP POM x ates oa ou eee eed uade dut e d Du Ne t Index 2 Paragraph 4 23 2 13 2 1 2 2 1 9 5 2 4 69 1 14 Table 4 1 1 12 1 3 1 13 4 13 5 1 2 8 2 7 1 16 2 10 4 20 4 27 1 10 4 1 1 14 4 2 4 2 4 2 4 11 2 38 2 1 2 3 1 3 5 7 4 114 1 11 4 17 1 8 1 1 1 11 4 6 5 1 2 28 2 27 1 13 2 30 4 9 4 12 1 5 4 1 1 11 4 1 4 1 4 1 5 3805 264 14 amp P INDEX Con t Subject Paragraph Page E Con t Explanation of Table Entries Operator PMCS shaded bat rrt wd wed rbd a ei bae 2 4 2 7 Unit PMCS ole re aba aes 4 29 4 13 External Controls and Indicators 2 2 2 3 F Fluid Disposal 3 2 et ede ed ers et eui edite ud eed er ufa 4 24 4 11 G General Lu
240. mp P 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 24 HYDRAULIC AND FLUID SYSTEMS GROUP 2401 PUMP AND MOTOR FIG 18 HYDRAULIC PUMP ASSEMBLY 1 PAFFF 4320014510045 13829 308 9310 156 PUMP HYBDRAUBIC xdi 1 2 22 5325007688563 80756 206 RING RETAINING sce cee RR T 3 PAFZZ 5365013614609 13829 391 3383 069 555 5 2 1 4 22 5365012360717 13829 391 3381 040 SPACER RING zd m Re tate 1 22 5330012360469 82338 391 2883 119 SEAL PLAIN 1 6 XAOZZ 13829 308 5030 201 SHAFT END 1 7 PAFZZ 4820004354391 13829 M1391K s VALVE 2 8 PAFZZ 5330012122222 38335 25316 GASKET 5 5 gee ele bb Sg ee Goad RIS 2 9 PAFZZ 3110012602561 13829 391 0381 906 BEARING ROLLER NEED 2 10 PAFZZ 5330008091052 13829 391 2882 051 SEAL NONMETALLIC 5 12 11 PAFZZ 3120013284294 13829 391 2185 913 BEARING WASHER 2 12 PAFZZ 3040014462408 13829 312 2920 130 GEARSHAFT SET SPUR 2 0 INCH 1 13 22 5330013408159 13829 391 2884 019 2254 5258 RR RR 2 14 22 13829 308 8020 901 HOUSING GEAR 1 15 XAFZZ 13829 308 9414 024 COVER PORT END 5 1 16 PAFZZ 5310013408353
241. n LUBRICATION INSTRUCTIONS a Lubrication instructions are in Appendix of this manual b All lubrication instructions are mandatory 3 1 3 2 Blank 5 3805 264 14 Section OPERATOR TROUBLESHOOTING PROCEDURES Paragraph Page Number Paragraph Title Number erc MM ET Explanation of Columns ee ER EEE eee Troubleshooting Symptom Index Operator Table 3 1 3 1 GENERAL a This section provides information for identifying and correcting malfunctions that you may find while operating the dump truck body b The Troubleshooting Symptom Index paragraph 313 lists common malfunctions which may occur and refers you to the proper page in Table 3 1 for a troubleshooting procedure C If you are unaware of the location of an item mentioned in troubleshooting refer to paragraphs 1 11 2 1 or 2 2 d Before performing troubleshooting read and follow all safety instructions found in the warning summary at the front of this manual e This section cannot list all malfunctions that may occur nor all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by the listed corrective actions notify your supervisor f When troubleshooting a malfunction 1 Locate the symptom or symptoms in paragraph 313 that best descri
242. n Can gl 9150 00 189 6729 55 Gallon Drum gl 16 C RAG Wiping 64067 7920 00 205 1711 7920 00 205 1711 50 Pound Bale Ib F 3 5 3805 264 14 amp P Section Il EXPENDABLE AND DURABLE ITEMS LIST Con t Section 1 2 3 4 5 Item National Item Name Description U M Number Level Stock Number CAGEC Part Number U I 17 F SEALANT Adhesive Silicone Rubber 94833 52498 8040 00 833 9563 5 Ounce Tube kt 18 O SOLDER Lead Alloy 81346 SN40BS 3439 00 247 6921 1 Pound Bar Ib 3439 00 265 7102 1 Pound Spool Roll Ib 19 O 9905 00 537 8954 STRAP Tiedown ea Electrical Components Box of 100 5975 00 984 6582 96906 MS3367 1 0 6 Inch Length 1 75 Inch Maximum Bundle Black 5975 00 935 5946 96906 MS3367 2 1 13 35 Inch Length 4 Inch Maximum Bundle Black 5975 00 903 2284 81349 M33671 4 0 4 Inch Length Black 20 O 9905 00 537 8954 TAG Marker ea 64067 9905 00 537 8954 50 each 21 O TAPE Antiseize 12 Inch Width 81755 P5025 2R 8030 00 889 3535 260 Inch Roll in 5 3805 264 14 amp P EXPENDABLE AND DURABLE ITEMS LIST Con t 1 2 3 4 5 Item National Item Name Description U M Number Level Stock Number CAGEC Part Number U I 22 O 8030 00 889 3535 TAPE Duct 2 Inch Width 39428 1791K70 5640 00 103 2254 60 Yard Roll yd 23 F TAPE Pressure Sensitive Adhesive Masking Flat 1 Inch Width 76892 MANSON1 1 2 5970 00 682 8536 60 Yard Rol
243. nd insert new pages as indicated below Remove Pages Insert Pages A B Blank 1 0 11 1 and Figure 12 11 1 and Figure 12 1 3 thru 1 6 0 3 thru I 6 13 and I 14 ET3 and I 14 DA Form 2028 Sample DA Form 2028 Sample DA From 2028 Three copies DA From 2028 Three copies 5 3805 264 14 amp P By Order of the Secretary of the Army GEORGE W CASEY JR General United States Army Chief of Staff Official a JOYCE E MORROW Administrative Assistant to the Secretary of the Army 1101301 DISTRIBUTION To be distributed in accordance with the initial distribution requirements for IDN 381066 TM 5 3805 264 148P TM 5 3805 264 14 amp P FOR INFORMATION ON FIRST AID REFER TO FM 4 25 11 WARNING CARBON MONOXIDE EXHAUST GASES CAN KILL Carbon monoxide is a colorless odorless deadly poison which when breathed deprives the body of oxygen and causes suffocation Exposure to air containing carbon monoxide produces symptoms of headache dizziness loss of muscular control apparent drowsiness and coma Permanent brain damage or death can result from severe exposure Carbon monoxide occurs in exhaust fumes of internal combustion engines Carbon monoxide can become danger ously concentrated under conditions of inadequate ventilation The following precautions must be observed to ensure safety of personnel when engine of dump truck is operated 1 2
244. nd install a serviceable counterpart in its place Replace is authorized by the MAC and assigned maintenance level is shown as the 3d position code of the SMR code 1 i Repair The application of maintenance services including fault location troubleshooting removal installation and disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system j Overhaul That maintenance effort service action prescribed to restore an item to a completely serviceable operational condition as required by maintenance standards in the appropriate technical publications i e DMWR Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition k Rebuild Consists of those services actions necessary for the restoration of unserviceable equip ment to a like new condition in accordance with original manufacturing standards Rebuild is the highest degree of materiel maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements e g hours miles considered in classifying Army equipment components B 3 EXPLANATION OF COLUMNS IN THE MAC SECTION a Column 1 Group Number Column 1 lists functional group code num
245. ndard Tool Requirements cete es Sep CBAR e e a 4 7 4 17 Tagging Wires and 4 8 SOLID 4 8 4 19 Heat Shrinkable Tubing 4 8 Electrical Ground 4 9 Lines ang a pedea d Ero ke shag eas Voca dde Pede dade dcs 4 22 Antiseize Tape 2 94 4 44 4 4 4 2 4 6 NAE RUE 4 10 Tubes Compression Fittings 32 x 4 24 Fluid 4 11 Service Replacement Parts and Kits bU RI MORE ULP 4 27 Electrical EXAM 4 12 4 7 GENERAL a These general maintenance instructions contain general shop practices and specific methods you must be familiar with to properly maintain the equipment You should read and understand these practices and methods before performing any maintenance procedures b Before beginning a task find out how much repair modification or replacement is needed to fix the equipment Sometimes the reason for equipment failure can be seen right away and complete teardown is not necessary Disassemble equipment only as far as necessary to repair or replace damaged parts
246. nder 5 23 5 4 HYDRAULIC PUMP REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Hydraulic oil drained Chapter 3 Section 1 Transmission tunnel access cover removed TM 9 2320 363 20 or TM 9 2320 302 20 Hydraulic control lever cable disconnected from hydraulic pump paragraph 4 73 Tools Test Equipment General mechanic s tool kit Item 8 Appendix 1 and plug set Item 1 Appendix 1 Adjustable wrench 10 Appendix Torque wrench Item 11 Appendix 1 c Installation Materials Parts Rags Item 16 Appendix Marker tags Item 20 Appendix Antiseize tape Item 21 Appendix F Four lockwashers Personnel Required Two General Safety Instructions DO NOT disconnect hydraulic lines while engine is running Use extreme caution when handling heavy parts WARNING DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel a REMOVAL CAUTION Hoses and ports in hydraulic components should be plugged to prevent contamina tion of hydraulic system paragraph 4 21 5
247. nel 4 32 5 3805 264 14 amp P 4 38 BODY UP SWITCH REPLACEMENT Con t a REMOVAL NOTE Wires should be tagged before disconnecting paragraph 4 17 1 Disconnect two wiring harness leads 2 from body up switch 1 NOTE To ensure proper installation note switch lever position 2 Remove two screws 4 and body up switch 1 from cylinder support frame 3 b INSTALLATION 1 Install body up switch 1 on cylinder support frame 3 with two screws 4 2 Connect two wiring harness leads 2 to body up switch 1 FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 917 1 and M917A1 w MCS Remove body props and lower dump body paragraph 2 15 e Check operation of body up switch paragraph 2 1 4 33 5 3805 264 14 amp P 4 39 TRANSPORT LOCK SWITCH REPLACEMENT This task covers a Removal Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS b Installation Tools Test Equipment General mechanic s tool kit Item 8 Materials Parts Tie wraps Item 19 Appendix F General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY WARNIN
248. ng 13 5 33 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t NOTE Perform steps 14 thru 19 to install plunger 14 Install two piston rings 12 piston ring 11 and new wear ring 10 to plunger 1 15 Install plunger 1 to sleeve 3 and install bot 9 tom retaining ring 9 to sleeve using 3 seal installation tool 5 34 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 16 Install new bottom guide ring 8 and new spi ral retaining ring 7 17 Install new seal 6 2 18 Install new wiper 4 to new wiper retainer 5 and install wiper retainer 4 19 Install retaining ring 2 6 lt gt 8 Cc FOLLOW ON TASKS e Install hydraulic cylinder paragraph 5 6 5 35 5 36 Blank 5 3805 264 14 amp P 6 GENERAL SUPPORT MAINTENANCE There is no General Support Maintenance for the M917A1 M917A1 w MCS M917A2 and M917A2 w MCS dump truck body 6 1 6 2 Blank 5 3805 264 14 amp P APPENDIX A REFERENCES A 1 SCOPE This appendix lists all forms field manuals technical manuals and other publications referenced in this manual and that apply to the operation and maintenance of the M917A1 917 1 w MCS M917A2 and M917A2 w MCS Dump Truck Body A 2 PUBLICATION INDEX DA Pam 25 30 Consolidated Index of Army Publications and Blank Forms should be consulted fre quently for latest
249. ns MCS control unit and Indica light 3 M917A1 w MCS malfunctions and is required tors M917A2 w MCS for proper opera for mission M917A2 tion 371 031 M917A1 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 4 During Dump Body b Monitor body up and body transport b Any indicator light or dump Con t Controls lock indicator lights 4 and 5 tailgate body control malfunctions and Indica release control valve lever 6 and tors PTO switch 7 for proper operation 371 046 M917A2 917 1 5 During Overall Be alert for evidence of hydraulic fluid Class hydraulic fluid leaks are Leakage leakage evident FRONT AND LEFT SIDE NOTE Begin After PMCS checks with dump body lowered and engine off 6 After Overall View a Check under vehicle for evidence of a Class hydraulic fluid leaks hydraulic fluid leakage are evident 2 12 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Ite
250. nstallation e Wiper retainer and seal should come out as plunger is lifted a few inches If not apply a three inch strip of tape at a 45 degree angle to a cleaned section of plunger Lower and again lift plunger to remove wiper retainer and seal 3 Lift plunger 1 to expose wiper retainer 5 and seal 6 Lower plunger and remove nylon sling Remove wiper retainer and seal from plunger Remove wiper 4 from wiper retainer Discard wiper wiper retainer and seal Remove tape from plunger if used 5 24 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 4 Remove spiral retaining ring 7 from sleeve 3 Discard spiral retaining ring 5 Using overhead lifting device with nylon sling raise plunger 1 a few inches and apply tape to a cleaned section of plunger 6 Lower and lift plunger 1 to expose bottom guide ring 8 Remove tape TA Lower plunger 1 and remove nylon sling Remove bottom guide ring 8 from plunger Discard bottom guide ring 5 25 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 8 Using two small screwdrivers remove bottom retaining ring 9 from groove of sleeve 3 Position four hydraulic cylinder disassembly tools equally spaced between bottom retain ing ring and sleeve NOTE Hydraulic cylinder disassembly tools will fall free as plunger with bottom retaining ring is removed from sleeve 9 Remove plunger 1 from sle
251. nsure proper adjustment of air cylinder on installation Install air cylinder 5 to tailgate release lever 7 with pin 6 and new cotter pin 8 Install two elbows 3 to air cylinder 5 Connect two air lines 4 to elbows FOLLOW ON TASKS Start engine and pressurize air system TM 9 2320 363 10 or 9 2320 302 10 e Remove body props and lower dump paragraph 2 15 e Set tailgate release control valve lever to LOCKED position 4 69 TM 5 3805 264 14 amp P 4 52 MCS TAILGATE REPLACEMENT M917A1 W MCS AND M917A2 W MCS This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions MCS remote control disconnected paragraph 2 2 Tailgate release control valve lever UNLOCKED position paragraph 2 1 Chassis air system drained TM 9 2320 363 10 or TM 9 2320 302 10 MCS air system drained Chapter 2 Section Operator PMCS Tailgate chains released paragraph 2 11 Installation Tools Test Equipment General mechanic s tool kit Item 8 Appendix e Lifting slings three Item 6 Appendix Suitable lifting device Personnel Required Two General Safety Instructions DO NOT disconnect air lines while air system is pressurized Use extreme caution when handling heavy parts Disconnect MCS tailgate wiring harness connector 3 from receptacle 10 WARNING DO NOT disconnect ai
252. number and manufacturer identified in the PART NUMBER and CAGEC columns to the left 4 FIG Column This column lists the number of the figure where the item is identified located in Section and Section III 5 ITEM Column The item number assigned to the item as it appears in the figure referenced in the FIG column C 5 SPECIAL INFORMATION a Usable On Code The Usable On Code appears in the lower left corner of the DESCRIPTION col umn heading Usable on codes are 7A1 M917A1 7A2 M917A2 7E1 M917A1 w MCS 2 917 2 w MCS b Fabrication Instructions Bulk materiels required to manufacture items are listed in the bulk materiel functional group of this RPSTL Part numbers for bulk materiels are also referenced in the Description col umn of the line item entry for the item to be manufactured fabricated Detailed fabrication instructions for items source coded to be manufactured or fabricated are found i Assembly Instructions Detailed assembly instructions for items source coded to be assembled from component spare repair parts are found Chapters 4 5 Items that make up the assembly are listed immediately following the assembly item entry or reference is made to an applicable figure d Kits Line item entries for repair kits appear in Group 9401 in Section e Index Numbers Items which have the word BULK in the FIG column will have an index number shown in the item column This index number i
253. ny general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON PLUS EXTENSION SIGNATURE Change 1 USAPPC V3 00 By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Chief of Staff Official UR UE SANDRA R RILEY Administrative Assistant to the Secretary of the Army 0508907 DISTRIBUTION To be distributed in accordance with the initial distribution number IDN 381066 requirements for TM 5 3805 264 14 amp P THE METRIC SYSTEM AND EQUIVALENTS Linear Measure 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches 1 Kilometer 1000 Meters 0 621 Miles Weights 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Kilogram 1000 Grams 2 2 Pounds 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons Liquid Measure 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1000 Milliliters 33 82 Fluid Ounces Square Measure 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Sq Kilometer 1 000 000 Sq Meters 0 0386 Sq Miles Cubic Measure 1 Cu Centimeter 1 000 Cu Millimeters 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Fee
254. o Cover Operating Body Props 2 6 SCOPE NOTE Refer to TM 9 2320 363 10 or TM 9 2320 302 10 for operating instructions for the dump truck chassis a This section provides instructions on operating the M917A1 M917A1 w MCS M917A2 and M917A2 w MCS dump truck body under usual conditions b Refer to Section IV of this chapter for operating instructions under unusual conditions C Before during and after operation perform applicable Operator PMC Chapter 2 Section 2 T PREPARING TO LOAD DUMP BODY a As required clean dump body of material previously carried paragraph 3 5 b Ensure that tailgate is closed paragraph 2 1 If operating an M917A1 w MCS or M917A2 w MCS ensure that MCS gates are closed paragraph 2 1 or 2 2 C With engine running ensure that dump body is fully lowered by checking body up indicator light on instrument panel paragraph 2 1 Light must be off Lower dump body if raised paragraph 2 10 WARNING DO NOT park on a slope Park on level ground only Parking on a slope could cause load to shift and dump truck to tip over Failure to follow this warning may result in death or injury to personnel or damage to equipment d Position dump body for loading 1 Position dump truck on firm level ground at a location convenient for loading 2 If
255. o catch any draining hydraulic fluid Ensure that all spills are cleaned up e Remove hose support clamps and tie wraps as necessary e Perform steps 1 thru to remove suction hose and fittings 4 136 5 3805 264 14 amp P 4 74 HYDRAULIC HOSES AND FITTINGS REPLACEMENT Con t 1 Loosen two clamps 14 and remove suction hose 15 and two clamps from adapter 13 and hose barb 16 Remove adapter 13 from hydraulic pump 12 3 Remove hose barb 16 and elbow 17 from bottom of hydraulic reservoir 4 NOTE Perform steps 4 thru 7 to remove return hose and fittings Remove return hose 19 from adapter 18 and tee 2 Remove adapter 18 from hydraulic pump 12 Remove oil sampling valve 1 from tee 2 NO Remove tee 2 from filter housing 3 NOTE Perform steps 8 thru 11 to remove two hydraulic cylinder hoses and fittings 8 Remove hose 8 from adapter 11 and elbow 5 9 Remove hose 9 from elbow 10 and elbow 7 10 Remove adapter 11 and elbow 10 from hydraulic pump 12 11 Remove elbow 5 and elbow 7 from hydraulic cylinder 6 4 137 TM 5 3805 264 14 amp P 4 74 HYDRAULIC HOSES AND FITTINGS REPLACEMENT Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions c INSTALLATION NOTE e Use antiseize tape on all pipe threads
256. o cover removed paragraph 4 64 One locknut Cargo cover chain removed paragraph 4 66 One spring pin Tools Test Equipment Five lockwashers General mechanic s tool kit Item 8j Appendix I NOTE Left and right side components of cargo cover support frame are removed and installed the same way left side is illustrated a REMOVAL Remove rubber strap from connecting arm 3 and swing arm 5 2 Remove spring pin 11 from shaft 6 on spring assembly 7 Remove swing arm 5 from shaft Discard spring pin 3 Remove nut 2 and eyebolt 4 and separate swing arm 5 and connecting arm 3 Discard locknut Remove two nuts 10 lockwashers 9 and screws 8 from spring assembly 7 Remove spring assem bly from dump body and from welded shaft support bar and tube 1 Discard lockwashers 336 013 4 110 5 3805 264 14 amp P 4 67 CARGO COVER SUPPORT FRAME AND ROLL UP REPLACEMENT Con t 5 Loosen set screw 13 and remove sprocket 20 with sprocket alinement key 12 from roll up bar 14 6 Remove three nuts 16 lockwashers 17 and screws 18 from left mounting bracket 15 and dump body Discard lockwashers T Loosen set screw 19 at each end of roll up bar 14 Remove left mounting bracket 15 and roll up bar Slide bracket from roll up bar 336 050 b CLEANING AND INSPECTION Clean and inspect all
257. o elbows 5 and sight tube 6 to hydraulic reservoir 11 3 Install strainer 4 with six screws 3 Install fill cap 2 5 6 Apply light coat of lubricating J to preformed packing and seal as they are assembled 4 Assemble filter housing 13 with new pre 1 formed packing 15 5 Install new seal 14 in filter housing mounting flange 6 Install pipe 12 to filter housing 13 7 Install filter housing 13 to hydraulic reservoir 11 with four screws 1 8 Install hydraulic oil filter element paragraph 4 7 78 9 Install hydraulic oil filter service indicator gage AE paragraph 4 79 336 049 FOLLOW ON TASKS Fill hydraulic reservoir Chapter 3 Section 1 4 144 5 3805 264 14 amp P 4 77 HYDRAULIC OIL FILTER ELEMENT REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Tools Test Equipment General mechanic s tool kit Item 8 Appendix Cap and plug set Item 1 Materials Parts Lubricating oil Item 13 or 14 Appendix F c Installation Materials Parts Con t Rags 16 Appendix One oil filter element One preformed packing General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY DO NOT disconnect hydra
258. o equipment Raise MCS tailgate 5 to dump body 8 4 71 TM 5 3805 264 14 amp P 4 52 MCS TAILGATE REPLACEMENT M917A1 W MCS AND M917A2 W MCS Con t 2 Position MCS tailgate 5 so that bottom pins 7 are resting on dump body stops 6 and tailgate hinge pin holes are alined with dump body hinge pin holes Install hinge pins 1 and lynch pins 2 to each side of MCS tailgate 5 Remove lifting slings 4 from MCS tailgate 5 Connect MCS quick disconnect air line 9 oa Connect MCS tailgate wiring harness connector 3 to receptacle 10 10 ANE Geo gt Cem M N ze FOLLOW ON TASKS e Lubricate tailgate hinge ping Chapter 3 Section Start engine and pressurize air systems TM 9 2320 363 10 or TM 9 2320 302 10 Settailgate release control valve lever to LOCKED position paragraph 2 1 Check operation of MCS gates using cab mounted control unit paragraph 2 1 e Check operation of MCS gates using MCS remote control paragraph 2 2 Latch tailgate chains paragraph 2 11 4 72 5 3805 264 14 amp P 4 53 MCS TAILGATE COVER REPLACEMENT M917A1 W MCS AND M917A2 W MCS This task covers a Removal c Installation b Cleaning and Inspection Initial Setup Tools Test Equipment Personnel Required Two General mechanic s tool kit Item 8 Appendix General Safety Instructions Materials Parts Use extreme caution when han
259. oaded could fall on personnel standing too close Failure to follow this warning may result in death or injury to personnel Hearing protection is required when performing loading operations Failure to follow this warning may result in injury to personnel Clear all personnel from around dump truck 5 3805 264 14 amp P 2 8 LOADING DUMP BODY Con t CAUTION Load dump body evenly Material must not be heaped so high that it spills over sides of body DO NOT overload Failure to follow this caution may damage equip ment b Load dump body Ensure that material is loaded evenly Cover load with cargo cover paragraph 2 14 2 9 TRANSPORTING LOAD CAUTION DO NOT transport load with PTO engaged Always disengage PTO when hydraulic power is no longer needed If PTO is engaged while dump truck is transporting a load severe damage to hydraulic pump PTO or transmission will result a Avoid sudden stops turns or accelerations This may cause load to shift b During off road operation avoid terrain with side slope Use vehicle s CTIS to change tire pressures as road conditions change Use CTIS in EMER emergency mode if dump truck becomes stuck 9 2320 363 10 or 9 2320 302 10 2 29 TM 5 3805 264 14 amp P 2 10 DUMPING LOAD WARNING Hearing protection is required when performing dumping operations Failure to follow this wa
260. ocation Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 4 Semi Cargo a Operate cargo cover and check for annual Cover smooth operation paragraph 2 14 b Remove chain cover paragraph 4 66 Inspect chain for dirt corro sion or other damage Check for proper chain adjustment Replace chain if damaged paragraph 4 66 c Lubricate chain sparingly with cor rosion preventive Item 8 Appen dix F d Lubricate roller shaft bearings 1 at left and right side roll up bar mounting brackets 2 Apply cor rosion preventive Item 8 Appen dix F sparingly e Install chain cover paragraph 4 66 5 Semi Dump Body a With dump body down inspect annual dump body and tailgate for cracks breaks bends weld breaks wear and missing or loose bolts b Inspect for corrosion dance with TM 43 0213 4 21 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body Con t To prevent burns use caution when removing fill cap of hydraulic reservoir when hydraulic fluid is hot Avoid contact with hot hydrau lic oil Failure to follow this warning may result in injury to personnel b Remove fill cap from reservoir Clean fill cap vent in
261. ocks a Air leaks are present 4 19 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body Con t Item No Interval Location Item To Check Service Procedure Not Fully Mission Capable If Semi annual Semi annual MCS gate Operation M917A1 w MCS and M917A2 w MCS Hydraulic System Operation Check operation of MCS gates para graph 2 12 Listen for air leaks Raise and lower dump body and check for smooth operation para graph 2 10 Be alert for hydraulic fluid leaks WARNING Observe the following safety regu lations when operating cargo cover a Never operate system under obstructions such as trees and power lines b Ensure that all personnel are clear of rear of dump body and the immediate area of the cover c Ensure that chain cover is in place d Keep all clothing away from moving parts e DO NOT cover load with crank handle installed Failure to follow this warning may result in death or injury to person nel Air leaks are present Class hydraulic fluid leaks present 4 20 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body Con t L
262. ode oko dn 4 XAOZZ 5X050 403633 COVER REAR SHEER Ud UE Jp 5 XDOZZ 5X050 403643 ROD TENS TONING 4 6 XAOZZ 5X050 403627 IUBE CYLINDER s eR T 7 MOOZZ 79146 010029 11 TUBE NONMETALLIC 3 8 X 11 CUT 1 FIT MAKE FROM BULK PN 6 00 68 lt cs Sub 8 PAOZZ 4730014462108 79146 016964 ELBOW PIPE TO TUBE 3 8 TO 1 4 9 KFOZZ 5X050 403638 PACKING PREFORMED PART OF KIT P N 2 404939 sid exu add ta tak 10 XAOZZ 5X050 403630 Goes See ae 1 11 XDOZZ 5X050 403644 es SCREW 5 5 4 12 PAOZZ 5310014814919 5 050 403632 NUT PLAIN HEXAGON 1 2 20 1 13 KFOZZ 5X050 403639 SEAL PLAIN PART OF KIT P N 404939 2 14 XDOZZ 5X050 403640 STRIP METAL PART OF KIT P N 404939 1 15 2 5220014748432 5 050 403631 GAGE RING PLAIN SET 2 HALVES 1 16 PFOZZ 5330014828766 5 050 403636 PACKING PREFORMED PART OF KIT P N 1 404939 x o9 17 XDOZZ 5X050 403641 HPT STON ROD 1 18 XDOZZ 5 050 403626 ded Soe S 1 19 22 5X050 403628 HEAD END 1 20 KFOZZ 5X050 404929 PREFORMED PACKING PART OF KIT P N 1 404938 6 a a 21 KFOZZ 5X
263. ody Up and Transport Lock Switches Wiring Harness 4 47 4 45 Beacon Warning Light Wiring Harness 4 49 Lights Wiring Harness 4 52 Truck to MCS Tailgate Wiring Harness Maintenance M917A1 w MCS and 9 2 ehe Rx RR Re ee 4 54 MCS Tailgate Wiring Harness Maintenance M917A1 w MCS M917A2 w MCS 4 58 4 49 Wiring Diagrams cec mk needa Ree CRGA E idee dein ROC nod RAUS 4 62 4 38 BODY UP SWITCH REPLACEMENT This task covers Removal m Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS b Installation Tools Test Equipment General mechanic s tool kit Item 8 Materials Parts Marker tags Item 20 Appendix General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to person
264. ol Requirements Storage or Shipment Preparation for Storage Care of Equipment in Administrative Preparation of Equipment for Administrative Removal of Equipment from Administrative Switch Replacement eR lee xin dita edidit M Transport LOCK zt e D x RA VEMM c neqae pi Table Entries Explanation of Tagging Wires and Hoses Tailgate Opening Adjusting Tailgate Replacement M917A1 917 2 Tailgate MCS Cover Replacement 917 1 w MCS M917A2 w MCS MCS Replacement M917A1 w MCS M917A2 w MCS Release Air Cylinder Replacement Replacement M917A1 and 917 2 Taillight Replacement Transport Lock Switch Replacement Transporting Load Troubleshooting Symptom Index Md EU Ult etu teet ete oia Troubleshooting Operator Bored ih Pat tale ah alata Uit kacana Truck to MCS Tailgate Wiring Harness Maintenance M
265. ol kit Item 9 Appendix Materials 1 Corrosion preventive Item 8 Appendix F 2 Dishwashing compound Item 3 Detergent Item 4 Lubricating Item 13 Appendix 5 Lubricating oil OE HDO 10 Item 14 Appendix 6 Lubricating oil OE HDO 30 Item 15 Appendix 7 Rags Item 16 Appendix 8 Cleaning solvent Item d Personnel 1 Driver Operator 2 Unit Maintenance Mechanic 4 16 TM 5 3805 264 14 amp P 4 33 LUBRICATION DATA Table 4 1 Lubrication Data SEMIANNUAL LUBRICANTS Lubricant Component Refill Capacity Expected Temperatures WD 40 Corrosion Preventive Cargo Cover Chain Cargo Cover Roller Shaft Bear ings As Required ALL TEMPERATURES For arctic operation refer to FM 9 207 ANNUAL LUBRICANTS Lubricant Component Refill Capacity Expected Temperatures OE HDO MIL L 2104 Oil Lubricating ICE Tactical OE HDO 10 6 F to 122 F 14 C to 50 C OEA MIL L 46167 4 F to 50 F Oil Lubricating ICE Arctic 20 C to 10 C Hydraulic Reservoir 12 75 gal 48 2 I OEA 67 F to 32 F 55 C to 0 C WD 40 Corrosion Preventive Cargo Cover Chain As Required ALL TEMPERATURES Cargo Cover Roller Shaft Bear ings For arctic operation refer to FM 9 207 TM 5 3805 264 14 amp P 4 34 MANDATORY REPLACEMENT PARTS NOTE Refer to Appendix C for mo
266. om control handle and brake band Discard locknut Replace handle grip 17 if damaged 6 Remove retaining ring 14 from crank shaft 24 Remove chain sprocket 13 from shaft Discard retaining ring if damaged T Remove three screws 12 and ratchet 11 from brake drum 6 8 Remove brake drum 6 and key 3 from crank shaft 24 5 336 040 c CLEANING AND INSPECTION Clean and inspect all components in accordance with Chapter 4 Section General Maintenance Instructions 4 104 5 3805 264 14 amp P 4 65 CARGO COVER CRANK ASSEMBLY MAINTENANCE Con t d ASSEMBLY NO ak WN gt Install key 3 and brake drum 6 on crank shaft 24 Position ratchet 11 on brake drum 6 and secure with three screws 12 Install chain sprocket 13 on crank shaft 24 with retaining ring 14 Attach brake band 7 to control handle 21 with screw 22 and new locknut 19 Position brake band 7 over brake drum 6 Position control handle 21 on pivot shaft 23 Install brake pawl 10 on crank assembly baseplate 25 with retaining ring 18 Install brake pawl spring 16 between control handle 21 and brake pawl 10 Secure brake pawl spring to pawl with new pushnut 15 Secure to control handle with retaining ring 20 Install brake band spring 8 between brake band 7 and crank assembly baseplate stud 4 Secure with new pushnut 9 INSTALLATION
267. on General Maintenance Instruc tions and the following a Inspect drive shaft and gearshaft for scoring or grooving on teeth Any scoring groov ing or burring of outside diameter of teeth requires replacement of shafts as a set If shafts are replaced roller bearings must also be replaced b Inspect thrust plates for wear pitting or discoloration If found replace thrust plates ASSEMBLY NOTE Apply a light coat of lubricating oil to surfaces of components as they are assem bled 1 Press two new roller bearings 22 into pump housing 19 Press two new ring seals 15 and new roller bearings 14 into end housing 11 Press new lip seal 16 into drive shaft side of end housing 11 Install two new check assemblies 17 to end housing 11 4 Cut two pocket seals 12 3 16 in 4 8 mm long and place in center slots of thrust plate 10 Use light grease to hold in place Place thrust plate with pocket seals facing machined surface over bearings 14 of end housing 11 and tap to about 1 32 in 0 8 mm from machined surface 5 Insert remaining four pocket seals 12 into place around thrust plate 10 Tap thrust plate down onto machined surface Cut excess seal from thrust plate 5 3805 264 14 amp P 5 5 HYDRAULIC PUMP REPAIR Con t Repeat step 5 for thrust plate on pump housing 19 Install pump housing 19 in vise with machined surface facing up NOTE Us
268. on dump body and install four bolts 3 eight flatwashers 2 and four new locknuts 1 4 115 TM 5 3805 264 14 amp P 4 71 SPILL SHIELD REPLACEMENT This task covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Item 8 Appendix Eight locknuts Personnel Required Two a REMOVAL Remove locknut 4 washer 3 bolt 1 and tab 2 from spill shield 7 Discard locknut 2 Repeat step 1 for opposite side 3 Remove six locknuts 5 six washers 6 six bolts 8 and spill shield 7 Discard locknuts ee deb tt pu ud 7 22 77 m 1 INE MC A uu ME WT um a 1 gt 4l A 4 d 3 A VA X amp V VA X E h 140 iN in Hx ANN HNN i Et 371 207 b INSTALLATION Position spill shield 7 on dump body and install six bolts 8 six washers 6 and six new locknuts 5 Position tab 2 on spill shield 7 and install bolt 1 washer 3 and new locknut 4 Repeat step 2 for opposite side 4 116 5 3805 264 14 amp P Section IX HYDRAULIC SYSTEM MAINTENANCE Paragraph Number Paragraph Title Hydraulic Control Lever Hydraulic Control Lever Cable
269. on fittings on linkage Remove dump body from body props and lower b Remove locking pin and operate transport lock Reinstall locking pin with transport lock at 3 o clock position paragraph 2 2 3 HYDRAULIC RESERVOIR WARNING To prevent burns use caution when removing fill cap of hydraulic reservoir when hydraulic fluid is hot Avoid contact with hot hydraulic oil Use extreme care when filling sampling or draining hydraulic oil Failure to follow this warning may result in injury to personnel a Daily with dump body down vehicle parked on level ground and engine off check sight tube to determine level of hydraulic oil in reservoir Level should be even with FULL mark on oil level decal If low remove fill cap remove any debris from strainer and clean fill cap and strainer with a clean rag Item 16 Appendix F Add OE HDO or OEA through fill cap opening to bring oil level up to FULL mark DO NOT overfill NOTE If reservoir must be filled while dump body is raised and supported on body props level of oil should be at bottom of sight tube Whenever hydraulic oil filter service indicator shows RED hydraulic oil filter element must be replaced b Annually with dump body down remove cap from drain tube on underside of reservoir and drain all oil Remove and clean fill cap and strainer Install strainer paragraph 4 74 Replace hydraulic oil filter ele ment paragraph 4 75 Clean drain plug and in
270. on wiring harness 4 between points of connection routing it along channels and openings in dump body 1 2 Connect wiring harness connector 5 to chassis wiring harness connector 6 3 Connect wiring harness leads 2 to three marker clearance lights 3 at rear hinge light bracket 7 4 Connect wiring harness to each taillight and install taillights paragraph 4 40 5 Connect wiring harness to marker clearance light on each side of dump body and install lights paragraph 4 41 6 Install two wiring harness terminal leads to backup alarm 9 2320 363 20 or 9 2320 302 20 7 Install new tie wraps FOLLOW ON TASKS e Connect batteries TM 9 2320 363 20 M917A1 and M917A1 w MCS Remove body props and lower dump body paragraph 2 15 e Check operation of dump body lights and backup alarm TM 9 2320 363 10 TM 9 2320 302 10 4 53 TM 5 3805 264 14 amp P 4 47 AND M917A2 W MCS TRUCK TO MCS TAILGATE WIRING HARNESS MAINTENANCE M917A1 W MCS This task covers a Removal b Repair Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS Tools Test Equipment General mechanic s tool kit Item 8 c Installation Materials Parts Tie wraps Item 19 Appendix F e Marker tags Item 20 Appen
271. onal Stock Number assigned to the item Use the NSN for requests requisitions d CAGEC Column 4 The Commercial and Government Entity CAGE Code C is a five digit alphanumeric code which is used to identify the manufacturer distributor or Government agency etc that sup plies the item C 4 5 3805 264 14 amp P C 3 EXPLANATION OF COLUMNS SECTIONS AND III Con t NOTE When you use an NSN to requisition an item the item you receive may have a differ ent part number from the part ordered PART NUMBER Column 5 Indicates the primary number used by the manufacturer individ ual company firm corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items f DESCRIPTION AND USABLE ON CODE UOC Column 6 This column includes the follow ing information 1 The Federal item name and when required a minimum description to identify the item 2 Physical security classification Not applicable 3 Items that are included in kits and sets are listed below the name of the kit or set 4 Spare repair parts that make up an assembled item are listed immediately following the assembled item line entry 5 Part numbers for bulk materiels are referenced in this column in the line item entry for the item to be manufactured fabricated
272. ontains requirements and procedures for administrative storage of equipment that is issued to and in use by Army activities worldwide b The requirements specified herein are necessary to maintain equipment in administrative storage in such a way as to achieve the maximum readiness condition Equipment that is placed in administrative storage should be capable of being readied to perform its mission within a 24 hour period or as otherwise may be prescribed by the approving authority Before equip ment is placed in administrative storage a current Preventive Maintenance Checks and Services PMCS should be completed and deficiencies corrected d Report equipment in administrative storage as prescribed for all reportable equipment Perform inspections maintenance services and lubrication as specified herein f Records and reports to be maintained for equipment in administrative storage are those pre scribed by DA Pam 738 750 for equipment in use g A 10 variance is acceptable on time used to determine the required maintenance actions h Accomplishment of applicable PMCS as mentioned throughout this chapter will be on a semi annual basis 4 80 DEFINITION OF ADMINISTRATIVE STORAGE The placement of equipment in administrative storage can be for short periods of time when a shortage of maintenance effort exists Items should be ready for use within the time factors as determined by the directing authority During the
273. or damaged tailgate locking linkage Notify Direct Support HYDRAULIC SYSTEM 7 DUMP BODY WILL RAISE AND OR LOWER Step 1 Check if Power Take Off PTO is operating properly Check PTO operation TM 9 2320 363 10 or TM 9 2320 302 10 Step 2 Check for damaged hydraulic hoses Replace damaged hydraulic hoses paragraph 4 74 Step 3 Check for damaged or out of adjustment hydraulic control lever cable Adjust hydraulic control lever cable paragraph 4 73 Replace damaged hydraulic control lever cable paragraph 4 73 4 30 5 3805 264 14 amp P Table 4 3 Unit Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4 Dump body still will not operate properly Notify Direct Support 8 DUMP BODY RAISES WITH HYDRAULIC CONTROL LEVER IN THE NEUTRAL POSITION AND PTO ENGAGED Step 1 Check for damaged or out of adjustment hydraulic control lever cable Adjust hydraulic control lever cable paragraph 4 73 Replace damaged hydraulic control lever cable paragraph 4 73 Step 2 Dump body still will not operate properly Notify Direct Support 9 DUMP BODY LOWERS WITH HYDRAULIC CONTROL LEVER IN THE NEUTRAL POSITION AND PTO ENGAGED Step 1 Check for damaged or out of adjustment hydraulic control lever cable Adjust hydraulic control lever cable paragraph 4 73 Replace damaged hydraulic control lever cable paragraph 4 73 Step 2 Dump body still will not operate properly Not
274. orm steps 1 thru 7 to assemble control box 1 Install bushing 23 and nut 22 to control box 9 2 Install end of cable 8 grommet 21 and locking plug 20 4 44 5 3805 264 14 amp P 4 43 MCS REMOTE CONTROL REPAIR M917A1 W MCS AND M917A2 W MCS Con t NOTE Perform steps 3 thru 5 for each of four switches 3 Install data plate 18 switch housing 19 and ring 17 to cover 12 4 Install retainer 16 and switch 15 to switch housing 19 5 Connect two wires 13 to switch 15 and tighten two screws 14 6 Install new gasket 10 to cover 12 T Install cover 12 to control box 9 and tighten four twist lock screws 11 4 45 TM 5 3805 264 14 amp P 4 43 MCS REMOTE CONTROL REPAIR M917A1 W MCS AND M917A2 W MCS Con t 8 Install jumper wire 7 to connector 5 9 With cable 8 thru connector housing 3 install connector 5 to wires of cable with seven screws 6 Push connector into connector housing 10 Install clamp 2 screw 1 and screw 4 FOLLOW ON TASKS e Check operation of MCS remote control paragraph 2 13 4 46 5 3805 264 14 amp P 4 44 MAINTENANCE BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS This task covers a Removal b Repair Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Ma
275. ound in the supply catalogs and spe cial tools are found in the Maintenance Allocation Chart MAC 1 2 DEFINITION OF COLUMNS a Column 1 Number No This number is assigned to the entry in the listing and is refer enced in the Initial Setup of maintenance paragraphs or narrative instructions to identify the tool needed e g General mechanic s tool kit Item 8 Appendix 1 b Column 2 Item Name Indicates the tool or tool set name and if required a description to iden tify the tool C Column 3 National Stock Number This is the National Stock Number NSN assigned to the tool Use it to request or requisition the tool d Column 4 CAGEC Part Number When no NSN is available a Commercial and Government Entity Code CAGEC followed by a part number will be used where possible e Column 5 Reference Indicates the technical manual or supply catalog in which the tool can be found Section TOOL IDENTIFICATION LIST 1 2 3 4 5 Item Item National CAGEC No Name Stock Number Part Number Reference 1 Cap and Plug Set 5340 00 450 5718 19207 10935405 2 Gun Air Blow 4940 00 333 5541 58536 A A 55543 TY2 SC 4910 95 CL A74 CL1 STA 3 Multimeter Digital 6625 00 519 0112 81349 ANPRM15 SC 4910 95 CL A74 4 Pan Drain 4910 00 387 9592 36540 17942 SC 4910 95 CL A74 5 Pliers Retaining Ring 5120 00 293 0186 19207 7082060 internal 3 062 6 250 in 6 Sling
276. perly connect the wires during assembly If you need to identify a loose wire look for identifying numbers near the end of the wire stamped on a permanent metal tag Compare this number to wire number on the appropriate electrical schematic Identify lines when you are taking off more than one line at the same time Mark tags with points to which lines and hoses must be connected If it is not obvious which end of a line goes where tag each end of the line d Identify and tag other parts as required by name and installed location 4 18 SOLDERING CAUTION Use low wattage soldering gun when soldering electrical wires connectors termi nal lugs and receptacles High wattage soldering guns may damage parts by over heating a Solder connection must be bright and clean before soldering Remove dirt and grease with a wire brush Item 4 Appendix or a pocket knife Item 8 Appendix 1 Solder used must be of lead alloy Item 18 fucus with soldering flux Item wires parts and soldering gun Item must be tinned for good connection and maximum transfer of heat b To prevent overheating damage to electrical parts when soldering and unsoldering connections hold bare wire lead or terminal lug close to soldering point with long roundnose pliers Item 8 Appendix i Pliers act as heat sink and absorb excess heat 4 19 HEAT SHRINKABLE TUBING Use the heat shrinkable tubing Item 24 Append
277. ph 2 13 e Assistance is required for this operation Driver inside cab operates dumping controls Assistant driver monitors area around dump body a Preparing to Dump 1 Position dump truck on level ground Set parking brake TM 9 2320 363 10 or TM 9 2320 302 10 2 Walk around dump truck and check the following a Wheels are on firm level ground b Dump truck is not leaning to one side Area behind tailgate is clear d Overhead clearance is sufficient e Transport lock is unlocked 3 o clock position paragraph 2 2 2 30 5 3805 264 14 amp P 2 10 DUMPING LOAD Con t 3 Secure mud flaps 1 out of way on hooks 2 when stockpiling or when dumping into a spreader CAUTION Adjustment chains are intended for use only during spreading operations If used when stockpiling damage to chains or tailgate may result 4 Adjust tailgate opening if 2 required paragraph 2 11 5 Uncover load paragraph 2 14 6 Start engine TM 9 2320 363 10 or TM 9 2320 302 10 NOTE Dump body will not raise when main light switch is in blackout mode 7 Place main light switch 6 in SER DRIVE or STOP LIGHT position TM 9 2320 363 10 or TM 9 2320 302 10 8 Engage PTO TM 9 2320 363 10 or TM 9 2320 302 10 9 Check that body transport lock indicator light 3 is not lit If lit unlock transport lock para graph 2 2
278. plate 6 13 Remove cylinder sleeve 23 from piston 25 14 Remove nut 26 from piston shaft 5 15 Remove piston 25 and metal washer 20 halves from piston shaft 5 NOTE Note direction of gaskets during removal to aid in installation 16 Remove two gaskets 19 and seal 24 from piston 25 17 Remove preformed packing 21 from piston shaft 5 22 336 018 4 88 5 3805 264 14 amp P 4 58 TAILGATE RELEASE MCS AIR CYLINDER REPAIR Con t b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions ASSEMBLY Apply a light coat of grease to preformed packing 21 and install on piston shaft 5 Apply a light of grease to piston 25 Install two gaskets 19 and seal 24 on piston 25 Install metal washer 20 halves on piston shaft 5 and install piston 25 on piston shaft Install nut 26 on piston shaft 5 Install cylinder sleeve 23 on piston 25 Install gasket 22 on bottom end plate 6 NO a gt 336 018 8 Apply a light coat of grease to preformed packing 14 and install on bushing 15 9 Install gasket 13 and bushing 15 on bottom end plate 6 10 Install plastic gasket 16 metal washer 17 and retaining ring 18 on bottom end plate 6 4 89 TM 5 3805 264 14 amp P 4 58 TAILGATE RELEASE MCS AIR CYLINDER REPAIR Con t 336
279. ported on body props paragraph 2 15 Cab shield removed paragraph 4 62 Hydraulic oil drained Chapter 3 Section 1 Tools Test Equipment General mechanic s tool kit Item 8 Appendix Cap and plug set Item 1 Nylon sling Item 6 Appendix Suitable lifting device Materials Parts Rags Item 16 e Marker tags Item 20 Appendix c Installation Materials Parts Con t Seven locknuts Two lockwashers Personnel Required Three General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY DO NOT disconnect hydraulic lines while engine is running Use extreme caution when handling heavy parts Hydraulic cylinder sleeves may extend down ward as hydraulic cylinder is lifted WARNING e NEVER work under a raised dump body unless it is secured in the raised posi tion with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel e DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel a REMOVAL CAUTION Hoses and ports in hydraulic components should be plugged to prevent contamina
280. primary mis sion 4 29 EXPLANATION OF TABLE ENTRIES a Item Number Item No Column Numbers in this column are for reference When completing DA Form 2404 Equipment Inspection and Maintenance Worksheet include the item number for the check service indicating a fault Item numbers also appear in the order you must perform checks and services for the interval listed b Interval Column This column tells you when you must perform the procedure in the procedure column 1 Semiannual procedures must be done once every six months 2 Annual procedures must be done once each year C Location Item to Check Service Column This column identifies the location and the item to be checked or serviced 4 13 TM 5 3805 264 14 amp P 4 29 EXPLANATION OF TABLE ENTRIES Con t NOTE WARNINGs and CAUTIONs appearing in your PMCS table should always be observed WARNINGs and CAUTIONs appear before applicable procedures These WARNINGs and CAUTIONs must be observed to prevent serious injury to yourself and others or to prevent your equipment from being damaged d Procedure Column This column gives the procedure you must perform to check or service the item listed in the Item to Check Service column to know if the equipment is ready or available for its intended mis sion or for operation You must perform the procedure at the time stated in the interval column e Not Fully Mission Capable If Column Information in
281. r Components Location and Description 1 11 1 5 Mandatory Replacement Parts 4 34 4 18 Marker Clearance Light Replacement 4 41 4 38 MCS Adjustment Tube Replacement 917 1 w MCS and M917A2 w MCS 4 60 4 93 Air Cylinder Replacement M917A1 w MCS and M917A2 w MCS 4 56 4 79 Air Cylinder Solenoid Assembly Replacement M917A1 w MCS and 917 2 5 4 57 4 82 Air Reservoir Replacement M917A1 w MCS M917A2 w MCS 4 55 4 77 Control Unit Maintenance M917A1 w MCS and M917A2 w MCS 4 42 4 39 Gate Replacement M917A1 w MCS 917 2 w MCS 4 54 4 75 Remote Control Repair M917A1 w MCS M917A2 w MCS 4 43 4 42 Tailgate Cover Replacement M917A1 w MCS and M917A2 w MCS 4 53 4 73 Tailgate Replacement M917A1 w MCS and M917A2 w MCS 4 52 4 70 Tailgate Wiring Harness Maintenance M917A1 w MCS and M917A2WIMGS iid EL Merl a ie fees B 4 48 4 58 Mud Flap 4 63 4 99 N Names Designations Abbreviations and Official Nomenclature 1 5 1 2 Official Nomenclature Names Designations and Abbreviations 1 5 1 2 Index 4 5 3805 264 14 amp P INDEX Con t Subject Paragraph Page Con t Operating
282. r lines while air system is pressurized Air system pressure must be released before air lines are disconnected A line disconnected under pres WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or Attach lifting slings 4 to MCS tailgate 5 and remove slack from lifting slings Remove lynch pins 2 and hinge pins 1 from each side of MCS tailgate 5 Lift MCS tailgate 5 from dump body 8 and place tailgate in a safe work area a REMOVAL 1 sure may cause personnel injury 2 Disconnect MCS quick disconnect air line 9 injury to personnel and damage to equipment b CLEANING AND INSPECTION tions 4 70 Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc 5 3805 264 14 amp P 4 52 MCS TAILGATE REPLACEMENT M917A1 W MCS AND M917A2 W MCS Con t U ms N G INSTALLATION WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage t
283. r the pin placement the larger the gate opening d When controlled spreading is completed after gates have been closed and dump body is down return locking pins 2 to top hole in adjustment tubes 1 to lock gates closed TM 5 3805 264 14 amp P 2 13 CONTROLLED SPREADING M917A1 W MCS AND M917A2 W MCS WARNING e NOT connect or disconnect MCS remote control when dump body is being raised or lowered Failure to follow this warning may cause personnel injury e When connected MCS remote control overrides cab control unit When remote control is disconnected cab control activates To avoid inadvertent opening or closing of gates ALWAYS check gate positions and position of toggle switches on both cab and remote controls before plugging in or unplugging remote con trol Toggle switches should be in CLOSED position Failure to follow this warn ing may cause personnel injury e DO NOT spread or dump payload with dump truck facing a steep upgrade or a steep side slope Dump truck may tip over backward or sideways Failure to fol low this warning may result in death or injury to personnel or damage to equip ment e NOT stand or walk behind dump truck when it is dumping or in raised posi tion When using MCS remote control always walk or stand to side of dump body Failure to follow this warning may result in personnel injury e Keep hands and feet away from gate openin
284. re applying sealant 3 When applying sealant ensure that the area is completely covered Press sealant into and around parts as necessary 4 Silicone sealant will set in 15 30 minutes depending on temperature and humidity c Loctite Adhesive Loctite adhesive Item 1 Appendix provides a seal against leakage and resistance to loosening when used in the assembly of threaded slip fitted or press fitted parts Always use grade of Loctite adhesive specified and never use when other retaining means are provided such as lockwires lock washers lockplates and fasteners DO NOT use Loctite adhesive on brass fittings plugs or items that need fre quent servicing or when operating temperature exceeds 300 F 149 C Apply Loctite adhesive as follows 1 Before application clean threads to remove oil grease and metal chips 2 Apply Loctite adhesive to second and third threads DO NOT apply to first thread to ensure system cleanliness 3 Loctite adhesive will dry in 6 24 hours at room temperature 4 Adjustments for elbows gages and valves can be made up to 24 hours after application without affecting the seal 4 16 STANDARD TOOL REQUIREMENTS a The following are general practices regarding the use of tools 1 Always use the proper tool kit and tools for the procedure being performed 2 Ensure that tools are clean and lubricated to reduce wear and to prevent rust 3 Keep track of tools Do not be careles
285. re information on mandatory replacement parts ANNUAL Nomenclature Qty CAGEC P N NSN Filter element hydraulic oil 1 5X050 403366 4330 01 446 3337 Preformed packing filter housing cover 1 60827 251 70 BN 5330 01 447 4034 4 18 5 3805 264 14 amp P Table 4 2 Unit Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Truck Body Item No Interval Location Item To Check Service Procedure Not Fully Mission Capable If Semi annual Tailgate Operation WARNING Unless otherwise specified per form all lubrication and preventive maintenance checks with dump truck on level ground transmission in N Neutral parking brake set and engine off Failure to follow this warning may result in person nel injury NOTE Perform all Operator PMCS Section Il as appro priate while performing Item No 1 4 checks Drive at least 5 mi 8 km to give enough time to detect malfunctions Dump truck s chassis air system activates both models tailgate locking mechanism and inter faces with MCS air system on the M917A1 w MCS and M917A2 w MCS to operate the MCS tailgate a Start engine and fully pressurize vehicle air systems TM 9 2320 363 10 TM 9 2320 302 10 Lis ten for air leaks b Operate tailgate release control valve lever in cab paragraph 2 1 Check that tailgate unlocks and l
286. rial has been spread Raise dump body periodically to keep material flowing evenly through gates 4 2 38 5 3805 264 14 amp P 2 13 CONTROLLED SPREADING M917A1 W MCS AND M917A2 W MCS Con t WARNING Care must be exercised when using the Material Control System MCS In the event material fails to flow through gates open gate using open control and clear jam using shovel DO NOT attempt to clear material using your hands or feet Failure to follow this warning may cause injury to personnel i If material becomes jammed in gates open gate and clear jam with BIl shovel j Close gates 4 by moving toggle switches 5 to CLOSED position Lower dump body paragraph 2 10 l Unplug MCS remote control 1 from receptacle 2 Stow remote control in storage pouch and place in box m Lock gates closed by returning adjustment tube locking pins to top hole in tubes paragraph 2 12 n Perform after dumping steps as applicable paragraph 2 10 D gt 02 S x 5222 2 39 5 3805 264 14 amp P 2 14 OPERATING CARGO COVER 2 40 a WARNING Observe the following safety regulations when operating cargo cover Never operate system under obstructions such as trees and power lines Ensure that all personnel are clear of rear of dump body and the immediate area of the cover Ensure that chain cover is
287. rication C Body Props 1 Use of body props permit inspection or maintenance to be safely performed underneath an empty raised dump body 2 Body props are located on outside of truck frame When not in use they are stowed in the horizontal position 5 3805 264 14 amp P 1 16 DUMP BODY Con t 3 A grease fitting on each body prop pivot point allows for lubrication d Lubrication Free Bearings There are composite lubrication free bearings with removable pins at the rear hinge and at the hydraulic cylinder pivot points Transport Lock 1 A manually operated transport lock is mounted on the left side of the dump body near the front it locks and unlocks the dump body from the truck frame For normal operation it is unlocked 2 The transport lock is placed in the locked position when the dump truck is being lifted and transported This actuates a transport lock switch which disengages the PTO thereby preventing the PTO from operating to power the hydraulic cylinder f Cargo Cover A cargo cover helps prevent the load from spilling out It is extended or retracted using the control handle or the removable crank handle g Tailgate Configuration The M917A1 and M917A2 differ from the M917A1 w MCS and M917A2 w MCS in tailgate configuration 1 M917A1 and M917A2 Tailgate PR lj Chains 336 006 Locking Linkage a The M917A1 and M917A2 use a nine panel convent
288. rning may result in injury to personnel e DO NOT attempt to dump in high wind High winds may disperse aggregate High winds may also cause dump truck to roll over when dump body is raised Failure to follow this warning may result in death or injury to personnel or dam age to equipment e Stay at controls while dumping If dump body leans or shifts to one side lower it immediately and check for one of the following underinflated or flat tires tires sinking in soft soil load shifting to one side of body high or gusty wind weak or broken leaf spring If one of these or any other problems are found do not continue dumping until the problem is corrected Failure to follow this warning may result in death or injury to personnel or damage to equipment e DO NOT spread or dump payload with dump truck facing a steep upgrade or a steep side slope Dump truck may tip over backward or sideways Failure to fol low this warning may result in death or injury to personnel or damage to equip ment e NOT park on a slope Park on level ground only Parking on a slope could cause load to shift and dump truck to tip over Failure to follow this warning may result in death or injury to personnel or damage to equipment NOTE e This paragraph describes dumping a load through the tailgate opening of either model dump truck e For instructions on controlled spreading using the 917 1 w MCS and M917A2 w MCS gates refer to paragra
289. rocessed for domestic shipment as indicated on DD Form 1397 it does not have to be reprocessed for storage unless corrosion and deterioration are found dur ing the inspection upon receipt List on SF Form 364 all discrepancies found because of poor preservation pack aging packing marking handling loading storage or excessive preservation Repairs that cannot be handled by the receiving unit must have tags attached listing needed repairs A report of these conditions will be submitted by the unit commander for action by an ordnance maintenance unit 4 152 5 3805 264 14 5 DIRECT SUPPORT MAINTENANCE Section DUMP BODY MAINTENANCE Paragraph Page Number Paragraph Title Number 5 1 Dump Body and Stabilizer Replacement 5 1 Cylinder Support Frame 5 7 5 1 DUMP BODY AND STABILIZER REPLACEMENT This task covers a Removal Initial Setup Equipment Conditions Chassis to dump body air lines disconnected paragraph 4 59 Chassis to dump body electrical harnesses dis connected thru 4 47 Mud flaps removed paragraph 4 63 Tools Test Equipment General mechanic s tool kit Item 8 Nylon slings Item 6 Torque wrench Item 12 Suitable lifting device with chains Materials Parts Fourteen locknuts Wooden blocks a REMOVAL 1 Remove s
290. rot or mildew 4 150 5 3805 264 14 amp P 4 82 CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE a Maintenance Services After equipment has been placed in administrative storage inspect ser vice and exercise as specified herein b Inspection Inspection will usually be visual and must consist of at least a walkaround examina tion of all equipment to detect any deficiencies Inspect equipment in open storage weekly and equipment in cov ered storage monthly Inspect all equipment immediately after any severe storm or environmental change The following are examples of things to look for during a visual inspection 1 Low or flat tires 2 Coolant fuel or oil leaks 3 Condition of preservatives seals and wraps 4 Corrosion or other deterioration 5 Missing or damaged parts 6 Water in compartments 7 Any other readily recognizable shortcomings or deficiencies Repair During Administrative Storage Keep equipment an optimum state of readiness Accomplish the required services and repairs as quickly as possible Whenever possible perform all maintenance on site d Exercising Exercise equipment in accordance with Table 4 4 Exercise Schedule and the follow ing instructions 1 Vehicle Major Exercise Depreserve equipment by removing only that material restricting exercise Close all drains remove blocks and perform all BEFORE operational checks Make several right and left 90 turns M
291. rt it to your supervisor 7 Fluid Leakage It is necessary for you to know how fluid leakage affects the status of your dump truck The following are definitions of the types classes of leakage you need to know to be able to determine the status of your equipment Learn and be familiar with them and remember when it doubt notify your supervi sor Leakage Definitions for PMCS Class Leakage indicated by wetness or discoloration but not great enough to form drops Class Il Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class Leakage great enough to form drops that fall from the item being checked inspected Operation is allowable with Class and Class leakage WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with Class or Class leaks check fluid lev els more frequently Class leaks must be reported immediately to your supervi sor Failure to do this will result in damage to vehicle and or components 5 3805 264 14 amp P Table 2 1 Operator Preventive Maintenance Checks Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If WARNING Unless otherwise specified perform all preventive maintenance checks with dump truck on level ground transmission in N Neutra
292. ry Wear protective gear such as safety goggles or lenses safety shoes rubber apron gloves etc 5 Notify others in the area if you are handling flammable materials Know the location of fire extinguishers and emergency procedures in case of accident or fire 1 2 5 3805 264 14 amp P 1 8 SAFETY CARE AND HANDLING Con t 6 Before performing maintenance ensure that dump truck is secured against movement Park vehicle on level ground place transmission in N Neutral and set parking brake TM 9 2320 363 10 for M917A1 M917A1 w MCS or TM 9 2320 302 10 for M917A2 and M917A2 w MCS If parking brake is not func tioning chock wheels 7 NEVER work under raised dump body unless body props are used to prop it safely in the raised position 8 When lifting heavy parts have someone help you Ensure that lifting or jacking equipment is working properly is of sufficient capacity for the assigned task and is secure against slipping 1 9 CORROSION PREVENTION AND CONTROL CPC a CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements made to prevent the problem in future items b While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials m
293. s a cross reference between the National Stock Number Index the Part Number Index and the bulk materiel list in Section f Associated Publications The publications listed below pertain to the M915 Family of Vehicles and its components Publication Short Title TM 9 2320 363 10 Operator s Manual for M915 Family of Vehicles TM 9 2320 363 20 Unit Maintenance Manual for M915 Family of Vehicles TM 9 2320 363 34 Direct Support and General Support Maintenance Man ual for M915 Family of Vehicles TM 9 2320 363 24P Unit Direct Support and General Support RPSTL for M915 Family of Vehicles TM 9 2320 302 Series M915 Family of Vehicles IETM 5 3805 264 14 amp P 6 HOW TO LOCATE REPAIR PARTS a When National Stock Number or Part Number is Not Known 1 First Using the Table of Contents determine the assembly group or subassembly group to which the item belongs This is necessary since figures are prepared for assembly groups and subassembly groups and listings are divided into the same groups 2 Second Find the figure covering the assembly group or subassembly group to which the item belongs b When National Stock Number or Part Number is Known 1 First Using the National Stock Number Index or Part Number Index find the pertinent NSN or part number The NSN Index is in National Item Identification Number NIIN sequence paragraph C 4a 1 The part numbers in the Part Number Index are listed in ascendin
294. s in Chapter 4j Section General Maintenance Instructions INSTALLATION 1 Connect wiring harness connector 4 to chassis wiring harness connector 3 2 Connect two wiring harness leads 5 to body up switch 6 3 Connect transport lock switch connector 1 to wiring harness connector 2 4 Secure wiring harness 7 with new tie wraps FOLLOW ON TASKS Connect batteries TM 9 2320 363 20 917 1 and M917A1 w MCS Check operation of body up and transport lock switches paragraph 2 1 4 48 5 3805 264 14 amp P 4 45 BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE This task covers a Removal b Repair Initial Setup Equipment Conditions Dump body raised and supported on body props paragraph 2 15 Batteries disconnected TM 9 2320 363 20 M917A1 and M917A1 w MCS Master battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS Tools Test Equipment General mechanic s tool kit Item 8j Appendix c Installation Materials Parts Marker tags Item 20 Appendix Materials Parts Con t Locknuts as required Tie wraps Item 19 Appendix pomme General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump
295. s with them 4 Return tools to toolbox when finished with repair or maintenance 5 Return toolboxes and tools to tool storage when not in use 6 Inventory tools before and after each use b Some maintenance tasks may require special or fabricated tools The Initial Setup of the proce dure will specify any special or fabricated tools needed to perform that procedure Use these special tools only for the maintenance procedures for which they are designed or called out If you are unfamiliar with a required tool See your supervisor 4 7 TM 5 3805 264 14 amp P 4 17 TAGGING WIRES AND HOSES a marker tags Item F to identify all electrical wires lines and any other parts which may be hard to identify or replace later Fasten tags to parts during removal by wrapping wire fasteners around or through parts and twisting ends together Position tags to be out of the way during cleaning inspection and repair Mark tags with a pencil pen or marker b Whenever possible identify electrical wires with the number of the terminal or wire to which it con nects If no markings can be found tag both wires or wire and terminal and use the same identifying mark for both If you cannot tag a wire because it must fit through a small hole or you cannot reach it write down the description of the wire and the point to which it connects or draw a simple diagram on paper Be sure to write down enough information so you will be able to pro
296. se 1 3 1 1 Assembly Instructions Disassembly and 4 13 4 6 B Beacon Warning Light Wiring Harness Maintenance 4 45 4 49 Body Prop Replacement 4 61 4 95 Body Props Operating 2 15 2 42 Body Up and Transport Lock Switches Wiring Harness Maintenance 4 44 4 47 Body Up Switch Replacement 4 38 4 33 Bracket Replacement 4 70 4 115 C Cab Shield Replacement 4 62 4 96 Cab Mounted Controls and Indicators 2 1 2 1 Care and Handling Safety 1 8 1 2 Care of Equipment in Administrative Storage 4 82 4 151 aestu one Fn RI Rer Er ea deb 5 3 5 9 Cargo Cover Chain and Sprockets Replacement 4 66 4 106 Crank Assembly Maintenance 4 65 4 103 ie ee Lady 2 14 2 38 Replacement 2 42 1255 ud e LLEVE e os 4 64 4 101 Support Frame and Roll Up Bar 4 67 4 110 Characteristics Capabilities and Features Equipment
297. shly Notify Unit Maintenance 8 DUMP BODY WILL NOT LOWER WHEN HYDRAULIC CONTROL LEVER IS PLACED IN DOWN POSI TION Step 1 Check for deployed body props Stow body props paragraph 2 15 Step 2 Check for obstructions Remove obstructions NOTE DO NOT overfill hydraulic reservoir ONLY add enough hydraulic oil to safely lower the dump body Recheck hydraulic oil with dump body in lowered position Add or drain oil as necessary Chapter 3 Section Step 3 Check the hydraulic oil level in sight tube on reservoir Add hydraulic oil if necessary Chapter 3 Section 1 Step 4 Dump body still will not lower Notify Unit Maintenance 3 7 3 8 Blank TM 5 3805 264 14 amp P Section Ill OPERATOR MAINTENANCE Paragraph Page Number Paragraph Title Number PEEL 3 9 3 5 eC T c rt Na deco See eat ats alan ea 3 9 3 4 GENERAL Lubrication and cleaning are the only maintenance procedures performed by the operator Required lubrication is specified in Chapter 3 Section 3 5 CLEANING a Road grime mud dust salt and material deposits inside dump body reduce payload and cause corrosion Clean dump body whenever these materials begin to accumulate 1 With dump body completely lowered use tailgate release control valve lever to release tail gate paragraph 2 1 WARNING Wear eye protection when using high pressure stream
298. sport Apply grease Item 11 Appendix to Lock four transport lock grease fittings 35 2 24 5 3805 264 14 Table 2 1 Operator Preventive Maintenance Checks and Services PMCS for M917A1 M917A1 w MCS M917A2 and M917A2 w MCS Dump Body Con t Location Item To Item Check Not Fully Mission No Interval Service Procedure Capable If 21 Monthly Tailgate a Apply grease Item 11 Appendix Locking to tailgate locking linkage grease fit Linkage ting 36 b Remove body props and lower dump body paragraph 2 15 22 Monthly Tailgate Apply grease Item 11 Appendix to Hinge Pins tailgate hinge pin grease fitting 37 2 25 2 26 Blank TM 5 3805 264 14 amp P Section 11 OPERATION UNDER USUAL CONDITIONS Paragraph Page Number Paragraph Title Number iive Preparing to Load Dump Loading Dump Transporting Load idee dex Re do a Deed tle Dumping Pod epe eae E Adjusting Tailgate Adjusting MCS Gate Openings M917A1 w MCS and 917 2 w MCS Controlled Spreading M917A1 w MCS and M917A2 5 Operating Carg
299. st for M915A2 M916A1 M916A2 M917A1 M917A1 wMCS Chassis TM 9 2320 363 24P Unit Direct Support and General Support Repair Parts and Special Tools List for M915A3 M916A3 917 2 and 917 2 wMCS TM 9 2320 302 24P Unit Maintenance Manual for M915A2 M916A1 M916A2 M917A1 and 917 1 wMCS Chassis TM 9 2320 363 20 Unit Maintenance Manual for M915A3 M916A3 M917A2 917 2 wMCS TM 9 2320 302 20 A 7 OTHER PUBLICATIONS Abbreviations and 5 ASME Y14 38 1999 Army Medical Department Expendable Durable Items CTA 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic CTA 50 970 Fuels and Lubricants Standardization Policy for Equipment Design Operation and Logistic SUDDOILE o e T dun tu e deta at ann aes E AULA eL ID AR 70 12 Military Standard Abbreviations for Use on Drawings Specifications Standards and in Technical MIL STD 12D Prevention of Motor Vehicle Accidents AR 385 55 5 3805 264 14 amp P APPENDIX MAINTENANCE ALLOCATION CHART Section l IN
300. stall Fill reservoir with OE HDO or OEA until level in sight tube is at FULL mark on oil level decal DO NOT overfill 4 STABILIZER Monthly raise dump body and support on body props paragraph 2 15 Apply GAA to five lubrication fittings on stabilizer Remove dump body from body props and lower 5 TAILGATE HINGE PINS Monthly apply GAA to each tailgate hinge pin lubrication fitting 6 TAILGATE LOCKING LINKAGE Monthly apply GAA to tailgate locking linkage lubrication fitting 7 BODY PROPS Semiannually raise dump body and support on body props paragraph 2 15 Apply GAA to each body prop lubrication fitting J 8 5 3805 264 14 amp P INDEX Subject Paragraph Page A Abbreviations Official Nomenclature Names and Designations 1 5 1 2 Adhesives Application of 4 15 4 7 Adjusting MCS Gate Openings M917A1 w MCS and 917 2 w MCS 2 12 2 37 Tailgate Opening gt Rx ae p koe ee ee 2 11 2 36 Administrative Storage Definition 4 79 4 149 Air Cylinder Repair Tailgate 5 4 58 4 87 Air Lines and Fittings Replacement Tailgate Release MCS 4 59 4 91 Antiseize Tape eei E m ERN E ETE UE ea IS 4 22 4 10 Application of Adhesives 4 15 4 7 Army Materiel Destruction to Prevent Enemy U
301. stem pressure must be released before air lines are disconnected A line disconnected under pres sure may cause personnel injury NOTE e Replacement of tailgate release or MCS air lines is the same Replacement of an MCS air line is shown e should be tagged before removal paragraph 4 17 e Note location of tie wraps prior to removal to aid in installation 4 91 5 3805 264 14 amp P 4 59 TAILGATE RELEASE MCS AIR LINES AND FITTINGS REPLACEMENT Con t 1 If removing an air line disconnect each end of air line 1 at fitting 2 2 If removing a fitting disconnect all air lines 1 from fitting 2 b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions c INSTALLATION NOTE For information on manufacturing air lines refer to Appendix Illustrated List of Manufactured Items 1 If installing a fitting connect all air lines 1 to fitting 2 2 If installing an air line connect each end of air line 1 to fitting 2 3 Install new tie wraps as required FOLLOW ON TASKS Start engine and pressurize air systems TM 9 2320 363 10 TM 9 2320 302 10 e Operate tailgate release control valve lever or MCS gates paragraph 2 1 or 2 13 Check for leaks e Install MCS tailgate cover if removed paragraph 4 53 4 92 5 3805 264 14 amp P 4 60 MCS ADJUSTMENT TUBE RE
302. ster battery switch OFF TM 9 2320 302 10 M917A2 and M917A2 w MCS Tools Test Equipment General mechanic s tool kit Item 8 Appendix c Installation Materials Parts Marker tags Item 20 Appendix Tie wraps Item 19 Appendix F General Safety Instructions NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY WARNING NEVER work under a raised dump body unless it is secured in the raised position with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel a REMOVAL NOTE e Wires should be tagged before disconnecting paragraph 4 17 e Note location of tie wraps and routing of wiring harness prior to removal to aid in installation 1 Remove tie wraps and discard 2 Disconnect transport lock switch connector 1 from wiring harness connector 2 4 47 TM 5 3805 264 14 amp P 4 44 BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTE NANCE Con t 3 Disconnect two wiring harness leads 5 from body up switch 6 4 Disconnect wiring harness connector 4 from chassis wiring harness connector 3 and remove wiring har ness 7 TA Oi ar N gt 20 b REPAIR NOTE Wiring harness need not be removed from vehicle to make repairs Repair wiring harness in accordance with instruction
303. storage period appropriate maintenance records will be kept 4 81 PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE a Storage Site 1 Select the best available site for administrative storage Separate stored equipment from equipment in use Conspicuously mark the area Administrative Storage 2 Covered space is preferred 4 149 TM 5 3805 264 14 amp P 4 81 PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE Con t 3 Open sites should be improved hardstand if available Unimproved sites should be firm well drained and free of excessive vegetation b Storage Plan 1 Store equipment so as to provide maximum protection from the elements and to provide access for inspection maintenance and exercising Anticipate removal or deployment problems and take suitable precautions 2 Take into consideration environmental conditions such as extreme heat or cold high humidity blowing sand dust or loose debris soft ground mud heavy snows or any combination thereof and take adequate precautions 3 Establish a fire plan and provide for adequate fire fighting equipment and personnel C Maintenance Services and Inspections 1 Maintenance Services Prior to storage perform the next scheduled PMCS 2 Inspection Inspect and approve the equipment prior to storage Do not place nonmission capable equipment in storage d Correction of Shortcomings and Deficiencies Correct all shortcomings and
304. t Temperature 5 9 F 32 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9 5 32 F APPROXIMATE CONVERSION FACTORS To Change To Multiply By To Change To Multiply By Inches Centimeters 2 540 Centimeters Inches 0 394 Feet Meters 0 305 Meters Feet 3 280 Yards Meters 0 914 Meters Yards 1 094 Miles Kilometers 1 609 Kilometers Miles 0 621 Sq Inches Sq Centimeters 6 451 Sq Centimeters Sq Inches 0 155 Sq Feet Sq Meters 0 093 Sq Meters Sq Feet 10 764 Sq Yards Sq Meters 0 836 Sq Meters Sq Yards 1 196 Sq Miles Sq Kilometers 2 590 Sq Kilometers Sq Miles 0 386 Acres Sq Hectometers 0 405 Sq Hectometers Acres 2 471 Cubic Feet Cubic Meters 0 028 Cubic Meters Cubic Feet 35 315 Cubic Yards Cubic Meters 0 765 Cubic Meters Cubic Yards 1 308 Fluid Ounces Milliliters 29 573 Milliliters Fluid Ounces 0 034 Pints Liters 0 473 Liters Pints 2 113 Quarts Liters 0 946 Liters Quarts 1 057 Gallons Liters 3 785 Liters Gallons 0 264 Ounces Grams 28 349 Grams Ounces 0 035 Pounds Kilograms 0 454 Kilograms Pounds 2 205 Short Tons Metric Tons 0 907 Metric Tons Short Tons 1 102 Pound Feet Newton Meters 1 356 Newton Meters Pound Feet 0 738 Pounds per Sq Kilopascals 6 895 Kilopascals Pounds per Sq 0 145 Inch Inch Miles
305. t Operate With Driver s MCS Gate Will Not Operate With Remote MCS Gate s Open or Close When Remote Control Is Connected TAILGATE Tailgate Assembly Lock Will Not 3 6 5 3805 264 14 amp P Table 3 1 Operator Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION MCS 917 1 W MCS AND M917A2 W MCS 1 MCS GATE WILL NOT OPERATE Step 1 Check position of MCS gate s adjustment tube locking pins Position locking pin s to desired operating position paragraph 2 12 Step 2 Check that all air tank drain valves are closed Close all draincocks Step 3 Start engine and check for possible air leaks at air reservoirs hoses fittings and MCS gate air cylinders Notify Unit Maintenance of any leaks Step 4 MCS gate still fails to operate Notify Unit Maintenance 2 MCS GATE WILL NOT OPERATE WITH DRIVER S CONTROLS Step 1 Check if MCS remote control is connected to left or right side of MCS tailgate Disconnect MCS remote control from MCS gate Step 2 Check position of MCS gate s adjustment tube locking pins Position locking pin s to desired operating position paragraph 2 12 Step 3 Check that all air reservoir draincocks are closed Close all draincocks Step 4 Start engine and check for possible air leaks at air reservoirs hoses fi
306. t key 12 from roll up bar 14 336 012 b CLEANING AND INSPECTION Clean and inspect all components in accordance with Chapter 4 Section General Maintenance Instructions 4 107 5 3805 264 14 amp P 4 66 CARGO COVER CHAIN AND SPROCKETS REPLACEMENT Con t INSTALLATION 4 108 Install sprocket alinement key 12 and sprocket 16 on roll up bar 14 Tighten set screw 15 Position chain 7 over sprocket 16 Install sprocket 10 on crankshaft 8 with retaining ring 9 Raise baseplate 11 and position chain 7 under sprocket 10 Lower baseplate to put tension on chain Tighten mounting screws 6 Apply corrosion preventive sparingly to chain 7 and to roller shaft bearings 13 on both ends of roll up bar 14 336 012 5 3805 264 14 amp P 4 66 CARGO COVER CHAIN AND SPROCKETS REPLACEMENT Con t 6 Install chain cover 2 with four screws 1 7 Install crank assembly cover 5 with four new starwashers 3 and screws 4 336 010 FOLLOW ON TASKS e Check operation of cargo cover paragraph 2 14 e Fully retract cargo cover paragraph 2 14 4 109 TM 5 3805 264 14 amp P 4 67 CARGO COVER SUPPORT FRAME AND ROLL UP BAR REPLACEMENT This task covers a Removal c Installation b Cleaning and Inspection Initial Setup Equipment Conditions Materials Parts Carg
307. t us know Send us an SF Form 368 Product Quality Defi ciency Report You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance Mail it to us Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 We ll send you a reply 1 7 WARRANTY INFORMATION The vehicles are warranted by Freightliner Corporation in accordance with TB 9 2320 363 15 M917A1 and M917A1 w MCS and TB 9 2320 302 15 M917A2 and M917A2 w MCS Warranty starts on the date found in block 23 DA Form 2408 9 in the logbook Report all defects in workmanship to your supervisor who will take appropriate action through your Unit Maintenance shop 1 8 SAFETY CARE AND HANDLING a First Aid For first aid information refer to FM 21 11 First Aid for Soldiers b Personnel Safety Precautions 1 Read and become familiar with all WARNINGS in the warning summary at the front of this manual 2 Pay attention to WARNING decals on the dump body These provide safety instructions and identify specific hazards which if not followed may result in serious injury or death to personnel 3 Throughout this manual WARNINGs and CAUTIONS are given immediately preceding the procedural steps to which they apply Read these WARNINGs and CAUTIONSs and follow them exactly 4 When performing maintenance protect yourself against inju
308. tall MCS tailgate cover paragraph 4 53 4 94 5 3805 264 14 amp P 4 61 BODY PROP REPLACEMENT This task covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Item 8 Appendix One spring pin Three lockwashers a REMOVAL Remove spring pin 5 and body prop 4 from pivot bracket 3 Discard spring pin 2 Remove two nuts 6 lockwashers 7 screws 2 and pivot bracket 3 from frame 11 Discard lock washers 3 Remove nut 8 lockwasher 9 screw 1 and support bracket 10 from frame 11 Discard lockwasher b INSTALLATION Install support bracket 10 to frame 11 with screw 1 new lockwasher 9 and nut 8 2 Install pivot bracket 3 to frame 11 with two screws 2 new lockwashers 7 and nuts 6 3 With body prop 4 positioned above support bracket 10 install body prop to pivot bracket 3 with new spring pin 5 FOLLOW ON TASKS e Lubricate body prop Chapter 3 Section 4 95 TM 5 3805 264 14 amp P 4 62 SHIELD REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Beacon warning light removed TM 9 2320 363 10 or TM 9 2320 302 10 Dump body raised and supported on body props paragraph 2 15 Beacon warning light wiring harness removed from cab shield paragraph 4 45
309. task covers a Removal b Cleaning Initial Setup Tools Test Equipment General mechanic s tool kit Item 8 Appendix a REMOVAL Remove reflector 1 from dump body or tailgate b CLEANING Clean reflector mounting surface in accordance with Chapter 4 Section IIl General Maintenance Instruc tions c INSTALLATION Remove backing paper from reflector 1 Install reflector on dump body or tailgate 4 113 TM 5 3805 264 14 amp P 4 69 DATA PLATE REPLACEMENT This task covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Item 8 Appendix Four drive screws a REMOVAL Remove four drive screws 2 and data plate 1 from dump body Discard drive screws a 2 op oo elle b INSTALLATION Install data plate 1 on dump body with four new drive screws 2 4 114 5 3805 264 14 amp P 4 70 SHOVEL BRACKET REPLACEMENT This task covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Item 8 Four locknuts a REMOVAL Remove four bolts 3 eight flatwashers 2 four locknuts 1 and shovel bracket 4 from dump body Discard locknuts 336 001 b INSTALLATION Position shovel bracket 4
310. this column tells you what fault will keep your equipment from being capable of performing its primary mission If you make check and service procedures that show faults listed in this column the equipment is not mission capable Follow standard operating procedures for maintaining the equipment or reporting equipment failure 4 30 GENERAL LUBRICATION PROCEDURES NOTE Refer to Appendix J Lubrication Instructions for Lubrication Chart key localized views and procedural notes a Recommended intervals are based on normal conditions of operation temperature and humidity When operating under extreme conditions lubricants should always be changed more frequently When in doubt notify your supervisor b Keep all lubricants in a closed container and store in a clean dry place away from extreme heat or cold Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep all lubrication equipment clean and ready for use Maintain a good record of all lubrication performed and report any problems noted during lubrica tion Refer to DA Pam 738 750 for maintenance forms and procedures to record and report any findings d Keep all external parts of equipment not requiring lubrication free of lubricants Before lubrication wipe lubrication fittings with a clean rag Item 16 After lubrication wipe off excess oil or grease to prevent accumulation of foreign matter Refer to FM
311. tings paragraph 4 59 Step 3 Check for leaking or damaged MCS air reservoir Replace MCS air reservoir paragraph 4 55 Step 4 Check for leaking or damaged MCS air cylinder Replace or repair MCS air cylinder paragraph 4 56 4 57 or 4 58 2 MCS GATE WILL NOT OPERATE WITH DRIVER S CONTROLS Step 1 Check for air leaks throughout vehicle chassis air system Tighten or replace leaking or damaged air system components TM 9 2320 363 20 or TM 9 2320 302 20 Step 2 Check MCS tailgate for leaking or damaged air system components Tighten or replace leaking or damaged components paragraphs 4 55 thru 4 59 NOTE For assistance in troubleshooting an MCS electrical malfunction refer to wiring diagrams paragraph 4 49 Step 3 Check MCS fuse for continuity Replace damaged fuse TM 9 2320 363 20 or TM 9 2320 302 20 Step 4 Check driver s MCS control unit switches for voltage and continuity Replace damaged switches paragraph 4 42 Step 5 Check truck to MCS tailgate wiring harness for voltage and continuity Repair or replace damaged truck to MCS tailgate wiring harness paragraph 4 47 Step 6 Check MCS tailgate wiring harness and air cylinder solenoids for voltage and continuity Repair or replace damaged MCS tailgate wiring harness paragraph 4 48 Replace damaged MCS air cylinder solenoids paragraph 4 57 4 28 5 3805 264 14 amp P Table 4 3 Unit Troubleshooting Con t MALFUNCTION TEST OR
312. tions c INSTALLATION WARNING Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts sup ported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment NOTE Use antiseize tape on all pipe threads paragraph 4 22 Install hydraulic pump 5 to PTO 21 with four screws 1 new lockwashers 2 and nuts 3 2 Install support bracket 7 to transmission housing 14 with two screws 10 Torque screws to 70 80 Ib ft 95 108 3 Install washer 8 and nut 9 to stud 6 of hydraulic pump 5 Install elbow 16 to control valve 4 5 Connect hose 15 to elbow 16 5 12 5 3805 264 14 amp P 5 4 HYDRAULIC PUMP REPLACEMENT Con t Install adapters 17 and 20 to control valve 4 Connect hoses 18 and 19 to adapters 17 and 20 Install adapter 13 to hydraulic pump 5 Connect suction hose 12 to adapter 13 and tighten clamp 11 FOLLOW ON TASKS hydraulic reservoir Chapter 3 Section 1 e Connect hydraulic control lever cable to hydraulic pump paragraph 4 73 e Install transmission tunnel access cover TM 9 2320 363 20 or TM 9 2320 302 20 5 13 TM 5 3805 264 14 amp P 5 5 HYDRAULIC PUMP REPAIR This task covers a Disassembly c Assembly b Cleaning and Inspection Initial Setup
313. trol lever in cab without first ensuring that all personnel are clear of dump body Failure to follow this warning may result in injury to person nel NEVER raise dump body without first checking for overhead obstructions such as trees and power lines Ensure that overhead clearance is sufficient Failure to follow this warning may cause death or injury to person nel 5 3805 264 14 amp P WARNING DUMP BODY OPERATION Con t e NEVER raise dump body more than half way with tailgate or MCS gates closed If dump body is raised fully without opening tailgate MCS gates dump truck center of gravity will shift rearward Dump truck could tip causing injury to personnel or damage to equipment DO NOT spread or dump payload with dump truck facing a steep upgrade or a steep side slope Dump truck may tip over backward or sideways Failure to follow this warning may result in death or injury to personnel or damage to equipment e DO NOT park on a slope Park on level ground only Parking on a slope could cause load to shift and dump truck to tip over Failure to follow this warning may result in death or injury to personnel or damage to equip ment NOT attempt to dump in high wind High winds may disperse aggregate High winds may also cause dump truck to roll over when dump body is raised Failure to follow this warning may result in death or injury to per sonnel or damage to equipment e Stay at controls
314. ts a REMOVAL 1 Remove four locknuts 8 screws 6 plate 5 and mud flap 7 from mounting plate 4 Discard locknuts 2 Remove two spring pins 2 washers 3 and shaft 9 and separate mounting plate 4 from weldment 1 on dump body Discard spring pins NM AN 25 9 AT th 4 99 5 3805 264 14 amp P 4 63 MUD FLAP REPLACEMENT Con t 3 Remove two locknuts 13 screws 11 anchor plate 12 and mounting plate 10 from mud 7 flap 7 Discard locknuts b INSTALLATION 1 Install mounting plate 10 and anchor plate 12 to mud flap 7 with two screws 11 and new locknuts 13 2 Install mounting plate 4 to weldment 1 on dump body with shaft 9 two washers 3 and new spring pins 2 through shaft 3 Install mud flap 7 and plate 5 to mounting plate 4 with four screws 6 and new locknuts 8 2 4 100 5 3805 264 14 amp P Section VII DUMP BODY ACCESSORY ITEMS MAINTENANCE Paragraph Number Page Paragraph Title Number Cargo Cover Cargo Cover Crank Assembly Maintenance Cargo Cover Chain and Sprockets Cargo Cover Support Frame and Roll Up Bar Reflector
315. ttings and MCS gate air cylinders Notify Unit Maintenance of any leaks Step 5 MCS gate still fails to operate Notify Unit Maintenance 3 GATE WILL NOT OPERATE WITH REMOTE CONTROL Step 1 Check if MCS remote control is properly connected to left or right side of MCS tailgate Connect remote control to MCS tailgate Step 2 Check position of MCS gate s adjustment tube locking pins Position locking pin s to desired operating position paragraph 2 12 3 5 5 3805 264 14 amp P Table 3 1 Operator Troubleshooting Con t MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3 Check that all air reservoir draincocks are closed Close all draincocks Step 4 Start engine and check for possible air leaks at air reservoirs hoses fittings MCS gate air cylinders Notify Unit Maintenance of any leaks Step 5 MCS gate still fails to operate Notify Unit Maintenance 4 MCSGATE S OPEN OR CLOSE WHEN REMOTE CONTROL IS CONNECTED Step 1 Check position of remote control toggle switches Position toggle switches to CLOSED position Step 2 Control gate s still opens or closes when remote control is connected Notify Unit Maintenance TAILGATE 5 TAILGATE ASSEMBLY LOCK WILL NOT RELEASE Step 1 Check that all air reservoir draincocks are closed Close all draincocks Step 2 Start engine and check for possible air leaks at air reservoirs hoses fittings and tailgate locking air cylinder Notify
316. uate ventilation and personal protective equipment before starting any welding operation TM 9 237 Contact your unit local Industrial Hygienist or Safety Officer for assistance Failure to follow this warning may result in injury to person nel CAUTION Before welding the following components must be disconnected DDEC ECU ABS ECU CTIS ECU Datalogger and batteries TM 9 2320 363 20 or TM 9 2320 302 20 Failure to follow this caution may damage electronic components 11 If stabilizer is damaged it may be removed at this time Refer to TM 9 237 Operator s Manual for Welding Theory and Application for instructions on welding components 5 3 5 3805 264 14 amp P 5 1 DUMP BODY AND STABILIZER REPLACEMENT Con t b INSTALLATION WARNING e Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment e Provide adequate ventilation and personal protective equipment before starting any welding operation TM 9 237 Contact your unit local Industrial Hygienist or Safety Officer for assistance Failure to follow this warning may result in injury to personnel CAUTION Before welding the following components must be disconnected DDEC ECU
317. ulic cylinder is lifted WARNING e Use extreme care when handling heavy parts Lifting cables chains hooks and slings must be in good condition and of suitable capacity Keep clear of parts supported only by lifting device Failure to follow this warning may result in death or injury to personnel and damage to equipment e Hydraulic cylinder sleeves may extend downward as hydraulic cylinder is lifted Expect sleeve movement any time hydraulic cylinder is handled Failure to do so may result in serious injury to personnel CAUTION Perform hydraulic cylinder repair in a clean work area to prevent contaminants from causing equipment failure NOTE A suitable container should be used to catch any draining hydraulic fluid Ensure that all spills are cleaned up 5 23 TM 5 3805 264 14 amp P 5 7 HYDRAULIC CYLINDER REPAIR Con t 1 Using overhead lifting device with nylon sling move hydraulic cylinder assembly to a vertical position with plunger 1 facing upward Securely block hydraulic cylinder in vertical position NOTE Perform steps 2 thru 10 to remove plunger from sleeve 2 Remove retaining ring 2 from sleeve 3 NOTE e Retaining rings piston rings seals wear rings guide rings wipers and wiper retainers should be noted by name and installed position immediately after removal and replacement parts from parts kit tagged paragraph 4 17 to aid i
318. ulic lines while engine is running WARNING e NEVER work under a raised dump body unless it is secured in the raised posi tion with body props and dump body is EMPTY Failure to follow this warning may result in death or injury to personnel e DO NOT disconnect hydraulic lines while engine is running Engine must be shut down and dump body fully lowered or supported on body props before lines are disconnected Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury to personnel 4 145 TM 5 3805 264 14 amp P 4 77 HYDRAULIC OIL FILTER ELEMENT REPLACEMENT Con t a REMOVAL CAUTION Ports in reservoir should be plugged to prevent contamination of hydraulic system paragraph 4 21 1 Loosen four screws 1 rotate filter housing cover 5 and lift cover from filter housing 2 2 Remove oil filter element 3 and discard 3 Remove preformed packing 4 from groove in filter housing cover 5 Discard preformed packing b CLEANING AND INSPECTION Clean and inspect components in accordance with Chapter 4 Section General Maintenance Instruc tions c INSTALLATION 1 Coat new preformed packing 4 with lubricat ing oil and install in groove of filter housing cover 5 2 Install new oil filter element 3 to filter housing 2 3 Install filter housing cover 5 to filter housing 2 with four screws 1 F
319. ults will keep your equipment from being capable of performing its primary mission If you make check and service procedures that show faults listed in this column do not operate the equipment Follow standard operating procedures for maintaining the equipment or reporting equipment failure 2 5 GENERAL PMCS PROCEDURES a Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If the dump truck does not perform as required refer to the appropriate trou bleshooting procedure Chapter 3 Section Il b If anything looks wrong and you can t fix it write it on your DA Form 2404 If you find something seriously wrong IMMEDIATELY report it to your supervisor C Before performing preventive maintenance read all the checks required for the applicable interval and prepare all the tools you need to make all the checks You ll always need a rag Item 16 Appendix or two WARNING Dry cleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protec tive gloves and goggles is suggested Use in well ventilated area Keep away from open flame and other sources of ignition 1 Keep It Clean Dirt grease oil and debris get in the way and may cover up a serious prob lem Clean as you work and as needed Use dry cleaning solvent Item 5
320. umn 5 specifies by code those common tool sets not individual tools common TMDE and special tools special TMDE and special support equipment required to perform the designated function Codes are keyed to Tools and Test Equipment in Section Hl f Column 6 Remarks When applicable this column contains a letter code in alphabetical order which is keyed to the remarks contained in Section IV B 4 EXPLANATION OF COLUMNS IN TOOLS AND TEST EQUIPMENT REQUIRE MENTS SECTION III a Column 1 Tool or Test Equipment Reference Code The tool or test equipment reference code correlates with a code used the MAC Section column 5 b Column 2 Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment C Column 3 Nomenclature Name or identification of the tool or test equipment d Column 4 National Stock Number The National Stock Number of the tool or test equipment e Column 5 Tool Number The manufacturer s part number model number or type number 5 3805 264 14 amp P B 5 EXPLANATION OF COLUMNS IN REMARKS SECTION IV a Column 1 Remarks Code The code recorded in Section II column 6 b Column 2 Remarks This column along with the related codes clarifies maintenance and inspection functions by different MOS involved in maintaining some components B 4 TM 5 3805 264 14 amp P Section Il MAINTENANCE
321. ure to follow this warning could result in death or injury to personnel or damage to equipment In moderate winds use cargo cover to keep material from blowing out of dump bed 2 17 OPERATION IN RAINY OR SNOWY WEATHER a In rainy or snowy weather use cargo cover to keep loads dry Wet loads may stick making dump ing difficult CAUTION DO NOT leave cargo cover extended over an empty dump body DO NOT attempt to uncover load without first removing any snow or water that has accumulated on cargo cover Cargo cover may be damaged if this caution is not followed b Remove any accumulated snow or water from cargo cover before attempting to uncover load 2 18 OPERATION IN COLD WEATHER Cold weather presents special problems because cold oil and hydraulic components should not be oper ated to capacity until the system has warmed up This can be accomplished by performing the following steps a Engage PTO TM 9 2320 363 10 or TM 9 2320 302 10 while engine is warming up Run engine at idle speed b Clear all personnel from around the dump body Operate hydraulic control lever and check operation of dump body at low engine rpms to verify normal operation paragraph 2 10 Keep in mind that oil has not been circulated through the hydraulic cylinder d Lower dump body and place hydraulic control lever Neutral position paragraph 2 10 2 43 2 44 Blank 5 3805 264 14 3 OPERATOR MAINTENANCE Sectio
322. used with new ones b Used tube assemblies in good condition can be installed to their original location without leaking Assemble new tubes compression sleeves and inverted nuts as follows Tube Inverted 1 Slide inverted nut onto end of tube 2 Slide compression sleeve onto end of tube 3 Repeat previous two steps for other end of tube as required d Install new tube assemblies as follows Compression Sleeve 1 Insert end of tube as far as it will go into compression fitting to which tube is being installed 2 Twist inverted nut into compression fitting and tighten inverted nut against compression sleeve with open end wrench Item 8 Compression sleeve will clamp down around tube and conform to internal surface of compression fitting and inverted nut 3 Repeat previous two steps for other end of tube as required Compression Sleeve Compression Fitting 4 24 FLUID DISPOSAL WARNING When servicing this vehicle performing maintenance or disposing of materials such as engine coolant transmission fluid lubricants battery acids or batteries and CARC paint consult your Unit Local Hazardous Waste Disposal Center or safety office for local regulatory guidance If further information is needed please contact the Army Environmental Hotline at 1 800 872 3845 TM 5 3805 264 14 amp P 4 25 SERVICE REPLACEMENT PARTS AND KITS Many service replacement parts are availa
323. vel work time shown in the MAC to determine the total to accomplish that maintenance func tion d Column 4 Maintenance Level Column 4 specifies each level of maintenance authorized to perform each function listed in Column 3 by indicating a work time required expressed as man hours in whole hours or decimals in the appropriate subcolumn This work time figure represents the active time required to per form that maintenance function at the indicated level of maintenance If the number or complexity of the tasks within the listed maintenance function vary at different maintenance levels appropriate work time figures are shown for each level The work time figure represents the average time required to restore an item assembly sub assembly component module end item or system to a serviceable condition under typical field operating condi tions This time includes preparation time equipment condition follow on tasks including any necessary disassembly assembly time troubleshooting fault location time and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC The symbol designations for the various maintenance levels are as follows Field includes subcolumns C Operator Crew O Unit F Direct Support Sustainment includes subcolumns H General Support D Depot e Column 5 Tools and Test Equipment Reference Code Col
324. w lockwashers 22 and nuts 23 to bracket 24 17 18 1N 26 23 25 Dp on 24 elf 8 Z CN 21 19 22 20 18 With transmission selector lever in D Down position install pivot pin 5 in bracket 16 and secure with retaining pin 4 Remove tag from cable 15 19 Install spacer 7 cable 15 clamp 8 two screws 6 new lockwashers 9 and nuts 10 to bracket 14 20 Place transmission selector lever in N Neutral position TM 9 2320 363 10 or TM 9 2320 302 10 21 Feed cab harness power and ground connectors 12 into shift tower 1 and install grommet 11 22 Connect shift tower jumper harness power and ground connectors 13 to cab harness power and ground connectors 12 Remove tags 4 134 5 3805 264 14 amp P 4 73 HYDRAULIC CONTROL LEVER CABLE REPLACEMENT Con t 23 Remove two top and two bottom screws 2 from front and rear of shift tower 1 24 Install six screws 2 and rear access panel 3 25 Repeat step 24 for front access panel FOLLOW ON TASKS 1 Install MCS control unit M917A1 w MCS paragraph 4 42 Install CTIS electronic control unit ECU TM 9 2320 363 20 or TM 9 2320 302 20 4 135 TM 5 3805 264 14 amp P 4 74 HYDRAULIC HOSES AND FITTINGS REPLACEMENT This task covers a Removal b Cleaning and Inspection Initial Setup Equipment Conditions Dump body ra
325. warning may cause death or injury to personnel 1 Sound horn if tactical situation permits 5 3805 264 14 amp P 2 10 DUMPING LOAD Con t NOTE Speed of dump body movement when it is being raised may be controlled with accelerator pedal 2 Squeeze T handle together and pull hydraulic control lever 6 back to UP position Body up indicator light 3 should come on as dump body is raised WARNING DO NOT try to loosen a sticky load by pulling forward or backward and braking abruptly Injury to personnel or damage to equipment may result NOTE Dump body will stop automatically when hydraulic cylinder is fully extended or when hydraulic control lever is placed in N Neutral position 3 Return hydraulic control lever 6 to N Neutral position when dump body is fully raised or has reached desired height 371 031 2 33 5 3805 264 14 amp P 2 10 DUMPING LOAD Con t Lowering Dump Body CAUTION Dump body must be lowered onto truck frame with engine running at idle speed Failure to follow this caution may damage hydraulic cylinder or dump body 1 With engine at idle speed squeeze T handle together and push hydraulic control lever 6 forward to DOWN position Body up indicator light 7 should turn off when dump body contacts truck frame POWER TAKE OFF CAUTION
326. y b Cleaning and Inspection Initial Setup Equipment Conditions Tailgate release MCS air cylinder removed para graph 4 51 or 4 56 MCS air cylinder solenoid assembly removed paragraph 4 57 Tools Test Equipment General mechanic s tool kit Item 8 Appendix a DISASSEMBLY Remove tube 11 from elbow 12 Remove elbow 12 from top end plate 3 c Assembly Materials Parts Ball bearing grease Item 12 3 Remove four screws 1 and mounting bracket 2 from top end plate 3 NOTE Note position of nut at air cylinder piston shaft clevis during removal to ensure proper adjustment of air cylinder during installation Remove tie rods 4 from top end plate 3 Remove clevis 8 and nut 7 from piston shaft 5 Remove four retaining nuts 9 and lockwashers 10 from tie rods 4 Remove top end plate 3 with tie rods attached from bottom end plate 6 Separate bottom end plate 6 from piston shaft 5 336 016 NOTE Note position and direction of gaskets during removal to aid in installation 5 3805 264 14 amp P 4 58 TAILGATE RELEASE MCS AIR CYLINDER REPAIR Con t 9 Remove retaining ring 18 metal washer 17 and plastic gasket 16 from bottom end plate 6 10 Remove bushing 15 and gasket 13 from bottom end plate 6 11 Remove preformed packing 14 from bushing 15 336 017 12 Remove gasket 22 from bottom end
327. y be done on the item at a lower level of maintenance if authorized by the Maintenance Allocation Chart MAC and SMR codes b The maintenance code entered in the fourth position tells whether or not the item is to be repaired and identifies the lowest maintenance level with the capability to do complete repair i e perform all authorized Repair functions The maintenance code in the fourth position will indicate authorization to one of the following levels of maintenance Code Application Explanation Unit Maintenance or aviation unit maintenance is the lowest level that can do complete repair of the item ase ot Direct Support Maintenance or aviation intermediate maintenance is the lowest level that can do complete repair of the item 5 3805 264 14 amp P C 3 EXPLANATION OF COLUMNS SECTIONS AND III Con t Code Application Explanation MEE General Support Maintenance is the lowest level that can do complete repair of the item Specialized Repair Activity SRA is the lowest level that can do complete repair of the item Dies fake ages Depot Maintenance is the lowest level that can do complete repair of the item VERE ue Nonreparable No repair is authorized aoa BiG kes No repair is authorized No parts or special tools are authorized for the maintenance of a B coded item However the item may be recondi tioned by
328. y worn Mark inflated and repaired tires with a crayon for checking at the next inspection b Batteries Leave batteries in place in equipment Disconnect battery cables TM 9 2320 363 20 or TM 9 2320 302 20 Ensure that batteries are fully charged when equipment is stored and are returned to a full charge during each equipment exercising C Seals Seals may develop leaks during storage or shortly thereafter If leaking persists refer to the applicable maintenance section in this manual for corrective maintenance procedures 4 84 REMOVAL OF EQUIPMENT FROM ADMINISTRATIVE STORAGE a Activation Restore the equipment to normal operating condition in accordance with the instruc tions contained Chapter 4 Section II b Servicing Resume the maintenance service schedule in effect at the commencement of storage or service the equipment before the scheduled dates in order to produce a staggered maintenance workload 4 85 PREPARATION OF EQUIPMENT FOR SHIPMENT a Refer to FM 55 21 TM 55 601 and TM 743 200 1 for additional instructions on processing stor age and shipment of materiel b Vehicles that have been removed from storage for shipment do not have to be reprocessed if they will reach their destination within the administrative storage period Reprocess only if inspection reveals any corro Sion or if anticipated in transit weather conditions make it necessary C When a vehicle is received and has already been p
329. ystem Maintenance 5 10 CHAPTER 6 GENERAL SUPPORT APPENDIX REFERENCES i e s bd E RA RA RARE a E XE APPENDIX MAINTENANCE ALLOCATION CHART B 1 APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LISTS C 1 Section L Introduction exl hea na Saw iex b ERA eg hd Section IL Repair Parts 1 1 ELECTRICAL SYSTEM MISCELLANEOUS ITEMS CONTROL UNIT ASSEMBLY MCS 1 1 CONTROL SWITCHES 2 1 d EE LA M UP TAILLIGHTS MARKER LIGHTS AND REFLECTORS WIRING HARNESS BEACON LIGHT 9610 SENDING UNITS AND WARNING SWITCHES 5 1 BODYUP AND TRANSPORT LOCK SWITCHES 5 1 HULL OR CHASSIS WIRING HARNESS WIRING HARNESS DUMP BODY LIGHTS 6 MCS GATE HARNESS AND MCS POWER HARNESS BODYUP TRANSPORT LOCK HARNESS AND MATERIAL CONTROL CHASSIS HARNESS etica rire etos redeo sca 8 Change 1 ii

TM 5-3805-264-14&P - Liberated Manuals

Contents

Download Pdf Manuals

Related Search

Related Contents

TM 5-3805-264-14&amp;P - Liberated Manuals

Contents

Download Pdf Manuals

Related Search

Related Contents

TM 5-3805-264-14&P - Liberated Manuals