TM 08780B-20

TM 08780B-20
U.S. MARINE CORPS TECHNICAL MANUAL
ORGANIZATIONAL MAINTENANCE
FOR
TRUCKS, 8 X 8
LOGISTICS VEHICLE SYSTEM
(DIESEL)
CONSISTING OF
POWER UNIT, FRONT,

4 X 4, MK48 (NSN 2320-01-177-5167)
4 X 4, MK48A1 (NSN 2320-01-417-3180)
TRAILER, POWERED
CONTAINER HAULER,
4 X 4, MK14 (NSN 2320-01-176-0469)
4 X 4, MK14A1 (NSN 2320-01-417-5294)
TRAILER, POWERED,
WRECKER/RECOVERY
4 X 4, MK15 (NSN 2320-01-176-6928)
4 X 4, MK15A1 (NSN 2320-01-417-8144)
TRAILER, POWERED,
FIFTH WHEEL, SEMI-TRAILER ADAPTER,
4 X 4, MK16 (NSN 2320-01-176-0467)
4 X 4, MK16A1 (NSN 2320-01-417-5293)
TRAILER, POWERED,
DROPSIDE, CARGO W/CRANE,
4 X 4, MK17 (NSN 2320-01-176-0468)
4 X 4, MK17A1 (NSN 2320-01-417-5296)
OSHKOSH TRUCK CORPORATION

DAAE07-83-C-H418
DAAE07-95-C-X057
THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR OPERATIONAL PURPOSES.
DISTRIBUTION IS LIMITED TO U S GOVERNMENT AGENCIES ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE
REFERRED TO COMMANDANT OF THE MARINE CORPS (ARD), WASHINGTON, D C 20380-0001
FOR OFFICIAL USE ONLY
JUNE 2004
PCN 180 002327 00
TM 08780B-20
DEPARTMENT OF THE NAVY

Headquarters, U. S. Marine Corps
Washington, DC 20380-0001
30 June 2004
1. This Technical Manual (TM 08780B-20), authenticated for Marine Corps use and effective
upon receipt, provides organization maintenance instructions for the Logistics Vehicle System
(LVS) series of vehicles, consisting of the Front Power Unit MK48/48A1, Trailer, Powered,
Container Hauler MK14/14A1, Trailer, Powered, Wrecker/Recovery MK15/15A1, Trailer,
Powered, Fifth Wheel, Semi-Trailer Adapter MK16/16A1 and Trailer, Powered, Dropside,
Cargo with Crane MK17/17A1.
2. Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC

may be submitted via the Internet using website: https://pubs.ala.usmc.mil/front.htm, scrolling
down to the NAVMC 10772 Tracking Program and following instructions provided. It may also
be submitted by electronic mail to mbmatcommarlogbases@logcom.usmc.mil, or by mailing
paper copy of NAVMC 10772 in an envelope addressed to: Commander, Marine Corps Systems
Command, Attn: Assistant Commander Acquisition and Logistics (LOG/TP), 814 Radford Blvd,
Suite 20343, Albany, Georgia, 31704-0343.
3. TM 2320-20/12A Volume 1 dated 28 May 1999 and TM 2320-20/12A Volume 2 dated 28

May 1999 are hereby superseded for Marine Corps use.
BY DIRECTION OF THE COMMANDANT OF THE MARINE CORPS
OFFICIAL
S. I. SCHULER
Colonel, USMC
Program Manager, Motor Transport (PMM151)
Marine Corps Systems Command
DISTRIBUTION: PCN 180 002327 00
1/(2 blank)
TM 08780B-20
INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.
LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is
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TM 08780B-20
TABLE OF CONTENTS
Page
How to Use This Manual .................................................................................................. xvii
CHAPTER 1. INTRODUCTION ................................................................................. 1-1

1-1 Overview .................................................................................. 1-1
Section I. General Information............................................................................... 1-1

1-2 Scope ........................................................................................ 1-1
1-3 Maintenance Forms, Records and Reports............................... 1-1
1-4 Destruction of Materiel to Prevent Enemy Use........................ 1-1
1-5 Preparation for Storage or Shipment ........................................ 1-1
1-6 Repair of Parts, Special Tools and Support Equipment ........... 1-2
1-7 Reporting Equipment Improvement Recommendations .......... 1-2
1-8 Warranty Information............................................................... 1-2
Section II. Equipment Description and Data ........................................................... 1-2

1-9 Equipment Characteristics........................................................ 1-2
1-10 Principles of Operation............................................................. 1-2
1-11 Location and Description of Major Components ..................... 1-2
CHAPTER 2. VEHICLE MAINTENANCE ................................................................ 2-1

2-1 Overview .................................................................................. 2-1
Section I. Service Upon Request............................................................................ 2-1

2-2 General ..................................................................................... 2-1
2-3 Service Upon Request .............................................................. 2-1
Section II. Preventive Maintenance Checks and Services (PMCS) ........................ 2-2
2-4 General ..................................................................................... 2-2
2-5 PMCS Tables............................................................................ 2-2
Section III. Troubleshooting ..................................................................................... 2-33

2-6 STE/ICE Troubleshooting........................................................ 2-33
2-7 Standard Troubleshooting ........................................................ 2-91
Section IV. Maintenance Procedures ........................................................................ 2-607

2-8 Introduction .............................................................................. 2-607
2-9 General Removal Instructions .................................................. 2-607
2-10 General Disassembly Instructions ............................................ 2-607
2-11 General Cleaning Instructions .................................................. 2-608
2-12 General Inspection Instructions................................................ 2-610
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2-13 General Repair Instructions...................................................... 2-612

2-14 General Assembly Instructions ................................................ 2-613
CHAPTER 3. ENGINE................................................................................................. 3-1

3-1 Overview .................................................................................. 3-1
3-2 Description and Data ................................................................ 3-1
3-3 Engine Oil Service.................................................................... 3-4
3-4 Rocker Cover and Gasket Replacement ................................... 3-8
3-5 Oil Filter Adapter Replacement ............................................... 3-11
3-6 Oil Pan and Gasket Replacement ............................................. 3-13
3-7 Exhaust Manifold and Gasket Replacement ............................ 3-16
3-8 Engine Oil Sampling Valve (LVSA1 Series Vehicles Only)... 3-19
3-9 New Replacement Dipstick Installation ................................... 3-21
CHAPTER 4. FUEL SYSTEMS................................................................................... 4-1

4-1 Overview .................................................................................. 4-1
4-2 Fuel System Principles of Operation........................................ 4-1
4-3 Fuel Supply Pump Replacement .............................................. 4-4
4-4 Fuel Supply Pump Repair......................................................... 4-7
4-5 Hand Priming Pump Replacement ........................................... 4-14
4-6 Air Cleaner Assembly Replacement ........................................ 4-17
4-7 Air Cleaner Element Replacement ........................................... 4-24
4-8 Air Restriction Indicator Replacement..................................... 4-27
4-9 Intake Ducting Replacement .................................................... 4-29
4-10 Left Fuel Tank Replacement .................................................... 4-34
4-11 Right Fuel Tank Replacement .................................................. 4-42
4-12 Fuel Line, Vent and Fitting Replacement ................................ 4-53
4-13 Shutdown Solenoid Replacement............................................. 4-56
4-14 Shutdown Solenoid Replacement
(LVSA1 Series Vehicles Only) ................................................ 4-61
4-15 Throttle Control Solenoid Replacement................................... 4-69
4-16 Throttle Cylinder Replacement ................................................ 4-72
4-17 Throttle Cylinder Repair .......................................................... 4-75
4-18 Fuel/Water Separator Service................................................... 4-79
4-19 Fuel/Water Separator Replacement.......................................... 4-82
4-20 Fuel/Water Separator Repair .................................................... 4-89
4-21 Secondary Fuel Filter and Adapter Replacement..................... 4-95
4-22 Ether Starting Aid Replacement............................................... 4-98
4-23 Throttle Treadle Valve Replacement ....................................... 4-101
CHAPTER 5. EXHAUST SYSTEM ............................................................................ 5-1

5-1 Overview .................................................................................. 5-1
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5-3 Muffler/Pipe Replacement ....................................................... 5-2
5-4 Exhaust Crossover Tube Maintenance ..................................... 5-8
CHAPTER 6. COOLING SYSTEM............................................................................. 6-1

6-1 Overview .................................................................................. 6-1
6-2 Cooling System Description..................................................... 6-1
6-3 Radiator Service ....................................................................... 6-3
6-4 Radiator Grille and Grate Replacement ................................... 6-5
6-5 Coolant Filter and Adapter Replacement ................................. 6-8
6-6 Thermostat and Housing Replacement..................................... 6-11
6-7 Cooling System Hose and Tube Replacement ......................... 6-19
6-8 Radiator Testing ....................................................................... 6-26
CHAPTER 7. ELECTRICAL SYSTEM ...................................................................... 7-1

7-1 Overview .................................................................................. 7-1
7-3 Alternator Circuit Breaker and Diode Replacement ................ 7-6
7-4 Alternator Replacement............................................................ 7-9
7-5 Voltage Regulator Maintenance ............................................... 7-15
7-6 Starter Solenoid Replacement .................................................. 7-18
7-7 Starter Replacement ................................................................. 7-21
7-8 Starter Relay Replacement ....................................................... 7-26
7-9 Cooling System Switch Replacement ...................................... 7-29
7-10 Oil Pressure Switch Replacement ............................................ 7-32
7-11 Instrument Panel Assembly Replacement ................................ 7-34
7-12 Instrument Panel Harness Replacement ................................... 7-36
7-13 Instrument Panel Harness Replacement
7-14 Circuit Breaker Replacement ................................................... 7-65
7-15 Toggle Switch Replacement..................................................... 7-68
7-16 Steering Selector Switch Replacement..................................... 7-70
7-17 Turn Signal Switch and Flasher Replacement ......................... 7-72
7-18 Turn Signal Switch and Flasher Replacement
7-19 Speedometer/Tachometer Replacement ................................... 7-78
7-20 Electrical Gauge Replacement ................................................. 7-81
7-21 Magnetic Switch Replacement ................................................. 7-84
7-22 Ether Start Switch Replacement............................................... 7-86
7-23 Ignition Switch Replacement ................................................... 7-88
7-24 Master Light Switch Replacement ........................................... 7-90
7-25 Stop Light Switch Replacement ............................................... 7-92
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7-26 Neutral Safety Switch Maintenance ......................................... 7-95

7-27 Hi Idle Neutral Switch Replacement........................................ 7-99
7-28 Relay Replacement................................................................... 7-101
7-29 Dashboard Warning and/or Indicator Light Replacement........ 7-103
7-30 Headlight Maintenance............................................................. 7-105
7-31 Clearance Light Replacement .................................................. 7-110
7-32 Clearance Light Mounting Bracket Replacement .................... 7-113
7-33 Dome Light Replacement......................................................... 7-115
7-34 Front Composite Light Replacement ....................................... 7-117
7-35 Map Light Replacement ........................................................... 7-121
7-36 Rear Composite Light Replacement......................................... 7-124
7-37 Worklight Replacement............................................................ 7-127
7-38 Beacon Light Replacement ...................................................... 7-129
7-39 Sending Unit Replacement....................................................... 7-132
7-40 Fuel Level Sending Unit Replacement..................................... 7-135
7-41 Buzzer Warning System Replacement ..................................... 7-138
7-42 Alarm Replacement .................................................................. 7-141
7-43 Low Air Pressure Switch Replacement.................................... 7-143
7-44 Fuel Restriction Sensor Replacement....................................... 7-145
7-45 Battery and Battery Box Replacement ..................................... 7-147
7-46 Battery and Battery Box Replacement
(LVSA1Series Vehicles Only) ................................................. 7-155
7-47 Slave Connector Replacement.................................................. 7-166
7-48 Wiring Harness Maintenance ................................................... 7-169
7-49 Optic Ribbon Light Source Replacement................................. 7-184
7-50 Optic Ribbon Replacement ...................................................... 7-186
7-51 Resistor Replacement ............................................................... 7-188
7-52 Dimmer Switch Replacement................................................... 7-190
7-53 Electrical Control Unit (ECU) Power Cable Replacement,
FPU, (ABS Modified Vehicles Only) ...................................... 7-192
7-54 Electrical Control Unit (ECU) Power Cable Replacement,
RBU, (ABS Modified Vehicles Only) ..................................... 7-197
7-55 Electrical Control Unit (ECU) Relay Assembly
Replacement (ABS Modified Vehicles Only).......................... 7-203
7-56 Antilocking Brake System (ABS Warning Light
Replacement (ABS Modified Vehicles Only).......................... 7-206
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CHAPTER 8. TRANSMISSION .................................................................................. 8-1

8-1 Overview .................................................................................. 8-1
8-3 Transmission Oil Change and Spin-on Filter Replacement ..... 8-4
8-4 Shift Control Replacement ....................................................... 8-8
8-5 Shift Control Repair ................................................................. 8-11
8-6 Shift Tower Lamp Replacement............................................... 8-13
8-7 Shift Cable Maintenance .......................................................... 8-15
8-8 Transmission Lockup Switch Replacement ............................. 8-22
8-9 Transmission Lockup Solenoid Valve Replacement................ 8-24
8-10 Governor Replacement............................................................. 8-27
8-11 Modulator Valve Replacement................................................. 8-29
8-12 Oil Filter Bracket Replacement ................................................ 8-31
8-13 Oil Filter Bracket Replacement
8-14 Oil Pan, Gasket and Internal Filter Replacement ..................... 8-37
8-15 Transmission Cooler Replacement........................................... 8-41
8-16 Transmission Breather Replacement........................................ 8-43
CHAPTER 9. TRANSFER CASE................................................................................ 9-1

9-1 Overview .................................................................................. 9-1
9-3 Transfer Case Oil Change ........................................................ 9-3
9-4 2-Speed Shift Linkage Maintenance ........................................ 9-5
9-5 Shift Lever Replacement .......................................................... 9-12
9-6 Lubrication Lines and Fitting Replacement ............................. 9-14
9-7 Transfer Case Lubrication Pump Replacement........................ 9-19
9-8 Transfer Case Breather Replacement ....................................... 9-21
9-9 Lockup Air Chamber Replacement .......................................... 9-23
CHAPTER 10. PROPELLER SHAFTS ......................................................................... 10-1

10-1 Overview .................................................................................. 10-1
10-3 Propeller Shafts and Universal Joint Maintenance................... 10-2
10-4 Cardan Joint Repair .................................................................. 10-12
10-5 Pillow Block Bearing Replacement ......................................... 10-15
CHAPTER 11. FRONT AXLE....................................................................................... 11-1

11-1 Overview .................................................................................. 11-1
11-2 No. 1 Axle Principles of Operation .......................................... 11-1
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11-3 No. 1 Axle Oil Change ............................................................. 11-2

11-4 Front Axle Breather Service..................................................... 11-5
11-5 Nose Box Breather Maintenance.............................................. 11-7
11-6 No. 1 Axle Shaft Maintenance ................................................. 11-9
CHAPTER 12. REAR AXLES ....................................................................................... 12-1

12-1 Overview .................................................................................. 12-1
12-3 No. 2, 3 and 4 Axle Oil Change ............................................... 12-2
12-4 Axle Shaft Replacement (No. 2, 3 and 4 Axles) ...................... 12-4
12-5 Rear Axle Breather Service...................................................... 12-7
CHAPTER 13. TRANSMISSION .................................................................................. 13-1

13-1 Overview .................................................................................. 13-1
13-3 Antilocking Brake System........................................................ 13-6
13-4 Brake Inspection and Adjustment (No. 1 Axle) ....................... 13-8
13-5 Brake Inspection and Adjustment (No. 2, 3 and 4 Axles)........ 13-10
13-6 Brake Shoe Replacement (No. 1 Axle) .................................... 13-14
13-7 Brake Shoe Replacement (No. 2, 3 and 4 Axles) ..................... 13-17
13-8 Wedge Brake Maintenance (No. 1 Axle) ................................. 13-20
13-9 Brake Spider and Skein Replacement (No. 1 Axle) ................. 13-25
13-10 Camshaft and Slack Adjuster Replacement
(No. 2, 3 and 4 Axles) .............................................................. 13-28
13-11 Brake Spider and Bracket Replacement
(No. 2, 3 and 4 Axles) .............................................................. 13-34
13-12 Brake Chamber Replacement (No. 2, 3 and 4 Axles) .............. 13-37
13-13 Brake Chamber Replacement (No. 1 Axle).............................. 13-42
13-14 Brake Treadle Valve Replacement........................................... 13-45
13-15 Relay Valve Replacement (MK48) .......................................... 13-52
13-16 Relay Valve Replacement (MK14, 15, 16, 17) ........................ 13-58
13-17 Quick Release Valve Replacement .......................................... 13-63
13-18 Quick Release Valve Replacement
13-19 Pressure Protection Valve Replacement................................... 13-69
13-20 Spring Brake Control Valve Replacement ............................... 13-72
13-21 Parking Brake Valve Maintenance........................................... 13-75
13-22 Tractor Protection Valve Replacement .................................... 13-80
13-23 Air Line and Fitting Replacement ............................................ 13-83
13-24 Front Air Manifold Replacement ............................................. 13-88
13-25 Rear Air Manifold Replacement .............................................. 13-92
13-26 Main Air Manifold Replacement ............................................. 13-95
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13-27 Left Instrument Panel Air Manifold Replacement ................... 13-102

13-28 One-Way Check Valve Replacement....................................... 13-106
13-29 Ball Valve Replacement ........................................................... 13-109
13-30 Right Instrument Panel Air Manifold Replacement................. 13-112
13-31 Quick Disconnect Fitting Replacement.................................... 13-116
13-32 Quick Build-up Air Reservoir Replacement ............................ 13-118
13-33 Right Air Reservoir Replacement ............................................ 13-124
13-34 Left Air Reservoir Replacement............................................... 13-133
13-35 Rear Unit Air Reservoir Replacement...................................... 13-140
13-36 Glad Hand Replacement........................................................... 13-146
13-37 Air Governor Maintenance....................................................... 13-150
13-38 Air Dryer Maintenance............................................................. 13-158
13-39 Hand Control Valve Replacement............................................ 13-170
13-40 Trailer Air Supply Valve Replacement .................................... 13-175
13-41 Traction Control Valve Replacement....................................... 13-178
13-42 Electronic Control Unit/Air control Valve Replacement ......... 13-182
13-43 Antilocking Brake System Sensor Replacement...................... 13-188
13-44 Quick Release Valve Replacement (ABS only)....................... 13-193
13-45 R14 Valve Replacement (ABS only) ....................................... 13-197
CHAPTER 14. WHEELS AND TIRES.......................................................................... 14-1

14-1 Overview .................................................................................. 14-1
14-3 Hub, Drum, Toner Ring and Wheel Bearing Replacement
(No. 2, 3 and 4 Axles) .............................................................. 14-2
14-4 Hub, Drum and Wheel Bearing Replacement (No. 1 Axle)..... 14-9
14-5 Wheel and Tire Replacement ................................................... 14-15
14-6 Tire Maintenance (Non Run Flat) ............................................ 14-19
14-7 Tire Maintenance (Run Flat) .................................................... 14-28
CHAPTER 15. STEERING SYSTEM ........................................................................... 15-1

15-1 Overview .................................................................................. 15-1
15-3 Steering Wheel Replacement ................................................... 15-3
15-4 Steering Column Replacement ................................................. 15-6
15-5 Steering Column Repair ........................................................... 15-9
15-6 Steering Linkage and Universal Joint Maintenance................. 15-12
15-7 Drag Link Maintenance............................................................ 15-15
15-8 Tie Rod Maintenance ............................................................... 15-19
15-9 Pitman Arm Maintenance......................................................... 15-22
15-10 Bell Crank Maintenance ........................................................... 15-25
15-11 Cab 90 Degree Gear Box Replacement.................................... 15-30
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15-12 Frame 90 Degree Gear Box Replacement ................................ 15-34

15-13 Yaw Feedback Linkage Maintenance ...................................... 15-37
15-14 Steering Shaft Assembly Maintenance..................................... 15-43
15-15 Fuse Link Maintenance ............................................................ 15-47
15-16 Steering System Hose and Fitting Replacement ...................... 15-54
15-17 Steering Adjustment ................................................................. 15-56
CHAPTER 16. FRAME.................................................................................................. 16-1

16-1 Overview .................................................................................. 16-1
16-3 Fifth Wheel Ramp Replacement .............................................. 16-2
16-4 Landing Leg Assembly Replacement....................................... 16-5
16-5 Landing Leg Assembly Repair................................................. 16-11
16-6 Pintle Replacement................................................................... 16-15
CHAPTER 17. SUSPENSION ....................................................................................... 17-1

17-1 Overview .................................................................................. 17-1
17-3 Shock Absorber and Bushing Replacement ............................. 17-2
17-4 Torque Rod Replacement (MK48)........................................... 17-4
17-5 Torque Rod Replacement (MK14, 15, 16 and 17) ................... 17-10
CHAPTER 18. CAB AND BODY ................................................................................. 18-1

18-1 Overview .................................................................................. 18-1
18-2 Cab and Body ........................................................................... 18-1
18-3 Door Replacement .................................................................... 18-2
18-4 Door Repair .............................................................................. 18-4
18-5 Mud Flap Replacement ............................................................ 18-12
18-6 Cab Step Replacement.............................................................. 18-14
18-7 Vehicle Step Replacement........................................................ 18-17
18-8 Windshield Glass Replacement................................................ 18-19
18-9 Rear Window Glass, Door Vent Window Glass and
Peep Glass Replacement .......................................................... 18-22
18-10 Door Glass and Regulator Replacement .................................. 18-25
18-11 Seat Cushion Replacement....................................................... 18-27
18-12 Seat and Frame Assembly Replacement .................................. 18-29
18-13 Seat Belt Replacement.............................................................. 18-33
18-14 Seat Belt Replacement (LVSA1 Series Vehicles Only)........... 18-35
18-15 Access Cover and Panel Replacement ..................................... 18-38
18-16 Roof Vent Replacement ........................................................... 18-43
18-17 Skid Plate Grille Replacement ................................................. 18-45
18-18 Skid Plate and Skid Plate Frame Replacement ........................ 18-47
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18-19 Engine Access Door Replacement ........................................... 18-52

18-20 Tool Box and Stowage Compartment Replacement
(MK14, 15, 17)......................................................................... 18-54
18-21 Tools Box and Stowage Compartment Replacement
18-22 Stowage Compartment Replacement (MK16) ......................... 18-63
18-23 Grab Handle Replacement (LVSA1 Series Vehicles Only)..... 18-70
CHAPTER 19. WINCHES ............................................................................................. 19-1

19-1 Overview .................................................................................. 19-1
19-3 Winch Cable Maintenance ....................................................... 19-2
19-4 Winch Control Handle Repair (MK16).................................... 19-4
CHAPTER 20. CRANE .................................................................................................. 20-1

20-1 Overview .................................................................................. 20-1
20-3 Junction Box Maintenance (MK15) ......................................... 20-11
20-4 Junction Box Maintenance (MK17) ......................................... 20-25
20-5 Proximity Switch Replacement ................................................ 20-39
20-6 Solenoid Dump Valve Wiring Replacement ............................ 20-45
20-7 Main Power Wiring Replacement ............................................ 20-50
20-8 Neutral Switch Replacement .................................................... 20-55
20-9 Relay Replacement................................................................... 20-57
20-10 Circuit Breaker Replacement (Junction Box) .......................... 20-60
20-11 Extension Cylinder No. 1 Replacement ................................... 20-63
20-12 Extension Cylinder No. 2 Replacement ................................... 20-70
20-13 Left Outrigger Cylinder Replacement ...................................... 20-77
20-14 Right Outrigger Cylinder Replacement.................................... 20-83
20-15 Stabilizer Cylinder Replacement.............................................. 20-89
20-16 A-Frame Maintenance.............................................................. 20-95
20-17 Hose Breakage Valve Replacement ......................................... 20-112
20-18 Manifold Replacement (MK17) ............................................... 20-119
20-19 Manifold Replacement (MK15) ............................................... 20-124
20-20 Basic Solenoid Valve Maintenance.......................................... 20-131
20-21 Electrical Failure Valve Replacement ...................................... 20-139
20-22 Stabilizer Selector/Locking Valve Replacement...................... 20-149
20-23 Outrigger Selector/Locking Valve Replacement (MK15) ....... 20-153
20-24 Outrigger Selector/Locking Valve Replacement (MK17) ....... 20-157
20-25 Stowage Box Maintenance (MK15)......................................... 20-161
20-26 Stowage Box Maintenance (MK17)......................................... 20-164
20-27 Placard Replacement ................................................................ 20-166
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20-28 Stabilizer Pad Maintenance ...................................................... 20-172

20-29 Stowing Cable Replacement .................................................... 20-177
20-30 Main Control Lever Maintenance ............................................ 20-179
20-31 Auxiliary Control Lever Maintenance ..................................... 20-184
20-32 Travel Lock Pin Maintenance .................................................. 20-186
20-33 Testing Main Crane Relief Pressure......................................... 20-189
20-34 Holding Valve(s) Adjustment .................................................. 20-191
20-35 Outrigger Beam Adjustment .................................................... 20-202
CHAPTER 21. CRANE (LVSA1 SERIES VEHICLES ONLY) ................................... 21-1

21-1 Overview .................................................................................. 21-1
21-3 Junction Box Maintenance ....................................................... 21-9
21-4 Remote Control Stowage Box Replacement (MK17A1) ......... 21-29
21-5 Tilt Sensor and Alarm Replacement ........................................ 21-32
21-6 Crane Tubing Replacement (MK15A1) ................................... 21-35
21-7 Crane Tubing Replacement (MK17A1) ................................... 21-39
21-8 Crane Hoses Replacement (MK15A1)..................................... 21-42
21-9 Crane Hoses Replacement (MK17A1)..................................... 21-54
21-10 Hoist Cable Replacement ......................................................... 21-66
21-11 Hook Block Assembly Maintenance ........................................ 21-69
21-12 Boom Sheave Replacement...................................................... 21-77
21-13 Power Cable Replacement........................................................ 21-81
21-14 Remote Control Harness Replacement..................................... 21-84
21-15 Overload Shutdown Cable Replacement.................................. 21-87
21-16 Control Solenoid Cable Replacement ...................................... 21-90
21-17 Tilt Sensor Harness Replacement............................................. 21-95
21-18 Remote Control Box Repair ..................................................... 21-98
21-19 Holding Valve Replacement .................................................... 21-108
CHAPTER 22. BODY ACCESSORY ITEMS............................................................... 22-1

22-1 Overview .................................................................................. 22-1
22-3 Windshield Wiper Motor Replacement.................................... 22-2
22-4 Windshield Wiper Motor Replacement
22-5 Windshield Wiper Arm and Blade Replacement ..................... 22-8
22-6 Wiper Control Valve Replacement .......................................... 22-11
22-7 Windshield Wiper Control Valve Replacement ....................... 22-14
22-8 Washer Reservoir Hose and Nozzle Replacement ................... 22-17
22-9 Washer Reservoir Hose and Nozzle Replacement
x
TM 08780B-20
Page
22-10 Mirror Replacement ................................................................. 22-24

22-11 Air Horn Replacement.............................................................. 22-26
22-12 Air Horn Repair........................................................................ 22-29
22-13 Air Horn Valve Replacement ................................................... 22-31
22-14 Electric Horn Replacement ...................................................... 22-34
22-15 Heater Replacement ................................................................. 22-36
22-16 Heater Blower Replacement..................................................... 22-39
22-17 Heater Blower Repair ............................................................... 22-41
22-18 Heater Core Replacement......................................................... 22-43
22-19 Heater Hose and Fitting Replacement...................................... 22-45
22-20 Defroster Hose, Plenums and Control Cable Replacement...... 22-49
22-21 Heater Control Cable Replacement .......................................... 22-54
22-22 Tire Winch Cable Replacement ............................................... 22-56
22-23 Tire Winch Repair .................................................................... 22-58
CHAPTER 23. HYDRAULIC SYSTEM ....................................................................... 23-1

23-1 Overview .................................................................................. 23-1
23-3 Hydraulic System Service ........................................................ 23-6
23-4 Selector Valve .......................................................................... 23-14
23-5 Yaw Control Valve Replacement............................................. 23-17
23-6 Hydraulic Filter Replacement .................................................. 23-20
23-7 Hydraulic Filter Replacement
23-8 Yaw Cylinder Replacement...................................................... 23-28
23-9 Hydraulic Reservoir Replacement............................................ 23-31
23-10 Hydraulic Oil Level Gauge Replacement ................................ 23-36
23-11 Hydraulic Oil Cooler Replacement .......................................... 23-39
23-12 Hydraulic Oil Filter Housing Maintenance .............................. 23-42
23-13 Hydraulic Filter Housing Maintenance
23-14 Hydraulic Hose and Fitting Replacement ................................ 23-54
23-15 Hydraulic Hose Reel Replacement........................................... 23-66
23-16 Auxiliary Hydraulic Hose Replacement................................... 23-67
23-17 Auxiliary Hydraulic Hose Reel Roller Replacement ............... 23-70
23-18 Auxiliary Hydraulic Hose Reel Roller Replacement
23-19 Directional Relief Valve Filter Screen Replacement ............... 23-76
23-20 Hi-Pressure Hydraulic Filter and Head Replacement
(MK15A1/MK17A1-LVSA1 Series Vehicles Only) ............... 23-78
23-21 Hi-Pressure Hydraulic Filter and Head Replacement
(MK48A1-LVSA1 Series Vehicles Only) ............................... 23-83
xi
TM 08780B-20
Page
CHAPTER 24. SPECIAL PURPOSE KITS

24-1 Overview .................................................................................. 24-1
24-3 Machine Gun Mount Replacement........................................... 24-2
24-4 Machine Gun Platform Replacement ....................................... 24-5
24-5 Machine Gun Hatch Replacement............................................ 24-7
CHAPTER 25. NON-ELECTRICAL GAUGES

25-1 Overview .................................................................................. 25-1
25-3 Air Pressure Gauge Replacement............................................. 25-2
Appendix A References.............................................................................................. A-1

Appendix B Maintenance Allocation Chart ............................................................... B-1
Appendix C Repair Parts, Special Tools and Equipment........................................... C-1
Appendix D Expendable Supplies and Materials List................................................ D-1
Appendix E Illustrated List of Manufactured Items .................................................. E-1
Appendix F Torque Limits ........................................................................................ F-1
Appendix G Schematic and Wiring Diagrams ........................................................... G-1
Appendix H STE/ICE Card ........................................................................................ H-1
Appendix I LVS Extended Storage Maintenance Procedures .................................. I-1
Glossary .................................................................................................................. Glossary-1
Alphabetical Index ................................................................................................. INDEX-1
xii
TM 08780B-20
LIST OF TABLES
Table Number Page
2-1 Organizational Preventive Maintenance Checks and Services................. 2-3

2-2 Antilocking Brake System Diagnosis Code.............................................. 2-602
xiii
TM 08780B-20
WARNING SUMMARY
The following is a list of warnings that appear in this manual. LVS mechanics must become
familiar with all warnings. Severe injury or death can be avoided by mechanics who understand
the vehicle and are alert to possible dangers.
• Remove rings, bracelets, wristwatches and neck chains before working around the
vehicle or other vehicles. Jewelry can catch on equipment and cause injury or may short across
an electrical circuit and cause severe burns or electrical shock.
• Adhesives and solvents burn easily and give off harmful vapors. To avoid injury, use in a
well ventilated area and keep away from flame.
• Compressed air used for cleaning purposes will not exceed 30 psi. Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
• Improper cleaning methods and use of unauthorized cleaning solvents will injure
personnel and damage equipment.
• To prevent personal injury when working under the truck always block the wheels.
• Snaprings are spring steel and may pop off when being removed. Wear eye protection
when removing snaprings to prevent personal injury.
• To prevent personal injury when working with fuel do not smoke or use open flame.
Fuel is flammable and may explode. Keep fire extinguisher within reach.
• During vehicle operation the exhaust pipe and muffler can become very hot. Be careful
not to touch these parts with your bare hands or allow your body to come in contact with the pipe
of muffler. Exhaust system parts can become hot enough to cause serious burns.
• Do not reach into radiator fan area with engine running. The fan is thermostatically
controlled and may engage without warning, causing serious personal injury.
• Cooling system components become hot during operation. To avoid personal injury, do
not service cooling system components until they have cooled down.
• Let radiator cool before removing cap. Remove radiator cap in two steps. First, place a
thick cloth over the cap and slowly rotate cap counterclockwise to its first stop. Pause, then let
pressure escape from cooling system. Rotate cap further counterclockwise until you can remove
it. Failure to follow this procedure can result in serious burns.
• Always remove negative battery ground cables first or install them last to avoid sparks
that can cause an explosion. Failure to follow this precaution may result in serious injury to you
and other personnel.
xiv
TM 08780B-20
• To prevent personal injury, drain all air pressure from the air system before removing air
lines or components.
• The brake linings contain asbestos. Asbestos dust can cause cancer. Avoid breathing
dust from brake linings or creating dust while servicing.
• Do NOT mix hose assembly components from different manufacturers. During assembly
repair make sure all components (hose and fittings) are from the same manufacturer. Never
reuse existing hose. Always replace with new hose. If you can not positively identify the
manufacturer of ALL components or you cannot obtain replacement parts from the same
manufacturer, REPLACE THE ENTIRE ASSEMBLY. Hose assemblies made up of different
manufacturer’s parts can fail. Failure to comply could result in death or serious injury to
personnel.
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU. CARBON MONOXIDE IS

WITHOUT COLOR OR SMELL, BUT CAN KILL YOU. BREATHING AIR WITH
CARBON MONOXIDE PRODUCES SYMPTOMS OF HEADACHE, DIZZINESS, LOSS OF
MUSCULAR CONTROL, A SLEEPY FEELING AND COMA. BRAIN DAMAGE OR
DEATH CAN RESULT FROM HEAVY EXPOSURE. CARBON MONOXIDE IS IN THE
EXHAUST FUMES OF FUEL-BURNING HEATERS AND INTERNAL COMBUSTION
ENGINES. CARBON MONOXIDE CAN BECOME DANGEROUSLY CONCENTRATED
UNDER CONDITIONS OF NO VENTILATION. PRECAUTIONS MUST BE FOLLOWED
TO INSURE CREW SAFETY WHEN THE PERSONNEL HEATER OR ENGINE OF ANY
VEHICLE IS OPERATED FOR ANY PURPOSE.
(1) DO NOT DRIVE ANY VEHICLE WITH INSPECTION PLATES, COVER

PLATES OR ENGINE COMPARTMENT COVERS REMOVED UNLESS NECESSARY
FOR MAINTENANCE PURPOSES.
(2) BE ALERT AT ALL TIMES DURING VEHICLE OPERATION FOR

EXHAUST ODORS AND EXPOSURE SYMPTOMS. IF EITHER ARE PRESENT,
IMMEDIATELY VENTILATE PERSONNEL COMPARTMENTS. IF SYMPTOMS
PERSIST, REMOVE AFFECTED CREW TO FRESH AIR AND KEEP WARM. DO NOT
PERMIT PHYSICAL EXERCISE. IF NECESSARY, GIVE ARTIFICIAL RESPIRATION
AND GET IMMEDIATE MEDICAL ATTENTION.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD

VENTILATION.
WARNING
FRONT AND REAR FRAMES PIVOT. STAY CLEAR OF TIRES AND ARTICULATION
JOINT AREA WHILE ENGINE IS RUNNING.
xv
TM 08780B-20
HOW TO USE THIS MANUAL
a. Overview. This manual covers all components and systems in individual

chapters. Each chapter is divided into the following sections as needed:
(1) General Information. This section provides necessary information and

makes the chapter more useful.
(2) Description and Data. This section provides descriptions of components,

theories of operation and data tables the user needs in order to understand the equipment. This
information is limited to the maintenance level of this manual.
(3) General Maintenance. This section provides replacement, repair and

maintenance instructions for the components and systems. These instructions are presented in a
logical order, grouping similar tasks near each other.
b. Manual Use. As a maintenance technician, you are responsible for maintaining

the equipment covered in this manual. The best way to do this is with the aid of your
maintenance manual. Below is a sample problem:
PROBLEM. The operator reports low oil pressure.
(1) How do you start?
Turn to the Cover of this manual.
On the right-hand side, you will find a listing for TROUBLESHOOTING.

Along with the listing is a page number and a black marker. Follow either the page number
reference or the black marker to the first page in the TROUBLESHOOTING section.
(2) What is the quickest way to find the solution to the problem? Turn to
paragraph 2-7.
This paragraph begins with the Troubleshooting Symptom Index. Follow

the Index until you find the problem (Low Oil Pressure, in this case). Now go to the page cited
directly to the right of the malfunction.
(3) What caused the problem? Use paragraph 2-7, Troubleshooting.
Here you will find the most likely causes of the problem. After following
each step, in the order listed and finding the problem (let’s say a defective engine oil-pressure
gage) go to the referenced paragraph.
(4) How do you fix the problem? Turn to paragraph 7-18, Electrical Gauge
Replacement.
xvi
TM 08780B-20
This is the maintenance procedure for electrical gages. It is arranged in

step-by-step order so that everything you need to know to replace the oil pressure gage is
covered. The INITIAL SETUP page provides preliminary data that you must know before
starting the task. Remember, you must be familiar with all maintenance procedures before you
begin the maintenance task.
Your maintenance manual is easy to use. Plus, it eliminates mistakes you

might make by warning you of possible problems before they occur. To protect personnel and
equipment, you must read and follow all WARNINGS and CAUTIONS.
c. Repair Parts and Special Tools. For repair parts and special tools used on this
vehicle, refer to TM 08780B-24P.
xvii/(xviii blank)
TM 08780B-20
CHAPTER 1
INTRODUCTION
1-1. OVERVIEW
This chapter familiarizes the technician with standard forms, record data, and the equipment for
use at the Second Echelon Maintenance Level. This information is covered in the following
sections:
Section I. General Information

Section II. Equipment Description and Data
Section I. General Information
1-2. SCOPE
a. Type of Manual. This technical manual contains instructions for Organizational

(Second Echelon) Maintenance for the Logistics Vehicle System (LVS).
b. Equipment Name and Model Numbers. The components of the LVS covered in
this manual include:
MK48/48A1-Power Unit, front, 4 x 4
MK14/14A1-Trailer, powered, Container Hauler, 4 x 4
MK15/15A1-Trailer, powered, Wrecker/ Recovery, 4 x 4
MK16/16A1-Trailer, powered, Fifth Wheel, Semitrailer Adapter, 4 x 4
MK17/17A1-Trailer, powered, Dropside Cargo w/Crane, 4 x 4
1-3. MAINTENANCE FORMS, RECORDS, AND REPORTS
Equipment record procedures refer to TM 4700-15.
1-4. DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE
Procedures for destruction of materiel to prevent enemy use can be found in TM 750-244-2.
1-5. PREPARATION FOR STORAGE OR SHIPMENT
Information about storage or shipment of the LVS can be found in Appendix I of this manual.
1-1
TM 08780B-20
1-6. REPAIR PARTS, SPECIAL TOOLS AND SUPPORT EQUIPMENT
All repair parts, special tools and support equipment are listed in TM 08780B-24P.
1-7. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS
If the Logistics Vehicle System needs improvement, let us know. Send us an EIR. 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. Put it on an SF 368 (Quality Deficiency Report). Submit to:
Commanding General
Marine Corps Logistics Base
Code 808
Albany, Georgia 31704-5000
1-8. WARRANTY INFORMATION
The LVS Series vehicles are warranted by Oshkosh Truck Corporation for 15 months or 15,000
miles (24,135 km), whichever comes first. The warranty starts on the date found in block 23,
DA Form 2408-9, in the logbook. Report all defects in material or workmanship to your
NCOIC, who will take appropriate action.
Section II. Equipment Description and Data
1-9. EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
For a complete description of characteristics, capabilities, and features of the Logistics Vehicle
System, refer to TM 08780B-10.
1-10. PRINCIPLES OF OPERATION
The principles of operation for the vehicle can be found in TM 08780B-10. The principles of
operation for individual components can be found in the applicable maintenance chapters within
this manual.
1-11. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Refer to TM 08780B-10 for the location and description of the major components of the
Logistics Vehicle System.
1-2
TM 08780B-20
CHAPTER 2
VEHICLE MAINTENANCE
2-1. OVERVIEW
This chapter provides information authorized for Second Echelon Maintenance level mechanics.
The following sections cover maintenance procedures for the LVS.
Section I. Service Upon Receipt

Section II. Preventive Maintenance Checks and Services (PMCS)
Section III. Troubleshooting
Section IV. Maintenance Procedures
Section I. Service Upon Receipt
2-2. GENERAL
Upon receipt of a new, used or reconditioned vehicle, you must determine if the vehicle has been
properly prepared for service. The following paragraph provides the service requirements to
prepare the vehicle for use.
2-3. SERVICE UPON RECEIPT
a. Visually inspect the entire vehicle for shipping damage, signs of vandalism or
missing parts.
b. Perform Semi-annual PMCS checks at the Organizational Level.
c. Check the level of lubricant in all components. Refer to LI 2320-12/9, LO

9-2320-297-12.
d. Install ether starting aid canister. Refer to paragraph 4-22 in this manual.
NOTE
Perform these checks or have the operator perform them.
e. Perform all PMCS checks at the Operators Level.
f. Check all Basic Issue Items. Refer to TM 08780B-10 to be sure every item is
present, is in good condition and is properly mounted or stowed.
2-1
TM 08780B-20
Section II. Preventive Maintenance Checks and Services (PMCS)
2-4. GENERAL
This section contains Preventive Maintenance Checks and Services (PMCS) requirements for the
MK48/48A1/14/14A1 through MK48/48A1/17/17A1 LVS vehicles.
2-5. PMCS TABLES
The PMCS tables contain checks and services necessary to find and correct defects before they
result in serious damage to the vehicle. Use table 2-1 to perform your PMCS at the specified
intervals. Explanations of the columns used in these tables are as follows:
a. Item Number Column. This column lists the numbers of all necessary checks and
services in logical order of performance regardless of interval. This column may be used as a
source of item numbers for maintenance forms required to record the results of the PMCS.
b. Interval Columns. There are three interval column heads: ‘S’, ‘A’ and ‘B’. Each
column stands for a specific time interval at which a maintenance check is to be made. The
following is an explanation of these columns:
(1) If a check is performed every 6 months (semi-annually), a dot will be

found within the ‘S’ column.
(2) If a check is performed every 12 months (annually), a dot will be found

within the ‘A’ column.
(3) If a check is performed every 24 months (biennially), a dot will be found

within the ‘B’ column.
c. Items to be Inspected Column. This column is divided into groups such as road
test, cab interior, transmission and brakes. Each group identifies a general location on the
vehicle in which specific items are to be inspected. Items are listed in order regardless of
interval.
d. Procedures Columns. This column contains a brief description of the inspections,

checks and services to be performed on each item listed.
2-2
TM 08780B-20
Table 2-1. Organizational Preventive Maintenance Checks and Services
S - Semiannually A - Annually B - Biennially

Item Interval Item To Be
Procedures
No. S A B Inspected
PRIOR TO ROAD TEST
1. CAB INTERIOR
NOTE
Prior to road test, perform all operator PMCS checks listed in TM

08780B-10.
• a. Check operator and crew seats and seat belts for loose mountings
and damage.
• b. While starting vehicle, listen for unusual noises and difficult

cranking at starter.
• c. Listen for unusual engine noises, hesitations and varying speed. Be

alert for excessive vibration and smell of fuel, oil or exhaust.
• d. Observe gauges for any low or abnormal readings.
• e. Test for engine response to throttle treadle feed. Check for sticking
or binding of throttle treadle.
• f. Check brake treadle valve for slow or no response, air leaks or

blocked exhaust. Check brake treadle for proper adjustment. Refer
to Direct Support/Intermediate Maintenance (3rd Echelon).
• g. Check for operator and crew seats and seat belts for loose
mountings and damage. Replace operator or crew seat or seat belt
mountings if damaged or missing. Tighten loose parts. Refer to
paras 18-13 and 18-14.
2-3
TM 08780B-20
Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

Procedures
No. S A B Inspected
ROAD TEST
2. BRAKES
• a. Reach a desired speed and apply brakes with steady force. Vehicle
should stop smoothly without side-pull or vibrations.
• b. After stopping vehicle and with transmission in gear, release brake

treadle. The wheel brakes should release immediately.
• c. On a level surface, set parking brake, shift transfer to direct range

and shift transmission to drive (D). Run engine at 1,000 rpm.
Vehicle should not move.
3. STEERING
• a. Check vehicle response to steering wheel action. Vehicle should

respond instantly. Check steering wheel free play. With vehicle
moving forward, free play should not exceed approximately 1-1/2
inches in either direction.
• b. With the vehicle moving on straight and level ground, lightly hold
steering wheel to detect pull, wander or shimmy.
CAUTION
DO NOT HOLD STEERING WHEEL IN THE EXTREME LEFT OR

RIGHT POSITION FOR LONGER THAN 10 SECONDS. OIL
OVERHEATING AND PUMP FAILURE CAN RESULT.
• c. With the vehicle stopped, turn steering wheel and check for hard or
erratic steering and backlash. Check for proper response of yaw
cylinders to steering wheel movement in both directions. Steering
should operate smoothly with no backlash.
2-4
TM 08780B-20

Procedures
No. S A B Inspected
ROAD TEST
4. TRANSFER CASE
• a. Check transfer case shift lever for proper operation.
• b. Operate vehicle in both DIRECT and LOW range. Transfer should

shift smoothly with no unusual noise.
ENGINE
5.
CAUTION
WHEN CHECKING ENGINE LOAD SPEED, MAKE SURE THE

ENGINE DOES NOT EXCEED GOVERNED SPEED OF 2250 RPM.
• a. Check engine operation at all permissible load speeds.
• b. Check engine’s Jacobs Brake for proper operation in both HIGH

and LOW positions.
6. TRANSMISSION
• a. Check transmission temperature gauge for proper operation and

correct temperature.
• b. Check transmission for smooth shifting and proper response in all

speed ranges.
• c. Listen for unusual noises corning from transmission when shifting.
7. SUSPENSION
• Observe how the vehicle responds to road shocks. If the vehicle sways or
is constantly bouncing this indicates suspension problems.
2-5
TM 08780B-20

Procedures
No. S A B Inspected
AFTER ROAD TEST
8. BATTERIES
WARNING
DO NOT WEAR WATCHES, RINGS OR OTHER JEWELRY WHEN

SERVICING BATTERIES. THEY CAN SHORT OUT BATTERY
TERMINALS. DO NOT SMOKE OR USE OPEN FLAME AROUND
BATTERIES. BATTERIES MAY EXPLODE FROM A SPARK.
BATTERY ACID IS HARMFUL TO SKIN AND EYES.
• a. Inspect battery cables for frays, splits or looseness.
• b. Check the specific gravity of each battery cell and record readings.
9. FUEL SYSTEM
• a. Check fuel lines and fittings for leaks.
• b. Change fuel-water separator element (1). Refer to paragraph 4-18.
2-6
TM 08780B-20

Procedures
No. S A B Inspected
10. WHEELS AND TIRES
• a. Inspect wheel side rings (1) and clamp plate (2) for damage, dents
or breaks. Check clamp plate (2) for loose mounting bolts. Tighten
bolts to 80 foot-pounds (108 N*m).
• b. Make sure all wheel stud nuts (3) are present and tightened to 650-
750 foot-pounds (881-1,017 N*m).
2-7
TM 08780B-20

Procedures
No. S A B Inspected
10. WHEELS AND TIRES (Continued)
• c. Check each tire for wear using tire depth gauge. Three separate sets
of measurements must be taken to determine overall tread wear.
Measure tread depth at outside edge (1), center (2) and inside edge
(3) at approximately 12 o’clock, 4 o’clock and 8 o’clock positions
around outside of tire. Tread depth should be no less than 3/32 inch
(2.38 mm).
NOTE
Tires should be rotated only on the same side and within the same
tandem.
• d. Rotate tires. Switch tires on No. 1 and 2 axles on right side. Switch
tires on No. 3 and 4 axles on right side. Switch tires on No. 1 and 2
axles on left side. Switch tires on No. 3 and 4 axles on left side.
2-8
TM 08780B-20

Procedures
No. S A B Inspected
11. STEERING
• a. Check steering system U-joints (1) and shafts (2) for looseness,
breaks, cracks, rust or wear.
• b. Check steering gear (3) mounting bolts for looseness. Inspect gear
(3) for leaks.
• c. Inspect pitman arm (4) for cracks, breaks or loose mounting.
• d. Inspect upper and lower drag links (5) for looseness, breaks or
cracks. Tighten nuts on both drag links at bellcrank and at steering
arm to 185-200 foot-pounds (250-271 N*m).
• e. Inspect bellcrank (6) for looseness, breaks or cracks.
• f. Inspect fuse link assembly (7) for looseness, breaks or cracks.
• g. Inspect yaw cylinder feedback linkage (8) for looseness, breaks,

cracks or bends.
• h. Inspect both yaw cylinders (9) for scoring, bends or leakage.
2-9
TM 08780B-20

Procedures
No. S A B Inspected
11. STEERING (Continued)
• i. Inspect tie rods (1) for breaks or looseness.
• j. Follow routing of all hydraulic steering lines, hoses and tubes to

inspect for loose fittings, rubbing, chafing, cracks, bends, breaks or
leaks. Tighten if loose and replace or repair hoses or lines that are
damaged. Refer to paragraph 15-16.
2-10
TM 08780B-20

Procedures
No. S A B Inspected
12. SUSPENSION
• a. Check spring leaves (1) for cracks or breaks. Report damaged

spring leaves to Direct Support/Intermediate Maintenance (3rd
Echelon).
• b. Inspect spring leave ends (2) for alignment. Spring leave ends (2)
must be within 1/4 inch (6.35 mm) of each other. Report
misalignment exceeding 1/4 inch (6.35 mm) to Direct Support/
Intermediate Maintenance (3rd Echelon).
• c. Inspect Spring U-bolts (3) for cracks, breaks or looseness.
d. Inspect spring seat (4) for cracks, breaks or looseness.
• e. Inspect spring pressure plate (5) for cracks, breaks or looseness.
• f. Inspect front and rear shock absorbers (6) for oil leaks or damage.
• g. Inspect front and rear shock absorber rubber bushings (7 and 8) for
cracks, dry rotting, damage or looseness.
2-11
TM 08780B-20

Procedures
No. S A B Inspected
12. SUSPENSION (Continued)
• h. Inspect lockout strut (1) for cracks, breaks or obvious damage.
• i. Check lockout strut sensor (2) cap and chain (3) for damage.
NOTE
Perform step (j) for LVSA1 series vehicles only.
• j. Check articulation joint lockout strut sensor (2.1) cap and chain
(3.1) for damage.
• k. Check front torque rods (1 thru 6) for damage and for looseness
where they attach to frame and axles. Tighten all mounting bolts to
225 foot-pounds (305 N*m). Refer to paragraph 17-4.
• l. Check rear torque rods (7 thru 12) for damage and for looseness
where they attach to axles and frame. Tighten all mounting bolts to
440-580 foot-pounds (596-786 N*m). Refer to paragraph 17-5.
• m. Check the mounting brackets of torque rods (9 and 10) for cracks,
breaks or loose mounting on frame. Torque mounting bolts to 440-
580 foot-pounds (596-786 N*m). Refer to paragraph 17-5.
2-12
TM 08780B-20

Procedures
No. S A B Inspected
12. SUSPENSION (Continued)
• n. Check for metal to metal contact between spring seat (13) and
spring seat cap (14) or between spring seat (13) and inner retainer
(15) on rear suspension. Alert Direct Support Maintenance to
replace trunnion bushings if metal to metal contact occurs.
2-13
TM 08780B-20

Procedures
No. S A B Inspected
13. PROPELLER SHAFTS
• a. Inspect all propeller shafts (1) for bends or cracks.
• b. Make sure all flange mounting screws (2) and U-joint mounting
screws (3) are tight.
• c. Inspect U-joints (4) and slip spline (5) for wear and play and for
broken or missing lubrication fittings. There should be no play at
U-joints.
• d. Inspect pillow blocks (b) for cracks, breaks or looseness.
• e. Inspect center bearing (8) for cracks, breaks or looseness.
• f. Inspect Cardan joint (7) for cracks, breaks or looseness.
2-14
TM 08780B-20

Procedures
No. S A B Inspected
14. BRAKES
• a. Inspect brake adjustment. Refer to paragraphs 13-4 and 13-5.
• b. Inspect brake shoe linings. If linings are less than 1/4 inch (6.35
mm) thick, linings should be replaced. Refer to paragraphs 13-6
and 13-7.
• c. Inspect inside the spring brake chambers for mud, water or other
debris. If any is found, remove the spring chamber and send to
Direct Support/Intermediate Maintenance (Third Echelon). Refer to
paragraphs 13-8 and 13-13 in this manual.
2-15
TM 08780B-20

Procedures
No. S A B Inspected
15. TRANSFER CASE
• a. Remove breather (1) from transfer case. Refer to paragraph 9-8.

Wash breather in solvent (item 53, Appendix D) and allow to air
dry.
• b. Inspect oil seals (2) for damage or leaks.
• c. Inspect transfer case (3) for leaks, cracks, damage and loose bolts.
• d. Inspect transfer case shift cable (4) for kinks, excessive play, wear
or damage.
2-16
TM 08780B-20

Procedures
No. S A B Inspected
16. TRANSMISSION
• a. Inspect transmission for cracks, leaks or obvious damage.
• b. Inspect transmission shift cable (1) for kinks, excessive play, wear
or damage.
• c. Check transmission drain plug (2) for looseness. Torque to 15-20

foot-pounds (22-27 N*m).
• d. Inspect transmission oil pan bolts (3) for looseness. Tighten pan
bolts (3) to 10-13 foot-pounds (13-17 N*m).
• e. Inspect output shaft seal (4) for damage or leaks. If there are signs
of oil leaks, notify Direct Support/Intermediate Maintenance (3rd
Echelon).
• f. Remove breather (5) from transmission. Refer to paragraph 8-16.

Wash breather in solvent (item 53, Appendix D) and allow to air
dry.
2-17
TM 08780B-20

Procedures
No. S A B Inspected
17. FRONT AXLES
• a. Remove breathers (1 and 2) from each axle housing. Refer to

paragraph 11-4 and 12-5. Wash breathers in solvent (item 53,
Appendix D) and allow to air dry. Install breathers in each axle
housing.
• b. Check each input and output shaft seal (3) for damage and leaks. If
there are signs of oil leaks, notify Direct Support/Intermediate
Maintenance (3rd Echelon).
• c. Inspect each front axle ball (4) for excessive grease. If there are
signs of excessive grease, this indicates worn or damaged wiper
seal. Notify Direct Support/Intermediate Maintenance (3rd
Echelon).
• d. Inspect wheel bearings (5) for looseness, damage or wear. Refer to

paragraph 14-3 and 14-4.
• e. Check trunnion bearing cover (6) for damage or wear.
• f. Inspect axle shaft and cage ring assembly. Clean and repack,
2-18
TM 08780B-20

Procedures
No. S A B Inspected
18. REAR AXLES
• a. Remove breathers (1 and 2) from each axle housing. Refer to

paragraph 12-5. Wash breathers in solvent (item 53, Appendix D)
and allow to air dry. Install breathers in each axle housing.
• b. Check each input and output shaft seal (3) for damage and leaks. If
there are signs of oil leaks, notify Direct Support/intermediate
Maintenance (3rd Echelon).
• c. Inspect wheel bearings (4) for scoring, pitting or discoloration.

Replace seals. Refer to paragraphs 14-3 and 14-4.
2-19
TM 08780B-20

Procedures
No. S A B Inspected
19. FRAME
• a. Inspect for broken crossmembers (1), broken welds and loose,

broken or missing bolts.
• b. Inspect articulation joint (2) for breaks or cracks.
• c. Check for loose coupling bolts (3). Lubricate and torque to 375
foot-pounds (508.5 N*m) if needed.
• d. Replace all coupling nuts and bolts (3). Lubricate and torque to 375
foot-pounds (508.5 N*m).
2-20
TM 08780B-20

Procedures
No. S A B Inspected
20. HYDRAULIC SYSTEM
• a. Replace hydraulic fluid filter (1). Refer to paragraph 23-6 (or 23-7
for LVSA1 series vehicles only).
NOTE
Perform steps a.1 and a.2 for LVSA1 series vehicles only.
• a.1. Replace high pressure filter (1.1) on MK48A1. Refer to paragraph

23-21.
• a.2. Replace high pressure filter (1.2) on MK15A1 or MK17A1. Refer

to paragraph 23-20.
• b. Drain and fill hydraulic reservoir (2). Refer to LI 2320-12/9, LO

2320-297-12. Remove and clean screen (3). Refer to paragraph
23-3.
• c. Remove and clean directional relief valve filter screen (4). Refer to
paragraph 23-19.
2-21
TM 08780B-20

Procedures
No. S A B Inspected
21. AIR INTAKE SYSTEM
a. Inspect air cleaner (1), hoses (2) and tubing (3) for cracks, breaks or
loose connections that could permit unfiltered air to enter system.
Replace as required. Refer to paragraph 4-9.
b. Change both primary and secondary air filter elements. Refer to

paragraph 4-7.
2-22
TM 08780B-20

Procedures
No. S A B Inspected
22. COOLING SYSTEM
• a. Inspect all hoses (1) for looseness, splits, wear or cracks that could
cause leaks. Inspect hose clamps (2) for wear. Replace as required.
Refer to paragraph 6-7.
• b. Test coolant. Refer to TB 750-651. Service cooling system if

necessary. Refer to paragraph 6-3.
• c. Drain, flush and refill coolant. Refer to paragraph 6-3.
• d. Replace coolant water filter. Refer to paragraph 6-5.
2-23
TM 08780B-20

Procedures
No. S A B Inspected
23. ENGINE
• a. Inspect oil filter housing (1) for oil leaks and looseness. Tighten
bolts to 30-35 foot-pounds (40-47 N*m).
• b. Inspect all oil lines (2) for cracks, frays or wear that could cause
leaks.
• c. Check oil pan bolts (3) and oil pan drain plug (4) looseness.
Tighten pan bolts to 10-20 foot-pounds (13-27 N*m). Tighten oil
drain plug to 33-37 foot-pounds (44-50 N*m).
2-24
TM 08780B-20

Procedures
No. S A B Inspected
23. ENGINE (Continued)
• d. Check starter (1) for loose wire connections and missing bolts or
hardware. Tighten starter bolts to 137-147 foot-pounds (185-200
N*m).
• e. Inspect rocker cover gaskets (2) for oil leaks. Replace rocker cover
gaskets if oil leaks exist. Refer to paragraph 3-4.
• f. Inspect all engine compartment wiring for frays, splits, missing

insulation or poor connections. Repair or replace any worn wiring.
• g. Inspect alternator wiring (3) for frays, splits, missing insulation or

loose terminal connections. Repair or replace any worn wiring.
• h. Check that alternator mounting bolts (4) are tightened to 35 foot-

pounds (47 N*m).
• i. Check engine mount bolts (5) for correct torque 170 foot-pounds
(230 N*m) wet.
2-25
TM 08780B-20

Procedures
No. S A B Inspected
24. EXHAUST SYSTEM
WARNING
DO NOT TOUCH HOT EXHAUST PIPES WITH BARE HAND.

SEVERE BURNS WILL RESULT.
• Check exhaust manifold (1), exhaust pipes (2), muffler (3), heat shield (4)
and tailpipe (5) for leaks indicated by soot marks. Inspect all bolts,
mounting clamps and heat shield for tightness. Check rain cap (6) to
make sure it operates freely and that it closes the top of the tailpipe when
the engine is not running.
2-26
TM 08780B-20

Procedures
No. S A B Inspected
25. COMPRESSED AIR SYSTEM
• a. Drain air reservoirs (1). If any moisture is expelled, inspect air

dryer and replace desiccant filter if necessary. Refer to paragraph
13-38. If moisture is milky, blue or green, serious internal engine
or compressor malfunctions are indicated. Notify Direct
Support/intermediate Maintenance (3rd Echelon).
• b. Inspect all air reservoirs and their attaching valves, lines and
connections for looseness, bends, dents and cracks that could cause
leaks.
• c. Replace air dryer desiccant (2). Refer to paragraph 13-38.
• d. Check air governor (3) for leaks. Make sure governor mounting
bolts are tight.
• e. Check air governor for proper operation. Adjust governor as

required. Refer to paragraph 13-37.
2-27
TM 08780B-20

Procedures
No. S A B Inspected
26. PINTLE HOOK AND LANDING LEGS
• a. Inspect pintle hook for damage. Check pintle for proper operation.
• b. Inspect landing legs for breaks or bends and loose mounting bolts.
Check for proper operation.
27. CRANE (MK15/15A1 AND 17/17A1)
• a. Check all hydraulic lines and hoses for splits, cracks or signs of
wear. Make sure all lines are secure and properly routed.
• b. Perform operational check using all crane controls. Check for

smooth operation of crane and outrigger controls. Crane and
outrigger controls should not bind or stick.
• c. With boom raised and extended, inspect crane hydraulic cylinders

for bends or scoring.
• d. Check for loose crane mounting bolts.
• e. Load test crane. Refer to TB 43-0142.
NOTE
Step (f) is not required on LVSA1 series vehicles.
• f. Check adjustment of both outrigger beams. Refer to paragraph 20-

35.
2-28
TM 08780B-20

Procedures
No. S A B Inspected
28. A-FRAME (MK15/15A1)
• a. Inspect A-Frame for cracks, bends, broken welds or loose

mounting.
• b. Inspect A-Frame cylinder for leaks, bends or scoring.
• c. Inspect A-frame snatch block for proper operation.
• d. Inspect towing cable for kinks, broken strands or wear.
29. WINCH (MK15/15A1 AND 16/16A1)
• a. Check winch for loose mounting bolts.
• b. Operate winch. Make sure engine governor maintains 2,200 ± 50

RPM. If engine surges, notify Direct Support/Intermediate
Maintenance (Third Echelon). Refer to TM 08780B-10 for winch
operation.
30. FIFTH WHEEL (MK16/16A1)
• Check fifth wheel and ramps for loose mounting bolts.
2-29
TM 08780B-20

Procedures
No. S A B Inspected
31. BODY AND FRAME
• Inspect sheet metal, frame rails, crossmembers and mounting brackets for
rusting or rust through condition. Look for bubbling or discolored paint
which indicates rusting from the inside. Pay particular attention to areas
where dirt may collect. Remove panels or parts if necessary for
inspection.
• Apply corrosion control products to the following areas:
a. Inside cab
NOTE
Application of corrosion control materials will require the removal of
panels and covers to gain access to the electrical components in the
cab.
Apply Cortec VCI 238 electrical spray (item 15.1, Appendix D) to ALL
electrical terminations, switches and all other electrical components
found in the cab, especially the following:
• All relays and circuit breakers located in the electrical control box.
• Low air pressure and stop light switches on the brake treadle valve.
• All electrical connections to gauges and switches located on the
dash and side panels.
• All connections to the ignition switch panel.
• Fan switch and connections at the heater panel.
b. Outside cab
NOTE
Apply corrosion control products, only to areas that have surface
damage that could allow rust and corrosion to form, if left untreated.
Apply Cortec VCI 386 (Item 60.1, Appendix D) and a final topcoat of
CARC paint, as required to:
• Auxiliary hydraulics selector valve on right fender.
• Hydraulic return filter housing on hydraulic reservoir.
• Motion control valve.
2-30
TM 08780B-20

Procedures
No. S A B Inspected
31. BODY AND FRAME (Continued)
NOTE
Brass connectors for air and hydraulics do not require use of corrosion
control products. However, all steel connections do require corrosion
control products.
• All quick disconnect hose ends and other fittings at the
articulation joint.
• All steel air line bulkhead connections at the articulation joint.
c. Rear modules MK14/14A1, 15/15A1, 16/16A1, 17/17A1:
NOTE
Apply corrosion control products only to areas that have surface
damage that could allow rust and corrosion to form, if left untreated.
Brass connectors do not require use of corrosion control products.

However, all steel connections do require corrosion control products.
Apply Cortec VCI 386 (Item 60.1, Appendix D) and a final topcoat of
CARC paint, as required; to all quick disconnect hose ends and other
fittings for air and hydraulic line connections at rear module.
NOTE
If your vehicle has a special purpose kit installed, continue with items
32-35. If your vehicle does not have a special purpose kit, go to item
36, Final Road Test.
32. MACHINE GUN MOUNT
• a. Check gun mount for loose or missing hardware and bolts. Tighten
bolts as required.
• b. Refer to TM 08686A-13&P for Preventive Maintenance Checks

and Services.
2-31
TM 08780B-20

Procedures
No. S A B Inspected
33. EXTENDED PINTLE
Check extended pintle for cracks or broken welds. Make sure hook is
secure and locking mechanism operates properly.
34. REAR BODY TOW UNIT
a. Check tow unit for cracks or broken welds.
b. Check tow unit for damaged air lines and hoses. Inspect glad hands
for missing or rotted seals.
35. LIFT SLINGS
a. Inspect for tears or rips. Check clevis and pin for bends or breaks.
b. Load test lift slings. Refer to TB 43-0142.
36. FINAL ROAD TEST
After all services and inspections have been completed, take vehicle on a
road test to make sure all corrections have been accomplished. Correct or
report any defects or malfunctions that occur during this test.
2-32
TM 08780B-20
Section III. Troubleshooting
2-6. STE/ICE TROUBLESHOOTING
This task covers: a. Introduction g. Cable Assemblies

b. STE/ICE Maintenance h. Vehicle Test Cards (VTC)
c. STE/ICE Description i. Types of Readouts
d. Vehicle Test Meter (VTM) j. Operating Modes
e. Transducer Kit (TK) k. Testing
f. Transport Case l. STE/ICE Tests
Initial Setup:
References: TM 9-4910-571-12&P
Applicable Configurations: MK48/48A1
a. Introduction. This portion of the troubleshooting section covers the use of

Simplified Testing Equipment for Internal Combustion Engines (STE/ICE). STE/ICE may be
used to test the engine, fuel or electrical systems of the LVS MK48. These tests cover vehicle
testing and primary fault isolation. The STE/ICE system consists of the Vehicle Test Meter
(VTM), a Transducer Kit (TK), a Technical Manual (TM), a transport case, six electrical cables
and a set of Vehicle Test Cards (VTC).
b. STE/ICE Maintenance. Maintenance of the STE/ICE system is covered in TM 9-

4910-571-12&P.
c. STE/ICE Description
(1) STE/ICE is portable and can be operated on either 12 or 24 volts. Power

can be drawn from the MK48/48A1 electrical system or from a separate source.
(2) The STE/ICE system includes multimeter functions and the following
tests:
a. Voltage (AC and DC)

b. Current (High and Low)
c. Resistance
d. Pressure and Vacuum
e. Temperature
f. Compression Balance
g. Starter System
2-33
TM 08780B-20
d. Vehicle Test Meter (VTM). The VTM is a tool used by the mechanic to test
electrical and mechanical parts. Readings are either PASS/FAIL or digital displays in units
familiar to the mechanic (psi, rpm, volts, etc). The VTM is connected to the MK48/48A1
through either the permanent Diagnostic Connector Assembly (DCA) or the transducers from the
TK. The DCA provides power for the VTM and connections to the most commonly used test
points, without the need for additional connections. This is called the DCA mode of operation.
Additional tests may be performed by installing transducers from the TK. This is called the TK
mode of operation. The main features of the VTM are as follows:
(1) The POWER SWITCH is a push ON/ pull OFF type switch that controls
power to the VTM. The switch contains a four amp circuit breaker that pops out if the VTM
draws more than four amps. If this happens, check all connections carefully before resetting or
sending the VTM to be repaired.
(2) The two TEST SELECT SWITCHES are used to select the test to be
performed. There are ten positions on each switch, numbered 0 thru 9. The numbers dialed in
are read by the VTM when the TEST BUTTON is pressed.
(3) The TEST BUTTON, when pressed and released, starts the selected test.
The TEST BUTTON must be released quickly. Holding it down will cause an offset test to be
done.
(4) The READOUT DISPLAY shows different information during testing.

Readouts of up to four characters may be displayed, for example (.8.8.8.8). There are three types
of readouts. STATUS READOUT keeps the mechanic informed of what is happening with
regard to power application, test passage, etc. NUMERICAL READOUT displays measured
value in units of the measurement being taken. For example, if you are measuring 0-45 volts, the
number 24 on the display indicates 24 volts. ERROR READOUT indicates a problem, such as,
wrong test selected, VTM faulty, etc.
2-34
TM 08780B-20
Vehicle Test Meter (VTM)
(5) The FLIP CARDS list the two digit test numbers and a summary of the
test procedures.
(6) The POWER/DCA CONNECTOR, J1, connects the VTM to the DCA
using cable W1 or it connects directly to a power source using cable W5.
(7) The TRANSDUCER CABLE CONNECTORS, J2 AND J3, connect the

VfM to any transducer in the TK using cables W4. These cables pass power to and signals from
the transducer. Connectors J2 and J3 are the same and may be used one at a time or in
combination.
(8) The TEST PROBE CONNECTOR J4 is used to connect cable W2 to the

VTM when doing manual voltage and resistance tests.
e. Transducer Kit (TK). The TK contains transducers, adapters and fittings in a

molded storage tray. Make sure that the TK items are kept clean and the MK48 mounting
surface is clean before installing any TK item. Dirt entering the engine may cause damage.
(1) PRESSURE TRANSDUCERS. There are two pressure transducers in the

TK. The transducer with a red stripe measures from minus 30 inches HG to plus 25 PSIG. The
transducer with the blue stripe measures from 0 to 1,000 PSIG, both positive and negative. Each
transducer has a small breather hole on the side that must not be plugged. Never use high
pressure air to clean the breather holes. Air pressure of 20 psi or less may be used.
(2) PULSE TACHOMETER. Make sure that the slotted hole in the engine
tachometer drive shaft is clear before installing.
2-35
TM 08780B-20
(3) CURRENT PROBE. This probe is used to measure amperage draw in the
electrical system.
(4) THREADED ADAPTORS. Be careful not to attempt to install pipe

threaded adapters into straight threaded adapters or vice versa.
Each transducer has a built-in identification resister that the VTM uses to
determine if the correct transducer is connected for the test being made. If it does not match,
error code E002 will be displayed.
1. Hose and Fitting Assembly (TK Item 10) 14. Street Tee 112 (TK Item 23)
2. Current Probe (TK Item 11) 15. Street Tee 114 (TK Item 24)
3. Reducer 314 (TK Item 12) 16. Street Tee 118 (TK Item 25)
4. Reducer 112 (TK Item 13) 17. Street Elbow 1/4 (TK Item 26)
5. Reducer 318 (TK Item 14) 18. Street Elbow 1/8 (TK Item 27)
6. Pipe Plug 1/4 (TK Item 15) 19. Inverted Flare Tee (TK Item 28)
7. Pipe Plug 1/8 (TK Item 16) 20. Connector Adapter (TK Item 29)
8. Pressure Transducer Blue Stripe 21. Ignition Adapter (TK Item 30)
(TK Item 17) 22. Adapter, Tachometer Drive
9. Male Connector 1/4 (TK Item 18) (TK Item 31)
10. Pipe Reducer Coupling (TK Item 19) 23. Fuel Line Adapter (TK Item 32)
11. Adapter (TK Item 20) 24. Air Chuck (TK Item 33)
12. Snubber (TK Item 21) 25. Pulse Tachometer (TK Item 34)
13. Pressure Transducer Red Stripe 26. Flexible Hose Assembly (TK Item 35)
(TK Item 22) 27. Long Hex Pipe Nipple (TK Item 36)
2-36
TM 08780B-20
f. Transport Case. The transport case is designed to store and protect all of the
components of the STE/ICE system during transportation.
g. Cable Assemblies. The cable assemblies are referred to by the cable numbers and
a name that describes how each is used.
(1) CABLE W1 is the DCA CABLE.

(2) CABLE W2 is the TEST PROBE CABLE.
(3) CABLE W3 is the IGNITION ADAPTER CABLE.
(4) CABLE W4 is the TRANSDUCER CABLE.
(5) CABLE W5 is the POWER CABLE.
Two W4 cables may be joined, using an adapter, to form one long cable. If you suspect that a
cable is bad, refer to TM 9-4910-571-12&P for testing the cable.
h. Vehicle Test Cards (VTC). A set of VTC is included to provide testing

information for each type of vehicle that STE/ICE can be used on.
i. Types of Readouts
(1) STATUS READOUT. This readout keeps you informed about the status
of the test equipment. There are four status readouts.
(a) Readout .8.8.8.8 appears each time the VTM is turned ON. It
means that there is power to the VTM and that all elements of the display are working.
2-37
TM 08780B-20
(b) When ._._._._ readout is displayed, it means one of two things.

First, after power is turned ON, it means the VTM is ready for testing. Second, during a
compression imbalance test, it means testing is in progress.
(c) Readout .9.9.9.9 indicates that the VTM is reading a test value
beyond the range of its measurement capability. Either the wrong test has been selected for what
is being measured or there is a problem in the vehicle.
(d) PASS/FAIL. This is the result of a test on a component. Either the

component passes or fails the test.
(2) PROMPTING MESSAGE. This readout tells the mechanic to do

something. After the proper action is taken, the test will automatically continue. There are
seven prompting messages.
(a) UEH signals the mechanic to enter the vehicle identification

number (VID). VID numbers are found under TEST DATA on the flip cards, on the VTC and in
the G01 test chain in this manual. The LVS MK48 VID is 18.
(b) CYL signals the mechanic to enter the number of cylinders on the
TEST SELECT switches.
(c) GO signals the mechanic to crank the engine in compression

balance or first peak tests.
(d) CIP signals the mechanic to apply full throttle in a CI power test.
(e) OFF signals the mechanic to stop cranking in compression balance

test or to release the accelerator in the CI power test.
(f) CAL signals the mechanic to release the TEST button during an
offset test.
(g) 66 signals the mechanic to dial in 99 during the confidence test.
(3) NUMERICAL READOUT. This readout is a measured valve in the units

of the test being made. The numbers are always positive, unless a minus sign shows.
(4) ERROR READOUT. There are 17 different readouts and they all start
with E. They warn you that something is wrong. You must correct the problem to continue
testing. A list showing what each message number means is shown on the flip cards. If the error
message will not go away, refer to TM 9-4910-571-12&P.
(5) CONFIDENCE ERROR READOUT. There are 44 different confidence

error readouts and they all start with C. They are used when repairing the VTM.
2-38
TM 08780B-20
j. Operating Modes. STE/ICE can be operated in three modes.
(1) DCA MODE. In the DCA mode, the VTM is connected to the MK48 at
the DCA plug permanently mounted in the cab. The DCA plug is connected to a wiring harness
that is routed to test points on the MK48/48A1.
(2) TK MODE. In the TK mode, the VTM is connected to the MK48/48A1

using the adapters, transducers and cable assemblies. The transducers are installed to make the
tests. They are removed when the tests are completed. One or more cables are needed to
connect required points and to supply power to the VTM.
(3) COMBINED MODE. The DCA and TK modes can be used at the same
time to perform certain tests.
k. Testing.
(1) DATA ENTRY TESTS. At the beginning of testing, you are usually
required to enter the VID into the VTM. The VTC will show what data is needed. This tells the
VTM what vehicle it is connected to.
(a) TEST 58. The number of cylinders must be entered separately.

When test 58 is selected, the VTM will respond with CYL. At this point, dial in the number of
cylinders on the test select switches and press TEST. The VTM will not perform a test, but will
remember the number of cylinders. If the wrong number is entered, one of the following error
messages will be displayed: E007, E010, E014 or E015.
(b) TEST 60. When test 60 is selected, the VTM will respond with
UEH. At this point, dial the VID into the VTM and press test. The VTM will not perform a test,
but will remember the VID. If the wrong number is entered, one of the following error messages
will be displayed: E007 or E010.
(2) DATA DISPLAY TESTS. Tests 59, 61, 62, 63 and 64 are used to display
data already stored in the VTM.
(a) Test 59 displays stored cylinder information when the test button is
pressed.
(b) Test 61 displays the VID when the test button is pressed.
(c) Test 62 displays the DCA ID number when the test button is
pressed.
(d) Test 63 displays the ID number of the transducer attached to

connector J2.
2-39
TM 08780B-20
(e) Test 64 displays the ID number of the transducer- attached to

connector J3.
Transducer ID Numbers
TRANSDUCER ATTACHED ID NUMBER DISPLAYED

TO 12 OR 13 BY TEST 63 OR 64
Pressure transducer -15 to +25 4
PSIG (red stripe)
Pressure transducer 0-1,000 PSIG 7
(blue stripe)
Pulse tachometer 10
Current probe 13
(3) OFFSET TESTS. The STE/ICE VTM will perform an offset test when
the test number is entered and the test button is pressed and held down until the VTM displays
CAL. The offset test allows for differences in the VTM, test leads and transducers. Once the
offset is performed the VTM automatically corrects for the offset before displaying measured
values. An offset value will be displayed and must be checked against limits from the VTC. If
this value is outside these limits, either the transducer or cable are faulty and must be replaced.
Offset tests are done in both the DCA and TK modes. All tests requiring offset are identified by
a star (*) on the flip cards and by OFFSET LIMITS on the VTC. All offset tests are performed
with the DCA or TK connected, test probe leads should be shorted together. Make sure no
stimulus is being applied to the transducer.
(4) CONTROL TESTS. These tests are used to change the way a test is
displayed or the way it is run. There are five control tests.
(a) Test 01 (interleave). This test measures engine speed and

alternately makes a second measurement, such as fuel pressure or alternator voltage. To start
this test, dial 01 into the test select switches and press the test button. When PASS is displayed,
dial in the second test number and again press the test button.
(b) Test 02 (minimum value). This test displays the minimum value
measured during a test. To start this test, dial 02 into the test select switches and press the test
button. When PASS is displayed, dial in the second test number and again press the test button.
The minimum value will now be displayed and is updated when a lower value is measured.
(c) Test 03 (maximum value). This test is done exactly as test 02

except that the maximum measured value is displayed.
(d) Test 04 (peak-to-peak value). This test will display the peak-to-
peak value of battery volts (test 67), alternator output volts (test 82), 45 volts DC (test 89) and
1500 amps DC (test 90). To start test, dial 04 into test select switches and press test. When
PASS is displayed, dial in test numbers 82, 89, 90 or 67 and again press test button.
2-40
TM 08780B-20
(e) Test 05 (Initiate SI full power simulation) is not used on LVS

MK48.
l. STE/ICE Tests
(1) Test procedures are arranged in GO and NO-GO chains. In the GO chain,
a correct result from each test leads to a GO to the next test. If the MK48/48A1 fails a test, the
result leads to a corrective action, higher level of maintenance or to the NO-GO chain. The NO-
GO chain contains steps to find the cause of failure and is arranged to detail fault isolation and
corrective actions.
Go Page Test Title

Test Number
Number
GO1 2-44 VTM Connections and Checkout
GO2 2-50 First Peak Test - Starter Current
GO3 2-52 Engine Start - Lubrication Check
GO4 2-55 Charging Circuit and Battery Voltage Test
GO5 2-57 Engine Warmup/Coolant Check/Oil
Pressure Test/Fuel Filter Restriction Test
GO6 2-60 Governor Check/Power Test
GO7 2-62 Idle Speed/Governor Check
GO8 2-63 Compression Unbalance Test
No-Go Page Test Title

Test Number
Number
NG05 2-66 Low Oil Pressure Check
NG20 2-68 No Crank - No Start
NG30 2-69 Engine Crank - No Start
NG31 2-73 Gage Test
NG50 2-75 Charging Circuit Tests
NG80 2-76 Starter Circuit Tests
NG81 2-82 Battery Tests
NG90 2-87 Governor/Power Test Fault Isolation
NG130 2-90 Engine Tightness Test
(2) To use the test chains, the condition of the MK48/48A1 need not be
known. The passing of all tests, in order, will quickly show that an MK48 has no problem. The
failing of one or more tests will lead to fault isolation and corrective action. The only problems
needed to indicate the need for STE/ICE testing are, engine will not start or engine will not run
properly.
2-41
TM 08780B-20
2-42
TM 08780B-20
2-43
TM 08780B-20
(3) Unneeded tests can be avoided by going directly to the proper test when
the actual problem is known.
NOTE
The GO1 test must be performed before any other tests.
2-44
TM 08780B-20
2-45
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2-46
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2-47
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2-48
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GAUGE TEST
2-73
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END OF TASK
2-90
TM 08780B-20
2-7. STANDARD TROUBLESHOOTING
a. General. The troubleshooting charts in this paragraph are presented in the same
order as the chapters in this manual. Engine first, fuel systems second, exhaust systems third,
etc. They provide information needed to correctly isolate, diagnose and correct malfunctions
within the systems. Each malfunction symptom given for an individual component or system is
followed by step(s) leading to the cause of the malfunction and the actions needed to correct it.
Before taking any action to correct a possible malfunction, follow these rules:
(1) Obtain as much information from the operator as possible about the
malfunction.
(2) Never overlook the possibility that the problem may be of simple origin
and may be repairable with a simple adjustment.
(3) Use all of your senses to observe and locate troubles.
(4) Use all available test equipment to help find and isolate problems.
(5) Whenever possible, isolate the system first and then the component
causing the malfunction.
(6) Remember, for every failed part there is a cause. Whenever possible,
determine the cause of the failure before assuming the malfunction is fully repaired.
(7) Use standard automotive theories and principles when troubleshooting the
vehicle.
To quickly find the troubleshooting procedure you need, use the Symptom Index.
Symptoms are listed by components or system headings.
2-91
TM 08780B-20
Troubleshooting Symptom Index
Page
Engine
1. Engine Fails to Crank............................................................................... 2-99

2. Engine Cranks, but Will Not Start ........................................................... 2-106
3. Hard to Start, Runs Rough, Lacks Power ................................................ 2-106
4. Engine Does Not Develop Full Power..................................................... 2-107
5. Low Engine Oil Pressure ......................................................................... 2-108
6. High Oil Consumption............................................................................. 2-108
7. Engine Will Not Stop Running ................................................................ 2-110
8. Excessive Black or Gray Exhaust (Engine Temperature
160 Degrees F or Above)......................................................................... 2-114
9. Blue Exhaust Smoke (Engine Temperature 160 Degrees F or Above) ... 2-115
10. White Exhaust Smoke (Engine Temperature 160 Degrees F
or Above) ................................................................................................. 2-115
11. Oil Leakage From Exhaust Pipe or Breathers
(Excessive Crankcase Pressure)............................................................... 2-115
Fuel System
1. Engine Will Not Start or Stalls ................................................................ 2-116

2. Engine Does Not Start When Ether Starting Aid is Used in
Cold Weather ........................................................................................... 2-123
Exhaust System
Exhaust Noisy .......................................................................................... 2-125
Cooling System
Engine Overheats ..................................................................................... 2-126
Electrical System
1. Batteries Fail to Maintain Charge or

Discharge Rapidly.................................................................................... 2-130
2. Charging System Does Not Operate ........................................................ 2-134
3. Electrical Systems Do Not Work............................................................. 2-140
4. Electric Gauges Do Not Work ................................................................. 2-144
5. Ether Starting Aid Does Not Work.......................................................... 2-150
6. Engine Brake Does Not Operate.............................................................. 2-155
7. Engine HI Idle Does Not Work ............................................................... 2-163
8. Air Pressure Warning Light and/or Buzzer Do Not Work ...................... 2-174
2-92
TM 08780B-20
Troubleshooting Symptom Index (Continued)
Page
Electrical System (Continued)
9. Air Pressure Warning Light and/or Buzzer Do Not

Work When Only One System Drops Below 65 PSI .............................. 2-178
10. Turn Signal Indicator or One or More Turn
Signals Do Not Work............................................................................... 2-180
11. Brake Lights Do Not Work...................................................................... 2-196
12. Marker Lights Do Not Work.................................................................... 2-206
13. One or More Parking Lights Do Not Work. ............................................ 2-213
14. Headlights Do Not Work, Low and/or HI Beam
and Indicator ............................................................................................ 2-221
15. Worklight(s) Do Not Work...................................................................... 2-230
16. Dome Light Does Not Work.................................................................... 2-236
17. Map Light Does Not Work ...................................................................... 2-239
18. Beacon Light Does Not Work.................................................................. 2-242
19. One or More Blackout Marker Light(s) Do Not Work............................ 2-248
20. Blackout Brake Lights Do Not Work ...................................................... 2-254
21. Suspension Lockup Warning Light Does Not
Come On When Caps Are Off ................................................................. 2-258
22. Suspension Lockup Warning Light Does Not Go Out
When Caps Are On .................................................................................. 2-262
23. Air Dryer and/or Fuel/Water Separator Heater Do Not Work................. 2-265
24. One or Both Horns Do Not Work ............................................................ 2-268
25. Hydraulic Steering Disengage Light Does Not Work ............................. 2-271
26. Traction Control Valve Indicator Light(s) Do Not Work........................ 2-275
27. Instrument Panel (Gage) Lights Do Not Work ........................................ 2-278
28. One or Both Speeds On Heater Blower Do Not Work ............................ 2-283
29. Hydraulic Low Oil Level Alarm and/or Light Does Not Work............... 2-288
Transmission
1. Transmission Oil Temperature Gauge Stays Over 250 Degrees F

(121 Degrees C) ....................................................................................... 2-297
2. Transmission Noisy ................................................................................. 2-298
3. Transmission Will Not Shift Into Gear.................................................... 2-299
4. Transmission Slips Out of Gear or Operates Erratically ......................... 2-300
5. Transmission Leaks ................................................................................. 2-301
6. Oil Thrown From Filler Tube .................................................................. 2-303
7. Excessive Creep in First and Reverse...................................................... 2-305
8. Transmission Oil Dirty ............................................................................ 2-305
9. Automatic Shifts Occur at Too High or Low a Speed ............................. 2-308
10. Transmission Shifts Rough ...................................................................... 2-309
2-93
TM 08780B-20
Page
Transmission (Continued)
11. Vehicle Moves in Neutral ........................................................................ 2-309

12. Transmission Slips in All Gears .............................................................. 2-311
Transfer Case
1. Constant Noise When in Low Range and/or Direct Range .................... 2-312
2. Lubricant Leaks at Drive Yokes .............................................................. 2-314
3. Transfer Case Overheats .......................................................................... 2-315
4. Differential Lockup Will Not Engage or Disengage ............................... 2-316
Propeller Shafts
Driveline Vibration or Noise ................................................................... 2-317
Nose Box
1. Nose Box Overheats ................................................................................ 2-319

2. Lubricant Leaks at Drive Yoke................................................................ 2-320
3. Nose Box Noisy ....................................................................................... 2-321
Axles
1. Differential(s) Noisy ................................................................................ 2-322

2. Lubricant Leaks at Pinion or Axle Shafts ................................................ 2-323
3. Controlled Traction Differential Will Not Engage or Disengage............ 2-325
4. Vehicle Will Not Move............................................................................ 2-327
Air System
1. No Air Pressure or Slow Buildup ............................................................ 2-329

2. Throttle Air Cylinder Does Not Work ..................................................... 2-335
3. Compressor Cycles Constantly or Safety Valve Opens Before
Compressor Unloads................................................................................ 2-337
4. Compressor Noisy.................................................................................... 2-338
5. Coolant and/or Lubricant Leaks from Compressor ................................. 2-339
6. Air Pressure Above 150 PSI (1,034 kPa), Safety Valve
Does Not Release..................................................................................... 2-340
7. Left and/or Right Windshield Wiper Does Not Work ............................. 2-342
8. Windshield Washers Do Not Work ......................................................... 2-347
9. Air Horn Does Not Work......................................................................... 2-350
2-94
TM 08780B-20
Page
Air System (Continued)
10. Axle Differentials Will Not Lock or Unlock ........................................... 2-352

11. Transfer Case Will Not Lock Up or Unlock............................................ 2-357
12. Braking is Uneven, Slow or Brakes Overheat ......................................... 2-360
13. Service Brakes Will Not Release or Release Slowly............................... 2-367
14. Pressure Drops More Than 25 PSI (172 kPa) on Air Pressure
Gauge When Brakes are Applied............................................................. 2-372
15. Parking Brakes Will Not Release ............................................................ 2-377
16. Parking Brakes Will Not Apply............................................................... 2-382
17. Air Pressure Gauge Indicators Do Not Read the Same ........................... 2-385
18. Dryer Constantly Cycling or Purging ...................................................... 2-405
19. Safety Valve on Air Dryer Releasing Air ................................................ 2-407
20. Air Dryer Does Not Purge ....................................................................... 2-409
21. Desiccant Material Expelled From Purge Valve ..................................... 2-411
Hydraulic Steering System
1. Vehicle Steers Hard in One or Both Directions....................................... 2-413

2. Front Wheels Turn, Yaw Cylinders Do Not Move.................................. 2-419
3. Front Wheels Will Not Turn in Either Direction ..................................... 2-424
4. Steering is Oversensitive.......................................................................... 2-427
5. Vehicle Wanders...................................................................................... 2-429
Winch MK15/15A1
Winch Will Not Operate in One or Both Directions................................ 2-435
Winch MK16/16A1
Winch Will Not Operate in One or Both Directions................................ 2-438
Suspension
1. Vehicle Wanders or Shimmies................................................................. 2-448

2. Vehicle Leans to One Side....................................................................... 2-451
Crane Electric- MK15A1 and MK17A1
1. Crane Does Not Operate .......................................................................... 2-452

2. Remote Control Does Not Operate .......................................................... 2-460
3. Hoist Does Not Lower with Remote Control .......................................... 2-466
2-95
TM 08780B-20
Page
Crane Electric- MK15A1 and MK17A1 (Continued)
4. Hoist Does Not Raise with Remote Control ............................................ 2-471

5. Boom Does Not Lower with Remote Control ......................................... 2-479
6. Boom Does Not Raise with Remote Control........................................... 2-487
7. Boom Does Not Telescope in with Remote Control ............................... 2-495
8. Boom Does Not Telescope Out With Remote Control............................ 2-502
9. Crane Will Not Swing Clockwise Using Remote Control....................... 2-504
10. Crane Will Not Swing Counterclockwise Using Remote Control........... 2-517
11. Tilt Alarm Does Not Operate................................................................... 2-525
Crane Hydraulics - MK15A1 And MK17A1
1. Outrigger Beams/Jack Cylinders Do Not Operate................................... 2-534

2. Boom Does Not Raise Or Lower ............................................................. 2-535
3. Boom Does Not Telescope ...................................................................... 2-537
4. Hoist Does Not Operate ........................................................................... 2-539
5. Crane Does Not Swing ............................................................................ 2-541
6. Mast Does Not Raise Or Lower............................................................... 2-543
Crane Electric
1. Crane Inoperative..................................................................................... 2-545

2. Remote Control Does Not Work.............................................................. 2-556
3. Capacity Alert System Does Not Work
(Crane Overload Protection) .................................................................... 2-558
Crane Hydraulics - MK15 and MK17
1. Crane Functions are Slow ........................................................................ 2-563

2. Outrigger Beams Will Not Extend or Retract or Operates Slowly.......... 2-566
3. Stabilizer Leg Will Not Extend or Retract or Operates Slowly............... 2-572
4. Stabilizer Legs Will Not Hold Load ........................................................ 2-578
5. Crane Will Not Rotate, Rotates Slowly or Rotates in Only One
Direction .................................................................................................. 2-580
6. Main Boom Will Not Operate.................................................................. 2-583
7. Folding Boom Will Not Operate.............................................................. 2-587
8. Extension Boom Will Not Operate .......................................................... 2-592
9. Crane Will Not Lift Load......................................................................... 2-596
2-96
TM 08780B-20
Page
MK15 A-Frame Hydraulics
1. A-Frame Cylinder Will Not Operate Or Operates Slowly....................... 2-598
Antilocking Brake System
1. One or Both ABS Warning Lights Come on and Remain on .................. 2-600
End Of Troubleshooting Symptom Index
2-97
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE
1. Engine Fails To Crank
WARNING
• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE

SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.
• ENGINE MAY CRANK AND START DURING TROUBLESHOOTING TESTS. TO

PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR
BEFORE TURNING IGNITION SWITCH TO START POSITION.
NOTE
• Ignition switch must be in the ON position for all voltage tests.
• Electrical system voltage (22 to 30 volts) will be written as 24 volts in this section of the
manual.
Test 1. Make sure transmission shift selector is in the neutral (N) position. Move selector in
and out of neutral (N) several times.
• If engine now cranks, go to Test 6.
• If engine does not crank, go to Test 2.
Test 2. Check for 22 volts minimum reading on dash voltmeter gauge.

• If gauge reads 22 volts minimum, go to Test 4.
• If gauge does not read 22 volts minimum, go to Test 3.
2-98
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Check for 24 volts on battery terminals (wires 138 and 139).
• If 24 volts are present, go to Test 4.
• If 24 volts are not present, refer to ELECTRICAL SYSTEMS troubleshooting,
Malfunction No. 1, in this section.
2-99
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Slide rubber boot back and inspect neutral safety switch for visible damage.
• If no damage is visible, go to Test 5.
• If switch is damaged, replace switch. Refer to paragraph 7-26 in this manual.
NOTE
If ignition switch is turned to START position and released to ON position, it must be reset by
turning to OFF position before turning to START position again.
Test 5. With ignition switch held in START position, check for 24 volts on wire 021 of
neutral safety switch.
• If 24 volts are not present, go to Test 6.
Test 6. With ignition switch held in START position, check for 24 volts on wire 436 of
neutral safety switch.
• If 24 volts are present, adjust or replace switch as needed. Refer to paragraph
7-26 in this manual.
Test 7. With ignition switch held in START position, check for 24 volts on wire 436 terminal
of ignition switch.
• If 24 volts are present, repair or replace wire 436 between ignition switch and
neutral safety switch. Refer to paragraph 7-48 in-this manual.
Test 8. Check for 24 volts on wire 431 terminal of ignition switch.

• If 24 volts are present, replace ignition switch. Refer to paragraph 7-23 in this
manual.
2-100
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-101
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Check for 24 volts on wire 431 terminal of circuit breaker No. 5.
circuit breaker.
2-102
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
of starter relay.
• If 24 volts are not present, repair or replace wire 021 between neutral safety
switch and starter relay. Refer to paragraph 7-48 in this manual.
Test 11. Check for continuity between wire 196 terminal of starter relay and ground.
• If ground is good, go to Test 14.
• If ground is bad, repair or replace wire 196 between starter relay and ground.
Refer to paragraph 7-48 in this manual.
Test 12. Check for 24 volts on wire 046 terminal of starter relay.
• If 24 volts are present, repair or replace wire 430 between starter relay and circuit
breaker No. 5. Refer to paragraph 7-48 in this manual.
2-103
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 13. Check for 24 volts on wire 046 terminal of starter solenoid.
• If 24 volts are present, repair or replace wire 046 between starter and starter relay.
• If 24 volts are not present, repair or replace wire 139 between starter and batteries.
of starter relay.
• If 24 volts are not present, replace relay. Refer to paragraph 7-8 in this manual.
Test 15. With ignition switch held in START position, check for 24 volts in wire 045 terminal
of starter solenoid.
• If 24 volts are not present,- repair or replace wire 045 between starter relay and
starter solenoid. Refer to paragraph 7-48 in this manual.
Test 16. With ignition switch held in START position, check for 24 volts on jumper plate
terminal of starter solenoid.
• If 24 volts are present, to Test 18.
Test 17. Remove negative battery cable (wire 138) and check for continuity between battery
end of cable 138 and cable 138 at starter end plate.
• If continuity is found, go to Test 18.
• If no continuity is found, repair or replace cable (wire 138). Refer to paragraph
Test 18. Check for continuity of jumper wire between terminal on starter end plate and starter
solenoid.
• If no continuity is found, replace jumper. Refer to paragraph 7-6 in this manual.
Test 19. Check for continuity between wire 148 at starter end plate and chassis ground.
• If continuity is found, replace starter solenoid. Refer to paragraph 7-6.
• If continuity is not found, repair or replace wire 148.
• If engine fails to crank, go to Test 20.
2-104
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 20. Check for 24 volts between wire 938 terminal on starter and wire 139 terminal on
starter solenoid.
• If 24 volts are present, replace starter. Refer to paragraph 7-7 in this manual.
END OF TEST
2-105
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Engine Cranks, but Will Not Start
Test 1. Check fuel tanks for fuel.

• If right side fuel tank has three inches (7.6 cm) or more of fuel, go to Test 2.
• If out of fuel, add fuel and prime system as needed. Refer to TM 08780B-10.
Test 2. Check engine cranking speed.

• If cranking speed is normal, refer to FUEL SYSTEMS troubleshooting,
Malfunction 1, in this manual.
• If cranking speed is slow, refer to ELECTRICAL SYSTEMS and perform
troubleshooting tests as needed.
NOTE
Slow cranking speed can be caused by internal seizure of engine. If this is found to be the
cause of slow speed, refer problem to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
3. Hard To Start, Runs Rough, Lacks Power
Test 1. Check air restriction indicator on dash.

• If yellow, go to Test 2.
• If red, reset and start engine. Refer to TM 08780B-10. If still red, replace air
filter. Refer to paragraph 4-7 in this manual.
Test 2. Check fuel system for leaks, damage or contamination.

• If necessary, refer to FUEL SYSTEM troubleshooting, Malfunction 1, in this
manual.
• If no problem is found, go to Test 3.
• If damage is found perform repair or refer problem to Direct Support/Intermediate
Maintenance (Third Echelon).
Test 3. Check throttle treadle valve for proper operation.

• Refer to AIR SYSTEM troubleshooting, Malfunction 2, in this manual.
NOTE
If malfunction still exists, refer problem to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-106
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Engine Does Not Develop Full Power
Test 1. Check fuel system for leaks, damage or contamination.

• Refer to FUEL SYSTEM troubleshooting tests.
• If no problem is found, go to Test 2.
Test 2. Check air filter and intake tubing for damage or restrictions.
• If not damaged or restricted, go to Test 3.
• If damaged or restricted, repair or replace as needed. Refer to paragraphs 4-6 thru
4-9 in this manual.
Test 3. Check for brakes dragging.

• If brakes are not dragging, refer problem to Direct Support/Intermediate
• If brakes are dragging, refer to chapter 13 of this manual.
END OF TEST
2-107
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Low Engine Oil Pressure
Test 1. Check engine oil level on dipstick.

• If level is correct, go to Test 3.
• If level is not correct, drain or add oil as needed to correct level. Refer to LI
2320-12/9, LO 9-2320-297-12. Then go to Test 2.
Test 2. Check oil filter, oil lines and engine for leaks.
• If no leaks are found, go to Test 3.
• If leaks are found, repair or replace parts as needed.
• If beyond capabilities, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).
Test 3. Check oil pressure gauge and warning light circuits.

• Refer to ELECTRICAL SYSTEM troubleshooting in this manual.
NOTE
If malfunction is still present, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).
END OF TEST
6. High Oil Consumption
Test 1. Check engine for oil leaks.

• If leaks are found, repair or replace parts as needed.
• If beyond capabilities, refer problem to Direct Support, Third Echelon,
Maintenance.
Test 2. Check dipstick and tube for correct length and marking. Compare with known good
parts, if needed.
• If correct, go to Test 3.
• If not correct, repair or replace as needed. Refer to paragraph 3-6 in this manual.
Test 3. Check for engine overheating.

• If overheating, refer to COOLING SYSTEM troubleshooting in this manual.
NOTE
If malfunction still exists, refer problem to Direct Support, Third Echelon Maintenance.
2-108
TM 08780B-20
END OF TEST
GAUGE
2-109
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Engine Will Not Stop Running
WARNING
• DURING ENGINE OPERATION THE ENGINE AND RELATED PARTS CAN

BECOME VERY HOT. BE CAREFUL NOT TO TOUCH THESE PARTS WITH
YOUR BARE HANDS OR ALLOW YOUR BODY TO COME IN CONTACT WITH
THEM. ENGINE PARTS CAN BECOME HOT ENOUGH TO CAUSE SERIOUS
BURNS.
• TO PREVENT PERSONAL INJURY, ENGINE MUST BE SHUT DOWN BEFORE

STARTING TROUBLESHOOTING TESTS.
CAUTION
IF ENGINE IS RUNNING ABOVE ITS GOVERNED SPEED (2,250 RPM) AND
CLIMBING UNCONTROLLABLY, BLOCK THE AIR PASSAGES AT THE AIR CLEANER
INLET WITH MATERIAL THAT WILL SEAL OFF THE AIR PASSAGES. ALERT
DIRECT SUPPORT/INTERMEDIATE MAINTENANCE (THIRD ECHELON) THAT THE
ENGINE HAS BEEN SHUT DOWN IN THIS MANNER AND MAY REQUIRE REPAIR.
NOTE
If the engine is running at idle or within governed speed (2,250 rpm) perform the following
steps in order to shut down engine.
(1) Open engine access door and manually pull shut down solenoid linkage toward
solenoid as far as it will go.
(2) Tighten governor shaft nut and inspect shut down solenoid linkage for binding.
Pull shut down solenoid linkage toward solenoid as far as it will go.
(3) Back off nut on solenoid push rod closest to solenoid all the way and manually
pull shut down solenoid linkage toward solenoid.
(4) Disconnect fuel line at fuel/water separator’s primary fuel filter. This will cut
off the engine’s fuel supply and cause air to enter the system. Once the shut down problem
has been repaired the fuel system must be primed. If engine had to be shut down by removing
fuel line, send to Direct Support/Intermediate Maintenance (Third Echelon).
2-110
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-111
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 1. DO NOT START ENGINE. With the aid of an assistant, place engine stop switch in
the STOP position and watch for movement of shut down linkage.
• If movement of shut down linkage is noticed, adjust or repair shut down linkage.
Refer to paragraph 4-13 of this manual.
• If no movement is noticed, go to Test 2.
Test 2. With engine stop switch held down, check for 24 volts on wire 019 terminal of shut
down solenoid.
Test 3. Check shut down solenoid ground wire for good connection.
• If connection is good, replace solenoid. Refer to paragraph 4-13 in this manual.
• If connection is bad, repair or replace ground wire, as needed. Refer to paragraph
2-112
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. With engine stop switch held down, check for 24 volts on wire 019 terminal of engine
stop switch.
• If 24 volts are present, repair or replace wire 019 between switch and solenoid.
Test 5. Check for 24 volts on wire 096 terminal of engine stop switch.
• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are present, repair or replace wire 096 between circuit breaker and
switch.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, refer to ELECTRICAL SYSTEM troubleshooting,
Malfunction 3, in this manual.
END OF TEST
2-113
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. Excessive Black Or Gray Exhaust (Engine Temperature 160 Degrees F Or Above)
WARNING
TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, PULL OUT

AUXILIARY/STEERING SELECTOR VALVE BEFORE PERFORMING ANY
TROUBLESHOOTING TESTS.
Test 1. Check air restriction indicator on dash.

• If yellow, go to Test 2.
• If red, reset and start engine. Refer to TM 08780B-10. If still red, replace air
filter. Refer to paragraph 4-7 in this manual.
Test 2. Check for correct fuel in tanks.

• If fuel is correct, go to Test 3.
• If fuel is not correct, drain and refill tanks. Refer to paragraphs 4-10 and 4-11 in
this manual and TM 08780B-10.
Test 3. Check exhaust pipe and muffler for damage or obstructions.

• If no damage or obstructions are found, refer problem to Direct Support, Third
Echelon, Maintenance.
• If damage or obstructions are found, repair or replace parts as needed. Refer to
paragraph 5-3 in this manual.
END OF TEST
2-114
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Blue Exhaust Smoke (Engine Temperature 160 Degrees F or Above)
• Refer problem to Direct Support, Third Echelon, Maintenance.
10. White Exhaust Smoke (Engine Temperature 160 Degrees F or Above)
Check for correct fuel in tanks.

• If fuel is correct, refer problem to Direct Support, Third Echelon, Maintenance.
• If fuel is not correct, drain and refill tanks. Refer to paragraphs 4-10 and 4-11 in
this manual and TM 08780B-10.
END OF TEST
11. Oil Leakage from Exhaust Pipe or Breathers (Excessive Crankcase Pressure)
Test 1. Check for a restriction in the breathers.

• If a restriction is found, clean or replace. Refer to paragraph 3-4 in this manual.
• If no restriction is found, go to Test 2.
Test 2. Check for restricted or damaged exhaust pipe or muffler.

• If restriction or damage is found, repair or replace parts as needed. Refer to
• If no restriction or damage is found, refer problem to Direct Support, Third
Echelon, Maintenance.
END OF TEST
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FUEL SYSTEM
1. Engine Will Not Start Or Stalls
WARNING

• DO NOT SMOKE OR USE OPEN FLAME. FUEL IS FLAMMABLE AND MAY

EXPLODE. KEEP FIRE - EXTINGUISHER WITHIN REACH.
Test 1. Check fuel level in both the right fuel tank and the left fuel tank.
• If both fuel tanks have three inches (7.6 cm) or more of fuel, go to Test 6.
• If left fuel tank has fuel and right fuel tank does not, go to Test 3.
• If both fuel tanks are empty, go to Test 2.
Test 2. Inspect both fuel tanks for damage and/or leaks.

• If damage or leaks are found, repair or replace fuel tank(s) as needed. Refer to
paragraph 4-10 and 4-11 in this manual.
• If no damage or leaks are found, fill both fuel tanks and prime fuel system. Refer
to paragraph 2-13 (TM 08780B-10).
Test 3. Check fuel shutoff valve on crossover fuel line from left fuel tank.
• If shutoff valve is closed, open it and check for fuel flow to right fuel tank.
• If shutoff valve is open and fuel does not flow to right fuel tank, go to Test 4.
• If fuel flows, add fuel and prime fuel system. Refer to paragraph 2-13 (TM
08780B-10).
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Test 4. Close both fuel shutoff valves and disconnect crossover fuel line from right fuel tank.
• If fuel flows through fuel line when left shutoff valve is opened, repair or replace
right fuel tank as needed. Refer to paragraph 4-10 and 4-11 in this manual.
• If fuel does not flow through fuel line when left shutoff valve is opened, go to
Test 5.
Test 5. Make sure that both fuel shutoff valves are closed and disconnect crossover fuel line
from left fuel tank.
• If fuel flows when left shut off valve is opened, repair or replace crossover fuel
line.
• If fuel does not flow, repair or replace left fuel shutoff valve and left fuel tank as
needed. Refer to paragraph 4-10 or 4-11 in this manual.
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Test 6. Check T-handle on top of fuel/water separator for fuel/air leaks.

• If fuel/air leak is found, tighten T-handle and/or replace 0-rings as needed. Refer
to paragraph 4-20 in this manual.
• If no air leak is found, go to Test 7.
Test 7. Check fuel/water separator bowl for contamination, leaks or damage.

• If contamination or damage is found, service, repair or replace fuel/water
separator as needed. Refer to paragraph 4-18 in this manual.
• If contamination or damage is not found, go to Test 8.
Test 8. Check fuel lines for loose connections, leaks and damage.
• If lines are loose, leaking or damaged, repair or replace as needed. Refer to
• If lines are not loose, leaking or damaged, go to Test 9.
Test 9. Check secondary fuel filter for leaks or damage.

• If leaking or damaged, tighten or replace secondary fuel filter as needed. Refer to
• If no leaks or damage are found, go to Test 10.
NOTE
Hand priming pump must be locked in closed position when not priming fuel system.
Test 10. Check hand priming pump for leaks and damage.
• If leaking or damaged, repair or replace as needed. Refer to paragraph 4-5 in this
manual.
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Test 11. Check for a fuel/air leak between primary filter inlet and fuel tank.
• If a fuel/air leak is found, tighten, repair or replace fuel line or fittings as needed.
• If no fuel/air leak is found, go to Test 12.
Test 12. Check primary filter seal ring for leaks or damage.
• If seal ring is leaking or damaged, replace it. Refer to paragraph 4-18 in this
manual.
• If seal ring is not leaking or damaged, go to Test 13.
Test 13. Check for cracked fuel standpipe in right fuel tank.
• If cracked, replace fuel standpipe. Refer to paragraphs 4-10 and 4-11 in this
manual.
• If not cracked, go to Test 14.
Test 14. Check drain valve for looseness and/or damaged seal ring.
• If drain valve is loose or seal ring is damaged, tighten valve or replace seal ring as
needed. Refer to paragraph 4-18 in this manual.
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Test 15. Check operation of fuel check valve on right fuel tank.
• If not operating properly, replace it. Refer to paragraph 4-12 in this manual.
• If operating properly, go to ENGINE troubleshooting in this chapter.
END OF TEST
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2. Engine Does Not Start When Ether Starting Aid Is Used In Cold Weather
WARNING

• DO NOT SMOKE OR USE OPEN FLAME. FUEL IS FLAMMABLE AND MAY

EXPLODE. KEEP FIRE EXTINGUISHER WITHIN REACH.
NOTE
Coolant temperature must be below 70 degrees F ± 10 degrees F (21 degrees C ± 5 degrees C)
before ether starting aid will work.
Test 1. Check ether supply cylinder.

• If cylinder is loose or empty, tighten or replace as needed. Refer to paragraph
• If not loose or empty, go to Test 2.
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Test 2. Check tubing between ether supply cylinder and engine for damage.
• If damaged, replace. Refer to paragraph 4-22 in this manual.
• If not damaged, go to Test 3.
Test 3. Check ether injector valve for damage.

• If not damaged and problem still exists, go to ELECTRICAL troubleshooting in
this chapter.
END OF TEST
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EXHAUST SYSTEM
Exhaust Noisy
WARNING
TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE

THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.
Test 1. Check muffler and exhaust pipes for damage and loose connections.
• If damaged or loose, repair or replace as needed. Refer to paragraph 5-3 in this
manual.
• If not damaged or loose, go to Test 2.
Test 2. Check exhaust manifolds for damage or leaks.

• If damaged or leaking, repair or replace as needed. Refer to paragraph 3-7 in this
manual.
END OF TEST
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COOLING SYSTEM
Engine Overheats
WARNING

• TO PREVENT PERSONAL INJURY, ALLOW ENGINE TO COOL TO ROOM

TEMPERATURE BEFORE OPENING COOLING SYSTEM.
Test 1. Remove radiator cap and check coolant level.

• Add coolant if needed. Refer to paragraph 6-3 in this manual.
• If no coolant is needed, go to Test 2.
Test 2. Check inside of radiator for scale or other deposits.

• If needed, flush and refill cooling system. Refer to paragraph 6-3 in this manual.
• If flushing is not needed, go to Test 3.
Test 3. Check coolant hoses and water pump for damage and/or leaks.
• If damaged or leaking, repair or replace as needed. Refer to paragraph 6-7 in this
manual for hoses. If leakage is detected at water pump, notify Direct
Support/Intermediate Maintenance (Third Echelon).
• If no damage or leaks are found, go to Test 4.
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Test 4. Check radiator for leaks or damage.

• If damaged or leaking, notify Direct Support, Third Echelon, Maintenance.
• If no leak or damage is found, go to Test 5.
Test 5. Check cooling fan blades and shroud for damage.

• If damaged, notify Direct Support, Third Echelon, Maintenance.
• If no damage is found, go to Test 6.
Test 6. Check that fan motor is coming on when coolant temperature exceeds 180 degrees F
(83 degrees C).
• If fan does not come on, refer to HYDRAULIC and ELECTRICAL
troubleshooting as needed.
• If fan does come on, go to Test 7.
Test 7. Remove thermostats (left and right) from engine. Refer to paragraph 6-6 in this
manual. Test thermostats as follows:
a. Suspend thermostats in a container of water so that they do not touch the sides
or bottom of the container.
b. Heat water. Thermostats should begin to open at 160 degrees F (79 degrees C)
and should be fully open at 180 degrees F (83 degrees C).
• If thermostats test good, reinstall them. If problem still exists, refer to the
HYDRAULIC and ELECTRICAL troubleshooting sections.
END OF TEST
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ELECTRICAL SYSTEM
NOTE
• System voltage (22 to 30 volts) will be written as 24 volts in this section of the manual.
• If available, perform STE/ICE tests first.
1. Batteries Fail to Maintain Charge or Discharge Rapidly
WARNING

Test 1. Check for loose connections and/or corroded battery terminals.
• If needed, service batteries. Refer to paragraph 7-45.
• If no service is needed, go to Test 2.
Test 2. Disconnect battery cables to isolate batteries. Refer to paragraph 7-45. Test each
battery separately.
NOTE
Batteries must be fully charged prior to testing. If batteries are not charged, they will indicate
a failure.
Fixed Load Test
a. Attach tester clamps to battery terminals -negative clamp to negative terminal,

positive clamp to positive terminal.
b. Apply a load of 312 ampheres to battery for 15 seconds.
c. Read voltage indicator at the end of 15 seconds.
d. Use chart to determine battery condition.
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VOLTAGE CHART
ESTIMATED MINIMUM REQUIRED VOLTAGE
TEMPERATURE UNDER 15 SEC. LOAD
70°F (21°C) & ABOVE 9.6
60°F (16°C) 9.5
50°F (10°C) 9.4
40°F (4°C) 9.3
30°F (-1°C) 9.1
20°F (-7°C) 8.9
10°F (-12°C) 8.7
0°F (-18°C) 8.5
• If voltage reading is equal to or more than minimum from chart, return the battery
to service, then go to Test 3.
• If voltage reading is less than minimum from chart, go to OPEN CIRCUIT
VOLTAGE TEST.
Open Circuit Voltage Test
a. Allow 10 minutes for battery voltage to stabilize after load test.
b Read voltage.
• If reading is 12.4 volts or above, but did not pass load test, replace battery.
• If reading is below 12.4 volts, charge battery and repeat load test. If battery
fails load test after charging, replace battery.
Reconnect batteries. Refer to paragraph 7-45 or paragraph 7-46 (MK48A1 series

vehicles only).
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Test 3. Start engine. Refer to paragraph 2-13 (TM 08780B-10). Check charging system
voltage at battery terminal posts (wires 138 and 139).
• If reading is 27.8 to 29.1 volts, go to Test 4.
• If reading is not 27.8 to 29.1 volts, go to Malfunction 2 in this section.
Test 4. Check for electrical draw. Turn off ALL electrical accessories. Disconnect negative
battery cable (wire 138) and STE/ICE wires (813 and 821). Leave wire (137) on
negative terminal and install nut. Connect a DC ampmeter (capable of reading 0.1
ampheres) between wires (138, 813 and 821) and negative battery terminal,
• If current draw is less than 0.1 ampere, no leakage is present.
• If current draw is 0.1 ampere or more, go to Test 5.
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Test 5. With DC ampmeter still connected (Test 4), disconnect wires from circuit breakers
one at a time. When current draw drops to less than 0.1 ampheres, repair affected
circuit(s) as needed.
Connect negative battery cable (wire 138) and STE/ICE wires (813 and 821).
Tighten nut to 15 foot-pounds (20.3 N*m).
END OF TEST
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2. Charging System Does Not Operate
WARNING

• TO PREVENT PERSONAL INJURY, ENGINE MUST BE COOL (ROOM

TEMPERATURE) BEFORE STARTING THIS PROCEDURE. RUN ENGINE
ONLY LONG ENOUGH TO TAKE VOLTAGE READINGS. EXHAUST PARTS
CAN BECOME HOT ENOUGH TO CAUSE SERIOUS BURNS.
NOTE
Batteries must be fully charged before beginning testing.
Test 1. With ignition switch OFF, check for 24 volts (battery voltage) on the positive wire
278/820 and negative wire 128/815 output terminals on the back of the alternator.
• If 24 volts are present, record reading and go to Test 6.
CAUTION
TO PREVENT EQUIPMENT DAMAGE, DISCONNECT NEGATIVE BATTERY CABLE

NO. 138 BEFORE GOING TO TEST 2.
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Test 2. Connect positive lead of voltmeter to positive wire 278 on output terminal on
alternator. Connect negative lead to ground. Check for 24 volts.
Test 3. Check for 24 volts on wire 278 at output side of circuit breaker number 14.
• If 24 volts are present, repair wire 278 from circuit breaker number 14 to
alternator.
NOTE
If circuit breaker number 14 shorts upon installation, replace diode at circuit breaker number
14.
Test 4. Check for 24 volts on wire 833 of input side of circuit breaker number 14.
• If 24 volts are present, replace circuit breaker number 14.
• If 24 volts are not present, repair or replace wire 833 from circuit breaker number
14 to batteries.
Test 5. Check for continuity between negative terminal wire 128 on alternator to ground.
• If continuity is not found, repair or replace wire 128 between alternator and
starter.
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Test 6. By-pass voltage regulator as follows:
a. Remove four capscrews and rear cover plate from alternator.
b. Insert a paper clip or small wire into brush access hole.
c. Connect a jumper lead from the paper clip to the negative output terminal.
d. Connect multimeter to positive and negative output terminals.
e. Reconnect negative battery cable No. 138.
f. Make sure all electrical accessories are OFF.
g. Start engine and run at 1,200-1,500 rpm. Refer to paragraph 2-13 (TM 08780B-
10).
h. Record multimeter reading and shut down engine.
• If voltage reading is lower or the same as in Test 1, replace alternator. Refer

• If voltage reading is higher, replace voltage regulator. Refer to paragraph 7-5

in this manual.
Test 7. Remove jumper lead, start engine and run at 1,200-1,500 rpm. Check output voltage.
• If voltage reading is lower than 27.8 volts or higher than 29.1 volts, replace
voltage regulator. Refer to paragraph 7-5 in this manual.
END OF TEST
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3. Electrical Systems Do Not Work
WARNING

Test 1. Check battery cable (wires 138 and 139) for loose connections and/or corrosion.
• If connections are good, go to Test 2.
• If connections are not good, clean and tighten as needed. Torque nuts to 15 foot-
pounds (20.3 N*m).
Test 2. Take a voltage reading across battery cables (wires 138 and 139).
• If voltage is 22 volts or above, go to Test 3.
• If voltage is below 22 volts, go to Malfunction 1.
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Test 3. Check for 24 volts on cable (wire 139) at starter solenoid.

• If 24 volts are not present, repair or replace cable (wire 139) or connectors as
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Test 4. Check for 24 volts on wire 046 of starter relay.

• If 24 volts are not present, repair or replace wire 046. Refer to paragraph 7-48 in
this manual.
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Test 5. Check for 24 volts on input terminal (wire 430) of circuit breaker No. 5.
this manual. Check quick disconnects in engine compartment.
END OF TEST
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4. Electrical Gauges Do Not Work
WARNING

NOTE
• Ignition switch must be in ON position for all voltage tests.
• If only one gauge does not work and vehicle is an LVSA1 series vehicle, go to Test 12.
• If only one gauge does not work and vehicle is a non-A1 series vehicle, go to Test 11.
• If all gauges do not work, go to Test 1.
Test 1. Check for 24 volts on wire 076 at circuit breaker No. 8.

Test 2. Check for 24 volts on input terminal wire 735 of circuit breaker No. 8.
manual.
Test 3. Check for 24 volts on wire 735 at ignition switch relay.

• If 24 volts are present, repair or replace wire 735 between relay and circuit
breaker. Refer to paragraph 7-48 in this manual.
Test 4. Check for 24 volts on wire 075 of ignition switch relay.

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Test 5. Check for 24 volts on wire 075 of ignition switch.

• If 24 volts are present, repair or replace wire 075 from ignition switch to relay
No.2.
Test 6. Check for 24 volts at wire 431 on ignition switch.

• If 24 volts are present, replace ignition switch.
Test 7. Check for 24 volts on wire 431 of circuit breaker number 5.

• If 24 volts are present, repair or replace wire 431 from circuit breaker number 5 to
ignition switch.
• If 24 volts are not present, go to ELECTRIC SYSTEM; Malfunction No. 3.
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Test 8. Check for 24 volts on wire 736 at relay No. 2.

Test 9. Check wire 435 at relay No. 2 for continuity to ground.

• If continuity is found, replace relay No. 2.
• If continuity is not found, repair or replace wire 435 from relay No. 2 to ground.
• If 24 volts are present repair or replace wire 736 from circuit breaker No. 6 and
relay No. 2.
• If 24 volts are not present, go to Malfunction No. 3.
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Test 11. Check for 24 volts on any wire 076 of terminal board. (All wires at terminal board
are marked 076).
• If 24 volts are not present, repair or replace wire 076 between terminal board and
circuit breaker No. 8. Refer to paragraph 7-48 in this manual.
Test 12. Disconnect wire from sending unit of the non-working gauge. Connect that wire to
ground.
• If gauge reads full scale, replace sending unit. Refer to paragraph 7-39 in this
manual.
• If gauge does not read full scale, go to Test 13.
Test 13. Using a jumper, connect sending unit terminal of gauge to a ground.
• If gauge reads full scale, repair or replace sending unit wire between gauge and
sending unit. Refer to paragraph 7-48 in this manual.
• If gauge does not read full scale, go to Test 14.
Test 14. Check for 24 volts on wire 076 at rear of gauge.

• If 24 volts are present, replace gauge. Refer to paragraph 7-20 in this manual.
• If 24 volts are not present and vehicle is an LVSA1 series vehicle, repair or
replace wire 076 between circuit breaker No. 8 and gauge. Refer to paragraph 7-
48 in this manual.
• If 24 volts are not present and vehicle is a non-A1 series vehicle, go to Test 15.
Test 15. Check for 24 volts on wire 076 of the non-working gauge at the terminal board.
• If 24 volts are present, repair or replace wire 076 between terminal board and
gauge.
END OF TEST
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5. Ether Starting Aid Does Not Work
WARNING

NOTE
• Engine coolant temperature must be below 70 degrees F ± 10 degrees F (21 degrees C
± 5 degrees C) for system to work.
Test-1. Check ether supply bottle.

• If empty, replace supply bottle. Refer to paragraph 4-22 in this manual.
• If not empty, go to Test 2.
Test 2. Disconnect wire 036 plug at ether solenoid. Check for 24 volts on wire 036 (male pin
No. 2 at harness) while ether switch is ON.
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Test 3. Check for continuity between pin one of wire 036 at ether start solenoid harness plug
and wire 036 at temperature sending unit.
• If continuity is not found, go to Test 4.
Test 4. Check for continuity between pin one on wire 036 at ether start solenoid harness plug
and pin one at plug connector from main harness.
• If continuity is found, replace wire 036 from temperature sending unit to plug
connector.
• If continuity is not found, replace wire 036 from plug connector to connector at
ether start solenoid.
Test 5. Check ether temperature sending unit for continuity. Reading should be 0 ohms
below 70 degrees F ± 10 degrees F (21 degrees C ± 5 degrees C).
• If reading is 0 ohms, go to Test 6.
• If reading is not 0 ohms, replace sending unit. Refer to paragraph 7-39 in this
manual.
Test 6. Check for 0 ohms reading between ground and ground wire 036 at sending unit.
• If reading is 0 ohms, replace solenoid. Refer to paragraph 421 in this manual.
• If reading is not 0 ohms, repair or replace wire 036. Refer to paragraph 7-48 in
this manual.
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NOTE
Input and output terminals are not marked on switch. Wire 036 is connected to both
terminals. Voltage will only be found on input terminal when the button is not pressed on.
Test 7. With ether switch ON, check for 24 volts on wire 036 at output terminal of ether
switch.
• If 24 volts are present, repair or replace wire 036 between switch and plug at
solenoid. Refer to paragraph 7-48 in this manual.
Test 8. Check for 24 volts on input terminal of ether switch wire 036.
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• If 24 volts are present, repair or replace wire 036 between switch and circuit
Test 10. Check for 24 volts on wire 640 at input terminal of circuit breaker No. 11.
manual.
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Test 11. Check for 24 volts on wire 640 at ignition switch.

circuit breaker. Refer to paragraph 7-48 in this manual.

Test 13. Check for 24 volts on wire 431 on input side of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 431 from circuit breaker No. 5 to
ignition switch.
• If 24 volts are not present go to ELECTRICAL SYSTEM, Malfunction No. 3.
END OF TEST
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6. Engine Brake Does Not Operate
WARNING

Test 1. Check for loose or broken wires and/or connections.

• If damaged wires are found, repair as needed. Refer to paragraph 7-48 in this
manual.
NOTE
Ignition switch must be in ON position for all voltage tests.
Test 2. Turn ignition switch and engine brake switch ON. Check engine brake indicator
light.
• If light is on, go to Test 4.
• If light is not on, go to Test 3.
Test 3. Remove indicator light bulb, refer to paragraph 7-29 in this manual. Check for 24
volts on center terminal of bulb socket.
• If 24 volts are present, replace bulb and go to Test 5.
Test 4. Turn engine brake switch on. Check for 24 volts on wire 713 at ON/OFF switch.
• If 24 volts are present, repair or replace wire 713 from ON/OFF switch to engine
brake indicator light.
• If 24 volts are not present go to Test 9.
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Test 5. Start engine. Refer to paragraph 2-13 (TM 08780B-10). Turn engine brake switch
ON. Open engine cover and check for 24 volts on wire 713 of buffer switch when
engine rpm is above 1,800.
• If 24 volts are not present, go to Test 6. Shut down engine.
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Test 6. Turn engine brake switch ON. Check for 24 volts on input side of transmission
lockup switch, wire 713.
Test 7. Turn engine brake switch ON. By-pass the transmission lockup switch with a jumper
lead. Check for 24 volts on wire 713 of buffer switch.
• If 24 volts are present, replace transmission lockup switch. Refer to paragraph
8-8 in this manual.
• If 24 volts are not present, repair or replace wire 713 between lockup switch and
buffer switch. Refer to paragraph 7-48 in this manual.
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Test 8. Turn engine brake switch ON. Check for 24 volts on wire 713 terminal of ON/OFF
switch.
• If 24 volts are present, repair or replace wire 713 between lockup switch and
ON/OFF switch. Refer to paragraph 7-48 in this manual.
Test 9. Check for 24 volts on wire 712 terminal of ON/OFF switch.

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ON/OFF switch. Refer to paragraph 7-48 in this manual.
Test 11. Check for 24 volts on input side of circuit breaker No. 9.
manual.
• If 24 volts are not present, go to Malfunction 4, Test 2. Follow the
troubleshooting test in Malfunction 4 until problem is solved.
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Test 12. Start engine. Refer to paragraph 2-13 (TM 08780B-10). Turn engine brake switch
ON. Accelerate engine to full rpm and release throttle quickly. Check for 24 volts on
wire 714 terminal of buffer switch during deceleration. Voltage will be present only
during deceleration.
• If 24 volts are not present, notify Direct Support/Intermediate Maintenance (Third
Echelon).
Test 13. With engine running and brake switch ON, manually engage buffer switch. Check
for 24 volts on wire 839 of governor lockup solenoid valve.
• If 24 volts are present, check solenoid valve coil for opens, shorts or grounds.
Check valve movement. Replace if needed. Refer to paragraph 8-9 in this
manual. Go to Test 14.
• If 24 volts are not present, repair or replace wire 839 between buffer switch and
solenoid valve. Refer to paragraph 7-48 in this manual.
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CORRECTIVE ACTION
Test 14. With engine running and brake switch ON, accelerate engine to full rpm and release
throttle quickly. Check for 24 volts on wire 714 terminal of engine brake HI/LOW
switch. Voltage will be present only during deceleration.
• If 24 volts are not present, repair or replace wire 714 between buffer switch and
HI/LOW switch. Refer to paragraph 7-48 in this manual.
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CORRECTIVE ACTION
Test 15. With engine running and brake switch ON, accelerate engine to full rpm and release
throttle quickly. Check for 24 volts on wire 716 at connector for right cylinder bank,
voltage will be present only during deceleration.
• If 24 volts are present, go to step 16.
• If 24 volts are not present, repair or replace wire 716 between connector and
Test 16. With engine running, brake switch ON and HI/LOW switch in HI position, accelerate
engine to full rpm and release throttle quickly. Check for 24 volts on wire 715 at
connector for left cylinder bank. Voltage will be present only during deceleration.
• If 24 volts are present, refer problem to Direct Support, Third Echelon,
Maintenance.
• If 24 volts are not present, repair or replace wire 715 between connector and
END OF TEST
2-162
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TEST OR INSPECTION
CORRECTIVE ACTION
7. Engine HI Idle Does Not Work
WARNING

NOTE
• Make sure auxiliary/steering valve is in the auxiliary position. Make sure winch
control switch is depressed and held in either in or out position.
• Do NOT disconnect plugs unless told to do so in the test.
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.
2-163
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 1. Using a sharp probe, check for 24 volts on wire 592 at HI idle solenoid on
transmission.
Test 2. Check ground wire from HI idle solenoid for good connection to ground.
• If ground is bad, clean contact point or repair ground wire.
• If ground is good, replace HI idle solenoid. Refer to paragraph 7-27 in this
manual.
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Check both sides of connector MC13 for 24 volts on wire 592 (pin x).
• If 24 volts are present on both sides of connector MC13, repair or replace wire
592 between connector MC13 and Hi idle solenoid. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of connector MC13 and not on the other side,
clean, repair or replace connector MC13 as needed. Refer to paragraph 7-48 in
this manual.
2-165
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Check both sides of connector MC6 for 24 volts on wire 592 (pin 18).
• If 24 volts are present on both sides of connector MC6, repair or replace wire 592
between connectors MC13 and MC6. Refer to paragraph 7-48 in this manual.
clean, repair or replace connector MC6 as needed. Refer to paragraph 7-48 in this
manual.
2-166
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Check for 24 volts on wire 592 terminal at relay No. 5.

• If 24 volts are present, repair or replace wire No. 592 between relay No. 5 and
connector MC6. Refer to paragraph 7-48 in this manual.
Test 6. Check for 24 volts on wire 516 terminal at relay No. 5.


• If 24 volts are not present, repair wire 838 between relay No. 5 and relay No. 8.
Test 8. Connect a jumper wire to wire 843 terminal on relay No. 5 to ground. Check for 24
volts at wire 592 at relay No. 5.
• If 24 volts are present, go to Malfunction 25, Test 5.
• If 24 volts are not present, replace relay No. 5. Refer to paragraph 7-28 in this
manual.
2-167
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CORRECTIVE ACTION
between connector MC6 and relay No. 5. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of connector MC6 and not on other side, clean,
repair or replace connector MC6 as needed. Refer to paragraph 7-48 in this
manual.
2-168
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Check both sides of connector MC18 for 24 volts on wire 516 (pin F).
516 between connector MC6 and connector MC18. Refer to paragraph 7-48 in
this manual.
this manual.
NOTE
For MK15, go to Test 13. For MK16, continue with Test 11.
Test 11. Check both sides of connector MC19 for 24 volts on wire 516 (pin D).
516 between connectors MC18 and MC19. Refer to paragraph 7-48 in this
manual.
this manual.
2-169
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 12. Check for 24 volts on wire 516 at diodes.

• If 24 volts are present, repair or replace wire 516 between diodes and connector
MC19. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, replace diodes. Refer to paragraph 19-4 in this manual.
2-170
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CORRECTIVE ACTION
Test 13. Check for 24 volts on both sides of connector MC20 at wire 516 (pin C).
• If 24 volts are present, repair or replace wire 516 between connector MC20 and
connector MC18.
Test 14. Open cover on junction box and check for 24 volts at terminal No. 3 on terminal
board No. 1.
• If 24 volts are present, repair or replace green wire between crane connector
MC20 (pin C) and terminal No. 3 on terminal board No. 1. Refer to paragraph 7-
48 in this manual.
2-171
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 15. Unplug connector at high idle wire harness leading from the solenoid dump valve.
Check for 24 volts on the male connector leading to the solenoid dump valve. Plug
connectors together.
• If 24 volts are not present, repair or replace wire between male connector and
solenoid dump valve. Refer to paragraph 7-48 in this manual.
Test 16. Open junction box cover and check for 24 volts on terminal No. 2 of terminal board
No. 1.
• If 24 volts are not present, repair or replace green wire between female connector
and terminal No. 2. Refer to paragraph 7-48 in this manual.
Test 17. Pull boot back at neutral switch on winch main control valve. Check for 24 volts on
white wire.
• If 24 volts are not present, repair or replace white wire between terminal No. 2
and neutral switch. Refer to paragraph 7-48 in this manual.
Test 18. Check for 24 volts on black wire at neutral switch in winch main control valve.
• If 24 volts are present, install boot and go to Test 19.
• If 24 volts are not present, replace neutral switch. Refer to paragraph 20-8 in this
manual.
2-172
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 19. Check for 24 volts at terminal No. 3 on terminal board No. 1.
• If 24 volts are not present, repair or replace black wire between neutral switch and
terminal No. 3 on terminal board No. 1.
Test 20. Unplug connector MC20 at crane wire harness. Check for 24 volts on pin C on crane
harness.
• If 24 volts are not available, repair or replace green wire between terminal No. 3
and pin C of crane connector.
END OF TEST
2-173
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. Air Pressure Warning Light and/or Buzzer Do Not Work
WARNING

NOTE
• Air system pressure must be below 65 psi.
Test 1. Remove bulb and check for 24 volts on center terminal of light socket.
• If 24 volts are present, replace bulb. Refer to paragraph 7-29 in this manual, then
go to Test 2.
2-174
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check wires 120 on low pressure switches for looseness.

• If wires 120 are tight, go to Test 3.
• If wires 120 are loose, tighten them.
NOTE
Disconnect wire 032 from terminal No. 4 on buzzer. This will remove low oil/high
temperature circuit from buzzer.
Test 3. Turn ignition switch to ON, remove wire 120 from top low pressure switch and touch
it to ground.
• If light and/or buzzer work, replace both low pressure switches. Refer to
• If light and/or buzzer do not work, go to Test 4.
Test 4. Turn ignition switch to ON and, using a jumper, connect terminal No. 5 of buzzer to
ground.
• If light and/or buzzer work, repair or replace wire 120 between buzzer and low
pressure switches. Refer to paragraph 7-48 in this manual.
• If light and/or buzzer do not work, go to Test 5.
Test 5. Check for 24 volts on terminal No. 7 of buzzer.
2-175
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check for 24 volts on circuit breaker No. 8 terminal for wire 079.
• If 24 volts are present, repair or replace wire 079 between buzzer and circuit
Test 7. Check for 24 volts on input terminal of circuit breaker No. 8.
manual.
Test 8. Check for 24 volts on wire 735 of ignition switch relay.
• If 24 volts are present, repair or replace wire 735 between relay and circuit
• If 24 volts are not present, refer to Malfunction No. 4, Test 2 of ELECTRICAL
troubleshooting.
2-176
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CORRECTIVE ACTION
Test 9. Check for 24 volts on terminal No. 2 of buzzer.

• If 24 volts are present, replace buzzer. Refer to paragraph 7-39 in this manual.
• If 24 volts are not present, repair or replace wires 076 or 120 between buzzer and
warning light. Refer to paragraph 7-48 in this manual.
END OF TEST
2-177
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Air Pressure Warning Light and/or Buzzer Do Not Work When Only One System Drops
Below 65 Psi
WARNING

NOTE
• Ignition switch must be in the ON position for all voltage tests.
• Air system pressure must be below 65 psi (448 kPa) in both systems.
Test 1. Remove wires No. 120 from sending unit. Touch wire one at a time to ground.
• If buzzer and/or light works with both wires were grounded, go to Test 2.
• If buzzer and/or light does not work when both wires were grounded, repair or
replace defective wire between low air pressure switch and terminal 120 on
buzzer and/or light that did not work.
Test 2. Connect either wire 120 to each sending unit one at a time.
• If buzzer and/or light work, sending unit is good.
• If buzzer and/or light does not work, replace sending unit. Refer to paragraph 13-
14 in this manual.
END OF TEST
2-178
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TEST OR INSPECTION
CORRECTIVE ACTION
2-179
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. Turn Signal Indicator or One or More Turn Signals Do Not Work
WARNING

NOTE
• If turn signal indicators do not work but turn signals do work, go to Test 16.
• Master light switch must be in either the STOPLIGHT position or the SERVICE
DRIVE position. Turn signal switch must be in left or right turn position, as needed.
Test 1. Check all affected turn signal bulb filaments.

• If filaments are broken, replace bulb(s) as needed. Refer to paragraphs 7-34 and
• If filaments are not broken, go to Test 2.
2-180
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TEST OR INSPECTION
CORRECTIVE ACTION
2-181
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check for flashing 24 volts reading on center contact of affected turn signal bulb
sockets.
• If 24 volts are present, try a new bulb in the socket and check ground for that
socket. If still not working, replace composite light assembly. Refer to paragraph
7-34 or 7-36 in this manual as needed.
Test 3. Unplug affected composite light turn signal wire (front, 001/460, 002/461), (rear,
003/22, 004/22).
• If 24 volts are present, repair or replace composite light plug. Refer to paragraph
7-48 in this manual. Or replace composite light. Refer to paragraph 7-34 or 7-36
in this manual as needed.
• If 24 volts are not present for rear turn signals, go to Test 4.
• If 24 volts are not present for front turn signals, go to Test 6.
2-182
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. For rear turn signals, check for flashing 24 volts on wires 003/22 (pin C) and 004/22
(pin A) on both sides of connector MC18.
• If 24 volts are present on one side and not on the other, clean, repair or replace
connector MC18 as needed. Refer to paragraph 7-48 in this manual.
003/22 or 004/22 as needed. Refer to paragraph 7-48 in this manual.
2-183
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. For rear turn signals, check for flashing 24 volts on wires 003/22 (pin 6) and 004/22
(pin 4) on both sides of connector MC4.
• If 24 volts are present on one side and not on the other, clean, repair or replace
connector MC4 as needed. Refer to paragraph 7-48 in this manual.
003/22 or 004/22 between connector MC4 and connector MC18 as needed. Refer
2-184
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
LVSA1 series vehicles have a new style turn signal switch and flasher module. It will be
necessary to remove turn signal switch from steering wheel post to gain access to pierce wire
insulation at the back of MC28.
Test 6. For front turn signals, check for flashing 24 volts at turn signal switch on wires 001
and 002.
• If 24 volts are present, repair or replace wires as needed. Refer to paragraph 7-48
in this manual.
2-185
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If 24 volts are not present, go to Malfunction 3, Tests 1 thru 5.
Test 8. Remove connector from rear of Master light switch. Check for 24 volts on pin F of
wiring harness plug.
• If 24 volts are not present, repair or replace wire 674 between circuit breaker No.
6 and Master light switch. Refer to paragraph 7-48 in this manual.
2-186
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Make sure Master light switch is in SERVICE DRIVE or STOPLIGHT position.
Using an ohmmeter, check for continuity between pin F and pin J on blackout light
switch.
• If no continuity is found, replace Master light switch. Refer to paragraph 7-24 in
this manual.
• If continuity is found, go to test 10.
2-187
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Reconnect connector to Master light switch. Check for 24 volts on wire 080 terminal
of circuit breaker No. 1.
• If 24 volts are not present, repair or replace wire 080 between Master light switch
and circuit breaker No. 1. Refer to paragraph 7-48 in this manual.
Test 11. Check for 24 volts on wire 837/080 terminal of circuit breaker No. 1.
• If 24 volts are not present, replace circuit breaker No. 1. Refer to paragraph 7-14
in this manual.
2-188
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TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
When working on LVSA1 series vehicles, skip Tests 12 through 15. Perform Tests 15.1
through 15.5 for LVSA1 series vehicles only.
Test 12. Remove instrument panel screws and tilt panel outward against steering wheel.
Check for 24 volts on wire 080 at turn signal flasher.
• If 24 volts are not present, repair or replace wire 080 between turn signal flasher
and circuit breaker No. 1. Refer to paragraph 7-48 in this manual.
Test 13. Check for flashing 24 volts on output side of turn signal flasher.
• If 24 volts are not present and flasher is an old style, replace turn signal flasher.
• If 24 volts are not present and flasher is a new style, check ground wire for
continuity and proper ground connection. If OK, replace signal flasher. Refer to
2-189
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 14. Check for flashing 24 volts on wires 001, 002, 003 and/or 004 where they come out
of the turn signal switch.
• If 24 volts are not present, replace turn signal switch. Refer to paragraph 7-17 in
this manual.
Test 15. Check for flashing 24 volts at plugs where turn signal switch wires plug into wiring
harness.
• If 24 volts are not present on both sides of plug, repair or replace wires as needed.
2-190
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 15.1. Remove clamp and turn signal switch and disconnect connector MC28. Check for 24
volts on wire 080 (terminal G) on both sides of harness connector MC28.
• If 24 volts are present on one side of connector and not on other, clean, repair or
replace connector MC28, as required. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC28, reconnect connector
MC28 and go to Test 15.2.
• If 24 volts are not present, repair or replace wire 080 between MC28 and blackout
light switch. Refer to paragraph 7-48 in this manual.
2-191
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 15.2. Remove harness connector MC29 at turn signal flasher unit. Position turn signal
switch to activate four way flashers. Check for 24 volts at wire 080 (terminal B) on
both sides of harness connector MC29.
• If 24 volts are present on one side of connector and not on other, clean, repair or
replace connector MC29, as required. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC29, go to Test 15.4.
• If 24 volts are not present, go to Test 15.3.
2-192
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 15.3. Check for continuity of wire 080 between MC28 and MC29, terminals F and B.
• If no continuity is found, repair or replace wire 080 or connectors. Refer to
• If continuity is found, replace turn signal switch. Refer to paragraph 7-18 in this
manual.
2-193
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 15.4. Check for continuity of flasher wire between MC28 and MC29, terminals H and A.
• If no continuity is found, repair or replace flasher wire or connectors. Refer to
• If continuity is found, go to Test 15.5.
Test 15.5. Check for flashing 24 volts on flasher wire.

If 24 volts are not present, check flasher ground wire for continuity and proper
ground connection. If OK, replace turn signal flasher. Refer to paragraph 7-18 in
this manual.
2-194
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 16. Check affected indicator bulb filaments.

• If filaments are broken, replace bulb(s) as needed. Refer to paragraph 7-35 in this
manual.
Test 17. Check for flashing 24 volts on center contact of affected indicator bulb sockets.
socket. If still not working, replace indicator light socket.
Test 18. Check for 24 volts on both sides of instrument harness plug, wires 001 and 002 (pin
A and pin B).
• If 24 volts are present on both sides of plug, repair or replace wires as needed
between plug and bulb sockets. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of the plug and not on the other, repair or
replace plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wires as needed between instrument
panel plug and turn signal switch. Refer to paragraph 7-48 in this manual.
END OF TEST
2-195
TM 08780B-20
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TEST OR INSPECTION
CORRECTIVE ACTION
11. Brakelights Do Not Work
WARNING

NOTE
• Master light switch must be in STOPLIGHT or SERVICE DRIVE position.
• Air system pressure must be between 60 and 120 psi.
• Brake treadle valve must be applied.
• Hand trailer brake valve in OFF position unless stated in test procedure.
Test 1. Check brake light bulb filaments.

• If filaments are broken, replace bulb(s) as needed. Refer to paragraph 7-36 in this
manual.
Test 2. With bulbs removed, check for 24 volts on center contacts of brake light bulb sockets.
Test 3. Check for proper grounding of light socket.

• If ground is bad, clean, repair or replace as needed. Refer to paragraph 7-36 in
this manual.
• If ground is good, replace composite light assembly. Refer to paragraph 7-36 in
this manual.
2-196
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TEST OR INSPECTION
CORRECTIVE ACTION
2-197
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TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
• Unless told to do so in the test being done, do not disconnect plug or connector.
Test 4. Check for 24 volts on both sides of plug at rear composite light wires 003 and 004.
• If 24 volts are present on one side of plug and not on the other, clean, repair or
replace plug as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of plug, replace composite light. Refer to
Test 5. Check for 24 volts on both sides of connector MC18, wire 003 (pin C) and 004 (pin
A).
this manual.
• If 24 volts are present both sides of connector MC18, repair or replace wires 003
and/or 004 between connector MC18 and plug at rear of composite lights. Refer
Test 6. Check for 24 volts on both sides of connector MC4, wires 003 (pin 6 and 004 (pin 4).
manual.
• If 24 volts are present on both sides of connector MC4, repair or replace wires
003 and/or 004 between connector MC4 and connector MC18. Refer to
2-198
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TEST OR INSPECTION
CORRECTIVE ACTION
2-199
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for 24 volts on wire 009 terminal of brake light switches, on left side of brake
treadle valve.
2-200
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for 24 volts on wire 009 on output terminal of circuit breaker No. 10.
• If 24 volts are present, repair or replace wire 009 between circuit breaker No. 10
and stop light switches. Refer to paragraph 7-48 in this manual.
Test 9. Check for 24 volts on wire 009 on input terminal of circuit breaker No. 10.
manual.
• If 24 volts are present, repair or replace wire 009 between circuit breakers No. 4
and No. 10. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to ELECTRICAL SYSTEMS troubleshooting,
Malfunction 3, Tests 1 thru 5.
2-201
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 11. Check for 24 volts on wire 005 terminal of brake light switches on treadle valve.
• If 24 volts are not present, replace brake light switches. Refer to paragraph 7-25
in this manual.
2-202
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 12. Disconnect plug at rear of Master light switch. Check for 24 volts on pin K of plug to
harness.
• If 24 volts are not present, repair or replace wire 005 between Master light switch
and stoplight switches. Refer to paragraph 7-48 in this manual.
Test 13. Using ohmmeter, check for continuity between terminals C and K on the Master light
switch.
this manual.
2-203
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 14. Reconnect plug to Master light switch. Remove screws and tilt instrument panel out
toward steering wheel. Check for 24 volts on wire 294 where it plugs into turn signal
switch wiring.
• If 24 volts are not present, repair or replace wire 294 between plug and Master
Test 15. Check for 24 volts at plugs for turn signal switch wires 003 and 004.
• If 24 volts are not present, replace turn signal switch. Refer to paragraph 7-17.
2-204
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 16. Check for 24 volts on wires 003 (pin 6) and 004 (pin 4) at connector MC4.
• If 24 volts are not present, repair or replace wires 003 and 004 between connector
MC4 and turn signal switch plugs. Refer to paragraph 7-48 in this manual.
END OF TEST
2-205
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
12. Marker Lights Do Not Work

WARNING

NOTE
For all voltage tests, the ignition switch must be in the ON position, the clearance light switch
must be in the ON position and the blackout light switch must be in either the STOPLIGHT
position or the SERVICE DRIVE position.
Test 2. Check for 24 volts on input side of circuit breaker No. 3.

manual.
Test 3. Check for 24 volts on wire 835 terminal of magnetic switch.

• If 24 volts are present, repair or replace wire 835 between magnetic switch and


Test 6. Check ground (wire 196) of magnetic switch.

• If ground wire is bad, repair or replace ground wire 196. Refer to paragraph 7-48
in this manual.
• If ground wire is good, replace magnetic switch. Refer to paragraph 7-21 in this
manual.
2-206
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for 24 volts on wire 837 of circuit breaker No. 1.

• If 24 volts are present, repair or replace wire 837 between magnetic switch and
and relay No. 1. Refer paragraph 7-48 in this manual.
2-207
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Check for 24 volts on wire 090 terminal of clearance light switch.
• If 24 volts are not present, repair or replace wire 090 between clearance light
switch and circuit breaker No. 3. Refer to paragraph 7-48 in this manual.
Test 10. Check for 24 volts on wire 012 terminal of clearance light switch.
• If 24 volts are not present, replace switch. Refer to paragraph 7-15 in this manual.
2-208
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TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
• For MK48 only, follow Tests 11 thru 13. For rear trailer units only, follow Tests 14
thru 18.
Test 11. For clearance marker lights on MK48, check for 24 volts on both sides of clearance
light plugs.
• If 24 volts are present on one side of plug and not the other, repair or replace plug.
switch and clearance light plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of plug, go to Test 12.
2-209
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 12. For MK48 clearance marker lights, check for 24 volts on center contact of bulb
socket.
• If 24 volts are not present, replace socket assembly. Refer to paragraph 7-31 in
this manual.
Test 13. For MK48 clearance marker lights, check for good ground at bulb socket.
• If ground is good, replace bulb. Refer to paragraph 7-31 in this manual.
• If ground is bad, clean, repair or replace socket as needed. Refer to paragraph
2-210
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 14. For rear trailer units, check for 24 volts on both sides of connector MC4, wire 012.
repair or replace connector MC4. Refer to paragraph 7-48 in this manual.
switch and connector MC4. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC4, go to Test 15.
Test 15. For rear trailer units, check for 24 volts on both sides of connector MC18, wire 012
(pin K).
• If 24 volts are not present, repair or replace wire 012 between connector MC4 and
• If 24 volts are present on both sides of connector MC18, go to Test 17.
2-211
TM 08780B-20
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 16. For rear trailer units, check for 24 volts on both sides of plugs at clearance lights.
• If 24 volts are present on one side of plug and not on the other side, repair or
• If 24 volts are not present, repair or replace wire 012 between clearance light plug
and intervehicular connector. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of plug, go to Test 17.
Test 17. For rear trailer units, check for 24 volts on center contact of bulb sockets.
• If 24 volts are not present, replace bulb socket assembly. Refer to paragraph 7-36
in this manual.
Test 18. For rear trailer units, check for good ground at bulb socket.
• If ground is bad, clean, repair or replace socket as needed. Refer to paragraph
END OF TEST
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13. One or More Parking Lights Do Not Work
WARNING

NOTE
• Master light switch must be in the SERVICE DRIVE position and the auxiliary
lighting switch must be in the PARK position for all voltage tests.
• For front park lights, go to Tests 1 thru 7. For rear park lights, go to Tests 9 thru 15.
Test 1. Check filaments of park light bulbs in front composite lights.

• If filaments are broken, replace bulbs. Refer to paragraph 7-34 in this manual.
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Test 2. Check for 24 volts on center contact of bulb socket(s).

Test 3. Check for good ground on front composite lights.

• If ground is good, replace composite light. Refer to paragraph 7-34 in this
manual.
• If ground is bad, clean or repair as needed. Refer to paragraph 7-48 in this
manual.
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Test 4. Unplug wire 491 at composite light(s) and check for 24 volts on wire harness plug.
• If 24 volts are present, replace front composite light. Refer to paragraph 7-34 in
this manual.
Test 5. Using a sharp probe, check for 24 volts on wire 491 (pin L) at rear of Master light
switch plug.
• If 24 volts are present, repair or replace wire 491 between composite light plug
and master light switch plug. Refer to paragraph 7-48 in this manual.
Test 6. Using a sharp probe, check for 24 volts on wire 674 (pin F) at rear of Master light
switch plug.
Test 7. Check for 24 volts on wire 674 at circuit breaker No. 6

• If 24 volts are present, repair or replace wire 674 between master light switch and
circuit breaker No. 6.
• If 24 volts are not present, go to Malfunction 3.
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Test 8. Unplug Master light switch and check for continuity between pin F and pin L on
Master light switch.
this manual.
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Test 9. Check filaments of park light bulbs in rear composite lights.

• If filaments are broken, replace bulbs. Refer to paragraph 7-36.
Test 10. Check for 24 volts on center contacts of bulb socket(s).

Test 11. Check for good ground on rear composite lights.

• If ground is good, replace composite light. Refer to paragraph 7-36 in this
manual.
• If ground is bad, clean or repair as needed. Refer to paragraph in this manual.
Test 12. Unplug wire 008 at composite light(s) and check for 24 volts on wire harness plug.
• If 24 volts are present, replace rear composite light. Refer to paragraph 7-36 in
this manual.
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NOTE
Test 13. Check for 24 volts on both sides of connector MC18, wire 008 (pin B).
008 between connector MC18 and composite light plug. Refer to paragraph 7-48
in this manual.
this manual.
Test 14. Check for 24 volts on both sides of connector MC4, wire 008 (pin 5).
between connector MC4 and connector MC18. Refer to paragraph 7-48 in this
manual.
manual.
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Test 15. Using a sharp probe, check for 24 volts on wire 008 (pin H) at rear of Master light
switch plug.
• If 24 volts are present, repair or replace wire 008 between Master light switch and
plug H. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, refer to Test 7.
END OF TEST
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14. Headlights Do Not Work, Low and/or Hi Beam and Indicator
WARNING

NOTE
• Master light switch must be in SERVICE DRIVE position before any troubleshooting
tests are done.
• Make sure auxiliary lighting lever (on Master light switch) is in the OFF position.
• If hi beam headlights do not work but low beam headlights work properly, go to Tests
12 thru 14.
• If hi beam indicator does not work go to Tests 15 thru 17.
Test 1. Place dimmer switch in LOW beam position. Using a sharp probe to pierce the
insulation, check for 24 volts on wire 006 behind headlight plug (under dash).
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Test 2. Remove headlight sealed beam from mounting. Refer to paragraph 7-30 in this
manual. Check for 24 volts at plug for wire 018 on headlight bucket.
• If 24 volts are not present, repair or replace headlight bucket. Refer to paragraph
Test 3. Check for good ground on wire 091.

• If ground is good, replace sealed beam. Refer to paragraph 7-30 in this manual.
• If ground is bad, repair as needed. Refer to paragraph 7-48 in this manual.
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Test 4. Check for 24 volts on wire 006 terminal of dimmer switch.

• If 24 volts are present, repair or replace wire(s) 006 between dimmer switch and
headlight plug. Refer to paragraph 7-48 in this manual.
Test 5. Check for 24 volts on wire 017 terminal of dimmer switch.

• If 24 volts are present, replace dimmer switch. Refer to paragraph 7-52 in this
manual.
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and dimmer switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, replace circuit breaker No. 7. Refer to paragraph 7-14 in
this manual.
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Test 8. Using a sharp probe, check for 24 volts at rear of Master light switch plug wire 084
(pin M).
• If 24 volts are present, repair or replace wire 084 between Master light switch and
Test 9. Using a sharp probe, check for 24 volts at rear of Master light switch wire 674 (pin
F).
• If 24 volts are present go to Test 11.
Test 10. Check for 24 volts at wire 674 at circuit breaker No. 6.
and Master light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present go to Malfunction 3.
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Test 11. Disconnect plug from rear of Master light switch and check for continuity between
pin F and pin M.
• If continuity is not found, replace Master light switch. Refer to paragraph 7-24 in
this manual.
Test 12. If high beam headlights do not work, make sure Master light switch is in SERVICE
DRIVE position and dimmer switch is in HI beam position. Check for 24 volts at
wire 007 terminal of dimmer switch.
• If 24 volts are not present, replace dimmer switch. Refer to paragraph 7-52 in this
manual.
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Test 13. Disconnect plug for wire 007 at rear of headlight bucket. Check for 24 volts at plug.
• If 24 volts are not present, repair or replace wire 007 between headlight bucket
and dimmer switch. Refer to paragraph 7-48 in this manual.
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Test 14. Reinstall plug for wire 007 and with headlight sealed beam removed, check for 24
volts on headlight bucket connector for wire 017.
• If 24 volts are not present, replace headlight bucket. Refer to paragraph 7-30 in
this manual.
• If 24 volts are present, replace sealed beam. Refer to paragraph 7-30 in this
manual.
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Test 15. Check hi beam indicator bulb filament.

• If filament is broken, replace bulb as needed. Refer to paragraph 7-35 in this
manual.
• If filament is not broken go to Test 16.
Test 16. Check for 24 volts on center contact of high beam indicator bulb socket.
socket. If still not working, replace hi beam indicator light socket.
Test 17. Check for 24 volts on both sides of instrument harness plug wire 018 (pin M).
• If 24 volts are present on both sides of the plug, repair or replace wire as needed
between plug and bulb socket. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of the plug and -not the other, repair or replace
plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 018 as needed between
instrument harness plug and dimmer switch. Refer to paragraph 7-48 of this
manual.
END OF TEST
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15. Worklight(S) Do Not Work
WARNING

NOTE
Before performing any troubleshooting tests, turn the worklight(s) switch to the ON position,
worklight switch in cab to the ON position and the Master light switch to the STOPLIGHT or
SERVICE DRIVE position.
Test 1. Disconnect plug at worklight handle and check for 24 volts on wire 040 (pin B) of
wire harness plug.
Test 2. Check for continuity between pin A of the harness plug and ground.
• If continuity is not found, repair or replace ground wire between pin A of harness
plug and ground. Refer to paragraph 7-48 in this manual.
Test 3. Make sure switch on worklight is in the ON position and check for continuity
between pin A and pin B of receptacle on worklight.
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Test 4. Disassemble worklight. Refer to paragraph 7-37 in this manual. Check for continuity
between the two terminals of the sealed beam.
• If continuity is not found, replace sealed beam. Refer to paragraph 7-37 in this
manual.
Test 5. With worklight switch in ON position, check for continuity between input and output
terminals of switch.
• If continuity is not found, replace switch. Refer to paragraph 7-37 in this manual.
Test 6. Check each wire within the worklight for continuity.

• If continuity is not found, repair or replace wiring as needed. Refer to paragraph
• If continuity is found, reassemble worklight and reinstall.
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NOTE
Test 7. Using a sharp probe, check for 24 volts on both sides of connector MC5 wire 040 (pin
S).
• If 24 volts are present on one side of the connector MC5 and not on the other side,
repair or replace connector MC5, as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present on both sides of the connector MC5, repair or replace wire
040 between connector MC5 and the plug at the worklight. Refer to paragraph 7-
48 in this manual.
• If 24 volts are not present on both sides of the connector MC5, go to Test 8.
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Test 8. Check for 24 volts on wire 040 at output terminal of worklight switch in cab.
• If 24 volts are present, repair or replace wire 040 between worklight switch and
plug C. Refer to paragraph 7-48 in this manual.
Test 9. Check for 24 volts on wire 040 at input terminal of worklight switch in cab.
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switch. Refer to paragraph 7-48 in this manual.
manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section,
END OF TEST
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16. Dome Light Does Not Work
WARNING

NOTE
Master light switch must be in the STOPLIGHT or SERVICE DRIVE position and dome light
switch must be in the ON position before doing any troubleshooting tests.
Test 1. Check dome light bulb for broken filament.

• If broken, replace bulb. Refer to paragraph 7-33 in this manual.
• If not broken, go to Test 2.
Test 2. Check for 24 volts on center contact of dome light bulb socket.
Test 3. Check for good ground for dome light socket.

• If ground is bad, repair or replace dome light socket as needed. Refer to
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Test 4. Check for 24 volts on wire 153 terminal of dome light switch.
• If 24 volts are present, repair or replace wire 153 between dome light and dome
light, switch. Refer to paragraph 7-48 in this manual.
Test 5. Check for 24 volts on wire 027 terminal of dome light switch.
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• If 24 volts are present, repair or replace wire 027 between dome light switch and
circuit breaker No. 3.

manual.
• If 24 volts are not present, go to Malfunction 12, Test 3 in this section.
END OF TEST
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17. Map Light Does Not Work
WARNING

NOTE
Master light switch must be in the SERVICE DRIVE or STOPLIGHT position and map light
switch must be in the ON position before performing any troubleshooting tests.
Test 1. Check map light bulb for broken filament. Refer to paragraph 7-35 in this manual.
• If broken, replace bulb. Refer to paragraph 7-35 in this manual.
• If not broken, go to Test 2.
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Test 2. Check for 24 volts on center contact of map light bulb socket.
• if 24 volts are not present, go to Test 4.
Test 3. Check for a good ground for map light bulb socket.
• If ground is bad, repair or replace map light as needed. Refer to paragraph 7-35 in
this manual.
Test 4. With switch on, check for 24 volts on output terminal of map light switch.
• If 24 volts are present, repair or replace wire between map light and switch.
Test 5. Check for 24 volts on wire 413 terminal of map light switch.
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and map light switch. Refer to paragraph 7-48 in this manual.
• If volts 24 are not present, go to Test 7.
manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section of the
manual.
END OF TEST
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18. Beacon Light Does Not Work
WARNING

• BEACON LIGHT POWER SUPPLY CONTAINS PARTS THAT HOLD

DANGEROUS VOLTAGES (UP TO 500 VOLTS) EVEN WHEN OFF. TO
PREVENT PERSONAL INJURY, MAKE SURE POWER IS OFF AND DO NOT
TOUCH TOP OR BOTTOM OF THE CIRCUIT BOARD. DO NOT TOUCH THE
LEADS TO ANY CAPACITOR OR THE TRANSFORMER. HANDLE CIRCUIT
BOARD BY EDGES ONLY.
NOTE
Master light switch must be in STOPLIGHT or SERVICE DRIVE position and beacon light
switch must be ON for all voltage tests.
Test 1. Using a sharp probe, pierce the insulation on wire 029 above the plug located about
half way down the mounting bracket. Check for 24 volts at this point.
• If 24 volts are not present, go Test 7.
CAUTION
TO PREVENT DAMAGE TO POWER SUPPLY, DO NOT TURN BEACON LIGHT ON

WHEN STROBE LIGHT TUBE IS REMOVED. THIS CAN DAMAGE THE POWER
SUPPLY.
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Test 2. Turn beacon light OFF and remove lens. Refer to paragraph 7-38 in this manual.
Perform the following tests:
a. Set multimeter to read at least 450 volts. Connect leads to the large capacitor
under the circuit board. Connect the positive meter lead to the positive capacitor
lead and the negative meter lead to the negative capacitor lead. Make sure that
meter lead clips pierce the insulating coating on the capacitor leads. Turn beacon
light ON and note voltage.
b. Turn beacon light OFF. Set multimeter to read at least 200 volts. Connect
negative meter lead to ground. Using a sharp probe on the positive meter lead,
pierce the insulating coating on the lead from the 22 mfd capacitor. Turn beacon
light ON and note voltage.
c. Turn beacon light OFF. Set multimeter to read at least-3 volts. Connect negative
meter lead to ground. Using a sharp probe on the positive meter lead, pierce the
insulating coating on pin 3 of IC 555. Be careful not to touch any other pin of IC
555. Turn beacon light ON and note voltage.
Voltage readings should be as follows:
a. 350 to 450 volts

b. 200 volts
c. 2.5 to 3.5 volts
• If all three voltages (a, b and c) are present and correct, replace strobe light
tube. Refer to paragraph 7-38 in this manual.
• If one or two of the voltages (a, b or c) are not present or correct, replace
power supply. Refer to paragraph 7-38 in this manual.
• If none of the voltages (a, b or c) are present, go to Test 3.
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Test 3. Turn beacon light OFF. Remove strobe light tube. Refer to paragraph 7-38 in this
manual. Check for continuity between ground and pins 6 and 7 of strobe light tube
socket. A small amount of resistance (20-30 ohms) may be found. This is normal.
Reinstall strobe light tube.
NOTE
parts. Probe from the rear of the plug or connector at the wire or pin called for in the
• Unless told to do so in the test, do not disconnect plug or connector.
Test 4. Remove the three screws and clip holding the power supply to the base. Carefully
torn power supply over, turn beacon light ON and check for 24 volts on both sides of
power supply plug (white wire on harness side and red wire on power supply side).
• If 24 volts are not present, repair or replace wire 029 between power supply plug
and plug on mounting bracket. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on the white wire and not on the red wire, repair or replace
power supply plug as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of the plug, go to Test 5.
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Test 5. Check for continuity between black and violet wires from power supply to ground.
• If continuity is not found, repair or replace black and/or violet wires between
power supply and ground. Be sure to check plug for continuity from one side to
the other. Refer to paragraph 7-48 in this manual.
Test 6. Check for 24 volts on power supply circuit board where the red wire connects to the
board.
• If 24 volts are present, replace beacon light assembly. Refer to paragraph 7-38 in
this manual.
• If 24 volts are not present, repair or replace red wire between plug and circuit
board. Refer to paragraph 7-48 in this manual.
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Test 7. Check for 24 volts on output terminal wire 029 of beacon light toggle switch.
• If 24 volts are present, repair or replace wire 029 between switch and plug on
mounting bracket. Refer to paragraph 7-48 in this manual.
Test 8. Check for 24 volts on input terminal wire 029 of beacon light switch.
• If 24 volts are present, replace beacon light switch. Refer to paragraph 7-15 in
this manual.
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and beacon light switch. Refer to paragraph 7-48 in this manual.
this manual.
END OF TEST
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19. One Or More Blackout Marker Light(S) Do Not Work
WARNING

NOTE
Master light switch must be in BLACKOUT MARKER or BLACKOUT DRIVE position before
doing any troubleshooting tests.
Test 1. Remove lens from composite light, remove bulb and check for broken filament(s).
• If filaments) are broken, replace bulb. Refer to paragraphs 7-34 and 7-36 in this
manual as needed.
• If filament(s) are not broken, go to Test 2.
Test 2. Check for 24 volts on center contact of bulb socket(s).

Test 3. Check for a good ground to the bulb socket(s).

• If ground is good, replace bulb. Refer to paragraphs 7-34 and 7-36 in this manual.
• If ground is bad, repair or replace light as needed. Refer to paragraphs 7-34 and
Test 4. Unplug composite light(s) at wire 680/20, for front lights or 680/24 for rear lights.
Check for 24 volts on harness plug (wire 680/20 or 680/24).
• If 24 volts are present, replace composite light. Refer to paragraphs 7-34 or 7-36
in this manual.
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NOTE
• For the rear composite lights, go to Test 5. For the front composite lights, go to Test 7.
• When told to check both sides of a plug or connector, probe the male and female parts.
Probe from the rear of the plug or connector, at the wire or pin called for in the test.
This will check the continuity of the plug or connector and let you know if it is usable
or needs repair.
Test 5. Check for 24 volts on both sides of the connector MC18 wire 024 (pin S).
• If 24 volts are present on both sides of the connector, repair or replace wire 024
between composite light plug and connector MC18. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of the connector and not on the other, repair or
replace connector MC18 as needed. Refer to paragraph 7-48 in this manual.
Test 6. Check for 24 volts on both sides of connector MC4 wire 024 (pin 18).
this manual.
• If 24 volts are present on one side of the connector MC4 and not on the other,
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Test 7. Disconnect plug on rear of Master light switch. Check for 24 volts on pin F of plug.
Test 8. With plug still disconnected, check for continuity between pin F and pin E on the
back of the Master light switch.
• If continuity is not found, replace blackout light switch. Refer to paragraph 7-24
in this manual.
and Master light switch. Refer to paragraph 7-48 in this manual.
manual.
END OF TEST
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20. Blackout Brake Lights Do Not Work
WARNING

NOTE
• Before doing any troubleshooting tests, check operation of service drive stop lights. If
they do not work, refer to Malfunction 11, BRAKE LIGHTS DO NOT WORK first. If
they are working, go on to Test 1.
• Master light switch must be in BLACKOUT MARKER or BLACKOUT DRIVE

position, air system pressure must be between 60 and 120 psi (413.7 to 827.4 kPa) and
brake treadle valve must be applied before performing any troubleshooting test.
Test 1. Remove lens from rear composite lights and check for broken filaments in blackout
brake light bulbs. Refer to paragraph 7-36 in this manual.
• If filaments are broken, replace bulb. Refer to paragraph 7-36 in this manual.
Test 2. Check for 24 volts on center contact of bulb sockets.

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Test 3. Check for a good ground to bulb sockets.

• If ground is bad, repair or replace composite lights as needed. Refer to paragraph
Test 4. Disconnect wire 678/23 plug at rear of composite light and check for 24 volts on plug
from harness.
• If 24 volts are present, repair or replace composite light as needed. Refer to
NOTE
Test 5. Check for 24 volts on both sides of connector MC18 wire 678 (pin H).
• If 24 volts are present on both sides of the connector, repair or replace wire 678
between connector and plug at composite light. Refer to paragraph 7-48 in this
manual.
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Test 6. Check for 24 volts on both sides of connector MC4 wire 678 (pin 9).
this manual.
• If 24 volts are present on one side of the connector MC4 and not on the other,
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Test 7. Using a sharp probe, check for 24 volts or wire 678 (pin N) at rear of Master light
switch plug.
• If 24 volts are present, repair or replace wire 678 between composite light plug
and Master light switch plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, replace Master light switch. Refer to paragraph 7-24 in
this manual.
END OF TEST
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21. Suspension Lockup Warning Light Does Not Come On When Caps Are Off
WARNING

NOTE
• Ignition switch must be ON for all voltage tests.
• Do not unplug any parts unless told to do so in the test.
Test 1. Remove warning light bulb and check for a broken filament. Refer to paragraph 7-29
in this manual.
• If filament is broken, replace bulb.
• If filament is not broken, go to Test 2.
Test 2. Check for 24 volts on center contact of bulb socket.

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and warning light socket. Refer to paragraph 7-48 in this manual.
this manual.
manual.
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NOTE
• Unless told to do so in the test, do not disconnect plug or connector.
Test 5. Check for continuity between wire 852 at warning light bulb socket and wire 852 A at
relay No. 6.
• If continuity is present, go to Test 6.
• If continuity is not present, repair or replace wires between warning light socket
and relay No. 6.
Test 6. Check for continuity between wire 435 at relay No. 6 and ground.
• If no continuity is found, repair or replace wire 435 between relay No. 6 and
ground. Refer to paragraph 7-48 in this manual.
Test 7. Unplug connector at relay No. 6 and check for continuity between 852 A terminal and
435 Terminal at relay No. 6.
• If continuity is not found, replace relay. Refer to paragraph 7-28 in this manual.
• If continuity is found, go to Malfunction 22 in this section.
END OF TEST
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22. Suspension Lockup Warning Light Does Not Go Out When Caps Are On
WARNING

NOTE
• Ignition switch must be ON for all voltage tests.
Test 1. Check for 24 volts on wire 805 terminal of relay No. 6.

• If 24 volts are not found, repair or replace wire 805, between relay No. 6 and
Test 2. Remove wire 852 from relay No. 6. Using a jumper wire, connect relay No. 6
terminal 852 to ground.
• If suspension lockup warning light goes out, go to Test 3.
• If suspension lockup warning light stays on, replace relay No. 6. Refer to
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Test 3. Remove wire 852 from relay No. 6. Check for continuity between wire 852 at relay
No. 6 and both sides of connector MC4 (pin 1).
• If continuity is found on both sides of connector MC4, go to Test 4.
• If continuity is found on one side of connector MC4 and not on the other side,
• If no continuity is found on either side of connector MC4, repair or replace wire
852 between connector and relay No. 6.
Test 4. Check continuity of wire 852 from rear of connector MC4 (pin 1) to pin A on driver’s
side sensor plug.
• If no continuity is found, repair or replace wire 852 between connector MC4 and
driver’s side sensor plug.
Test 5. Make sure sensor caps are properly installed on both sides of the MK48. Probing
from the rear of the plug, check for continuity between pins A and B and ground on
the driver’s side plug.
• If continuity is found on pin B and not on pin A, repair or replace plug and/or cap
as needed. Refer to paragraph 7-48 in this manual.
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CORRECTIVE ACTION
Test 6. Check for continuity between pin B on driver’s side plug and pin A on passenger’s
side plug.
• If continuity is not found, repair or replace wire 852 between the two plugs.
Test 7. Probing from rear of plug, check for continuity between pins A and B and ground on
passenger’s side plug.
• If continuity is found on pin B and not pin A, repair or replace plug and/or cap as
• If continuity is not found on pin A or pin B, repair or replace wire 435 between
plug and ground. Refer to paragraph 7-48 in this manual.
END OF TEST
2-264
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
23. Air Dryer and/or Fuel/Water Separator Heater Do Not Work
WARNING

NOTE
Ignition switch must be in the ON position for all voltage tests.
Test 1. Check for 24 volts on wire 538 of fuel/water separator and/or air dryer.
• If 24 volts are present at air dryer, but not fuel/water separator, repair or replace
wire 538 between air dryer and fuel/water separator. Refer to paragraph 7-48 in
this manual.
Test 2. Check for good ground at fuel/water separator and/or air dryer.
• If ground is good, repair or replace defective heater. Refer to paragraph 13-38 in
this manual for air dryer or paragraph 4-20 in this manual for fuel/water separator.
2-265
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CORRECTIVE ACTION
and air dryer or fuel/ water separator.
• If 24 volts are not present, go Test 4.
this manual.
2-266
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Check for 24 volts at wire 640 terminal of ignition switch.

• If 24 volts are not present, replace ignition switch. Refer to paragraph 7-23 in this
manual.
Test 6. Check for 24 volts at wire 431 at ignition switch.

• If 24 volts are present, replace ignition switch. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present go to Step 7.
Test 7. Check for 24 volts at wire 431 terminal on circuit breaker No. 5.
and ignition switch.
• If 24 volts are not present, refer to Malfunction 3 in this section.
END OF TEST
2-267
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TEST OR INSPECTION
CORRECTIVE ACTION
24. One or Both Horns Do Not Work
WARNING

Test 1. With horn button depressed, check for 24 volts on wire 168 terminal of non-working
horn.
Test 2. Check for good ground at non-working horn.

• If ground is good, replace horn as needed. Refer to paragraph 22-14 in this
manual.
2-268
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. With horn button depressed, check for 24 volts on wire 168 at relay No. 3.
• If 24 volts are present, repair or replace wire 168 between relay No. 3 and horns.
Test 4. Check for volts on wire 031/279 at relay No. 3.

• If 24 volts are present, repair or replace wire 031 between relay No. 3 and circuit
breaker No. 5. Refer to paragraph 7-48 in this manual.
2-269
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CORRECTIVE ACTION
manual.
• If 24 volts are not present go to Malfunction 3 in this section.

this manual.
Test 8. With horn button depressed, check for good ground on wire 016 at relay No. 3.
• If ground is bad, repair or replace horn switch and/or wire 016. Refer to
• If ground is good, replace relay No. 3. Refer to paragraph 7-48 in this manual.
END OF TEST
2-270
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
25. Hydraulic Steering Disengage Light Does Not Work
WARNING

NOTE
• Selector valve must be in the auxiliary hydraulics (out) position for all tests.
• This test is not applicable to MK48/14 configuration.
Test 1. Remove bulb and check for broken filament.

• If filament is broken, replace bulb. Refer to paragraph 7-29 of this manual.

Test 3. Check for continuity between wire 843 terminal of light bulb socket and ground.
• If continuity is found, replace bulb.
2-271
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Probing from the rear with a sharp probe, check both sides of warning light connector
MC2, wire 843 (pin 1) for continuity to ground.
• If continuity is found on both sides of connector MC2, repair or replace wire 843
between bulb socket and connector MC2. Refer to paragraph 7-48 in this manual.
• If continuity is found on one side of the connector MC2 and not on the other side,
Test 5. Check continuity to ground on wire 843 at relay No. 5.

• If continuity is found, repair or replace wire 843 between connector MC2 and
relay No. 5. Refer to paragraph 7-48 in this manual.
2-272
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check both sides of connector MC6 wire 843 (pin 13) for continuity to ground.
between relay No. 5 and connector MC6. Refer to paragraph 7-48 in this manual.
2-273
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for continuity to ground on wire 843 terminal of steering disengage switch.
• If continuity is found, repair or replace wire 843 between switch and connector
MC6. Refer to paragraph 7-48 in this manual.
Test 8. Check for continuity to ground on ground terminal of steering disengage switch.
• If continuity is not found, repair or replace ground wire between switch and
• If continuity is found, replace steering disengage switch. Refer to paragraph 7-16
in this manual.
END OF TEST
2-274
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
26. Traction Control Valve Indicator Light(S) Do Not Work
WARNING

NOTE
• Air pressure must be between 60 and 120 psi (413-826 kPa).
• Do Tests 1 thru 6 if either or both lights are not working. Then go to Tests 7 and 8 if
transfer case lockup light is not working or Tests 9 thru 11 if axle lockup light is not
working.
Test 1. Remove bulb(s) and check for broken filaments(s).

• If filament(s) are broken, replace bulb. Refer to paragraph 7-29 in this manual.

Test 3. Check bulb socket for good ground.

• If ground is bad, repair or replace ground wire. Refer to paragraph 7-48 in this
manual.
2-275
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Check for 24 volts on wire 279/092 terminal of transfer case lockup light switch.
this manual.
this manual.
Test 7. Engage transfer case lockup switch and check for 24 volts on wire 092 terminal of
transfer case lockup light switch.
• If 24 volts are not present, replace switch. Refer to paragraph 13-41 in this
manual.

• If 24 volts are not present, repair or replace wire 092 between bulb socket and
• If 24 volts are present, check bulb socket for ground or replace bulb socket. Refer
Test 9. Check for 24 volts on wire 279 terminal of axle lockup switch.
• If 24 volts are not present, repair or replace wire 279 between transfer case lockup
switch and axle lockup switch. Refer to paragraph 7-48 in this manual.
Test 10. Engage axle lockup switch and check for 24 volts on output terminal of axle lockup
switch.
• If 24 volts are not present, replace axle lockup switch. Refer to paragraph 13-41
in this manual.
2-276
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CORRECTIVE ACTION

• If 24 volts are present, check bulb socket for good ground or replace bulb socket.
END OF TEST
2-277
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TEST OR INSPECTION
CORRECTIVE ACTION
27. Instrument Panel (Gauge) Lights Do Not Work
WARNING

NOTE
• Master light switch must be in STOPLIGHT or SERVICE DRIVE position.
• Auxiliary lighting switch on Master light switch must be in HI panel light position.
• Do Tests 1 thru 8 if instrument panel lights do not work in the HIGH position. Do
Tests 9-13 if instrument panel lights do not work in the LOW position.
Test 1. Remove light bulb(s), as needed and check for broken filaments. Refer to paragraph
• If filament(s) are broken, replace bulb(s). Refer to paragraph 7-29 in this manual.

Test 3. Check for good connection between bulb socket and ground.
manual.
2-278
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CORRECTIVE ACTION
NOTE
Test 4. Check for 24 volts on both sides of instrument panel plug, wire 052 (pin U).
• If 24 volts are present on both sides of plug, repair or replace wire 052 between
plug and bulb socket(s). Refer to paragraph 7-48- in this manual.
• If 24 volts are present on one side of the plug and not on the other, repair or
2-279
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Using a sharp probe, check for 24 volts at rear of Master light switch plug, wire 052
(pin B).
• If 24 volts are present, repair or replace wire 052 between Master light switch
plug and instrument panel plug. Refer to paragraph 7-48 in this manual.
Test 6. Unplug Master light switch and check for 24 volts on wire 674 (pin F) of harness
plug.
• If 24 volts are present, go to test 8.
and Master light plug. Refer to paragraph 7-48 in this manual.
Test 8. With plug removed, check for continuity between pin F and pin B of Master light
switch.
this manual.
• If low panel lights remain inoperative go to Test 9.
Test 9. Place auxiliary lighting switch in LO panel light position. Check for continuity
between pin F and pin A of Master light switch.
this manual.
Test 10. Install plug onto rear of Master light switch. Using a sharp probe, check for 24 volts
on wire 677 (pin A) at rear of Master light switch plug.
• If 24 volts are not present, repair or replace Master light switch plug. Refer to
2-280
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TEST OR INSPECTION
CORRECTIVE ACTION
2-281
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CORRECTIVE ACTION
Test 11. Check for 24 volts on wire 677 input terminal of resistor.
• If 24 volts are not present, repair or replace wire 677 between resistor and Master
Test 12. Check for four to six volts on output terminal of resistor.
• If four to six volts are not present, replace resistor. Refer to paragraph 7-51 in this
manual.
• If four to six volts are present, go to Test 13.
Test 13. Check for four to six volts at center contact of bulb socket.
• If four to six volts are not present, repair or replace wire 677 between resistor and
wire 052.
END OF TEST
2-282
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
28. One or Both Speeds On Heater Blower Do Not Work
WARNING

NOTE
• Ignition switch must in ON position for all voltage tests.
• Make sure heater blower switch is in HI position.
• If only low speed is inoperative, do Tests 8 thru 10.
Test 1. Check for 24 volts on wire 070 terminal of blower motor.

2-283
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check for good ground on ground terminal of blower motor.

manual.
• If ground is good, replace blower motor. Refer to paragraph 22-16 in this manual.
Test 3. Check for 24 volts on wire 070 terminal of blower motor switch.
• If 24 volts are present, repair or replace wire 070 between switch and blower
motor plug.
2-284
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If 24 volts are present, repair or replace wire 082 between switch and circuit
breaker. Refer to paragraph 7-48 of this manual.
this manual.
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for 24 volts on wire 640 terminal of ignition switch.

and ignition switch. Refer to paragraph 7-48 in this manual.
Test 8. Check for 24 volts at wire 431 on ignition switch.

Test 9. Check for 24 volts on wire 431 of circuit breaker No. 5.

ignition switch.
• If 24 volts are not present, go to ELECTRICAL system troubleshooting
Malfunction 3.
2-286
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Place blower motor switch in LO position. Check for 24 volts on wire 071 terminal
of resistor.
• If 24 volts are present, repair or replace wire 071 between resistor and plug.
• If 24 volts are not present, replace switch. Refer to paragraph 7-15 in this manual.
Test 12. Check for 16 volts on output terminal of resistor.

• If 16 volts are not present, replace resistor. Refer to paragraph 22-17 in this
manual.
END OF TEST
2-287
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
29. Hydraulic Low Oil Level Alarm and/or Light Does Not Work
WARNING

NOTE
• Steering selector switch must be IN.
• The sending unit has a test circuit built into it and will activate alarm and light for a
short time when ignition is first turned ON.
• Hydraulic oil level must be below oil level sending unit for Tests 2 thru 18.
Test 1. Unplug hydraulic low oil level sender. Using a jumper wire, connect wire 525 (pin 2)
of harness plug to ground.
• If alarm and light work, go to Test 2.
• If alarm works and light does not, go to Test 5.
• If alarm does not work and light does, go to Test 8.
• If both alarm and light do not work, go to test 10.
Test 2. Check for continuity between pin 2 and pin 3 of sending unit plug.
• If continuity is not found, replace sending unit. Refer to paragraph 7-39 in this
manual.
Test 3. Check for continuity between pin 3 (wire 435) of sending unit harness plug and
ground.
• If continuity is not found, repair or replace plug or wire 435. Refer to paragraph
Test 4. Remove jumper wire and reconnect sending unit plug. Check for continuity between
pin 2 on both sides of plug and pin 3 on both sides of plug.
• If continuity is not found on both pins 2 and 3, repair or replace plug. Refer to
2-288
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TEST OR INSPECTION
CORRECTIVE ACTION
2-289
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TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Remove warning light bulb and check for broken filament.
• If filament is broken, replace bulb. Refer to paragraph 7-29 in this manual.

alarm. Refer to paragraph 7-48 in this manual.
Test 7. Check for continuity between ground contact of bulb socket and ground.
• If continuity is not found, repair or replace wire 525 between bulb socket and
alarm. Refer to paragraph 7-48 in this manual.
Test 8. Check for 24 volts on wire 033 terminal of alarm.

• If 24 volts are not present, repair or replace wire 033 between alarm and bulb
socket.
Test 9. Check for continuity between wire 525 terminal of alarm and ground.
• If continuity is not found, repair or replace wire 525 between alarm and bulb
socket.
• If continuity is found, replace alarm. Refer to paragraph 7-42 in this manual.
Test 10. Check for 24 volts on wire 033 terminal of alarm and warning light.
2-290
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-291
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 11. Check for 24 volts at wire 033/778 output terminal at relay No. 9.
• If 24 volts are present, repair or replace wire 033 between relay and alarm.
Test 12. Check for 24 volts at wire 033A input terminal at relay No. 9.
Test 13. Check for continuity between wire 435 at relay No. 9 and ground.
• If continuity is not found, repair or replace wire 435 between relay No. 9 and
Test 14. Unplug connector at relay No. 9 and check for continuity between 778A terminal and
435 terminal at relay No. 9.
• If continuity is not found, replace relay No. 9. Refer to paragraph 7-48 in this
manual.
2-292
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 15. Check for 24 volts at terminal 778A of relay No. 9.

• If 24 volts are present, replace relay No. 9. Refer to paragraph 7-28 in this
manual.
Test 16. Check for 24 volts on wire 778A at circuit breaker No. 8.
• If 24 volts are present, repair or replace wire 778A between relay No. 9 and
this manual.
Test 18. Check for 24 volts at wire 033A at relay No. 4.

• If 24 volts are present, repair or replace wire 033A between relay No. 4 and relay
No. 9. Refer to paragraph 7-48 in this manual.
Test 19. Check for 24 volts at wire 840A at relay No. 4.

Test 20. Check for 24 volts at wire 840A on circuit breaker No. 13.
• If 24 volts are present, repair or replace wire 840A between circuit breaker No. 13
and relay No. 4. Refer to paragraph 7-28 in this manual.
Test 21. Check for 24 volts at wire 736A at circuit breaker No. 13.
this manual.
Test 22. Check for 24 volts at wire 736A at circuit breaker No. 4.
and circuit breaker No. 13.
2-293
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 23. Remove wire 843 from relay No. 4 and check for 24 volts at wire 033A at relay
No. 4.
Test 24. Disconnect wire 843 from hydraulic steering disengage switch. Check for continuity
between wire 843 and ground.
• If continuity is found, repair or replace wire 843 between switch and relay No. 4.
• If continuity is not found, replace hydraulic steering disengage switch. Refer to
2-294
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 25. Check for continuity between ground and wire 525 terminal of alarm and warning
light socket.
• If continuity is found, replace alarm and warning light. Refer to paragraphs 7-42
and 7-29 in this manual.
NOTE
Test 26. Check for continuity between ground and both sides of connector MC5, wire 525
(pin x).
between connector MC5 and alarm. Refer to paragraph 7-48 in this manual.
• If no continuity is found, go to Test 27.
2-295
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 27. Check for continuity on both sides of sending unit plug, wire 525 (pin 2).
• If continuity is found on both sides of sending unit plug, repair or replace wire
525 between plug C and sending unit plug. Refer to paragraph 7-48 in this
manual.
• If continuity is found on one side of the plug and not on the other, repair or
Test 28. Check for continuity between ground and both sides of sending unit plug, wire 435
(pin 3).
• If continuity is found on both sides of plug, replace sending unit. Refer to
• If continuity is found on one side of the plug and not on the other, repair or
• If continuity is not found, repair or replace wire 435 between plug and ground.
END OF TEST
2-296
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION
1. Transmission Oil Temperature Gauge Stays Over 250 Degrees F (121 Degrees C)
WARNING
TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE

Test 1. Check for clogged transmission oil filter.

• If clogged, replace filter. Refer to paragraph 8-3 in this manual.
• If not clogged, go to Test 2.
Test 2. Check for a restriction in the transmission oil cooler.

• If restricted, repair or replace as needed. Refer to paragraph 8-15 in this manual.
• If no restriction is found, go to Test 3.
Test 3. Check fluid level.

• If incorrect, add or remove fluid as needed. Refer to LI 2320-12/9, LO 9-2320-
297-12.
• If fluid level is correct go to ELECTRICAL SYSTEM Troubleshooting
Malfunction 4 to check gauge operation.
END OF TEST
2-297
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Transmission Noisy
Test 1. Check fluid level.

• If incorrect, add or remove fluid as needed. Refer to LI 2320-12/9, LO 9-2320-
297-12.
• If problem still exists, go to Test 2.
Test 2. Check for a restriction in transmission oil cooler.
• If restricted, repair or replace as needed. Refer to paragraph 8-15 in this manual.
• If problem still exists, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).
END OF TEST
2-298
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Transmission Will Not Shift Into Gear
WARNING

CAUTION
TO PREVENT EQUIPMENT DAMAGE, PERFORM A VISUAL INSPECTION FOR

LEAKS AND MAKE SURE FLUID LEVEL IS CORRECT BEFORE OPERATING
VEHICLE. IF NEEDED, TIGHTEN ANY LOOSE CAPSCREWS, PLUGS OR
CONNECTIONS.
Test 1. Check shift lever and linkage from cab to transmission for proper adjustment and/or
damage.
• If damaged or misadjusted, repair, replace or adjust as needed. Refer to
paragraphs 8-4, 8-5 and 8-7 in this manual.
• If not damaged or misadjusted, go to Test 2.
Test 2. Check for correct fluid level,

• If incorrect, add or remove fluid as needed. Refer to LI-2320-12/9, LO 9-2320-
297-12.
Test 3. Check for correct lubricant.

• If wrong type of lubricant, change as needed. Refer to paragraph 8-3 in this
manual.
• If correct type of lubricant, go to Test 4.
Test 4. Check for clogged transmission oil filter.

• If clogged, replace filter. Refer to paragraph 8-3 in this manual.
• If not clogged, refer problem to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-299
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Transmission Slips Out Of Gear Or Operates Erratically
WARNING

CAUTION

CONNECTIONS.
Check shift lever and linkage from cab to transmission for proper adjustment and/or damage.
• If damaged or misadjusted, repair, replace or adjust as needed. Refer to
• If not damaged or misadjusted, send to Direct Support/intermediate Maintenance
(Third Echelon).
END OF TEST
2-300
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Transmission Leaks
WARNING

Test 1. Check for loose or damaged oil pan or gasket.

• If loose or damaged, repair or replace. Refer to paragraph 8-14 in this manual.
• If not loose or damaged, go to Test 2.
Test 2. Check for loose or damaged oil cooler or lines.

• If loose or damaged, repair or replace. Refer to paragraph 8-15 in this manual.
Test-3. Check for clogged or damaged breather.

• If clogged or damaged, service or replace breather. Refer to paragraph 8-16 in
this manual.
• If not clogged or damaged, go to Test 4.
Test 4. Check housing and seals for damage.

• If damaged, send to Direct Support/Intermediate Maintenance (Third Echelon).
Test 5. Remove cover from top of torque converter housing and check for oil.
• If leaking, send to Direct Support, Third Echelon, Maintenance.
• If not leaking and problem has not been solved, send to Direct
Support/Intermediate Maintenance (Third Echelon).
END OF TEST
2-301
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-302
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. Oil Thrown From Filler Tube
WARNING

Test 1. Check for loose, missing or wrong dipstick.

• If loose, missing or wrong, tighten or replace dipstick. Refer to TM 08780B-10.
• If not loose, missing or wrong, go to Test 2.
Test 2. Check for oil level too high.

• If too high, drain oil as needed. Refer to paragraph 8-3 in this manual.
• If oil level is correct, go to Test 3.
Test 3. Check for clogged or damaged breather.

• If clogged or damaged, service or replace breather. Refer to paragraph 8-16 in
this manual.
Test 4. Check for worn or damaged dipstick tube gasket.

• If worn or damaged, replace gasket. Refer to paragraph 8-14 in this manual.
• If problem still exists, send to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-303
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-304
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Excessive Creep In First And Reverse
WARNING

Check for throttle pedal binding (idle too high).

• If binding, repair or replace as needed. Refer to paragraph 4-23 in this manual.
• If not binding, send to Direct Support/Intermediate Maintenance (Third Echelon).
END OF TEST
8. Transmission Oil Dirty
WARNING

Test 1. Check that oil changes have been done at proper intervals.
• If not, change oil and filter. Refer to paragraph 8-3 in this manual.
• If oil has been changed at proper interval, go to Test 2.
2-305
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check for damaged oil filter.

• 1f not damaged, go to Test 3.
2-306
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Check temperature gauge for overheating.

• If overheating, go to Malfunction 1.
• If not overheating and problem still exists, send to Direct Support/Intermediate
END OF TEST
GAUGE
2-307
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Automatic Shifts Occur at Too High or Low a Speed
WARNING

Test 1. Check for proper oil level.

• If level is wrong, add or drain oil as needed. Refer to paragraph 8-3 in this
manual.
Test 2. Remove and check for sticking governor. Refer to paragraph 8-9 in this manual.
• If governor is not sticking, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
• If governor is sticking, remove and clean governor or replace.
END OF TEST
2-308
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. Transmission Shifts Rough
WARNING

CAUTION
CONNECTIONS.
Check for loose, damaged or misadjusted shift lever or linkage.

• If loose, damaged or misadjusted, repair, replace or adjust as needed. Refer to
• If not loose, damaged or misadjusted, send to Direct Support/Intermediate
END OF TEST
11. Vehicle Moves In Neutral
WARNING

CAUTION
CONNECTIONS.
Check for loose, damaged or misadjusted shift lever or linkage.

• If loose, damaged or misadjusted, repair, replace or adjust as needed. Refer to
• If not loose, damaged or misadjusted, send to Direct Support/Intermediate
END OF TEST
2-309
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-310
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
12. Transmission Slips In All Gears
WARNING

CAUTION

CONNECTIONS.
Check for low oil level.

• If low, add oil to proper level. Refer to paragraph 8-3 in this manual.
• If not low, send to Direct Support/Intermediate Maintenance (Third Echelon).
END OF TEST
2-311
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSFER CASE
1. Constant Noise When In Low Range and/or Direct Range
WARNING

Test 1. Check for correct lubricant and correct level.

• If wrong level or type of lubricant, change lubricant as needed. Refer to
Test 2. Check for loose, misadjusted or damaged shifter and/or linkage.

• If loose, misadjusted or damaged, adjust, repair or replace as needed. Refer to
• If not loose, misadjusted or damaged, go to Test 3.
2-312
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove one of the three oil feed lines from lubrication pump. Have assistant apply
parking brake, place transfer case in neutral, start engine and shift to drive. Allow
vehicle to idle. Watch for lubricant to flow from pump. It may take a moment for the
oil to flow.
• If lubricant does not flow from the pump, go to Test 4.
• If lubricant does flow from pump, send to Direct Support/Intermediate
Test 4. Check for clogged lubrication pump pickup strainer, pump pickup line or lubrication
feed lines. Refer to paragraph 9-6.
• If strainer, pump pickup line or lubrication lines are clogged, clean or replace as
required.
• If strainer, pump pickup line or lubrication lines are clear, replace transfer case
lubrication pump. Refer to paragraph 9-7.
END OF TEST
2-313
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Lubricant Leaks At Drive Yokes
WARNING

Test 1. Check for incorrect lubricant type and/or level.

• If incorrect, change lubricant or drain to proper level. Refer to paragraph 9-3 in
this manual.

• If clogged or damaged, clean or replace breather. Refer to paragraph 9-8 in this
manual.
• If not clogged or damaged, send to Direct Support/Intermediate Maintenance
(Third Echelon).
END OF TEST
2-314
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Transfer Case Overheats
WARNING

Test 1. Check for incorrect lubricant type and/or level.

• If incorrect, change lubricant or drain to proper level. Refer to paragraph 9-3 in
this manual.

• If clogged or damaged, clean or replace breather. Refer to paragraph 9-8 in this
manual.
Test 3. Check for damage or restricted lubricant line.

• If damaged or restricted, replace lubricant line. Refer to paragraph 9-6 in this
manual.
• If not damaged or restricted, send to Direct Support/Intermediate Maintenance
(Third Echelon).
END OF TEST
2-315
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Differential Lockup Will Not Engage Or Disengage
WARNING

Test 1. Check for damaged or restricted air lines to air chamber.

• If damaged or restricted, replace air lines as needed. Refer to paragraph 13-23 in
this manual.
• If not damaged or restricted, go to Test 2.
Test 2. Check for damaged or leaking air chamber.

• If damaged or leaking, replace air chamber. Refer to paragraph 9-9 in this
manual.
• If not damaged or leaking, send to Direct Support/Intermediate Maintenance
(Third Echelon).
END OF TEST
2-316
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
PROPELLER SHAFTS
Driveline Vibration or Noise
WARNING

Test 1. Check for damaged or worn universal joints.

• If damaged or worn, replace. Refer to paragraph 10-3 in this manual.
• If not damaged or worn, go to Test 2.
Test 2. Check for worn or damaged pillow block.

• If damaged or worn, replace pillow block. Refer to paragraph 10-5 in this
manual.
• If not damaged or worn, go to Test 3.
Test 3. Check for damaged propeller shaft.

Test 4. Check for damaged or worn cardan joint.

• If damaged or worn, replace. Refer to paragraph 10-4 in this manual.
• If not damaged or worn, send to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-317
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-318
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOSE BOX
1. Nose Box Overheats
WARNING

THAT SHIFT SELECTOR IS NEUTRAL AND PARKING BRAKE IS SET BEFORE
Test 1. Check for correct type and level of lubricant.

• If wrong type or level, change lubricant or adjust level as needed. Refer to
• If type and level are correct, go to Test 2.

• If clogged or damaged, replace breather. Refer to paragraph 11-4 in this manual.
(Third Echelon).
END OF TEST
2-319
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Lubricant Leaks At Drive Yoke
WARNING



• If clogged or damaged, replace breather. Refer to paragraph 11-4 in this manual.
(Third Echelon).
END OF TEST
2-320
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Nose Box Noisy
WARNING
Test 1. Check for proper type and level of lubricant.

• If wrong type or level, change lubricant or adjust level. Refer to paragraph 11-3
in this manual.
• If type and level are correct, send to Direct Support/Intermediate Maintenance
(Third Echelon)
END OF TEST
2-321
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AXLES
1. Differential(s) Noisy
WARNING


paragraphs 11-3 or 12-3 in this manual.
Test 2. Check for improperly lubricated, worn or damaged wheel bearings. Refer to
paragraph 14-3 or 14-4 in this manual.
• If wheel bearings are worn or damaged, replace them. Refer to paragraphs 14-3
• If not worn or damaged, send to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-322
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Lubricant Leaks At Pinion Or Axle Shafts
WARNING


• If lubricant type or level is wrong, change lubricant or adjust level. Refer to
• If lubricant type and level are correct, go to Test 2.

• If clogged or damaged, clean or replace breather. Refer to paragraphs 11-4 and
Test 3. Check for worn or damaged gaskets at axle shafts.

• If worn or damaged, replace gasket(s). Refer to paragraphs 11-6 and 12-4 in this
manual.
• If not worn or damaged, send to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-323
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-324
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Controlled Traction Differential Will Not Engage or Disengage
WARNING

Test 1. Check for loose or damaged airline to air chamber.

• If loose or damaged, repair or replace as needed. Refer to paragraph 13-23 in this
manual.
• If not loose or damaged, send to Direct Support/Intermediate Maintenance (Third
Echelon).
END OF TEST
2-325
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-326
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Vehicle Will Not Move
Test 1. Move driveline lockup control lever to TRANSFER CASE LOCKUP. Shift
transmission range selector to DRIVE.
• If vehicle now moves, go to Test 2.
• If vehicle does not move, go to Malfunction 3, Axle Troubleshooting in this
section of the manual.
2-327
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Move driveline lockup control lever to AXLE LOCKUP. Shift transmission range
selector to DRIVE.
• If vehicle now moves, go to Test 3.
• If vehicle does not move, go to Malfunction 3, Axle Troubleshooting in this
Test 3. Jack up No. 1 axle at the left side. Ensure that axle lockup is engaged. Try to turn
left wheel by hand.
• If wheel turns, axle shaft is broken. Refer to paragraph 11-6 in this manual to
repair axle shaft.
• If wheel does not turn, repeat Test 3 on right side of axle. If wheel does not turn,
axle is OK. Repeat Test 3 on No. 2, 3 and 4 axles.
• If wheel can be turned, refer to paragraph 12-4 for repair of broken axle shaft on
No. 2, 3 or 4 axles.
2-328
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM
1. No Air Pressure or Slow Build Up
WARNING

Test 1. Check for leaking or open air tank drain valves.

• If valves are open, close them.
• If valves are leaking, replace them as needed. Refer to-paragraph 13-32 in this
manual.
• If not open or leaking, go to Test 2.
Test 2. Check air lines and air system components for leaks.
• If air lines are leaking, repair or replace as needed. Refer to paragraph 13-23 in
this manual.
• If any components are leaking, repair or replace as needed. Refer to correct
paragraph for that component.
Test 3. Check for restriction or damage to air inlet line 600, running to compressor.
• If restricted or damaged, repair or replace as needed. Refer to paragraph 13-23 in
this manual.
• If not restricted or damaged, go to Test 4.
2-329
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-330
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
TO PREVENT PERSONAL INJURY, BE VERY CAREFUL WHEN LOOSENING OR
REMOVING AIR LINES. AIR PRESSURE CAN CAUSE A LINE TO WHIP. THIS MAY
RESULT IN PERSONAL INJURY.
Test 4. Carefully loosen and bleed air pressure from governor signal line 114 at governor.
When air pressure is gone, disconnect air line. Start engine. Refer to TM 08780B-
10. Very carefully loosen air line 183 at compressor and listen for air escaping.
• If no air is heard escaping, send to Direct Support, Third Echelon, Maintenance.
• If air is heard escaping, shut down engine, tighten line 183 and go to Test 5.
Test 5. Connect and tighten governor signal line 114 to governor. Drain all air pressure from
air tanks. Close drain valves on air tanks and start engine. Refer to TM 08780B-10.
Allow engine to run long enough to build pressure to 100-120 psi (689-826 kPa) no
more than 10 minutes.
• If 100-120 psi (689-826 kPa) is not present, adjust governor. Refer to paragraph
• If governor will not adjust, replace it. Refer to paragraph 13-37 in this manual.
• If 100-120 psi (689-826 kPa) is present, go to Test 6.
Test 6. Check for restricted or damaged compressor discharge line 183.

• If restricted or damaged, repair or replace air line. Refer to paragraph 13-23 in
this manual.
Test 7. Drain air pressure. Remove air dryer outlet line 184. Start engine. Refer to TM
08780B-10. Check for air flow from air dryer discharge port.
• If little or no air comes from air dryer’s discharge port, go to Test 8.
• If a large amount of air comes from discharge port, go to Test 9.
2-331
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Shut down engine and drain air pressure. Remove check valve from air dryer
discharge port. Start engine. Refer to TM 08780B-10. Check for air flow from air
dryer discharge port.
• If little or no air comes from air dryer discharge port, service, repair or replace air
dryer as needed. Refer to paragraph 13-38 in this manual.
• If air flow is greater than in Test 7, replace check valve. Refer to paragraph 13-38
in this manual.
2-332
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Drain air pressure from system. Install a test air gauge at quick disconnect on left air
tank. Start engine. Refer to TM 08780B-10. Watch both gauges during air pressure
build up.
• If test gauge builds quickly and dash gauge builds slowly, remove and inspect
inlet check valves. Replace as needed, refer to paragraph 13-34 in this manual.
• If both gauges build at same rate, go to Test 10.
Test 10. Check for restricted or damaged air line 184 between air dryer and quick build up air
tank.
• If air line is restricted or damaged, repair or replace as needed. Refer to
2-333
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 11. Drain air pressure from quick build up air tank. Disconnect air line 003 from quick
build up air tank. Remove pressure protection valve. Install a tee into quick build up
air tank and install pressure protection valve into tee. Install an air pressure test
gauge into the tee. Start engine. Refer to TM 08780B-10.
• If air does not discharge from pressure protection valve when gauge reaches about
70 psi (483 kPa) ± 10 psi (69 kPa), replace valve. Refer to paragraph 13-19 in
this manual.
• If air discharges, but test gauge reading climbs above 70 psi (483 kPa) ± 10 psi
(69 kPa), replace valve.
• If air discharges and test gauge pressure stays around 70 psi (483 kPa) ± 10 psi
(69 kPa), shut down engine and remove test gauge and tee. Install pressure
protection valve and air line 003. Start engine and allow pressure to build up. If
problem still exists, send to Direct Support, Third Echelon, Maintenance.
END Of TEST
2-334
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Throttle Air Cylinder Does Not Work
WARNING

• TO PREVENT PERSONAL INJURY, MAKE SURE ALL AIR PRESSURE IS

DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.
Test 1. Check dash gauge for proper system air pressure, 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) is not present, go to Malfunction 1.
Test 2. Loosen air line 415 running to throttle treadle valve at throttle treadle valve.
• If air escapes, go to Test 3.
• If no air escapes, repair or replace air line 415 between quick build-up air tank
and throttle treadle valve. Refer to paragraph 13-54 in this manual.
GAUGE
2-335
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Disconnect air line 416 at throttle treadle valve. Install test air gauge into throttle
treadle valve. Depress throttle treadle fully.
• If 60-75 psi (414-517 kPa) is present on test air gauge, go to Test 4.
• If 60-75 psi (414-517 kPa) is not present, repair or replace throttle treadle valve.
Test 4. Loosen air line 416 at tee fitting on throttle cylinder. Depress throttle treadle valve
fully.
• If no air escapes, repair or replace air line 416 between throttle treadle valve and
tee fitting.
Test 5. Remove throttle air cylinder from check valve. Install test air gauge into check valve.
Depress throttle treadle valve fully.
• If 60-75 psi (414-517 kPa) is present on test air gauge, repair or replace throttle
cylinder. Refer to paragraph 4-16 or 4-17 in this manual.
• If 60-75 psi (414-517 kPa) is not present on test air gauge, repair or replace check
valve. Refer to paragraph 4-16 in this manual.
2-336
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Compressor Cycles Constantly or Safety Valve Opens Before Compressor Unloads
WARNING


DRAINED BEFORE REMOVING-ANY AIR LINE OR AIR COMPONENT.
Test 1. Check all air lines and components for leaks.

• If leaking, repair or replace as needed.
• If not leaking, go to Test 2.
Test 2. Check for loose or damaged governor air signal line 114.
manual.
Test 3. Check safety valve for leaks or releasing at air pressures up to 120 psi (689-826 kPa).
• If leaks or releasing is found replace safety valve. Refer to paragraph 13-32 in
this manual.
• If no leaks or releasing is found go to Test 4.
Test 4. Check governor adjustment. Refer to paragraph 13-37 in this manual.

• If misadjusted, adjust governor.
• If governor will not adjust, replace governor.
END OF TEST
2-337
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Compressor Noisy
WARNING


Test 1. Check for loose or damaged compressor.

• If loose, tighten mounting capscrews.
• If damaged, send to Direct Support, Third Echelon, Maintenance.
• If not loose or damaged, go to test 2.
Test 2. Check for restricted or damaged lubricant lines to compressor.

• If lines are restricted or damaged, repair or replace them.
Test 3. Check for restricted or damaged coolant lines to compressor.

• If lines are restricted or damaged, repair of replace them.
• If not restricted or damaged, send to Direct Support, Third Echelon, Maintenance.
END OF TEST
2-338
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Coolant and/or Lubricant Leaks From Compressor
WARNING


Test 1. Check for damaged or loose coolant or lubricant lines.

• If loose or damaged, repair or replace as needed.
Test 2. Check compressor for leaking gaskets, seals or fittings.

• If leaking, tighten capscrews and fittings.
• If compressor still leaks, send to Direct Support, Third Echelon, Maintenance.
END OF TEST
2-339
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. Air Pressure Above 150 PSI (1,034 kPa), Safety Valve Does Not Release
WARNING


Test 1. Check for loose or damaged air signal line 114 to governor.
• If loose or damaged, repair or replace signal line 114. Refer to paragraph 13-23
in this manual.
• If not loose, go to Test 2.
2-340
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Adjust governor. Refer to paragraph 13-35 in this manual.

• If governor will not adjust, replace it. Refer to paragraph 13-37 in this manual.
• If governor will adjust, go to Test 3.
Test 3. Check safety valve. Pull valve stem - air should come out. Release valve stem - air
should stop.
• If manual release does not work, replace safety valve and/or repair air dryer as
END OF TEST
2-341
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Left and/or Right Windshield Wiper Does Not Work
WARNING


Test 1. Check dash gauge for proper system air pressure, 100-120 psi (689-826 kPa).
GAUGE
2-342
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check windshield wiper air lines and components for leaks or damage.
• If leaking or damaged, repair or replace as needed. Refer to Chapter 22 in this
manual.
• If not leaking or damaged, go to Test 3.
Test 3. Operate either the air horn or windshield washers.

• If either the air horn or the windshield washer operates, go to Test 6.
• If neither the air horn nor the windshield washer operates, go to Test 4.
Test 4. Loosen outlet line 073 from pressure protection valve.

• If air escapes, repair or replace air line 073 between pressure protection valve and
the air manifold. Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 5.
Test 5. Loosen pressure protection valve from bulkhead fitting.

• If air escapes, replace pressure protection valve. Refer to paragraph 13-19 in this
manual.
• If no air escapes, go to Malfunction 1.
2-343
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-344
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Wiper motors and wiper control valves on LVSA1 series vehicles differ slightly from wiper
motors and wiper control valves on non-LVSA1 vehicles. Test procedures are, however,
identical for LVSA1 and non-LVSA1 wiper motors and wiper control valves.
Test 6. Loosen air supply lines (032 and 035) running to non-working windshield wiper
control valve.
• If no air escapes, repair or replace air line (032 or 035) between control valve and
air manifold. Refer to paragraph 13-23 in this manual.
• If air escapes, go to Test 7 for windshield wiper(s) that do not work. Go to Test 8
for windshield wiper(s) that do not park.
Test 7. Drain air system. Remove air line running to non-working windshield wiper motor -
033-left or 036-right. Install test air gauge. Start engine and build air pressure to
100-120 psi (689-826 kPa). Refer to TM 08780B-10. Pull out affected wiper control
valve and turn to HIGH.
• If test air gauge reads 100-120 psi (689-826 kPa), replace windshield wiper
motor. Refer to paragraph 22-3 (or 22-4 for LVSA1 series vehicles only) in this
manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 9.
Test 8. Drain air system. Remove air line running to non-working windshield wiper motor -
034-left or 037-right. Install test air gauge. Start engine and build air pressure to
100-120 psi (689-826 kPa). Refer to TM 08780B-10. Push in affected wiper control
valve and hold.
• If test air gauge reads 100-120 psi (689-826 kPa), replace windshield wiper
motor. Refer to paragraph 22-3 (or 22-4 for LVSA1 series vehicles only) in this
manual.
2-345
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Wiper control valves on LVSA1 series vehicles differ slightly from wiper control valves on
non-LVSA1 vehicles. Test procedures are, however, identical for LVSA1 and non-A1 wiper
control valves.
Test 9. Drain air pressure. Remove test gauge and install air line to windshield wiper motor.
Remove other end of air line from wiper control valve. Install test gauge into wiper
control valve. Start engine and build air pressure to 100-120 psi (689-826 kPa).
Refer to TM 08780B-10. Place wiper control valve in the HIGH position or PARK
position as needed.
• If test air gauge does not read 100-120 psi (689-826 kPa), replace wiper control
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line. Refer
END OF TEST
2-346
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. Windshield Washers Do Not Work
WARNING


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPARTMENT.
NOTE
Washer fluid reservoirs on LVSA1 series vehicles differ from washer fluid reservoirs on non-
A1 vehicles. Test procedures are, however, identical for LVSA1 and non-A1 washer fluid
reservoir.
Test 1. Check washer fluid reservoir for disconnected fluid lines or low fluid level.
• If fluid lines are disconnected, connect them.
• If fluid is low, add fluid.
• If fluid lines are connected and level is correct, go to Test 2.
Test 2. Check dash gauge for 100-120 psi (689-826 kPa) air pressure.
• If not present, go to Malfunction 1.
• If present, go to Test 3.
Test 3. Push in washer control valve.

• If you cannot hear pump running, go to Test 6.
• If you can hear pump running, go to Test 4,
Test 4. Remove fluid discharge hose from top of reservoir. Place a rag over discharge outlet
of reservoir. Push in washer control valve.
• If fluid does not come from discharge outlet, remove reservoir cover and check
for plugged suction screen or clogged discharge hose between pump and reservoir
cover. Clean or replace as needed. Refer to paragraph 22-8 (or 22-9 for LVSA1
series vehicles only) in this manual.
• If fluid is discharged from outlet, go to Test 5.
Test 5. Check for restricted or damaged washer fluid lines or nozzles.

• If restricted or damaged, repair or replace as needed. Refer to paragraph 22-8 (or
22-9 for LVSA1 series vehicles only) in this manual.
2-347
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Washer fluid reservoir and washer control valve on LVSA1 series vehicles differ from washer
fluid reservoir and washer control valve on non-A1 vehicles. Test procedures are, however,
identical for A1 and non-A1 fluid reservoirs and control valves.
Test 6. Remove right air line to washer reservoir cover. Push in washer control valve.
Test 7. Check air hoses from cover to pump motor for restriction or damage.
• If restricted or damaged, repair or replace hoses. Refer to paragraph 22-8 (or 22-9
for LVSA1 series vehicles only) in this manual.
• If not restricted or damaged, replace pump motor and cover. Refer to paragraph
Test 8. With system air pressure available, 100-120 psi (689-826 kPa), operate air horn or
windshield wipers.
• If they do not operate, go to Malfunction 7, Tests 4 thru 6.
• If they do operate, go to Test 9.
Test 9. Remove outlet air line from washer control valve and push washer control valve in.
• If air escapes, repair or replace air hose between control valve and washer
reservoir. Refer to paragraph 22-8 (or 22-9 for LVSA1 series vehicles only) in
this manual.
GAUGE
2-348
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Loosen inlet air line 074 running to washer control valve.
NOTE
Washer control valve on LVSA1 series vehicles differs slightly from washer control valve on
non-A1 vehicles. Test procedures are, however, identical for LVSA1 and non-Al washer
control valves.
• If air escapes, replace washer control valve. Refer to paragraph 22-7 in this
manual.
• If no air escapes, repair or replace inlet air line 074. Refer to paragraph 13-23
in this manual.
END OF TEST
GAUGE
2-349
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Air Horn Does Not Work
WARNING


Test 1. Check dash gauge for 100-120 psi (689-826 kPa).

• If 100-120 psi (689-826 kPa) is not available, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is available, go to Test 2.
Test 2. Operate windshield wipers or washers.

• If they do not operate, go to Malfunction 7, Tests 4 and 5.
• If they operate, go to Test 3.
GAUGE
2-350
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Loosen air line 038 at air horn control valve.

• If air does not escape, repair or replace air line 038 between control valve and air
manifold. Refer to paragraph 13-23 in this manual.
Test 4. Loosen outlet air line at control valve and engage control valve.
• If air does not escape, replace control valve. Refer to paragraph 22-13 in this
manual.
Test 5. Loosen air line at air horn and engage control valve.
• If air does not escape, repair or replace air line between air horn and control
• If air does escape, repair or replace air horns as needed. Refer to paragraphs
22-11 and 22-12 in this manual.
END OF TEST
2-351
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. Axle Differentials Will Not Lock or Unlock
WARNING


Test 1. Check air pressure gauge for 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) are not available, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) are available, go to Test 2.
Test 2. Operate windshield wipers or air horn.

GAUGE
2-352
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Drain air pressure. Remove air line from non-working component.
Air line 069B - Inter-axle lockup No. 1 axle

Air line 069 - Inter-axle lockup No. 3 axle
Air line 069A - CTD lockup No. 1 axle
Air line 069D- CTD lockup No. 2 axle
Air line 069 - CTD lockup No. 3 axle
Air line 069 - CTD lockup No. 4 axle
Install test air gauge into air line. Start engine. Refer to TM 08780B-10. Build air
pressure to 100-120 psi (689-826 kPa). Shift drive line lockup switch to axle lockup
position.
• If 100-120 psi (689-826 kPa) is present, send to Direct Support, Third Echelon,
Maintenance.
• If 100-120 psi (689-826 kPa) is not present, go to Test 4.
Test 4. Loosen air line on the air manifold that supplies the non-working component. Shift
drive line lockup switch to axle lockup position.
• If air escapes, repair or replace air line between air manifold and non-working
component. Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 5 for rear module or Test 6 for front module.
2-353
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-354
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. For rear module, loosen air line 069C at front module air manifold. Shift drive line
lockup switch to axle lockup position.
• If air escapes, repair or replace air line 069C and/or quick couplers to rear module
air manifold. Refer to paragraph 13-23 in this manual.
Test 6. Loosen air line 069 at rear of drive line lockup switch. Shift drive line lockup switch
to axle lockup position.
• If air escapes, repair or replace air line 069 between lockup switch and air
2-355
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Loosen air line 071 from inlet port of axle lockup switch.
• If air escapes, replace drive line lockup switch. Refer to paragraph 13-41 in this
manual.
• If no air escapes, repair or replace air line 071 between air manifold and drive line
lockup switch. Refer to paragraph 13-23 in this manual.
END OF TEST
2-356
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11. Transfer Case Will Not Lockup or Unlock
WARNING


• If 100-120 psi (689-826 kPa) is not available, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is available, go to Test 2.
Test 2. Operate windshield wipers or air horn.

GAUGE
2-357
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Loosen air line 706 at lockup air chamber on transfer case. Shift drive line lockup
switch to transfer case lockup position.
• If air does not escape, go to Test 5.
Test 4. Remove pipe plug from top of declutch housing. Watch for movement of shift rod
when drive line lockup switch is shifted to transfer case lockup position.
• If shift rod moves, send to Direct Support, Third Echelon, Maintenance.
• If shift rod does not move, replace air chamber. Refer to paragraph 9-9 in this
manual.
2-358
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Loosen air line 706 at rear of drive line lockup switch. Shift drive line lockup switch
to transfer case lockup position. If air escapes, repair or replace air line 706 between
lockup switch and air chamber. Refer to paragraph 13-23 in this manual.
Test 6. Loosen air line 071 at inlet port of drive line lockup switch.
• If air escapes, replace drive line lockup switch. Refer to paragraph 13-41 in this
manual.
• If air does not escape, repair or replace air line 071 between lockup switch and air
END OF TEST
GAUGE
2-359
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
12. Braking is Uneven, Slow or Brakes Overheat
WARNING


Test 1. Check brake linings and brake adjustment. Refer to paragraph 13-4 in this manual for
axle No. 1 and paragraph 13-5 in this manual for axles No. 2, 3 and 4.
• If brake linings need replacement, refer to paragraph 13-6 for axle No. 1 and
paragraph 13-7 for axles No. 2, 3 and 4.
• If brakes need adjustment, refer to paragraphs 13-4 and 13-5 in this manual.
• If adjustment or replacement is not needed, go to Test 2.
2-360
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If 100-120 psi (689-826 kPa) are not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) are present, go to Test 3.
Test 3. Check all brake parts for leaks or damage.

• If leaks or damage are found, repair as needed.
WARNING
BEFORE RELEASING PARKING BRAKE, BLOCK WHEELS TO PREVENT

MOVEMENT AND PERSONAL INJURY.
Test 4. Release parking brake. Make sure all air chambers on axles No. 2, 3 and 4 are
completely retracted. Clevis locknut should be even with mounting bracket.
• If any air chamber does not retract completely, go to Malfunction 15 in this
• If all air chambers retract properly, go to Test 5.
Test 5. With parking brake released, apply service brake. Watch brake shoe movement on
No. 1 axle. On axles No. 2, 3 and 4, watch air chamber clevis movement.
• If service brakes apply, disassemble brakes and check for worn, damaged or oil
soaked brake parts. Repair or replace as needed.
• If any service brake does not apply, go to Test 6.
GAUGE
2-361
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-362
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Drain air pressure from system. Remove service brake air line from non-working air
chamber and install test gauge onto air line. Start engine and build air pressure to
100-120 psi (689-826 kPa). Refer to TM 08780B-10. Apply service brake.
• If 40-100 psi (276-689 kPa) is available, replace air chamber. Refer to paragraph
• If 40-100 psi (276-689 kPa) is not available, go to Test 7.
GAUGE
2-363
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Air chambers for axle No. 1 do not have a relay valve. Refer to Test 10.
Test 7. Remove air line from discharge port of relay valve controlling non-working air
chamber. Install test air gauge into relay valve discharge port. Apply service brake.
• If 40-100 psi (276-689 kPa) is present, repair or replace air line between air
chamber and relay valve. Refer to paragraph 13-23 in this manual.
2-364
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Remove air line 623 for No. 2 axle or air line 660 from control port of relay valve for
axles No. 3 and 4. Install test air gauge onto air line. Apply service brakes.
Test 9. Check air line on supply port of non-working relay valve for restriction or damage
(No. 536 for axle No. 2 and No. 014 for axles No. 3 and 4).
• If restricted or damaged, replace air line. Refer to paragraph 13-23 in this
manual.
2-365
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Remove stop light switch from left side of brake treadle valve (upper switch for axles
No. 3 and 4, lower switch for axle No. 2). Install test air gauge and apply service
brake. If 40-100 psi (276-689 kPa) are available, replace air line between treadle
valve and relay valve. Refer to paragraph 13-17 or 13-18 for LVSA1 vehicles in this
manual.
• If 40-100 psi (276-689 kPa) are not available, replace brake treadle valve. Refer
END OF TEST
2-366
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
13. Service Brakes Will Not Release Or Release Slowly
WARNING


• If only one indicator on dash gauge reads 100-120 psi (689-826 kPa), go to
Malfunction 18.
• If 100-120 psi (689-826 kPa) is present on both indicators of dash gauge, go to
Test 2.
GAUGE
2-367
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check air lines, brake chambers, relay valves and treadle valve for leaks or damage.
• If leaking or damaged, repair or replace as needed.
WARNING
BLOCK WHEELS TO PREVENT MOVEMENT AND PERSONAL INJURY WHEN

PARKING BRAKE IS RELEASED.
Test 3. Release parking brake, check that all air chambers retract completely. Clevis locknut
should be even with mounting bracket.
• If any air chamber does not retract completely, go to Malfunction 15.
• If all air chambers retract completely, go to Test 4.
2-368
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Check brake adjustment. Refer to paragraph 13-4 for axle No. 1 and paragraph 13-5
for axles No. 2, 3 and 4.
• If brakes are not adjusted properly, adjust them.
• If brakes are adjusted properly, go to Test 6.
Test 5. Apply and release service brake. Remove air line 623 for axle No. 2 or air line 660
for axles No. 3 and No. 4 at the control port of suspect relay valve.
• If air flow is present at suspect line, replace treadle valve. Refer to paragraph
• If air flow is not present, reconnect air line and go to Test 6.
2-369
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Apply and release service brake. Remove air line from service port of suspect air
chamber.
• If air escapes, replace relay valve. Refer to paragraphs 13-15 and 13-16 in this
manual.
2-370
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Remove brake drum. Check S-cams or wedges for binding. Check brake shoe return
springs for proper operation. Refer to paragraph 13-6 for axle No. 1. Refer to
paragraphs 13-8 and 13-10 for axles No. 2, 3 and 4.
• If any of the above problems are found, repair as needed.
END OF TASK
2-371
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14. Pressure Drops More Than 25 Psi (172 KPa) on Air Pressure Gauge When Brakes are
Applied
WARNING


Test 1. Check for 100-120 psi (689-826 kPa) on air pressure gauge.
Test 2. Check air chambers, air lines, relay valves and treadle valve for leaks or damage.
• If leaks or damage are found, repair or replace as needed.
GAUGE
2-372
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Apply service brakes and note which indicator drops more than 25 psi (172 kPa).
Green - axles No. 1 and 2, red - axles No. 3 and 4.
• If both indicators drop 25 psi (172 kPa) or more, troubleshoot both systems using
Test 4 and Test 6.
• If only one indicator drops 25 psi (172 kPa) or more, troubleshoot the affected
system using Test 4 thru Test 6.
GAUGE
2-373
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Remove air line from control port of affected relay valve. Install test air gauge onto
air line. Apply service brake.
• If air pressure drops over 25 psi (172 kPa) on air pressure gauge, leave air gauge
installed and go to Test 5.
• If air pressure does not drop on air pressure gauge, go to Test 6.
2-374
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Remove stop light switch from brake treadle valve (lower switch - axles No. 1 and 2,
upper switch - axles No. 3 and 4). Install a second test air gauge in stop light switch
port. Apply service brake.
• If air pressure drops 25 psi (172 kPa) at air pressure gauge and both test gauges
read the same, replace brake treadle valve. Refer to paragraph 13-14 in this
manual.
• If air pressure gauge drops 25 psi (172 kPa) and relay valve test gauge reads
lower than the treadle valve test gauge, repair or replace air line between treadle
valve and relay valve. Refer to paragraph 13-23 in this manual.
2-375
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Remove air line from service brake port of suspect brake chamber. Install test air
gauge. Apply service brake.
• If air pressure gauge drops 25 psi (172 kPa), repeat test at each brake chamber
connected to the relay valve. If all brake chambers test the same, replace relay
valve. Refer to paragraphs 13-15 and 13-16 in this manual.
• If air pressure gauge does not drop, replace that brake chamber. Refer to
NOTE
Axle No. 1 brake chambers do not have a relay valve. Test them in the same manner as Test 6,
except if air pressure drops, then repair or replace air line. Refer to paragraph 13-23 in this
manual.
END OF TEST
2-376
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
15. Parking Brakes Will Not Release
WARNING


Test 1. Check for 100-120 psi (689-826 kPa) on air pressure gauge.
• If 100-120 psi (689-826 kPa) are not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is present on only one indicator of dash gauge, go to
Malfunction 18.
GAUGE
2-377
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check air lines, fittings, valves and brake chambers for leaks or damage.
• If damage or leaks are found, repair or replace as needed.
• If no damage or leaks are found, go to Test 3.
Test 3. Remove spring brake air line from non-working brake chamber. Install test air gauge
onto air line. Release parking brake.
• If 100-120 psi (689-826 kPa) is present, replace brake chamber. Refer to
Test 4. Remove air line from suspect spring brake discharge port of relay valve. Install test
air gauge into discharge port. Release parking brake.
• If 100-120 psi (689-826 kPa) is present, repair or replace air line between brake
chamber and relay valve. Refer to paragraph 13-23 in this manual.
2-378
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Remove air line from control port of suspected relay valve (No. 612 for axle No. 2,
No. 622 for axles No. 3 and 4). Install test air gauge into air line. Release parking
brake.
Test 6. Carefully loosen air line on supply port of suspected relay valve (No. 607 for No. 2
axle, No. 620 for axles No. 3 and 4).
• If air escapes, replace relay valve. Refer to paragraphs 13-15 and 13-16 in this
manual.
• If no air escapes, repair or replace air line between relay valve air manifold and
air reservoir. Refer to paragraph 13-23 in this manual.
2-379
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Carefully loosen air line 612 on parking brake control valve. Release parking brake
(push valve in).
• If air escapes, repair or replace air line between control valve and relay valve.
Test 8. Carefully loosen air supply line 611 on parking brake control valve.
• If air escapes, replace control valve. Refer to paragraph 13-21 in this manual.
2-380
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Carefully loosen air line 611 at air manifold (by front glad hands).
• If air escapes, repair or replace air line 611. Refer to paragraph 13-23 in this
manual.
Test 10. Check air lines 618 and 614 for kinks or damage.
• If kinks or damage is not found, go to Test 11.
• If kinks or damage is found, repair or replace lines as needed.
Test 11. Carefully remove air line 614 at air manifold.

• If no air escapes, repair or replace air line 614 between air reservoir and air
Test 12. Carefully remove air line 618 at air manifold.

• If air escapes, replace both check valves. Refer to paragraph 13-24 in this
manual. If problem still exists, replace air manifold. Refer to paragraph 13-24 in
this manual.
• If no air escapes, repair or replace air line 618 between air reservoir and air
END OF TEST
2-381
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
16. Parking Brake Will Not Apply
WARNING


Test 1. Check brake adjustment. Refer to paragraph 13-4 for axle No. 1 and paragraph 13-5
for axles No. 2, 3 and 4.
• If misadjusted, adjust brakes.
• If not misadjusted, go to Test 2.
Test 2. Pull parking brake control knob to apply parking brake.

• If all parking brakes do not apply, go to Test 6.
• If some apply and one or more do not apply, go to Test 3.
2-382
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Loosen air line to the spring chamber that does not apply.
• If brake applies, go to Test 5.
• If brake does not apply, go to Test 4.
Test 4. Apply service brakes and watch actuator linkage.

• If linkage moves and brake applies, replace brake chamber. Refer to paragraph
• If linkage does not move, remove brake drum and repair or replace brake parts as
needed.
Test 5. Release and apply parking brake. Carefully loosen air line to the control port of the
affected relay valve (air line No. 612 for axle No. 2 or air line No. 622 for axles No. 3
or 4).
• If no air escapes, replace relay valve. Refer to paragraphs 13-15 and 13-16 in this
manual.
• If air escapes, replace parking brake control valve. Refer to paragraph 13-21 in
this manual.
END OF TEST
2-383
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-384
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
17. Air Pressure Gauge Indicators Do Not Read The Same
WARNING


Test 1. Check for 100-120 psi (689-826 kPa) on either indicator of the air pressure gauge.
• If 100-120 psi (689-826 kPa) are not present on either indicator, go to
Malfunction 1.
• If 100-120 psi (689-826 kPa) is present on one indicator but not the other, go to
Test 2.
Test 2. Check all air lines, valves, reservoirs and air chambers for leaks or damage.
• If leaks or damage are found, repair or replace as needed.
Test 3. Determine which system has low pressure.

• If green indicator is low, go to Test 4 for primary system.
• If red indicator is low, go to Test 12 for secondary system.
2-385
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-386
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Drain air system and disconnect air line 610 at rear of air pressure gauge. Install test
air gauge into air line No. 610. Start engine and build air pressure. Refer to TM
08780B-10.
• If 100-120 psi (689-826 kPa) is present on test air gauge, replace air pressure
gauge. Refer to paragraph 24-3 in this manual.
2-387
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Disconnect and plug air line No. 619 at brake treadle valve. Start engine and build air
pressure. Refer to TM 08780B-10.
• If green indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
brake treadle valve. Refer to paragraph 13-10 in this manual.
• If green indicator does not read 100-120 psi (689-826 kPa), go to Test 6.
2-388
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Disconnect and plug air line No. 614 at air manifold near the front glad hands. Start
engine and build air pressure. Refer to TM 08780B-10.
check valve in manifold. Refer to paragraph 13-28 in this manual.
2-389
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Disconnect air line No. 619 at left air tank of the MK48. Install test air gauge into air
tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line No.
614, 619 or 610 as needed. Refer to paragraph 13-23 in this manual.
2-390
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Disconnect and plug air line No. 536 at service brake relay valve. Start engine and
build air pressure. Refer to TM 08780B-10.
relay valve. Refer to paragraph 13-15 in this manual.
• If green indicator does not read 100-120 (689-826 kPa), go to Test 9.
2-391
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Disconnect air line No. 536 from left air tank on MK48. Install test air gauge into air
tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If green indicator on air pressure gauge reads 100-120 psi (689-826 kPa), repair or
replace air line No. 536. Refer to paragraph 13-23 in this manual.
Test 10. Disconnect air line No. 613 from left air tank on MK48. Install test air gauge onto
air line. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace inlet check
valve or air tank. Refer to paragraph 13-34 in this manual.
2-392
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 11. Disconnect air line No. 003 from front air tank on MK48. Install test air gauge into
air tank. Start engine and build air pressure. Refer to TM 08780B-10.
003 or pressure protection valve as needed. Refer to paragraphs 13-23 and 13-19
in this manual.
2-393
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
TO PREVENT PERSONAL INJURY, MAKE SURE ALL AIR PRESSURE IS DRAINED
BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.
Test 12. Disconnect air line No. 041 from air pressure gauge. Install test air gauge onto air
line No. 041. Start engine. Refer to TM 08780B-10. Build air pressure.
• If test gauge reads 100-120 psi (689-826 kPa), replace air pressure gauge. Refer
• If test gauge does not read 100-120 psi (689-826 kPa), go to Test 13.
GAUGE
2-394
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 13. Remove air line No. 006 from bulkhead fitting. Install test air gauge into air line No.
006. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), go to Test 14.
Test 14. Remove air line No. 041 from bulkhead fitting. Install test air gauge into bulkhead
fitting. Start engine and build air pressure. Refer to TM 08780B-10.
041 between bulkhead fitting and air gauge. Refer to paragraph 13-23 in this
manual.
Test 15. Remove air line No. 027 from bulkhead fitting and install a plug into bulkhead fitting.
Start engine and build air pressure. Refer to TM 08780B-10.
• If red indicator reads 100-120 psi (689-826 kPa), go to Test 16.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 17.
GAUGE
2-395
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-396
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 16. Disconnect and plug air line No. 027 at trailer brake hand control valve. Start engine
and build air pressure. Refer to TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
control valve. Refer to paragraph 13-39 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), repair or replace air line
No. 027 between control valve and bulkhead fitting. Refer to paragraph 13-23 in
this manual.
Test 17. Remove air line No. 073 from bulkhead fitting and install a plug into the bulkhead
fitting. Start engine and build air pressure. Refer to TM 08780B-10.
• if red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), refer to the
specific malfunction for the windshield wipers, windshield washers, air horn or
axle lockup as needed.
• If red indicator does not read 100-120 psi (689-826 kPa) replace bulkhead fitting.
2-397
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-398
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 18. Disconnect air line No. 005 from right air tank on MK48. Install test air gauge into
air tank. Start engine and build air pressure. Refer to TM 08780B-10.
005 and/or No. 006 as needed. Refer to paragraph 13-23 in this manual.
Test 19. Disconnect air line No. 618 from right air tank on MK48. Install plug into air tank
and test air gauge onto air line No. 618. Start engine and build air pressure. Refer to
TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), repair or
replace air line No. 618 and/or check valve at manifold. Refer to paragraphs
• If test air gauge reads any pressure, replace check valve at manifold. Refer to
WARNING
TO PREVENT PERSONAL INJURY, MAKE SURE ALL AIR PRESSURE IS DRAINED

BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.
Test 20. Disconnect air line No. 621 from right air tank. Install plug into air tank. Start
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), go to Test
21.
2-399
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-400
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 21. Disconnect air line No. 014 at quick disconnect near articulation joint on trailer. Start
• If red indicator reads 100-120 psi. (689-826 kPa), go to Test 23.
Test 22. Disconnect air line No. 621 from spring brake manifold. Install plug into air line.
Start engine and build air pressure. Refer to TM 08780B-10.
spring brake valve. Refer to paragraph 13-20 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), repair or replace air line
621 between spring brake valve and air tank. Refer to paragraph 13-23 in this
manual.
2-401
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 23. Disconnect air line No. 014 at left air tank of trailer. Install plug onto air line. Start
• If red indicator reads 100-120 psi (689-826 kPa), repair or replace air line 014
and/or shut off valve between air tank and quick disconnect. Refer to paragraph
2-402
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 24. Disconnect air line No. 014 from outlet side of right air tank on trailer. Install plug
into air tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If red indicator reads 100-120 psi (689-826 kPa), repair or replace right or left air
tank and/or inter-connecting air line No. 014 as needed. Refer to paragraph
13-33, 13-34 or 13-23.
2-403
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 25. Disconnect air line No. 014 at service brake relay valve on trailer. Install plug onto
air line. Start engine and build air pressure. Refer to TM 08780B-10.
relay valve. Refer to paragraph 13-16 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), repair or replace air line.
END OF TEST
2-404
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
18. Dryer Constantly Cycling or Purging
WARNING


Test 1. Check air system for leaking or damaged air lines, fittings, valves, air tanks or air
chambers.
• If leaks or damage are found, repair or replace as needed. Refer to Chapter 13.
Test 2. Check system air pressure for too high or too low a reading on air pressure gauge.
• If reading is not 100-120 psi (689-826 kPa), adjust governor. Refer to paragraph
• If reading is 100-120 psi (689-826 kPa), go to Test 3.
GAUGE
2-405
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Check for leaking purge valve in air dryer.

• If leaking, repair or replace as needed. Refer to paragraph 13-38 in this manual.
END OF TEST
2-406
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
19. Safety Valve on Air Dryer Releasing Air
WARNING


Test 1. Check for plugged or saturated desiccant cartridge. Refer to paragraph 13-38 in this
manual.
• If plugged or saturated, service air dryer. Refer to paragraph 13-38 in this
manual.
• If not plugged or saturated, go to Test 2.
Test 2. Check for damaged or leaking check valve between air dryer and front air reservoir.
• If leaking or damaged, replace check valve. Refer to paragraph 13-38 in this
manual.
• If not leaking or damaged, replace safety valve on air dryer. Refer to paragraph
END OF TEST
2-407
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-408
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
20. Air Dryer Does Not Purge
WARNING


Test 1. Check system air pressure gauge for 100-120 psi (689-826 kPa).
• If gauge reads between 100-120 psi (689-826 kPa), go to Test 2.
• If gauge does not read between 100-120 psi (689-826 kPa), adjust governor.
GAUGE
2-409
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check for damaged or leaking purge control air line No. 126.
• If damaged or leaking, repair or replace air line as needed. Refer to paragraph
• If not damaged or leaking, replace purge valve. Refer to paragraph 13-38 in this
manual.
END OF TEST
2-410
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
21. Desiccant Material Expelled From Purge Valve
WARNING


Test 1. Check that air dryer is properly mounted.

• If air dryer is loose and vibrating, repair as needed. Refer to paragraph 13-38 in
this manual.
• If air dryer is not loose, go to Test 2.
Test 2. Check desiccant for oil and/or anti-freeze contamination.

• If contaminated with oil or anti-freeze, send to Direct Support/Intermediate (Third
Echelon) Maintenance.
• If not contaminated, go to Test 3.
Test 3. Check heater and thermostat as follows:

1. Cool end cover to below 40 degrees F (4 degrees C).
2. Check for 24 volts on dryer terminal.
• If not present go to Electrical troubleshooting in this section of the manual.
• If 24 volts are present, replace end cover. Refer to paragraph 13-38 in this
manual.
END OF TEST
2-411
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-412
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC STEERING SYSTEM
CAUTION
ALWAYS REINSTALL PROTECTIVE CAPS ON HYDRAULIC FITTINGS AFTER

TESTING IS COMPLETE. FAILURE TO DO SO WILL ALLOW DIRT AND MOISTURE
TO ENTER HYDRAULIC FITTINGS.
1. Vehicle Steers Hard in One or Both Directions
WARNING
• TO PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR

OF VEHICLE WHEN YAW STEERING IS BEING USED. SPECIAL CARE MUST
BE TAKEN WHEN PERSONNEL ARE NEAR THE ARTICULATION JOINT.
• TIRE PRESSURE MUST BE CHECKED PROPERLY OR SERIOUS INJURY OR

DEATH MAY OCCUR.
Test 1 Check tire pressure. Refer to TM 08780B-10, paragraph 2-12.

• If not correct, service tire.
Test 2. Make sure selector valve is in the steering position.

• If not in, push valve to the steering position.
• If in the steering position, go to Test 3.
GAUGE
2-413
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Check for correct oil level and type. Refer to LI 2320-1219, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
Test 4. Check for hydraulic leaks and damaged lines that may cause oil flow restrictions.
• If lines leak or are damaged, repair as needed.
Test 5. Disconnect steering linkage from input side of steering gear. Refer to paragraph 15-
14 in this manual. Turn steering wheel in both directions and check for binding in
column or 90° gear boxes.
• If binding is found, repair or replace as needed. Refer to paragraphs 15-5, 15-6,
15-11 or 15-12 as needed.
• If no binding is found, go to Test 6.
2-414
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check for binding or damage to tie rod on front axle.

• If binding or damage is found, repair or replace as needed. Refer to paragraph
• If no binding or damage is found, go to Test 7.
Test 7. Check front axle ball and socket assemblies for binding or damage.
• If binding or damage is found, send to Direct Support, Intermediate (Third
2-415
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check bellcranks, pitman arm and drag links for binding or damage.
• If binding or damage is found, repair or replace as needed. Refer to paragraphs
15-7, 15-9 and 15-10 in this manual.
2-416
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Check power steering gear for looseness or damage.

• If power steering gear is loose or damaged, send to Direct Support, Intermediate
(Third Echelon) Maintenance.
• If power steering gear is not loose or damaged, go to Test 10.
2-417
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Check yaw control valve and yaw cylinders for damage.
• If damaged, repair or replace as needed. Refer to paragraphs 23-6 and 23-8 in this
manual.
Test 11. Check fuse link and yaw feedback linkage for looseness or damage.
• If loose or damaged, repair or replace as needed. Refer to paragraph 15-13 and
2-418
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 12. Check articulation joint for damage.

• If damage is found, send to Direct Support, Third Echelon, Maintenance.
Test 13. Check steering and front alignment.

• If steering and front alignment are correct, refer to Direct Support, Third Echelon,
Maintenance.
• If steering and front alignment are not correct, perform front alignment. Refer to
END OF TEST
2. Front Wheels Turn, Yaw Cylinders Do Not Move
WARNING
TO PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR OF

VEHICLE WHEN YAW STEERING IS BEING USED. SPECIAL CARE MUST BE TAKEN
WHEN PERSONNEL ARE NEAR THE ARTICULATION JOINT.
2-419
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 1. Make sure selector valve is in the STEERING position.

• If not in STEERING position, push valve to STEERING.
• If in STEERING, go to Test 2.
NOTE
Vehicle must either be in gear or have parking brake released to have yaw steering.
GAUGE
2-420
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check for correct oil level and type. Refer to LI 2320-1219, LO 9-2320-297-12.
• If leaks or damage are found, repair as needed.
Test 4. Check for damaged bellcrank, pitman arm and drag link.
• If damage is present, repair or replace damaged parts as needed. Refer to
• If no damage is present, go to Test 5.
2-421
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If damaged, repair or replace as needed. Refer to paragraphs 23-5 and 23-8 in this
manual.
Test 6. Check yaw feedback linkage for damage and proper adjustment.
• If damaged, repair or replace parts as needed. Refer to paragraph 15-13 in this
manual. If not adjusted properly refer to paragraph 15-17 in this manual.
• If no damage or misadjustment is found, go to Test 7.
2-422
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check fuse link for looseness or damage.

manual.

• If damage is found, send to Direct Support, Intermediate (Third Echelon)
Maintenance for yaw steering repairs.
• If no damage is found, send to Direct Support, Intermediate (Third Echelon)
Maintenance.
END OF TEST
2-423
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Front Wheels Will Not Turn In Either Direction
Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If leaks or damaged lines are present, repair as needed.
GAUGE
2-424
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Disconnect steering linkage from input side of steering gear. Refer to paragraph
15-14 in this manual. Turn steering wheel in both directions and check for binding in
column or 90° gear boxes.
• If binding is found, repair or replace components as needed. Refer to paragraphs
15-5, 15-6, 15-11 or 15-12 in this manual as needed.
• If no binding is found, go to Test 4.
2-425
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check front axle ball and socket assemblies for binding or damage.
• If binding or damage is found, send to Direct Support, Intermediate (Third
2-426
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check bellcranks, pitman arm and drag links for binding or damage.
• If binding is found, repair or replace components as needed. Refer to paragraphs
15-7,15-9 and 15-10 in this manual.
• If no binding or damage is found, refer to Direct Support, Intermediate (Third
END OF TEST
4. Steering is Oversensitive
Test 1. Check bellcrank, pitman arm and drag links for binding or damage.
• If binding or damage is found, repair or replace components as needed. Refer to
2-427
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check yaw control valve for damage.

• If damaged, repair or replace as needed. Refer to paragraph 23-5 in this manual.
• if no damage is found, go to Test 3.
2-428
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If loose or damaged, repair or replace as needed. Refer to paragraph 15-13 and

• If steering and front alignment is correct, refer to Direct Support/Intermediate
• If steering and front alignment is not correct, perform front alignment. Refer to
END OF TEST
5. Vehicle Wanders
WARNING
TO PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR OF

VEHICLE WHEN YAW STEERING IS BEING USED. SPECIAL CARE MUST BE TAKEN
WHEN PERSONNEL ARE NEAR THE ARTICULATION JOINT.
TIRE PRESSURE MUST BE CHECKED PROPERLY OR SERIOUS INJURY OR DEATH
MAY OCCUR.
Test 1. Check tire pressure. Refer to TM 08780B-10, paragraph 2-12.

Test 2. Check bellcrank, pitman arm and drag links for looseness, binding or damage.
paragraph 15-7, 15-9 and 15-10 in this manual.

• If power steering gear is loose or damaged, send to Direct Support/Intermediate
2-429
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-430
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If damaged, repair or replace components as needed. Refer to paragraphs 23-5
2-431
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If loose or damaged, repair or replace as needed. Refer to paragraphs 15-13 and

• If damage is found, send to Direct Support, Intermediate (Third Echelon)
Maintenance.
2-432
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Disconnect steering linkage from input side of steering gear. Refer to paragraph
15-14 in this manual. Turn, steering wheel in both directions and check for binding
or looseness in column or 90° gear boxes.
• If binding or looseness is found, repair or replace components as needed. Refer to
paragraph 15-5, 15-6, 15-11 or 15-12 as needed.
• If no binding or looseness is found, go to Test 8.
2-433
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for binding, looseness or damage to tie rod on front axle.
• If binding, looseness or damage is found, repair or replace as needed. Refer to
• If no binding, looseness or damage is found, go to Test 9.
Test 9. Check front axle ball and socket assemblies for binding, looseness or damage.
• If binding, looseness or damage is found, send to Direct Support, Intermediate
• If no binding, looseness or damage is found, go to Test 10.

• If steering and front alignment is correct, refer to Direct Support, Intermediate
• If steering and front alignment is not corrects perform front alignment. Refer to
END OF TEST
2-434
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WINCH MK15/MK15A1
CAUTION

Winch Will Not Operate In One or Both Directions
WARNING


NOTE
manual.
• Auxiliary hydraulic selector valve must be in the auxiliary hydraulic position.
Test 1. Check hydraulic oil level.

• Add hydraulic oil as needed. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If hydraulic oil level is correct, go to Test 2.
2-435
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Place manual-off-remote switch in the manual position. Without a load on the winch
line, operate the winch in and out.
• If winch does not operate, go to Test 4.
• If winch does operate properly, go to Test 3.
Test 3. Place manual-off-remote switch in the remote position. Using the remote control
unit, operate the winch in and out.
• If high idle engages and lever moves on the main control panel without operating
the winch, refer to Test 6 above.
• If high idle does not engage or lever on main control panel does not move, send to
Direct Support, Third Echelon, Maintenance.
2-436
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Unplug connector MC20 and check for 24 volts at pin A.

• If 24 volts are not present, refer to MK16 WINCH troubleshooting Malfunction 1,
Test 17.
• If 24 volts are present, refer to CRANE ELECTRIC troubleshooting, Malfunction
1.
END OF TEST
2-437
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WINCH MK16/MK16A1
CAUTION

Winch Will Not Operate In One or Both Directions
WARNING


NOTE
• Ignition switch must in ON position for all voltage tests.
manual.
Test 1. Check hydraulic oil level.

• Add hydraulic oil as needed. Refer to LI 2320-1219, LO 9-2320-297-12.
• If hydraulic oil level is correct, go to Test 2.
Test 2. Check all hoses and fittings for leaks or damage.

• If leaks or damage are found, replace hose or fitting. Refer to paragraph 23-14 in
this manual.
2-438
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove cap from connector and check for 24 volts at wire 844 (pin B) on both sides
of connector MC19.
2-439
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Connect remote control unit to vehicle’s connector. Unplug connector MC21 at
control valve. Depress and hold winch OUT button. Check for 24 volts on wire 681
pin No. 3. Depress and hold winch IN button. Check for 24 volts on pin No. 4.
• If 24 volts are present on both pins, go to Test 5.
• If 24 volts are not present on both pins, go to Test 6.
Test 5. Check for continuity at wires 435 (pin 1 and 2) and ground at connector MC21.
• If continuity is found, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).
• If continuity is not found, repair or replace wire(s) 435 between connector MC21
and ground. Refer to paragraph 7-48 in this manual.
2-440
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Remove remote control’s top cover. Check for 24 volts at wire 844 on terminal
NC. 1 of winch OUT switch.
Test 7. Check for 24 volts at jumper wire 279 on terminal No. 4 of winch OUT switch.
• If 24 volts are not present, repair or replace wire 279 between terminals No. 4 and
NC 1. Refer to paragraph 7-48 in this manual.
Test 8. Press and hold winch OUT switch. Check for 24 volts on terminal No. 3 of winch
OUT switch.
• If 24 volts are not present, replace winch OUT switch.
Test 9. Depress and hold winch OUT switch. Check for 24 volts at wire 279 on terminal
NC2 of winch IN switch.
• If 24 volts are not present, repair or replace jumper wire 279 between No. 3
terminal on winch OUT switch and terminal NC2 on winch IN switch. Refer to
Test 10. Depress and hold winch OUT switch. Check for 24 volts at NC1 on winch IN switch.
• If 24 volts are not present, replace winch IN switch. Refer to paragraph 7-48 in
this manual.
Test 11. Check for 24 volts at NC2 terminal of winch OUT switch.
• If 24 volts are not present, replace winch OUT switch. Refer to paragraph 19-4 in
this manual.
Test 12. Check for 24 volts at terminal No. 3 on winch IN switch.

• If 24 volts are not present, repair jumper wire between winch IN and winch OUT
2-441
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 13. Depress and hold winch IN switch. Check for 24 volts at terminal No. 4 on winch IN
switch.
• If 24 volts are not present, replace winch IN switch. Refer to paragraph 19-4 in
this manual.
2-442
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Do Test 14 to check winch IN circuit. Do Test 15 to check winch OUT circuit.
Test 14. Check for 24 volts at wire 682 (pin A) at both sides of connector MC19 with winch
IN switch depressed.
• If 24 volts are not present, repair or replace wire 682 between terminal No. 4 on
winch IN switch and connector MC19.
Test 15. Check for 24 volts at wire 681 (pin C) at both sides of connector MC19 with winch
OUT switch depressed.
• If 24 volts are not present, repair or replace wire 681 between connector MC19
and connector MC21. Refer to paragraph 7-48 in this manual.
Test 16. Check both sides of connector MC19 for 24 volts on wire 844 (pin B).
844 between connector MC19 and winch control switch. Refer to paragraph 7-48
in this manual.
clean, repair or replace connector MC19. Refer to paragraph 7-48 in this manual.
2-443
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 17. Check both sides of connector MC18 for 24 volts on wire 844 (pin N).
this manual.
this manual.
between connector MC6 and connector MC18. Refer to paragraph 7-48 in this
manual.
manual.
2-444
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If 24 volts are present, repair or replace wire 844 between circuit breaker 12 and
connector MC6.
Test 20. Check for 24 volts at input terminal at circuit breaker No. 12.
• If 24 volts are present, replace circuit breaker No. 12.
2-445
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 21 . Check for 24 volts at wire No. 640 at input terminal at circuit breaker No. 11.
• If 24 volts are present, replace buss bar connecting circuit breaker No. 11 and No.
12. Refer to paragraph 7-48 in this manual.
2-446
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

circuit breaker. Refer to paragraph 7-48 in this manual.

Test 24. Check for 24 volts on wire 431 on input side of circuit breaker No. 5.
ignition switch.
• If 24 volts are not present, go to ELECTRICAL SYSTEM, Malfunction No. 3.
END Of TEST
2-447
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
SUSPENSION
1. Vehicle Wanders or Shimmies
Test 1. Check tire pressure. Refer to TM 08780B-10, paragraph 2-12.

Test 2. Check shock absorbers and leaf spring assemblies for loose or damaged capscrews.
• Tighten loose capscrews securely.
• If capscrews are tight, go to Test 3.
Test 3. Check shock absorbers for damage or leaks.

• Replace damaged or leaking shock absorber(s). Refer to paragraph 17-3 of this
manual.
• If shock absorbers are not damaged or leaking, go to Test 4.
Test 4. Check torque rod mounting capscrews for damage or looseness.

• Replace or tighten all damaged or loose capscrews. Refer to paragraph 17-4 of
this manual.
• If problem still exists, go to Test 5.
2-448
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check tie rod ends, bellcrank, pitman arm and drag links for looseness, binding or
damage.

• If power steering gear is loose or damaged, send to Direct Support/Intermediate
2-449
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check front axle ball and socket assemblies for looseness, binding or damage.
• If looseness, binding or damage is found, send to Direct Support/Intermediate
• If no looseness, binding or damage is found, go to Test 9.
Test 9. Inspect wheel bearings for looseness, binding damage or wear. Refer to paragraph
14-3 or 14-4 in this manual.
• If looseness, binding, damage or wear is found, replace and/or adjust wheel
bearings. Refer to paragraph 143 or 14-4 in this manual.
• If no looseness, binding, damage or wear is found, go to Test 10.

• If steering and front alignment is correct, refer to Direct Support/Intermediate
• If steering and front alignment is not correct, perform front alignment. Refer to
END OF TEST
2-450
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Vehicle Leans To One Side
Test 1. Check all torque rods for damage.

• Replace all damaged torque rods. Refer to paragraph 17-4 and 17-5 in this
manual.
• If torque rods are not damaged, go to Test 2.
Test 2. Check all torque rod mounting capscrews for damage or looseness.
• Replace or tighten all damaged or loose capscrews. Refer to paragraph 17-4 and
17-5 of this manual.
• If problem still exists, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
END OF TEST
2-451
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CRANE ELECTRIC- MK15A1 AND MK17A1
1. Crane Does Not Operate
NOTE
• Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches
must be in the ON position for all voltage checks.
• Selector valve must be pulled out.
• Before performing crane troubleshooting procedures, the following items must be

verified:
• Make sure the PARKING BRAKE is applied.
• Make sure the transmission is in NEUTRAL.
• Make sure hydraulic steering system is functioning properly.
• Make sure the front power unit’s electrical system is functioning properly.
Test 1. Attempt to extend/lower outrigger beams/jack cylinders using crane controls on main
control valve bank.
• If outrigger beams/jack cylinders begin to extend and/or lower, problem is with
the crane electrical system. Refer to Test 3.
• If outrigger beams/jack cylinders do not move, go to Test 2.
2-452
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Push in Hydraulic Pressure Manual Override button and attempt to extend/lower
outrigger beams/jack cylinders, using crane controls on main control valve bank.
• If outrigger beams/jack cylinders begin to extend and/or lower, the problem is
with the crane electrical system or the hydraulic system shutdown solenoid, go to
Test 3.
• If the outrigger beams/jack cylinders do not move, the problem is with the
hydraulic system, go to Test 14.
Test 3. Loosen four screws and clips and open crane junction box cover. Check for 24 volts
between junction box terminal strip, position 1 and known good ground.
2-453
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Turn the IGNITION switch OFF. Disconnect rear module to crane connector MC20.
Check for 24 volts at wire 840, pin A.
• If 24 volts are present, the rear module electrical system is OK, the problem is in
the crane electrical system. Reconnect crane connector MC20 and go to Test 5.
• If 24 volts are not present, the problem is with the front or rear module electrical
system. Go to CRANE ELECTRIC Troubleshooting, Malfunction 1, Crane
Inoperative, Tests 5.1 through 5.6.
2-454
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Check for 24 volts between junction box terminal strip, position 2 and known good
ground.
• If 24 volts are not present, repair black wire between terminal strip, position 2 and
crane connector MC20. Refer to the electrical schematics and paragraph 7-48 in
this manual.
Test 6. Check for 24 volts at crane MAIN POWER switch (white wire).
• If 24 volts are not present, repair white wire between terminal strip, position 2 and
crane MAIN POWER switch. Refer to the electrical schematics and paragraph
Test 7. Check for 24 volts at crane MAIN POWER switch (black wire).
• If 24 volts are present, repair black wire from crane MAIN POWER switch to
terminal strip, position 1. Refer to the electrical schematics and paragraph 7-48 in
this manual.
• Reset crane MAIN POWER switch to OFF then to ON. If 24 volts are found
intermittently, check for shorts in the circuit. If no shorts are found and 24 volts
are still present intermittently or not at all, replace the crane MAIN POWER
Test 8. Check for 24 volts between junction box terminal strip, position 17 and a known good
ground.
2-455
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-456
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. With ignition switch in the OFF position, remove the three electrical connectors from
the Overload Shutdown System central unit. Inspect the electrical terminals for
damage or moisture.
• If electrical terminals are damaged or corroded, repair connector(s). Refer to
• If there is moisture inside the connectors, let the connectors dry out. After the
plugs have completely dried out, apply a light coat of dielectric grease to the wire
terminals of the plug. Reassemble the connectors and close the shell tight. Make
sure the cable strain reliefs are tight.
• If the electrical terminals appear to be OK, send to Direct Support/Intermediate
2-457
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Check for 24 volts between junction box terminal strip, position 5 and known good
ground.
Test 11. Check for 24 volts between shutdown relay, black wire, located in the junction box
and known good ground.
• If 24 volts are not present, repair black wire from terminal strip, position 17, to
shutdown relay. Refer to paragraph 7-48 in this manual.
Test 12. With ignition switch in the OFF position, check for continuity between black wire
and white wire (pins 3 & 4) on shutdown relay located in junction box.
• If no continuity is found, replace shutdown relay. Refer to paragraph 21-3 in this
manual.
• If continuity is found, repair white wire from shutdown relay to terminal strip,
position 5. Refer to paragraph 7-48 in this manual.
Test 13. Remove electrical connector from hydraulic system shutdown solenoid. With
ignition and MAIN POWER switches ON, check for 24 volts between terminals on
solenoid connector, position terminal on terminal 1 and negative terminal on terminal
2.
• If 24 volts are present, replace hydraulic system shutdown solenoid. Refer to TM
08780B-34, paragraph 19-43.
• If 24 volts are not present, repair white wire from terminal strip, position 5, to
hydraulic system shutdown solenoid or black wire from hydraulic system
shutdown solenoid to junction box ground strip. Refer to paragraph 7-48 in this
manual.
Test 14. Check hydraulic lines, hoses and fittings for leaks or damage that could restrict flow.
• If leaking or damaged lines are found, repair or replace lines as needed. Refer to
Test 15. Replace crane high pressure hydraulic filter, refer to paragraph 23-7. Start engine and
attempt to extend/lower jack cylinders.
• If jack cylinders operate properly, problem has been corrected.
• If problem remains, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
END OF TEST
2-458
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-459
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Remote Control Does Not Operate
NOTE
Before performing crane troubleshooting procedures, the following items must be verified:
• Make sure the transmission is in
• NEUTRAL. Make sure hydraulic steering system is functioning properly.
Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.
Test 1. Disconnect remote control cable from remote control hook-up connector on crane
sub-frame. Check for 24 volts between terminal H and known good ground.
• If 24 volts are not present, no power is getting to the remote control cable. There
is an open circuit in the black wire between terminal strip positions 1 and 7 or an
open circuit in the violet wire between terminal strip position 7 and the remote
control hook-up, terminal H. Refer to paragraph 7-48 in this manual.
2-460
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-461
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Is there continuity measured between remote control hook-up connector, terminal B
and known good ground?
• If continuity is not found, repair green wire between remote control hook-up
connector and ground terminal strip in crane junction box. Refer to paragraph
Test 3. Disconnect the remote control cable from the remote control unit. Check the cable
for continuity between the two cable ends on terminals B and H, one at a time.
• If continuity is not found on either location, replace the remote control cable.
• If continuity is found, reconnect the cable to the remote control unit and the
remote control hook-up connector. Then, go to Test 4.
2-462
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Turn MAIN POWER switch to the OFF position. Remove swing controller from
remote control unit for access to EMERGENCY STOP switch. Remove
EMERGENCY STOP switch from remote control unit, but do not disconnect wires.
Refer to paragraph 21-18 in this manual for specific instructions.
CAUTION
DO NOT ALLOW EMERGENCY STOP SWITCH, SWING CONTROLLER WIRES OR

TERMINALS TO CONTACT REMOTE CONTROL UNIT DURING TEST. FAILURE TO
COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT.
Turn MAIN POWER switch to ON position. Check for 24 volts at terminal of wire 4
of EMERGENCY STOP switch.
• If 24 volts are not present, turn MAIN POWER switch OFF and repair wire 4
inside remote control unit between EMERGENCY STOP switch and remote
control unit cable connector.
2-463
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Place EMERGENCY STOP switch in ON position. Check for 24 volts at terminal of
wire 8A of EMERGENCY STOP switch.
• If 24 volts are not present, EMERGENCY STOP switch is faulty. Refer to
• If problem remains, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
END OF TEST
2-464
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-465
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Hoist Does Not Lower With Remote Control
NOTE
• Make sure the PARKING BRAKE is applied
Test 1. Loosen screw and remove connector from hoist DOWN solenoid. Place MAIN
POWER and EMERGENCY STOP switches in ON position. Hold remote control
unit hoist controller in DOWN position and check for 24 volts between solenoid
connector, terminal 1 and known good ground. Connect connector and tighten screw.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 8.
Test 2. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal G.
• If no continuity is found on terminal G, replace the remote control cable.
2-466
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove hoist controller from remote control unit. Refer to paragraph 21-18 in this
manual. Place EMERGENCY STOP switch in ON position. Check for continuity
between the following locations:
From remote control cable connector pin To controller connector terminal

location: location:
Check 1 H 8E
Check 2 G 16
Check 3 B 2G
• If no continuity is found, repair the wiring within the remote control unit. Refer
2-467
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Tag and mark connectors on hoist controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:
Switch Terminals: Controller handle Test results:

position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full UP position No continuity (open)
Check 4 NO to COM Full UP position Continuity
• If the above test results are not obtained, replace switch(es). Refer to paragraph
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 5.
Test 5. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, blue wire, with controller lever in DOWN
position, to known good ground. Turn MAIN POWER switch OFF.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
• If 24 volts are present, reassemble remote control unit and go to Test 6.
Test 6. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
16 and known good ground with hoist controller held in the DOWN position. Turn
MAIN POWER switch to the OFF position.
• If 24 volts are not present, repair orange wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
Test 7. Check for continuity between terminal strip, position 16 and hoist DOWN solenoid
connector, position 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 16 and hoist DOWN solenoid. Refer to paragraph 7-48 in this manual.
2-468
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for continuity between hoist DOWN solenoid connector, position 2 and known
good ground.
• If no continuity is found, repair hoist DOWN solenoid ground circuit. Refer to
Test 9. Perform a resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specification, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.
END OF TEST
2-469
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-470
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Hoist Does Not Raise With Remote Control
NOTE
Test 1. Are the boom up and down and telescope out functions also not working?
• If none of the above listed functions operate, send to Direct Support/Intermediate
• If boom up/down and telescope out function properly, go to Test 2.
Test 2. Loosen screw and remove connector from hoist UP solenoid. Place ignition and
EMERGENCY STOP switches in ON position. Hold remote control unit hoist
controller in UP position and check for 24 volts between solenoid connector, terminal
1 and known good ground.
two cable ends, terminal F.
• If no continuity is found on terminal F, replace the remote control cable.
2-471
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-472
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Remove hoist controller from remote control unit. Refer to paragraph 21-18 in this
manual for specific instructions. Place EMERGENCY STOP switch in ON position.
Check for continuity between the following locations:

location: location:
Check 1 H 8E
Check 2 F 15
Check 3 B 2G
2-473
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Tag and mark connectors on hoist controller switches. Remove the connectors from

position:
go to Test 6.
2-474
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check for 24 volts from controller harness, white wire, with controller lever in UP
15 and known good ground with hoist controller held in the UP position. Turn MAIN
POWER switch to the OFF position.
• If 24 volts are not present, repair black wire between remote control hook-up
2-475
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-476
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for continuity between terminal strip, position 15 and hoist UP solenoid
connector, terminal 1.
position 15 and hoist UP solenoid. Refer to paragraph 7-48 in this manual.
Test 9. Check for continuity between hoist UP solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair hoist UP solenoid ground circuit. Refer to
2-477
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Perform a resistance check of solenoid coil. Resistance should between 23.7 and 26.3
ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
END OF TEST
2-478
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Boom Does Not Lower With Remote Control
NOTE
Test 1. Are the boom up, hoist up and telescope out functions also not working?
• If boom up, hoist up and telescope out function properly, go to Test 2.
Test 2. Loosen screw and remove connector from boom DOWN solenoid. Place
EMERGENCY STOP switch in ON position. Hold remote control unit boom
controller in DOWN position and check for 24 volts between solenoid connector,
terminal 1 and known good ground.
• If 24 volts are not present, turn MAIN POWER switch OFF and go to Test 9.
two cable ends, terminal N.
• If no continuity is found on terminal N, replace the remote control cable.
2-479
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-480
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Remove boom controller from remote control unit. Refer to paragraph 21-18 in this

location: location:
Check 1 H 8D
Check 2 N 13
Check 3 B 2F
Test 5. Tag and mark connectors on boom controller switches. Remove the connectors from

position:
go to Test 6.
2-481
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-482
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check for 24 volts from controller harness, blue wire, with controller lever in DOWN
13 and known good ground with boom controller held in the DOWN position. Turn
• If 24 volts are not present, repair pink wire between remote control hook-up
2-483
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-484
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for continuity between terminal strip, position 13 and boom DOWN solenoid
position 13 and boom DOWN solenoid. Refer to paragraph 7-48 in this manual.
Test 9. Check for continuity between boom DOWN solenoid connector, terminal 2 and
known good ground.
• If no continuity is found , repair boom DOWN solenoid ground circuit. Refer to
26.3 ohms.
END OF TEST
2-485
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-486
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. Boom Does Not Raise With Remote Control
NOTE
Test 1. Are the boom down, hoist up and telescope out functions also not working?
• If boom down, hoist up and telescope out function properly, go to Test 2.
Test 2. Loosen screw and remove connector from boom UP solenoid. Place EMERGENCY
STOP switch in ON position. Hold remote control unit boom controller in UP
position and check for 24 volts between solenoid connector, terminal 1 and known
good ground.
two cable ends, socket M.
• If no continuity is found on terminal M, replace the remote control cable.
2-487
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-488
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Remove boom controller from remote control unit. Refer to paragraph 21-18 in this

location: location:
Check 1 H 8D
Check 2 M 14
Check 3 B 2F
2-489
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Tag and mark connectors on boom controller switches. Remove the connectors from

position:
2-490
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14 and known good ground with boom controller held in the UP position. Turn
• If 24 volts are not present, repair brown wire between remote control hook-up
2-491
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-492
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for continuity between terminal strip, position 14 and boom UP solenoid
position 14 and boom UP solenoid. Refer to paragraph 7-48 in this manual.
Test 9. Check for continuity between boom UP solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair boom UP solenoid ground circuit. Refer to
26.3 ohms.
2-493
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-494
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Boom Does Not Telescope In With Remote Control
NOTE
Test 1. Loosen screw and remove connector from telescope IN solenoid. Place
EMERGENCY STOP switch in ON position. Hold remote control unit telescope
controller in IN position and check for 24 volts between solenoid connector, terminal
1 and known good ground.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test B.
two cable ends, terminal D.
• If no continuity is found on terminal D, replace the remote control cable.
2-495
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-496
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove telescope controller from remote control unit. Refer to paragraph 21-18 in
this manual. Place EMERGENCY STOP switch in ON position. Check for
continuity between the following locations:

location: location:
Check 1 H 8B
Check 2 D 12
Check 3 B 2C
2-497
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Tag and mark connectors on telescope controller switches. Remove the connectors
from the two controller switches. Check each switch for continuity between the
following switch terminal locations, with the controller lever in the position noted:

position:
Check 3 NC to COM Full OUT position No continuity (open)
Check 4 NO to COM Full OUT position Continuity
go to Test 5.
2-498
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
position to known good ground. Turn MAIN POWER switch to the OFF position.
2-499
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
12 and known good ground with telescope controller held in the IN position. Turn
• If 24 volts are not present, repair white wire between remote control hook-up
2-500
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for continuity between terminal strip, position 12 and telescope IN solenoid
position 12 and telescope IN solenoid. Refer to paragraph 7-48 in this manual.
Test 8. Check for continuity between telescope IN solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair telescope IN solenoid ground circuit. Refer to
• If continuity is found, go to Test 9
26.3 ohms.
END OF TEST
2-501
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. Boom Does Not Telescope Out With Remote Control
NOTE
Test 1. Are the boom up and down and hoist up functions also not working?
• If none of the above listed functions operate send to Direct Support/Intermediate
• If boom up/down and hoist-up function properly, go to Test 2.
Test 2. Loosen screw and remove connector from telescope OUT solenoid. Place MAIN
unit telescope controller in OUT position and check for 24 volts between solenoid
connector, terminal 1 and known good ground.
two cable ends, terminal C.
• If no continuity is found on terminal C, replace the remote control cable.
2-502
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-503
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Remove telescope controller from remote control unit. Refer to paragraph 21-18 in
this manual. Place EMERGENCY STOP switch in ON position. Check for
continuity between the following locations:

location: location:
Check 1 H 8B
Check 2 C 11
Check 3 B 2C
2-504
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Tag and mark connectors on telescope controller switches. Remove the connectors
from the two controller switches. Check each switch for continuity between the
following switch terminal locations, with the controller lever in the position noted:

position:
Check 3 NC to COM Full OUT position No continuity (open)
Check 4 NO to COM Full OUT position Continuity
go to Test 6.
2-505
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check for 24 volts from controller harness, blue wire, with controller in DOWN
position to known good ground. Turn MAIN POWER switch OFF.
2-506
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11 and known good ground with telescope controller held in the OUT position. Turn
• If 24 volts are not present, repair yellow wire between remote control hook-up
2-507
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Check for continuity between terminal strip, position 11 and telescope OUT solenoid
position 11 and telescope OUT solenoid. Refer to paragraph 7-48 in this manual.
Test 9. Check for continuity between telescope OUT solenoid connector, terminal 2 and
known good ground.
• If no continuity is found, repair telescope OUT solenoid ground circuit. Refer to
Test 10. Perform a resistance check of solenoid coil. Resistance should be 23.7 to 26.3 ohms.
2-508
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Crane Will Not Swing Clockwise Using Remote Control
NOTE
Test 1. Loosen screw and remove connector from swing CW solenoid. Place MAIN
unit swing controller in CW position and check for 24 volts between solenoid
two cable ends, terminal L.
• If no continuity is found on terminal, replace the remote control cable.
2-509
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-510
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove swing controller from remote control unit. Refer to paragraph 21-18 in this

location: location:
Check 1 H 8C
Check 2 L 10
Check 3 B 2B
2-511
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Tag and mark connectors on swing controller switches. Remove the connectors from

position:
Check 3 NC to COM Full CW position No continuity (open)
Check 4 NO to COM Full CW position Continuity
go to Test 5.
2-512
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check for 24 volts from controller harness, blue wire, with controller lever to CW
position to known good ground. Turn MAIN POWER switch to OFF position.
2-513
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10 and known good ground with swing controller held in the CW position. Turn
MAIN POWER switch to OFF position.
• If 24 volts are not present, repair tan wire between remote control hook-up
2-514
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for continuity between terminal strip, position 10 and swing CW solenoid
position 10 and swing CW solenoid. Refer to paragraph 7-48 in this manual.
Test 8. Check for continuity between swing CW solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair swing CW solenoid ground circuit. Refer to
26.3 ohms.
END OF TEST
2-515
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-516
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. Crane Will Not Swing Counterclockwise Using Remote Control
NOTE
Test 1. Loosen screw and remove connector from swing CCW solenoid. Place MAIN
unit swing controller in CCW position and check for 24 volts between solenoid
two cable ends, terminal A.
• If no continuity is found on terminal A, replace the remote control cable.
• if continuity is found, go to Test 3.
2-517
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-518
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove swing controller from remote control unit. Refer to paragraph 21-18 in this

location: location:
Check 1 H 8C
Check 2 A 9
Check 3 B 2B
2-519
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Tag and mark connectors on swing controller switches. Remove the connectors from

position:
Check 3 NC to COM Full CCW position No continuity (open)
Check 4 NO to COM Full CCW position Continuity
go to Test 5.
2-520
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check for 24 volts from controller harness, blue wire, with controller lever in CCW
position to known good ground. Turn MAIN POWER switch to OFF position.
2-521
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
POWER switch to ON position. Check for 24 volts between terminal strip, position 9
and known good ground with swing controller held in the CCW position. Turn
MAIN POWER switch to OFF position.
• If 24 volts are not present, repair red wire between remote control hook-up
2-522
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for continuity between terminal strip, position 9 and swing CCW solenoid
position 9 and swing CCW solenoid connector, terminal 1. Refer to paragraph
Test 8. Check for continuity between swing CCW solenoid connector, position 2 and known
good ground.
• If no continuity is found, repair swing CCW solenoid ground circuit. Refer to
Test 9. Perform resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
END OF TEST
2-523
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-524
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11. Tilt Alarm Does Not Operate
NOTE
• Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches
must be in the ON position for all voltage checks.
• Tilt alarm must be properly adjusted before troubleshooting is attempted. Refer to

paragraph 21-5 for adjustment procedure.
Test 1. Remove tilt alarm from mounting bracket to gain access to red wire. Are 24 volts
present at red wire on tilt alarm.
• If 24 volts are not present, repair red wire between tilt alarm and terminal 1 in
crane electrical junction box. Refer to paragraph 7-48 in this manual.
2-525
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Does tilt alarm sound when green wire terminal on tilt alarm is jumpered to a known
good ground
• If tilt alarm sounds, go to Test 3.
• If tilt alarm does not sound, replace tilt alarm. Refer to paragraph 21-5 in this
manual.
2-526
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Loosen four screws and clips and open crane junction box cover. Check for
continuity on green wire between tilt alarm switch and tilt alarm.
• If is not found, repair green wire. Refer to paragraph 7-48 in this manual.
2-527
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Is continuity measured across tilt alarm switch?

• If continuity is not found, replace tilt alarm switch. Refer to paragraph 21-3 in
this manual.
2-528
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Check for continuity on black wire between tilt sensor wire harness and power
ground block in junction box.
• If continuity is not found, repair black wire. Refer to paragraph 7-48 in this
manual.
2-529
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check continuity on white wire between tilt sensor wire harness and tilt sensor
switch.
• If continuity is not found, repair white wire. Refer to paragraph 7-48 in this
manual.
2-530
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for 24 volts at tilt alarm sensor red wire.

• If 24 volts are not present, repair red wire. Refer to paragraph 7-48 in this
manual.
2-531
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Remove green wire at tilt alarm. Are 24 volts present at green wire?
• If 24 volts are not present, replace tilt alarm sensor. Refer to paragraph 21-5 in
this manual.
2-532
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 9. Press down on one corner of the tilt alarm sensor. Does voltage lower on the green
wire from 24 volts to about .6 volts?
• If voltage does not lower from 24 volts, replace tilt alarm sensor. Refer to
END OF TEST
2-533
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CRANE HYDRAULICS- MK15A1 AND MK17A1
1. Outriggers Beams/Jack Cylinders Do Not Operate
NOTE
Test 1. Push in Hydraulic Pressure Manual Override button and attempt to extend/lower
outrigger beams/jack cylinders, using crane controls on main control valve bank.
• If outrigger beams/jack cylinders begin to extend and/or lower, the problem is
with the crane electrical system or the hydraulic system shutdown solenoid, go to
Malfunction 1, Crane does not operate, Test 3.
• If the outrigger beams/jack cylinders do not move, go to Test 2.
• If no leaks or damage are found, send to Direct Support/Intermediate (Third
Echelon) Maintenance,
END OF TEST
2-534
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Boom Does Not Raise or Lower
NOTE
This malfunction applies when both the remote control and manual control operations are
affected.
Test 1. Are the two hoses and fittings between the BOOM manual control valve and boom
hydraulic cylinders free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
Test 2. Are the three hoses and fittings between the two boom hydraulic cylinders free of
damage, crimps or leaks?
• If no leaks or damage are found, send to Direct Support, Intermediate (Third
END OF TEST
2-535
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-536
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Boom Does Not Telescope
NOTE
affected.
Test 1. Are the hoses and fittings between the TELESCOPE manual control valve and
telescope hydraulic cylinder free of damage, crimps or leaks?
Test 2. Are the three hoses and fittings going to the telescope hydraulic cylinder free of
damage, crimps or leaks?
Test 3. Attempt to telescope boom out. Check for dry boom wear pads.
• Lubricate dry boom wear pads. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If boom wear pads are OK or boom sections cannot be telescoped out, send to
Direct Support/Intermediate (Third Echelon) Maintenance.
END OF TEST
2-537
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-538
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Hoist Does Not Operate
NOTE
affected.
Test 1. Are tubes, hoses and fittings between the HOIST manual control valve and hoist
hydraulic motor manifold free of damage, crimps or leaks?
Test 2. Are the hoses and fittings between the hoist hydraulic motor manifold and the hoist
brake free of damage, crimps or leaks?
Test 3. Are the hoses and fittings between the hoist hydraulic motor and the return line tee
fitting free of damage, crimps or leaks?
END OF TEST
2-539
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-540
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Crane Does Not Swing
NOTE
affected.
Test 1. Are tubes, hoses and fittings between the SWING manual control valve and swing
hydraulic motor manifold free of damage, crimps or leaks?
Test 2. Are the hoses and fittings between the swing hydraulic motor manifold and the swing
brake free of damage, crimps or leaks?
Test 3. Are the hoses and fittings between the swing hydraulic motor and the return line tee
fitting free of damage, crimps or leaks?
END OF TEST
2-541
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-542
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. Mast Does Not Raise or Lower
NOTE
Test 1. Push in Hydraulic Pressure Manual Override button and attempt to raise/lower mast,
using crane controls on main control valve bank.
• If mast begins to raise and/or lower, go to Malfunction 1, Crane does not operate,
Test 3.
• If the mast does not move, go to Test 2.
paragraph 23-14.
END OF TEST
2-543
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-544
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CRANE ELECTRIC
CAUTION

1. Crane Inoperative
NOTE
• Make sure ignition switch is in ON position.
• Make sure MANUAL-OFF-REMOTE switch is in MANUAL position.
Test 1. See if the selector valve is in the Auxiliary Hydraulics position.

• If not, pull selector valve to the Auxiliary Hydraulics position.
GAUGE
2-545
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. Check for low hydraulic oil at reservoir.

• If low, add hydraulic as required. Refer to LI 2320-12/9, LO 9-2320-297-12 for
correct oil type and amount.
2-546
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
• If leakage or damaged lines are present, repair or replace lines as needed. Refer
• If no leaks or damage is present, go to Test 4.
Test 4. Move electrical failure valve to the CLOSED position.

• If crane will now operate manually, go to Test 5.
• If crane will not operate manually, send to Direct Support/Intermediate (Third
2-547
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. Unplug connector MC20 on main power cable. Check for 24 volts on pin A.
• If 24 volts are found, go to Test 6.
2-548
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
When told to check both sides of a plug or connector, probe both the male and female parts.
Probe from the rear of the plug or connector, at the wire or pin called for in the test. This will
check the continuity of the plug or connector and let you know if it is usable or needs repair.
Unless told to do so in the test being done, do not disconnect plug or connector.
Test 5.1. Check for 24 volts on both sides of connector MC18, wire 840 (pin F).
• If 24 volts are found on both sides of connector MC18, repair or replace wire 840
between connector MC18 and MC20. Refer to paragraph 7-48 in this manual.
• If 24 volts are found on one side of connector MC18 and not on the other side,
this manual.
2-549
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5.2. Check for 24 volts on wire 840 terminal of relay No. 4.
relay No. 4. Refer to paragraph 7-48 in this manual.
Test 5.3. Check for 24 volts on wire 840A terminal of Relay No. 4.
• If 24 volts are present, go to Test 5.6.
Test 5.4. Check for 24 volts on wire 840A terminal of circuit breaker No. 13.
and relay No. 4. Refer to paragraph 7-48 in this manual.
Test 5.5. Check for 24 volts on wire 736A terminal of circuit breaker No. 13.
• If 24 volts are not present, repair or replace wire 736A between circuit breaker
No. 13 and circuit breaker No. 4. Refer to paragraph 7-48 in this manual.
this manual.
Test 5.6. Check for 24 volts on wire 735 terminal of relay No. 4.
• If 24 volts are not present, repair or replace wire 735 between relay No. 4 and
• If 24 volts are present, go to Test 5.7.
2-550
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5.7. Check ground (wire 843) of relay No. 4.

• If ground wire is bad, repair or replace ground wire 843. Refer to paragraph 7-48
in this manual.
• If ground wire is good, replace relay No. 4. Refer to paragraph 7-28 in this
manual.
2-551
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Remove cover from junction box. Check for 24 volts on input side of circuit breaker
No. 1.
• If 24 volts are not present, repair or replace wire between circuit breaker No. 1
and pin A of connector MC20. Refer to paragraph 7-48 in this manual.
Test 7. Check for 24 volts on output terminal of circuit breaker No. 1.

• If 24 volts are not present, replace circuit breaker. Refer to paragraph 20-10 in
this manual.
2-552
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 8. Pull boot back and check for 24 volts on black wire on the neutral switch at the
electrical failure valve.
• If 24 volts are not present, repair or replace black wire between circuit breaker
No. 1 and neutral switch. Refer to paragraph 7-48 in this manual.
Test 9. Check for 24 volts on brown wire at neutral switch on electrical failure valve.
• If 24 volts are not present, replace neutral switch. Refer to paragraph 20-8 in this
manual.
Test 10. Unplug connectors at crane wire harness. Leading into the solenoid dump valve.
Check female connector on harness side for 24 volts.
• If 24 volts are not present, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
Test 11. Unplug connector at crane wire harness leading into the solenoid dump valve. Check
continuity between male connector on harness side and a known good ground.
• If continuity is found, replace solenoid dump valve. Refer to paragraph 20-20 in
this manual.
2-553
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 12. Disconnect male connector at crane wire harness leading into remote actuator box.
Check continuity between male connector and a good ground.
• If continuity is not found, go to Test 13. Leave connector disconnected.
• If continuity is found, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
Test 13. Check continuity between male connector and terminal No. 3 on terminal board
No. 2.
• If continuity is not found, repair or replace white wire between male connector
and terminal No. 3. Refer to paragraph 7-48 in this manual.
2-554
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 14. Unplug connector MC20 on main power cable. Check for continuity between pin B
on chassis side of harness and ground.
• If continuity is not found, repair or replace wire 435 between pin B and ground.
• If continuity is found, go to Test 15. Leave connector MC20 disconnected.
Test 15. Check for continuity between pin B on crane side of connector MC20 and terminal
No. 3 of terminal board No. 2.
• If continuity is not found, repair or replace white wire/and or jumper wire
between pin B of connector MC20 and terminal No. 3. on terminal board No. 2.
• If continuity is found, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
END OF TEST
2-555
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Remote Control Does Not Work
WARNING

NOTE
Unless called for in test being done, all electrical tests will be done with ignition switch ON,
selector valve - in auxiliary position (OUT) and crane unstowed.
Test 1. Check that manual-off-remote switch is in remote position.

• If switch is not in correct position, move to remote position.
• If switch is in correct position, go to Test 2.
Test 2. Check that electrical failure valve is in open (vertical) position.

• If not in correct position, move valve handle to vertical position.
• If in correct position, go to Test 3.
2-556
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Perform remote control bypass test.

Step 1. Remove remote control and cable from stowage compartment.
Step 2. At remote control stowage compartment, remove test plug from stowage
receptacle by pushing up on latch.
Step 3. Install test plug into cable receptacle and lock in place with latch.
CAUTION
TEST PLUG BUTTON SHOULD ONLY BE PRESSED BRIEFLY, PROLONGED
APPLICATION OF BUTTON WILL RESULT IN DAMAGED ACTUATOR BOX WIRING.
Step 4. Have helper briefly press in red button on test plug. Check that all control
levers are locked into center (neutral) position. A resistance should be felt and
levers will have little movement. These levers should be in a straight line.
• If any lever will not lock or does not line up, refer to Direct
Support/Intermediate (Third Echelon) Maintenance.
• If all levers lock and are lined up, go to test 4:
Test 4. Connect a known good remote control cable to remote control and connector.
Perform pre-operational safety check steps 8 through 12. Refer to para 2-16 or 2-32
in TM 08780B-10.
• If the remote control does not operate, contact Direct Support/Intermediate (Third
Echelon) Maintenance for repair of remote control.
• If remote control now operates, replace remote control cable.
END OF TEST
2-557
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Capacity Alert System Does Not Work (Crane Overload Protection)
NOTE
• Unless called for in test, all electrical tests will be done with ignition switch ON,
selector valve in auxiliary position (OUT) and crane unstowed.
• Remove capacity alert proximity switch and housing. Manually engage switch. Refer
Test 1. Make sure manual-off-remote switch is in manual position.

• If not in manual position, place switch in manual position.
• If switch is in manual position, go to Test 2.
Test 2. Make sure electrical failure valve is in open position (vertical).

• If not in open (vertical), open valve.
• If electrical failure valve is open (vertical), go to Test 3.
2-558
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Remove cover from junction box. Check for 24 volts on input side of circuit breaker
No. 2 (black wire).
• If 24 volts are not present, repair or replace black jumper wire between circuit
breakers number 1 and 2. Refer to paragraph 7-485 in this manual.
Test 4. Check for 24 volts on output terminal of circuit breaker No. 2.

• If 24 volts are not present, replace circuit breaker. Refer to paragraph 20-10 in
this manual.
Test 5. Check for 24 volts on terminal 1 of terminal block No. 1.

• If 24 volts are not present, repair or replace wire between circuit breaker No. 2
and terminal No. 1 of terminal board No. 1. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present, go to Test b.
2-559
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Remove insulation from proximity switch on folding boom. Refer to paragraph 20-5
in this manual. Check for 24 volts on brown/green wire.
• If 24 volts are not present, repair brown/green wire between proximity switch and
terminal 1 of terminal block No. 1. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, insulate brown/green wire and go to Test 7.
2-560
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 7. Check for continuity between blue/white wire and terminal No. 3 on terminal board
No. 2.
• If no continuity is found, repair white wire between proximity switch and terminal
No. 3 on terminal board No. 2. Refer to paragraph 7-48 in this manual.
• If continuity is found, reinsulate wires and go to Test 8.
Test 8. Remove black wire from relay terminal 85 in junction box. Using meter probe, pierce
the insulation at the black wire of proximity switch on folding boom. Check
continuity of black wire between proximity switch and end of wire.
• If no continuity is found, repair black wire. Refer to paragraph 7-48 in this
manual.
• If continuity is found, reconnect wire at relay and go to Test 9.
Test 9. Using a jumper wire, connect terminal 85 of relay to terminal 3 of terminal block No.
2. Remove black wire from relay terminal 30. Turn ignition ON and check for 24
volts on relay terminal 30.
• If 24 volts are present, replace proximity switch. Refer to paragraph 20-5 in this
manual.
• If 24 volts are not present, remove jumper wire, reconnect black wire to relay, an
go to Test 10.
2-561
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 10. Remove black wire from relay terminal 86. Check for 24 volts on black wire.
• If 24 volts are not present, repair or replace black wire between terminal 1 of
terminal block No. 1 and relay terminal 86. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present, reconnect black wire and go to Test 11.
Test 11. Remove black wire from relay terminal 87. Check for 24 volts on black wire.
• If 24 volts are not present, repair or replace black wire between terminal 1 on
terminal block No. 1 and relay terminal 87. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present, reconnect black wire and go to Test 12.
Test 12. Remove black wire from relay terminal 85. Using a jumper wire, connect terminal 85
to terminal 3 on terminal block No. 2. Remove black wire from relay terminal 30.
Check for 24 volts on relay terminal 30.
2-562
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 13. Check for 24 volts on pin A of capacity alert solenoid dump valve connector.
• If 24 volts are not present, repair or replace black wire between relay terminal 30
and pin A. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to test 14.
Test 14. Check for continuity between ground and pin B of capacity alert solenoid dump valve
connector.
• If continuity is not found, repair or replace white wire between pin B and terminal
7 of terminal block No. 2. Refer to paragraph 7-48 in this manual.
• If continuity is found, send to Direct Support, Third Echelon, Maintenance.
END OF TEST
2-563
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CRANE HYDRAULICS - MK15 AND MK17
CAUTION

1. Crane Functions are Slow
NOTE
• Transmission in neutral.
• Make sure the front power units electrical system is functioning properly.

GAUGE
2-564
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Check hydraulic line, hoses and fittings for leaks or damage that could restrict flow.
• If leakage or damaged lines are present, repair or replace lines as needed. Refer
• If no leakage or damage is present, go to Test 4.
Test 4. Check auxiliary hydraulic relief pressure, refer to paragraph 23-3 in this manual.
• If pressure is correct, go to Test 5.
• If pressure is not correct, adjust as required to obtain operating pressure, go to
Test 5.
• If adjustment cannot be obtained, refer problem to Direct Support/Intermediate
Test 5. Check main crane relief pressure. Refer to paragraph 20-33 of this manual.
• If pressure is correct, refer problem to Direct Support/Intermediate (Third
• If pressure is not correct, adjust as required to obtain operating pressure.
• If adjustment cannot be obtained, refer problem to Direct Support/Intermediate
END OF TEST
2-565
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Outrigger Beams Will Not Extend or Retract or Operate Slowly
NOTE
• Transmission in neutral.
• Make sure the hydraulic steering system is functioning properly.
Test 2. See if the selector valve is fully engaged in the Auxiliary Hydraulics position.
Test 3. See if the MANUAL/REMOTE switch is in the MANUAL position.

• If not, move switch to MANUAL.
• If switch is in MANUAL, go to Test 4.
2-566
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. See if the STABILIZER CYLINDER LOCK valve is in the LOCK position.
• If not, move to the LOCK position.
• If in the LOCK position, go to Test 5.
2-567
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. See if the STABILIZER EXTENSION lock valve is in the UNLOCK position.
• If not, move to the UNLOCK position.
• If in the UNLOCK position, go to Test 6.
2-568
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-569
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check stabilizer controls for full travel and smoothness (lack of binding).
• If controls do not operate properly, refer to paragraphs 20-30 and 20-31 in this
manual.
• If controls operate properly, go to Test 7.
NOTE
If outrigger beams will not extend, go to Test 7. If outrigger will not retract, go to Test 9.
Test 7. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge at test port on main control valve.
Start engine and allow to run at idle. Operate NEAR SIDE and FAR SIDE stabilizer
controls to fully extend outrigger beams. Check for 1,550-1,650 psi (10,687-11,377
kPa) at 130-150°F (54-66°C) reservoir temperature.
• If pressure is within specifications, go to Test 8.
• If pressure is not within specifications, refer to Direct Support/Intermediate (Third
Test 8. Inspect hoses, lines and fittings for damage or leaks.

• If damage or leakage are present, repair or replace parts as needed. Refer to
• If damage or leaks are not present, refer to Direct Support/Intermediate (Third
Test 9. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge at test port on main control valve.
Start engine and allow to run at idle. Operate NEAR SIDE and FAR SIDE stabilizer
control levers to fully retract outrigger beams. Check for 3,000 psi (20,685 kPa) at
130-150°F (54-66°C) reservoir temperature.
Test 10. Inspect STABILIZER SELECTOR/LOCKING control valves, cylinders and lines for
damage or leaks.
• If damage or leaks are present, repair or replace parts as needed. Refer to
paragraphs 20-13, 20-14, 20-30, 20-31 and 23-14 in this manual.
• If damage or leaks are not present, refer to Direct Support/Intermediate (Third
2-570
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
GAUGE
GAUGE
2-571
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Stabilizer Leg Will Not Extend or Retract or Operates Slowly
NOTE
• Make sure the PARKING BRAKE is applied and transmission is in neutral.
GAUGE
2-572
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. See if the selector valve is fully engaged in the Auxiliary Hydraulics position.
Test 3. See if the MANUAL/REMOTE switch is in the MANUAL position.

• If not, move switch to MANUAL.
• If switch is in MANUAL, go to Test 4.
2-573
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. See if the STABILIZER EXTENSION LOCK valve is in the LOCK position.
• If not, move to the LOCK position.
• If in the LOCK position, go to Test 5.
2-574
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 5. See if the STABILIZER CYLINDER lock valve is in the UNLOCK position.
• If not, move to the UNLOCK position.
• If in the UNLOCK position, go to Test 6.
2-575
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 6. Check stabilizer controls for full travel and smoothness (lack of binding).
• If controls do not operate properly, refer to paragraph 20-32 in this manual.
NOTE
If the stabilizer will not extend or moves slowly, continue to Test 7. If the stabilizer will not
retract or moves slowly, go to Test 9.
Test 7. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and allow to run at idle speed. Operate STABILIZER controls to fully
extend stabilizers. Check for 1,550-1,650 psi (10,687-11,377 kPa) at 130-150°F (54-
66°C) reservoir temperature.
Test 8. Check for blockage or restrictions in supply lines, lock valves, return lines and
manifold.
• If blockage or restrictions are found, repair or replace parts as needed. Refer to
paragraphs 23-14, 20-22, 20-18 and 20-19 in this manual.
• If blockage or restrictions are not found, refer to Direct Support/Intermediate
Start engine and allow to run at idle speed. Operate STABILIZER controls to fully
retract stabilizers. Check for 2,500-3,500 psi (17,237.5-24,132.5 kPa) at 130-150°F
(54-66°C) reservoir temperature.
Test 10. Check for blockage or restrictions in supply lines, lock valves, return lines and
manifold.
• If blockage or restrictions are found, repair or replace parts as needed. Refer to
paragraphs 23-14, 20-22, 20-18 and 20-19 in this manual.
• If blockage or restrictions are not found, refer to Direct Support/Intermediate
END OF TEST
2-576
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
GAUGE
GAUGE
2-577
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Stabilizer Legs Will Not Hold Load
NOTE
GAUGE
Test 2. Inspect all stabilizer CYLINDER LOCK AND EXTENSION LOCK valves for
damage, restrictions and blockage.
• If valve damage, restrictions or blockage are not present, go to Test 3.
• If valves are not functioning properly, repair or replace defective valves. Refer to
2-578
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Inspect stabilizer for damage.

• if damage is present, replace stabilizer. Refer to paragraph 20-15 in this manual.
• If damage is not present, go to Test 4.
Test 4. Inspect hoses, lines and fittings for leaks.

• If leakage is present, repair or replace parts as needed. Refer to paragraph 23-14.
• If no leakage is present, go to Test 4.1.
Test 4.1. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and run at idle speed. Operate STABILIZER controls to fully extend
stabilizers. Check for 1,550-1,650 psi (10,687-11,377 kPa) at 130-150°F (54-66°C)
reservoir temperature.
Test 5. Remove line from piston side of stabilizer leg and lockout valve. Install a 0-2,000 psi
(0-13,790 kPa) pressure gauge in line between stabilizer leg and lockout valve.
Extend stabilizer leg and close lockout valve. Check pressure gauge and record
reading. Have assistant operate control valve to extend stabilizer leg. Check pressure
gauge and record pressure reading.
• If pressure increase is noted, replace lockout valve. Refer to paragraph 20-22.
• If no pressure increase is noted; replace stabilizer cylinder. Refer to paragraph
20-19.
END OF TEST
GAUGE
2-579
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Crane Will Not Rotate, Rotates Slowly or Rotates In Only One Direction
NOTE
• Before performing crane troubleshooting procedures, the following items must be
verified:
GAUGE
2-580
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. See if MANUAL/REMOTE switch is in the desired operating function.

• If in the REMOTE position and the crane still will not rotate, refer to CRANE
ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the crane still will not rotate, go to Test 3.
Test 3. See if the crane is overloaded.

• If crane is overloaded, reduce crane’s reach or load.
• If crane is not overloaded, go to Test 4.
Test 4. Check for binding at crane base.

• If binding is present, refer to Direct Support/Intermediate (Third Echelon)
Maintenance.
• If binding is not present, go to Test 5.
2-581
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Start engine and let run at idle. Operate ROTATION control lever fully in each
direction. Check in each direction for 2,700-2,800 psi (18,616.5-19,306 kPa) at 130-
150°F (54-66°C) reservoir temperature.
• If pressure is within specifications, refer to Direct Support/Intermediate (Third
• If pressure is not within specifications, inspect hoses, lines and fittings for leaks
or damage. If no damage or leaks are found, refer to Direct Support/Intermediate
END OF TEST
GAUGE
GAUGE
2-582
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. Main Boom Will Not Operate
NOTE
• Make sure the front power unit’s electrical-system is functioning properly.
GAUGE
2-583
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 2. See if REMOTE/MANUAL switch is in the desired operating function.

• If in the REMOTE position and the main boom still will not operate, refer to
CRANE ELECTRICAL troubleshooting in this section of the manual.
• If in the MANUAL position and the main boom still will not operate, go to Test 3.
Test 3. Check MAIN BOOM control for full travel and smoothness (lack of binding).
• If control does not operate properly, refer to paragraphs 20-30 in this manual.

Test 5. Check for binding at the boom cylinder or restrictions in the lines.
• If binding or restrictions are present, lubricate cylinder or replace lines. Refer to
Lubrication Instruction (LI 2320-12/9, LO 9-2320-297-12) or paragraph 23-14 in
this manual.
• If binding or restrictions are not present, go to Test 6.
NOTE
If the main boom will not move upward, continue to Test 6. If the main boom will not lower,
go to Test 7.
Start engine and let run at idle. Lift MAIN BOOM control lever fully up. Check for
2,700-2,800 psi (18,616.5-19,306 kPa) at 130-150°F (54-66°C) reservoir temperature.
• If pressure is within specifications and boom still will not move or moves slowly,
go to Test 7.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3.
2-584
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
GAUGE
GAUGE
2-585
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Start engine and let run at idle. Hold MAIN BOOM control lever fully down. Check
for 2,450-2,550 psi (16,892.8-17,582.2 kPa) at 130-150°F (54-66°C) reservoir
temperature.
check capacity alert system for proper operation. Refer to CRANE
ELECTRICAL troubleshooting in this section of the manual.
auxiliary selector relief setting. Refer to paragraph 23-3.
END OF TEST
GAUGE
GAUGE
2-586
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Folding Boom Will Not Operate
NOTE

GAUGE
2-587
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. See if the MANUAL/REMOTE switch is in the desired operating function.

• If in the REMOTE position and the folding boom still will not operate, refer to
CRANE ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the folding boom still will not operate, go to Test
4.
2-588
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Check FOLDING BOOM control for full travel and smoothness (lack of binding).
• If control does not operate properly, refer to paragraph 20-31 in this manual.
• If control operates properly, go to Test 5.

Test 6. Check for binding at the cylinder or restrictions in the lines.

• If binding or restrictions are present, lubricate cylinder or replace lines. Refer to
lubrication instructions (LI 2320-12/9, LO 9-2320-297-12) or paragraph 23-14 in
this manual.
NOTE
If the folding boom will not move upward, continue to Test 7. If folding boom will not lower,
go to Test 8.
2-589
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Start engine and run at idle. Operate FOLDING BOOM control lever to fully raise
the boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-
• If pressure is within specifications and the folding boom will not move or moves
slowly, go to Test 8.
auxiliary selector relief setting. Refer to paragraph 23-3 in this manual.
Start engine and run at idle. Operate FOLDING BOOM control lever-to fully lower
boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-66°C)
reservoir temperature.
END OF TEST
2-590
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
GAUGE
GAUGE
2-591
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. Extension Boom Will Not Operate
NOTE
• Make sure PARKING BRAKE is applied and transmission is in neutral.
GAUGE
2-592
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

• If in the REMOTE position and the extension booms still will not operate, refer to
CRANE ELECTRICAL troubleshooting in this section of the manual.
• If in the MANUAL position and the extension booms still will not operate, go to
Test 3.
Test 3. Check EXTENSION BOOM control for full travel and smoothness (lack of binding).
• If control does not operate properly, refer to paragraphs 20-31 in this manual.
• If control operates properly, go to Test 4.
2-593
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for binding along extension beams and at cylinder. Also check for restriction
in lines.
• If binding or restrictions are present, lubricate extension beams or replace lines.
Refer to Lubrication Instructions (LI 2320-12/9, LO 9-2320-297-12) or paragraph
2-594
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Start engine and run at idle. Operate EXTENSION BOOM control lever to fully
extend boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-
END OF TEST
GAUGE
GAUGE
2-595
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Crane Will Not Lift Load
NOTE
Test 2. See if the MANUAL REMOTE switch is in the desired operating function.
• If in the REMOTE position and the crane still will not operate, refer to CRANE
ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the crane still will not operate, go to Test 3.

GAUGE
2-596
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 4. Install a 0-5,000 psi (0-34,34,475 kPa) pressure gauge on test port at main control
valve. Start engine and run at idle. Operate FOLDING BOOM control lever to fully
raise boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-
66°O reservoir temperature.
END OF TEST
GAUGE
GAUGE
2-597
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
MK15 A-FRAME HYDRAULICS
A-Frame Cylinder Will Not Operate or Operates Slowly
NOTE

GAUGE
2-598
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Test 3 not required for LVSA1 series vehicles.

• If in the REMOTE position and the A-Frame cylinder still will not operate, refer
to CRANE ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the A-Frame cylinder still will not operate, go to
Test 4.
Test 4. Check hydraulic lines, hoses, quick disconnects and fittings for leaks, damage or
loose connections that could restrict flow.
• If damaged or leaking lines are present, repair or replace lines as needed. Refer to
• If no damage or leaks are present, refer to Direct Support/Intermediate (Third
END OF TEST
2-599
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ANTILOCKING BRAKE SYSTEM
One or Both ABS Warning Lights Come on and Remain on
WARNING

BEFORE PERFORMING ANY TROUBLESHOOTING TEST

DRAINED BEFORE REMOVING ANY AIR LINES OR AIR CONNECTIONS
Test 1. Connect Info-Centre to test port on MK48/48A1 or rear body unit, as required.
Verify passenger side sensor is properly connected and positioned by rotating
curbside hub or wheel at a rate of approximately 1 revolution every 2 seconds. Refer
to paragraph 13-43.
• Info-Centre should display a bar in the 2B location, to left of 07 display while
wheel is turning. If not proceed to Test 3.
NOTE
Info-Centre may also lock sensor display by pressing on right hand button on face of Info-
Centre. Display will show WHL to left. You may then spin wheel and display will show S2B to
indicate this sensor is sensing wheel motion. This feature allows one person to perform this
test.
Test 2. Connect Info-Centre to test port on MK48/48Al or rear body unit, as required. Verify
passenger side sensor is properly connected and positioned by rotating curbside hub
or wheel at a rate of approximately 1 revolution every 2 seconds. Refer to paragraph
13-43.
• Info-Centre should display a bar in the 2A location, to left of 07 display while
wheel is turning. If not proceed to Test 3.
NOTE
Info-Centre may also lock sensor display by pressing on right hand button on face of Info-
Centre. Display will show WHL to left. You may then spin wheel and display will show S2A to
indicate this sensor is sensing wheel motion. This feature allows one person to perform this
test.
2-600
TM 08780B-20
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Test 3. Connect Info-Centre to test port on MK48/48Al or rear body unit, as required. Drive
vehicle above 6 miles per hour. ABS indicator lights should remain off. Info-Centre
display code should change from 07 to 00 and sensor indicator bars on each side of
the 00 should be displayed.
• If code other than 00 appears, record the code and follow the procedures for that
code in Table 2-2, Antilocking Brake System Diagnostics Codes.
END OF TEST
2-601
TM 08780B-20
Table 2-2. Antilocking Brake System Diagnostics Code
CODE MALFUNCTION CORRECTIVE ACTION

06, 07, 8.8, Indicates system is working A 00 with the vehicle moving or 07 while
A4, A5, C 1 stationary indicates that there are no active
faults.
Al-A5 are configuration codes and may not be

present. Ignore these.
8.8 is a self-diagnostics test.
C1 indicates the ABS is a 2S/2M system.

03 or 04 Wheel speed sensor or its Disconnect relevant sensor connector from
wiring has a short or open sensor. With a Volt/Ohm meter, measure the
circuit. resistance between the two pins in the sensor
connector housing. The resistance reading
should be between 980 and 2350 ohms. If the
reading is not within those specifications,
replace the sensor in accordance with paragraph
13-43 of this manual.
Disconnect wire harness from ECU. Check

main wire harness for open circuit or shorts in
sensor cable. Pins number 1 and 10 are for 2A
driver (roadside) sensor and pins number 2 and
11 are for 2B (curbside) sensor. Replace cable
in accordance with paragraph 13-43 of this
manual.
Check harness for damaged pins. Replace cable

in accordance with paragraph 13-43 of this
manual.
13 or 14 Wheel speed sensor out put While rotating wheel by hand, at a minimum of
(occurs when is insufficient when vehicle 1 revolution every 2 seconds, with a Volt/Ohm
vehicle is is moving. Gap between meter, measure AC voltage at sensor. Voltage
moving) sensor and exciter is too should be a minimum of 200 mil-volts. If
great. reading is less than 200 mil-volts, push sensor
until it touches exciter. Retest. If reading is
still less than 200 mil-volts, replace sensor.
2-602
TM 08780B-20
Table 2-2. Antilocking Brake System Diagnostics Code (Continued)
CODE MALFUNCTION CORRECTIVE ACTION

NOTE
If gap on both sensors is too great, fault
reading may not register. If ECU isn’t getting
voltage from either sensor, ECU will assume
vehicle is stationary; even when it is not. If
you suspect this is the case, check each wheel
separately for output.
23 or 24 Indicates there is an Check for broken sensor retaining clip,
(occurs when intermittent loss of sensor damaged exciter or excessive wheel bearing
vehicle is signal when vehicle is endplay at suspected wheel. Repair or replace
moving) moving. as necessary.
Check for loose, damaged or corroded sensor

electrical connection or broken cable. If cable
shows visible signs of external damage, perform
resistance and continuity check as in Codes 03
and 04. Clean, repair or replace components as
required. Retest system.
42 or 43 Wheel is slow to come back Check to ensure that brakes are releasing
(occurs when up to full speed when ABS completely. If not releasing properly, adjust
vehicle is releases brakes during ABS brakes. Retest system.
moving) event.
Check delivery hoses and tubing for damage.
Replace as necessary. Retest system.
Check exhaust port of ABS valve for

obstruction. Clean obstruction and retest
system.
Check primary air system for proper operation.

Retest system.
50, 51, 52 or ABS solenoid valve is Check valve for open circuit, short circuit or a
53 (occurs defective. short circuit to power supply. Replace solenoid.
when brakes Retest system.
are applied)
Check that all cable connectors are connected
properly and free of corrosion. Clean and
tighten cables as required. Retest system.
62, 63, 68 or Solenoid or its cable has an Disconnect appropriate solenoid connector and
69 open circuit. with a Volt/Ohm meter, check resistance at
solenoid pins. Reading across two bottom pins
should be between 30 and 36 ohms. Reading
between either one of the bottom pins and top
2-603
TM 08780B-20
pin should be between 15-18 ohms. If readings

are not within specifications, replace solenoid.
Retest system.
Check female terminals on connector for

excessive pin spread or corrosion. Clean pins
on terminal as necessary. Replace defective
hardware as required. Retest system.
Check that main wiring harness 28-pin

connector is completely latched to ECU and no
harness pins are damaged. Replace hardware as
necessary. Retest system.
Remove harness from ECU and using a

Volt/Ohm meter, check resistance between pins
3 and 13, 3 and 23, and 13 and 23 on blue valve
cable and pins 4 and 14, 4 and 24, and 14 and
24 on yellow valve cable. Resistance should be
approximately 32 ohms between pins 3 and 13
and 4 and 14. Resistance should be
approximately 16 ohms between pins 3 and 23,
13 and 23, 4 and 24, and 14 and 24. If
resistance is not within those specifications,
replace harness.
72, 73, 78 or Solenoid or cable has a short Check solenoid and cable for damage, excessive
79 circuit to ground (negative). wear, and chafing or exposed wires. Replace as
necessary.
Disconnect harness from ECU and using a

Volt/Ohm meter, check resistance between
vehicle chassis and pins 3, 13, and 23 for blue
valve and pins 4, 14, and 24 for yellow valve.
If resistance is less than 10 M ohms between
any pins, replace harness and retest.
If code still exists, replace ECU and retest.

82, 83, 88 or Solenoid or cable has a short Remove harness from ECU and using a
89 circuit to B+ (positive 28 Volt/Ohm meter, check for continuity between
volts) caused by damaged pins 3, 13 and 23 for blue valve cable and 4, 14,
solenoid or cable. and 24 for yellow cable and vehicle B+, with
battery and start switch in “ON” or “RUN”
position. If resistance is less than 10 M ohms
between any pin and B+, mover battery and
2-604
TM 08780B-20
start switch to “OFF” position. Replace

suspected components and retest system.
If code still exists, replace ECU and retest.

91 ABS voltage is below 8 Check for damaged or corroded wires, terminal
volts. or splice in ABS power supply circuit. Clean or
replace hardware as required. Check ground
and power connection. Retest system.
If power is coming from some where other than

the vehicle electrical system, make sure that test
battery is fully charged or voltage converter has
adequate voltage (21.0 to 33.0 volts) and current
capacity (11 amps).
NOTE
Do not use a battery charger.
92 ABS supply voltage is above Check voltage regulator for proper operation. If
33.1 volts. malfunctioning, replace.
If ABS system is being powered by a source

other than batter and start switch, verify power
supply is between 21.0 and 33.0 volts. Power
up system and retest.
80, 93, 99, ECU is defective. Replace ECU and retest.
EO-E9 or EA-
EF NOTE
If E-2 code appears on INFO-CENTRE, check
relay on ABS light before changing ECU.
13, 14, 23, 24, A “CA” code is an invitation to clear all faults
42, 43, CA or stored in history.
CC
NOTE
This will not be erased from memory until
vehicle is driven above 6 mph.
A “CC” code will be displayed during third

consecutive time that a Clear All is attempted.
This is an invitation to Clear Configuration and
should be avoided. If a “CC” is displayed,
power system down and power back up.
2-605
TM 08780B-20
ABS warning light stays on Power up ABS system. ABS warning lamp
permanently. should come on for 2 seconds then go off. If
light stays on, check wiring to light or for a fault
in the ABS system.
Check for diagnostic fault codes. If any code

other than 07 appears, review procedures in this
table that coincides with that code. After
problem is repaired, clear all stored faults and
cycle power to system to verify light goes out.
If a 07 is displayed and ECU memory contains a

13, 14, 23, 24, 42 or 43 code, the vehicle must
be driven above 6 mph to cause ABS light to go
out.
If there are no stored faults and a 07 code is

displayed and the ABS light is still on, the ABS
lamp is incorrectly wired. Refer to paragraph 7-
56 and correct any wiring problems and retest.
ABS warning light does not With vehicle battery and start switch “ON”,
illuminate. ABS warning lamp should illuminate. If it does
not, check function of lamp by applying 24
volts to lamp lines 3 and 4 (line 4 is positive and
line 3 in negative). If lamp does not illuminate,
replace lamp.
If lamp illuminates, check 3-amp fuse connector

for continuity. Replace connectors or fuse as
needed. Retest.
If lamp still doesn’t not illuminate, check

vehicle electrical system for faults.
2-606
TM 08780B-20
Section IV. Maintenance Procedures
2-8. INTRODUCTION
This section describes general procedures that apply to all parts of this manual. To avoid
repetition, these procedures will not be described in specific maintenance sections.
2-9. GENERAL REMOVAL INSTRUCTIONS
a. Work Required. Remove only those parts needing repair or replacement, Do not
disassemble a component any further than needed.
b. Preparation. Before removing any part of the electrical, hydraulic or air systems,
make certain system is not energized or pressurized. Disconnect battery cables. Relieve all
pressure from air system. Make sure brakes are locked and that all controls are in OFF position
before starting any removal procedure.
c. Removal. Make sure there is enough clearance to remove part. Disassemble

truck or adjacent parts as needed to provide working clearance.
d. Lifting. Always use chain hoist, jack or other aid when lifting heavy parts. Make
certain load limit of lifting device exceeds weight being lifted. Position and rig lifting device
before disconnecting part for removal.
e. Identification. Tag or mark all similar parts, such as electrical leads, before
disconnecting and removing such parts. This will make proper assembly easier. Be sure to
identify mating ends of electric, hydraulic and air lines as they are disconnected.
f. Position of Valves. Before removing valve handles, mark or diagram their

positions when open and closed. This will help during assembly.
g. Electrical Wires. Electrical wires are identified on the electrical schematic by a

three digit number. The actual wire may be identified by two digits if number is less than 100.
2-10. GENERAL DISASSEMBLY INSTRUCTIONS
a. Cleanliness. Work area must be kept as clean as possible. This will prevent
contamination of internal parts. This is especially true for valves, cylinders and other hydraulic
or air system parts.
b. Expendable Parts. As indicated in this manual, all gaskets, packings and seals
removed during repair must be discarded and replaced with new parts. These items are usually
damaged during removal. In the same way, all lockwire, lockwashers, cotter pins and like items
must be replaced at time of assembly.
2-607
TM 08780B-20
c. Removing Seals. -When removing gaskets, packings or seals, do not use any
metal tool that will scratch the surfaces next to these items.
d. Disassembly. Before disassembly of any item, study the illustration carefully.

Note relationship of internal parts. Knowing details of a component will speed up disassembly
and assembly and will help avoid mistakes.
e. Parts Protection. To prevent moisture and dirt from entering open housings, lines
and other openings, apply protective caps and plugs as soon as possible after disassembly. Wrap
all removed parts in clean paper or dip parts in preservative oil.
2-11. GENERAL CLEANING INSTRUCTIONS
WARNING
• CLEANING SOLVENTS MAY BE TOXIC TO SKIN, EYES AND RESPIRATORY

TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR
PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY
ADEQUATE.
• NEVER USE GASOLINE TO CLEAN PARTS. GASOLINE IS HIGHLY

FLAMMABLE. SERIOUS PERSONAL INJURY COULD RESULT IF FUEL
IGNITES DURING CLEANING.
CAUTION
• PETROLEUM SOLVENTS MAY DAMAGE PARTS THAT ARE IN CONTACT

WITH HYDRAULIC FLUIDS.
• DO NOT CLEAN TIRES, LUBRICANT SEALS, RUBBER HOSES OR

ELECTRICAL COMPONENTS WITH SOLVENT MIXTURE.
a. Cleaning Solvents. Use only approved cleaning solvents to clean parts. Dry
cleaning solvent, PD 680 is commonly used. Always work in a well ventilated area.
WARNING
COMPRESSED AIR USED FOR CLEANING AND DRYING PURPOSES WILL NOT
EXCEED 30 PSI. USE ONLY WITH EFFECTIVE CHIP GUARDING AND PERSONAL
PROTECTIVE EQUIPMENT (GOGGLES/SHIELD, GLOVES, ETC.).
b. Removing Deposits. After soaking parts in solvent, wash away deposits by

flushing or spraying. Where necessary, brush with a soft bristle brush moistened in solvent. Use
compressed air to dry all parts, except bearings. Bearings must be allowed to air dry.
2-608
TM 08780B-20
c. Tools. Do not use scrapers, wire brushes, abrasive wheels or compounds in

cleaning parts, unless called for in detailed instructions. These procedures may weaken a highly
stressed part.
d. Ball and Roller Bearings. When cleaning ball or roller bearings, place them in a
basket and suspend them in a container of dry cleaning solvent. If needed, use a brush to remove
caked grease, chips, etc. Avoid rotating bearing before solid particles are removed to prevent
damaging races and balls. When bearings have been cleaned, coat them lightly with lubricating
oil to remove solvent.
e. Rubber Parts. Do not clean O-rings or other rubber parts in dry cleaning solvent.
These parts should be wiped clean with a clean, dry, lint-free cloth.
WARNING
STEAM CLEANING CREATES HAZARDOUS NOISE LEVELS AND SEVERE BURN

POTENTIAL. EYE, SKIN AND EAR PROTECTION IS REQUIRED.
f. Exterior Parts. Steam clean all exterior parts thoroughly before removing. This
will make inspection and disassembly easier.
WARNING
SOLVENTS USED WITH A SPRAY GUN MUST BE USED IN A SPRAY BOOTH WITH
FILTER. FACE SHIELD MUST BE USED BY PERSONNEL OPERATING SPRAY GUN.
g. Engine, Cab and Body. Use a spray gun and solvent mixture for cleaning exterior
of engine, cab and body. Allow mixture to remain on item surface for about 10 minutes before
rinsing. Rinse with hot water under 80 to 120 pounds of pressure, if available. An ordinary
garden hose with nozzle may be used if other equipment is not available. Rinse thoroughly.
h. Degreasing Machine. A degreasing machine may be used to remove heavy grease

and oil accumulations from metal parts.
i. Passages. After removing parts from degreasing machine and before coating with
rust preventive, check all oil passages and cavities for dirt or blockage. A thin, flexible wire
should be run through oil passages to make certain that they are not clogged. Individual
passages that are dirty may be cleared using a pressure spray gun and dry cleaning solvent.
CAUTION
TO PREVENT CORROSION, PARTS SHOULD BE DIPPED IN RUST PREVENTIVE

COMPOUND WITHIN TWO HOURS AFTER DEGREASING.
2-609
TM 08780B-20
j. Electrical Parts. Electrical parts, such as coils, junction blocks, switches and
igniters, which use insulating materials, should not be soaked or sprayed with cleaning solutions.
Clean these parts with a clean, lint-free cloth moistened with dry cleaning solvent.
CAUTION
DO NOT USE SOAP OR ALKALIES FOR CLEANING TANK INTERIORS.
k. Oil and Fuel Tanks. Pay special attention to all warnings and cautions when
working on vehicle’s fuel tank. Oil tanks and fuel tanks should be flushed, using a spray gun and
dry cleaning solvent.
l. Battery. Exterior surfaces of the electrical system and battery should be cleaned
with a weak solution of baking soda and water. Apply solution with a bristle brush to remove
any corrosion.
CAUTION
NEVER USE GASOLINE OR OTHER PETROLEUM BASE PRODUCTS TO CLEAN OR
PRESERVE HYDRAULIC SYSTEM PARTS.
m. Hydraulic System. When cleaning hydraulic system parts use dry cleaning
solvent, PD-680. Clean and dry parts thoroughly to make sure that no residue remains. If a
coating of preservative is required before assembly, apply a light film of preservative oil. If
petroleum-free solvents are not available, use the same hydraulic fluid as used in the truck’s
system.
2-12. GENERAL INSPECTION INSTRUCTIONS
a. Sealing Surfaces. Inspect all surfaces in contact with gaskets, packings or seals.
Make sure there are no nicks, burrs or scratches. If any defect is found, remove or repair it as
outlined under the General Repair Instructions in this manual.
b. Bearings. Check bearings for rusted or pitted balls, races or separators. Check
balls and races for brinnelling, abrasion and serious discoloration. Following are causes for
bearing rejection:
(1) Cuts or grooves parallel to ball or roller rotation.
(2) Fatigue pits (not minor machine marks or scratches).
(3) Cracks.
c. Inspection. Inspection consists of checking for defects such as distortion, wear,

cracks and pitting. Parts under heavy load or pressure must be inspected more thoroughly.
Clean all parts before inspection.
2-610
TM 08780B-20
d. Drain Plugs. When removing drain plugs from transmission, engine or hydraulic
system components, inspect sediment adhering to plug. A build-up of grit and/or fine metal
particles may indicate part failure. A few fine particles are normal. This inspection is effective
in determining defective parts prior to internal inspection of parts.
e. Gears. Gear inspection cannot be described in detail here. There are too many
differences in size and shape of gears. The following steps can be used to make a general visual
inspection of all gears. Follow all steps listed within repair instructions for final inspection.
(1) NORMAL WEAR. Loss of metal from the surface of gear teeth. Wear
must not prevent gears from meshing or performing properly.
(2) INITIAL PITTING. This may occur when a pair of gears is first started in
service. It may continue until most high spots have been reduced, as long as contact surfaces are
not affected. This pitting is not necessarily serious.
(3) DESTRUCTIVE PITTING. This type of pitting occurs after initial

pitting, often at an increasing rate. This will destroy contact area and reduce the gear’s ability to
carry a load. Rapid destruction will occur with use.
(4) ABRASIVE WEAR. This damage is caused by the fine particles carried
in the lubricant or imbedded in the gear teeth. These particles may come from many sources:
metal detached from gear teeth or bearings, abrasives not completely removed before assembly,
sand or scale from castings or other impurities in oil or air.
(5) SCORING. Slight scoring, scuffing, galling or other surface damage is

identified by tears or scratches in the direction of sliding. It starts in areas having the highest
stress and speed. This is usually at the tip of the teeth.
(6) BURNING. Burning is indicated by discoloration and loss of hardness

due to excessive temperature. This is caused by too much friction resulting from overload,
overspeed, lack of backlash or faulty lubrication. If discoloring can be wiped off with clean
cloth, such discoloring usually can be traced to oilburn-stains, which are not serious.
(7) ROLLING. This damage occurs mainly on plastic gears. Rolling is when
material is pushed out of shape without breaking off. This is caused by heavy, even loads,
sliding or overheating.
(8) BRINELLING. This can be identified by tiny indentation or ridges on the

shoulder or race of a bearing.
f. Splines. Inspect shaft splines for wear, pitting, rolling, peening and fatigue
cracks. In many cases, the same inspection procedure will apply to gears. However, the
problem, if present, will often be much less pronounced. Have a magnetic particle inspection
performed on splines, if needed.
2-611
TM 08780B-20
g. Tubing and Hose. Check all hose surfaces for broken or frayed fabric. Check for
breaks caused by sharp kinks or rubbing against other parts of the truck. Inspect copper tubing
lines for kinks. Inspect the fitting threads for damage. Replace any part found defective.
Following assembly and during initial truck operation, check for leaks.
h. Electrical Parts. Inspect all wiring harnesses for chafed or burned insulation.
Inspect all terminal connectors for loose connections and broken parts.
i. Metal Parts. Visually inspect all castings and weldments for cracks. Parts that
carry a great load should receive magnetic particle inspection. Critical nonferrous parts may be
inspected with fluorescent penetrant.
2-13. GENERAL REPAIR INSTRUCTIONS
WARNING
DRILLING AND GRINDING OPERATIONS ARE HAZARDOUS TO THE EYES. EYE

PROTECTION IS REQUIRED.
a. Burrs. Remove burrs from gear teeth with a fine-cut file or hand grinder.
b. Exterior Parts. Chassis and exterior painted parts may be resurfaced where paint
is damaged or where parts have been repaired, by using an abrasive disc driven by a flexible
shaft.
c. Bearings. Remove residue and oil stain from bearing races with crocus cloth.
d. Protective Parts. During repair operations, protect bare steel surfaces from rusting
when not actually undergoing repair work. Dip parts in or spray them with corrosion preventive
compound. The same protective coating may be applied to other metals to prevent rust.
Aluminum parts may require protection in atmospheres having a high salt content. Steel parts
must always be protected.
NOTE
The above procedure is used with polished and machined steel parts not protected by
cadmium, tin, copper or other plating or surface treatment. Bare metal surfaces must be free
of moisture when protective coating is applied.
e. Welding. Welding and brazing may be used to repair cracks in external steel
parts, such as brackets, panels and light framework. These repairs should be made only when
replacement parts are not available. Do not weld or braze castings, running parts or parts under
great stress except in emergencies.
2-612
TM 08780B-20
f. Stud Installation. When installing studs in engine block and axle housings, use a
driver designed for the stud to be installed. A worn stud driver may damage the end thread. This
makes it necessary to use a chasing die before a nut can be screwed on. This procedure will
remove cadmium plating and allow corrosion, which will make future disassembly difficult and
cause stud to be backed out with nut. Before driving a stud, inspect hole for chips and liquid.
Blow out any foreign matter. Start stud by hand. If it will not start into hole, it is too large or
has defective end thread. Before final insertion, coat thread with antiseize compound, turn stud
in slowly to prevent overheating and galling of casting metal.
g. Electrical Parts. Replace all broken worn or burned electrical wiring. Wires with
several broken strands must be replaced. Broken strands will increase the resistance of the wire
and impair efficiency of electrical components, especially the ignition system.
h. Hoses. Replace all broken, frayed, crimped or soft flexible lines and hoses.
Replace stripped or damaged fittings. Replace entire flexible hose if fittings are damaged. Make
sure hose clamps do not crimp hoses.
i. Fasteners. Replace any bolt, screw, nut or fitting with damaged threads. Inspect
tapped holes for thread damage. If cross-threading or galling is evident, retap the holes for the
next oversize screw or stud. When retapping will weaken the part or when the cost of the part
makes retapping impractical, replace the damaged part. Chasing threads with the proper size tap
or die may often be enough.
j. Dents. Straighten minor body dents by bumping with a soft-faced hammer while
using a wooden block backing.
k. Sheet Metal Repair. Repair minor skin cracks by installing patches.
l. Mounting Holes. Reshape oval mounting holes to round. Drill to receive bushing
with required inner diameter. Stake bushing in place with center punch.
2-14. GENERAL ASSEMBLY INSTRUCTIONS
a. Preparation. Remove grease from new parts before installation.
b. Packing Installation. Lubricate all packings with a thin coating of light mineral
oil before installation. Slightly stretch packing and place into position. Rotate component on
flat surface or uniformly press the packing into position.
c. Pipe joints. Use nonhardening pipe-joint compound or thread sealing tape when
joining piping.
d. Gaskets. To provide added sealing for gasket, coat both sides with sealant.
Remove all traces of previous gasket and sealant before installing new gasket.
2-613
TM 08780B-20
e. Silicone Sealant
WARNING
ON DIRECT CONTACT, UNCURED SILICONE SEALANT IRRITATES EYES. IN CASE

OF CONTACT FLUSH EYES WITH WATER AND SEEK MEDICAL ATTENTION.
AVOID PROLONGED CONTACT WITH SKIN.
Silicone sealant is often used instead of a gasket to seal mating parts. The mating parts must be
clean, dry and free of oil or grease for proper adhesion. After silicone sealant has been applied,
the mating parts must be assembled within 15 minutes. Silicone sealant starts to set-up in 15
minutes and takes 24 hours to completely cure. Excess silicone sealant should be wiped off after
assembling the mating parts.
f. Oil Seals. Install oil seals with seal lip facing towards lubricant, applying an even
force to outer edge of seal. Coat oil seals evenly with grease before installing. If oil seals will be
installed over keyed or splined shafts, use a guide. This will prevent sharp edge of keyway or
splines from cutting the leather or neoprene seal. Construct guides of very thin gauge sheet
metal and shape to required diameter. However, make certain guide edges are not sharp. Bend
them slightly inward so they do not cut the seal.
g. Seal Rings. Coat seal rings with oil and carefully install into their bores. If seal
rings must be installed over threaded parts, temporarily wrap the threads with tape to protect the
seal ring. Then remove the tape.
h. Bearings and Shafts. During assembly of shafts and bearings in housings, first
mount bearing on shaft. Then install the assembly by applying force to shaft. When mounting
bearings on shafts, always apply force to the inner races of the bearing.
i. Bearing Lubrication. Lubricate bearings before reassembly with the type of

lubricant normally used in the related housing or container. This will provide lubrication during
the first run-in until lubricant from the system can reach the bearings.
2-614
TM 08780B-20
CHAPTER 3
ENGINE
3-1. OVERVIEW
The following chapter covers maintenance procedures for the vehicle’s engine.
3-2. DESCRIPTION AND DATA
a. Detroit 8V92TA Diesel Engine. The Detroit 8V92TA diesel engine is a

turbocharged, aftercooled, two cycle engine with eight cylinders in a V-type configuration. Each
cylinder has 92 cubic inches for a total displacement of 736 cubic inches.
The following information describes engine components that are maintained at the
Organizational Maintenance level.
b. Rocker Cover. The engine’s rocker covers encloses valves, Jacobs brake and fuel
injector assemblies at the top of each cylinder head. Rocker covers also incorporate breather
housings.
c. Oil Filter and Adapter. The oil filter is a spin-on type that attaches to the oil fitter
adapter. The adapter has a by-pass valve that opens at 18-21 psi (124-145 kPa). The by-pass
valve will open should the oil filter become clogged.
d. Fuel Pump. A positive gear-type fuel pump transfers fuel from fuel tanks through
the filter to fuel injectors. The fuel pump is attached to the governor housing. It is driven off the
right-hand blower rotor by means of a drive coupling fork. It is not mandatory to time fuel pump
because the fuel injectors are self-timing.
3-1
TM 08780B-20
e. Shutdown Solenoid. This is an electrically controlled solenoid used to shut down

or stop the engine. The solenoid is attached to the stop lever on the governor. When activated,
the shutdown solenoid pulls in the stop lever. The stop lever operates a series of internal fuel
rods to shut off the fuel injectors.
f. Throttle Cylinder. This is an air actuated cylinder that is controlled by the

vehicle’s treadle valve. The throttle cylinder attaches to the speed control lever on the governor.
When regulated air reaches the cylinder, a push rod moves the speed control lever. The control
lever moves internal fuel rods and levers that regulate the amount of fuel in the injector.
g. Thermostats and Housing. Engine coolant temperature is controlled by two

thermostats. Each thermostat is located in a housing attached to the water outlet end of each
cylinder head. Thermostats will stay closed, letting coolant circulate within the engine. When
coolant temperature reaches 160°F - 197°F (71°C - 91.6°C) thermostats open and allow coolant
to circulate to the radiator where it cools.
3-2
TM 08780B-20
h. Water Pump. This is a centrifugal-type pump that circulates engine coolant

through the cylinder block, cylinder heads, oil cooler and radiator. Pump is mounted on engine
front cover and is driven off of right front camshaft gear.
i. Alternator. This is a flanged mounted alternator that is driven by the blower drive
gear by means of a drive coupling. The alternator has an integral regulator that regulates voltage,
keeping it at approximately 24 volts. The regulator can be slightly adjusted to provide the
desired output.
j. Starter. The starter is an electric motor with a solenoid and drive gear. When the
starter is activated, the drive moves outward and meshes with the flywheel ring gear. The starter
is mounted on the left side of flywheel housing.
3-3
TM 08780B-20
3-3. ENGINE OIL SERVICE
THIS TASK COVERS: a. Draining

b. Cleaning/Inspection
c. Installation
INITIAL SETUP Reference

LI 2320-12/9
Applicable Configurations LO 9-2320-297-12
MK48
Equipment
Materials/Parts Condition Condition
Engine oil (item 35, Appendix D) TM Description
Pipe sealant (item 48, Appendix D) TM 08780B-20 Right side panel
Oil element filter (23518524) item 3 removed (para 18-15).
a. Draining
WARNING
DO NOT DRAIN OIL WHEN ENGINE IS HOT. SEVERE BURNS WILL RESULT.
NOTE
• Oil capacity is 24 quarts. Make certain container used to catch oil is large enough.
• It is necessary to use a pipe or funnel to direct flow of oil around nose box and into the
container.
(1) Place a large container under the drain plug (1).
(2) Remove drain plug (1) and allow oil to drain into container.
(3) Remove magnetic plug (2).
3-4
TM 08780B-20
(4) Place a container under oil filter element (3).
(5) Using oil filter wrench, remove oil filter element (3) and discard.
(1) Clean drain plug (1). Refer to paragraph 2-11.
(2) Clean magnetic plug (2). Refer to paragraph 2-11.
(3) Clean oil filter adapter (4) with a clean, lint free cloth.
(4) Inspect threads on plugs (1 and 2). Refer to paragraph 2-12.
(5) Replace all parts failing inspection.
c. Installation
CAUTION
TO PREVENT DAMAGE TO SEAL (5), DO NOT OVERTIGHTEN OIL FILTER

ELEMENT (3).
(1) Coat seal (5) with clean engine oil. Install new oil filter element (3) into
oil filter adapter (4) and hand tighten until seal (5) touches oil filter adapter (4).
(2) Tighten oil filter element (3) an additional 2/3 turn.
3. Oil Filter Element

4. Oil Filter Adapter
5. Seal
3-5
TM 08780B-20
(3) Apply pipe sealant to threads on drain and magnetic plugs (1 and 2).
(4) Install magnetic plug (2). Torque magnetic plug (2) to 33-37 foot-pounds
(45-50 N*m).
(5) Install drain plug (1). Torque drain plug (1) 33-37 foot-pounds (45-50
N*m).
(6) Remove cap (6) from filler tube (7).
(7) Add 24 quarts (22.70 liters) of clean engine oil. Refer to LI 2320-12/9,
LO 9-2320-297-12.
(8) Check dipstick (8) for proper oil level. Fill as needed.
(9) Install cap (6) onto filler tube (7).
(10) Start engine and run for 10 minutes. Refer to paragraph 2-13 (TM
08780B-10). Check for leaks.
(11) Shut down engine. Wait five minutes, then recheck dipstick (8) for proper
oil level. Fill as needed.
END OF-TASK
NOTE
Follow-On Maintenance
TM 08780B-20 Install right side
panel (para 18-15).
3-6
TM 08780B-20
3-7
TM 08780B-20
3-4. ROCKER COVER AND GASKET REPLACEMENT
THIS TASK COVERS: a. Removal

c. Installation
INITIAL SETUP
Applicable Configurations Equipment

MK48 Condition Condition
TM Description
Materials/Parts TM 08780B-10 Engine access door
Engine oil (item 35, Appendix D) open (para 2-1).
Gasket, rocker cover (5104081) item 8
Seal, breather housing (5103646) item 13
Seal, oil tube (5104105) item 19
a. Removal
CAUTION
CLEAN AROUND EACH ROCKER COVER BEFORE REMOVING FROM ENGINE.

THIS WILL KEEP DUST AND DIRT FROM ENTERING ENGINE.
NOTE
Follow steps (1) thru (6) for right and left rocker covers.
(1) Loosen hose clamp (1) and remove breather vent tube (2) from breather
housing (3).
(2) Remove two 12 point capscrews (4), retainers (5) and isolators (6) from
rocker cover (7).
(3) Remove rocker cover (7) and gasket (8). Discard gasket (8).
(4) Remove three screws (9) and retainer (10).
(5) Remove element (11) and retainer (12).
(6) Using a rubber mallet, tap breather housing (3) from inside rocker cover
(7). Remove breather housing (3) and seal (13). Discard seal (13).
NOTE
Follow steps (7) thru (9) for right rocker cover only.
(7) Remove oil cap (14) from chain (15).
3-8
TM 08780B-20
(8) Remove three screws (16) from strainer (17) and remove strainer and
chain (15).
(9) Remove oil fill tube (18) and seal (19). Discard seal (19).
(10) Remove engine data plates (20) if damaged.
(1) Clean all parts. Refer to paragraph 2-11.
(2) Inspect rocker cover (7) for cracks or dents.
(3) Inspect isolators (6) for cracks or wear.
(4) Inspect oil cap (14) for cracks.
c. Installation
(1) Install new seal (13) in rocker cover (7),
(2) Install breather housing (3) into rocker (7) with vent tube facing rear of
engine.
(3) Install retainer (12) and element (11) into breather housing (3).
(4) Place retainer (10) over element (11). Install three screws (9).
(5) Install new seal (19) and oil fill tube (18) in right rocker cover (7).
(6) Install strainer (17) and chain (15).
(7) Install three screws (16). Connect fill tube cap (14) to chain (15).
(8) Install new gasket (8) into groove of cover (7).
(9) Coat mating surface of gasket (8) and cylinder head with light coat of
clean engine oil.
(10) Install rocker cover (7) on engine.
(11) Install isolators (6), retainers (5) and 12 point caps-crews (4). Torque
capscrews (4) to 15-20 foot-pounds (20.3 - 27 N*m).
3-9
TM 08780B-20
(12) Install breather tube (2) and clamp (1) onto breather housing (3). Tighten
hose clamp (1).
END OF TASK
NOTE
TM 08780B-10 Close engine access
door (para 2-1).
1. Hose Clamp
2. Breather Vent Tube
3. Breather Housing
4. 12 Point Capscrew (4)
5. Retainer (4)
6. Isolator (4)
7. Rocker Cover (2)
8. Gasket
9. Screw (3)
10. Retainer
11. Element
12. Retainer
13. Seal
14. Oil Cap
15. Chain
16. Screw (3)
17. Strainer
18. Oil Fill Tube
19. Seal
20. Data Plate (2)
3-10
TM 08780B-20
3-5. OIL FILTER ADAPTER REPLACEMENT

c. Installation
INITIAL SETUP Equipment

Condition Condition
Applicable Configurations TM Description
M K48 TM 08780B-20 Access cover
removed (para 18-15).
Materials/Parts
Gasket (8921312) item 5
Lockwasher (6) (MS 35338-46) item 2 Oil filter removed
(para 3-3).
a. Removal
(1) Tag and remove two capscrews (1) and lockwashers (2). Discard
lockwashers (2).
(2) Tag and remove four capscrews (3) and lockwashers (2). Discard
lockwashers (2).
(3) Remove oil filter adapter (4) and gasket (5). Discard gasket (5).
WARNING
SPRING (8) IS UNDER TENSION. RELEASE SPRING SLOWLY TO PREVENT INJURY.
(4) Remove screw (6), retainer (7), spring (8) and piston (9) from oil filter
adapter (4).
(2) Inspect all parts. Refer to paragraph 2-12.
c. Installation
(1) Install piston (9), spring (8), retainer (7) and screw (6) into oil filter
adapter (4). Tighten screw (6) securely.
3-11
TM 08780B-20
(2) Install gasket (5) and oil filter adapter (4).
(3) Install four shorter capscrews (3) with new lockwashers (2) and tighten
securely.
(4) Install two capscrews (1) with new lockwashers (2) and tighten securely.
END OF TASK
NOTE
TM 08780B-20 Install oil filter
(para 3-3).
TM 08780B-10 Start engine and

check for oil leaks (para 2-13).
TM 08780B-20 Install access cover

(para 18-15).
1. Capscrew (2)
2. Lockwasher (6)
3. Capscrew (4)
4. Oil Filter Adapter
5. Gasket
6. Screw
7. Retainer
8. Spring
9. Piston
3-12
TM 08780B-20
3-6. OIL PAN AND GASKET REPLACEMENT

c. Installation
INITIAL SETUP Personnel Required

1 MOS 3521
Applicable Configurations 1 Assistant
MK48
Equipment
Silicone sealant (item 5, Appendix D) TM Description
Gasket (NSN 5330-00-972-8108) item 13 TM 08780B-20 Engine oil drained
Lockwasher (30) (MS35338-46) items 8 and 11 (para 3-3).
a. Removal
(1) Remove filler tube (1) and elbow (2).
(2) Loosen nut (4) and remove dip stick (5). Remove adapter (6).
(3) Remove two capscrews (7) and lockwashers (8) from oil pan brackets (9).
Discard lockwashers (8).
(4) Remove 28 capscrews (10) and lockwashers (11) from oil pan (3).
(5) Pull oil pan (3) from engine block (12).
(6) Remove and discard gasket (13).
(7) Remove pipe plugs (14 and 15).
(8) Remove pipe plug (16) only if oil pan (3) is being replaced.
(2) Inspect oil pan (3) for warpage, cracks or dents.
(3) Clean all gasket material, sealant or debris, from mating surfaces of oil
pan (3) and engine block (12).
(4) Inspect all other parts. Refer to paragraph 2-12.
3-13
TM 08780B-20
c. Installation
(1) If removed, install pipe plug (16). Torque to 75-85 foot-pounds (102-115
N*m).
(2) Install pipe plugs (14 and 15). Torque to 33-37 foot-pounds (45-50 N*m).
(3) Apply sealant and install new gasket (13) on oil pan (3).
(4) Install oil pan (3) on engine block (12) so oil pan brackets (9) are at rear of
engine.
(5) Install 28 capscrews (10) and new lockwashers (11). Hand tighten only.
CAUTION
OVERTIGHTENING CAPSCREWS (7 AND 10) MAY DAMAGE GASKET (13).
(6) Install two capscrews (7) and new lockwashers (8) on oil pan brackets (9).
Torque to 10-20 foot-pounds (13-27 N*m).
(7) Starting with center capscrew on each side, tighten capscrews (10),
working alternately toward each end of pan (3). Torque capscrews to 10-20 foot-pounds (13-27
N*m).
(8) Install elbow (2) and filler tube (2). Tighten nut (1) securely.
(9) Install adapter (6) and dipstick (5). Tighten nut (4) securely.
END OF TASK
NOTE
TM 08780B-20 Fill oil pan with
clean engine oil (para 3-3).

check for oil leaks (para 2-13).
3-14
TM 08780B-20
1. Filler Tube
2. Elbow
3. Oil Pan
4. Nut
5. Dipstick
6. Adapter
7. Capscrew (2)
8. Lockwasher (2)
9. Oil Pan Brackets
10. Capscrew (28)
11. Lockwasher (28)
12. Engine Block
13. Gasket
14. Pipe Plug
15. Pipe Plug
16. Pipe Plug
3-15
TM 08780B-20
3-7. EXHAUST MANIFOLD AND GASKET REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-10 Engine access door
open (para 2-1).
Materials/Parts
Cleaning solvent (item 53, Appendix D) TM 08780B-20 Air cleaner assembly
Exhaust gasket (4) (NSN 5330-00-862-6929) removed (para 4-6).
item 7
a. Removal
WARNING
ALLOW EXHAUST SYSTEM TO COOL BEFORE SERVICING. EXHAUST PARTS CAN

BE HOT ENOUGH TO CAUSE SEVERE BURNS.
(1) Loosen clamp (1) on right exhaust manifold (2). Slide clamp (1) back and
out of the way.
(2) Remove two nuts (3) and hold down crabs (4).
(3) While holding right exhaust manifold (2), remove three nuts (5) and
washers (6).
(4) Remove right exhaust manifold (2) and gasket (7). Discard gasket (7).
(5) Loosen clamp (8) and remove elbow (9).
(6) Repeat steps (2) thru (4) to remove left exhaust manifold.
(2) Inspect manifold studs (10) and nuts (3 and 5) for damage.
(3) Clean carbon from exhaust manifold ports and engine mating surface.
3-16
TM 08780B-20
(4) Using straightedge, check exhaust manifold mating surface for

straightness.
(5) Check manifolds (2) for cracks.
c. Installation
(1) Install new manifold studs (10) if removed. Torque manifold studs (10) to
25-40 foot-pounds (34-54 N*m).
(2) Install new gasket (7) with crimped side of gasket (11) facing cylinder
head.
(3) Install elbow (9) on right exhaust manifold (2). Leave clamp (1) loose.
WARNING
EXHAUST MANIFOLD (2) IS HEAVY. USE CARE WHEN INSTALLING TO PREVENT

PERSONAL INJURY.
(4) Install right exhaust manifold (2) so manifold guide (12) lies on top of
block rest (13) and elbow (9) aligns with turbocharger bracket (14).
(5) While holding exhaust manifold, install three washers (6), dish side
towards nut and nuts (5), on studs. Hand tighten nuts (5).
(6) Install two hold down crabs (4) and nuts (3). Hand tighten nuts (3).
(7) Tighten five nuts (3 and 5) starting in the center of exhaust manifold,
alternating toward each end. Torque nuts (3 and 5) to 30-35 foot-pounds (41-47 N*m).
(8) Tighten two clamps (8 and 1) securely.
(9) Repeat steps (1) thru (7) for left exhaust manifold.
END OF TASK
3-17
TM 08780B-20
NOTE
TM 08780B-20 Install air cleaner
assembly (para 4-6).
TM 08780B-10 Close engine access

door (para 2-1).
Start engine and check

for exhaust leaks (para 2-13).
1. Clamp
2. Right Exhaust Manifold
3. Nut (2)
4. Hold Down Crabs
5. Nut (3)
6. Washer (3)
7. Gasket (2)
8. Clamp
9. Elbow
10. Manifold Stud (5)
11. Crimped Side Of Gasket
12. Manifold Guide
13. Block Guide
14. Turbocharger Bracket
3-18
TM 08780B-20
3-8. ENGINE OIL SAMPLING VALVE (LVSA1 SERIES VEHICLES ONLY)

c. Assembly
INITIAL SETUP
Applicable Configurations
MK48A1
Materials/Parts
Locknut (2) (1600460) item 6
Pipe sealant (item 48, Appendix D)
a. Removal
(1) Remove oil sampling valve (1) from reducer (2).
(2) Remove reducer (2) from adapter (3).
(3) Remove hose (4) from adapter (3).
(4) Remove adapter (3) from bracket (5).
(5) Remove two locknuts (6), capscrews (7) and bracket (5) from filter
bracket(8). Discard locknuts (6).
(1) Clean all parts. Refer to paragraph 2-11,
(2) Inspect all parts for damage. Refer to paragraph 2-12.
c. Installation
(1) Install bracket (5) on filter bracket (8) using two capscrews (7) and new
locknuts (6). Tighten locknuts (6) securely.
(2) Install adapter (3) on bracket (5). Tighten adapter (3) securely.
(3) Install hose (4) on adapter (3). Tighten hose (4) securely.
3-19
TM 08780B-20
NOTE
Apply pipe sealant to all pipe threads before installing.
(4) Install reducer (2) on adapter (3). Tighten reducer (2) securely.
(5) Install sampling valve (1) on reducer (2). Tighten sampling valve (1)
securely.
END OF TASK
NOTE
check for leaks (para 2-13).
1. Oil Sampling Valve

2. Reducer
3. Adapter
4. Hose
5. Bracket
6. Locknut (2)
7. Capscrew (2)
8. Filter Bracket
3-20
TM 08780B-20
3-9. NEW REPLACEMENT DIPSTICK INSTALLATION
THIS TASK COVERS: a. Dipstick Preparation
INITIAL SETUP
MK48
a. Dipstick Preparation
CAUTION
REPLACEMENT DIPSTICK AS RECEIVED WILL NOT BE THE CORRECT LENGTH.

DIPSTICK MUST NOT BE INSTALLED WITHOUT FIRST CUTTING TO CORRECT
LENGTH AND MARKING THE LOW AND HIGH OIL LEVELS.
(1) Cut dipstick (1) to total length (x dimension).
NOTE
Dipstick can be marked in a number of ways. Scribe, punch mark or drill (.05 in., 1.27 mm)
the level indicators on the flat surface of the dipstick.
(2) Mark LOW oil level (dimension z) on dipstick (1).
(3) Mark HIGH oil level (dimension y) on dipstick (1).
END OF TASK
DIMENSION IN. CM
X CUT TO 14.25 36.20
Z MARK AT 1.38 3.50
Y MARK AT 12.09 30.70
3-21/(3-22 blank)
TM 08780B-20
CHAPTER 4
FUEL SYSTEMS
4-1. OVERVIEW
The following chapter covers principles of operation, repair and replacement procedures for the
vehicle’s fuel system.
4-2. FUEL SYSTEM PRINCIPLES OF OPERATION
a. General Description. With one 75 gallon tank on each fender, the LVS has a total
fuel capacity of 150 gallons. Diesel fuel from the tanks reaches the engine through a fuel/water
separator, a filter, a pump and injectors. A priming pump is included in the system for use when
air has gotten into the system. This pump is by-passed under ordinary operating conditions.
4-1
TM 08780B-20
b. Fuel Tanks. Two 75 gallon diesel fuel tanks. One fuel tank is mounted on each
fender, above the No. 2 axle.
c. Priming Pump. Hand pump used to prime fuel system when air has gotten into
the fuel system (as when the vehicle has run out of fuel). After air has entered the system, the
system must be primed before the engine will start.
d. Fuel/Water Separator. Three stage device used to separate water from fuel and
filter out solid particles. In the first stage, a centrifuge separates large solid particles and water
from the fuel. The water and large particles sink to the bottom of the fuel bowl where they
remain, until the fuel bowl is drained because they are heavier than fuel. In the second stage,
water that is still in the system condenses on the separator shell. When droplets form, their
weight causes them to fall to the bottom of the fuel bowl. In the third stage, a replaceable filter
element traps solid particles still in the fuel.
e. Secondary Filter. Replaceable filter that traps extremely fine particles that have
passed through previous filtration.
4-2
TM 08780B-20
f. Fuel Pump. Draws fuel from fuel tanks and sends it to injectors on the engine.
The fuel pump must be primed if air has gotten into the system. Otherwise, it will not work.
g. Injectors. Devices that atomize, meter and inject the correct amount of fuel into
the appropriate cylinder at the right moment. There is one injector per cylinder.
4-3
TM 08780B-20
4-3. FUEL SUPPLY PUMP REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Engine access panel
removed (para 18-15)
Materials/Parts
Pipe sealant (item 48, Appendix D) Loosen four hose
Gasket (NSN 5330-00-212-6290) item 5 clamps on bypass
tube (para 6-6).
General Safety Instructions

Do not smoke or use open flame. Fuel is
flammable and may explode. Keep fire
extinguisher within reach.
a. Removal
(1) Tag and remove two fuel lines (1).
(2) Remove three capscrews (2).
NOTE
Drive fork is loose on fuel pump shaft and may fall off when pump is removed.
(3) Remove fuel pump (3) and drive fork (4).
NOTE
Remove two fuel line elbows (6), coupling (7), nipple (8) and plugs (9) only if fuel pump will
be replaced.
(5) Remove two elbows (6), coupling (7), nipple (8) and two plugs (9) from
fuel pump (3).
4-4
TM 08780B-20
c. Installation
(1) If removed, install two plugs (9) on fuel pump (3).
(2) Install new gasket (5) on fuel pump (3).
(3) Install drive fork (4) on fuel pump shaft (10).
NOTE
Open drain hole in fuel pump (3) must face down.
(4) Align drive fork (4) with slots in adaptor plate in governor housing (11).
(5) Install fuel pump (3) with three capscrews (2). Tighten capscrews (2)
securely.
(6) If removed, apply pipe sealant to elbow threads and install two elbows (6),
coupling (7) and nipple (8).
(7) Install two fuel lines (1). Tighten fuel lines (1) securely.
END OF TASK
NOTE
TM 08780B-20 Tighten bypass tube
hose clamps (para 6-6).
Install engine access panel (para 18-15).

check for fuel or coolant leaks (para 2-13).
4-5
TM 08780B-20
1. Fuel Line (2)

2. Capscrew (3)
3. Fuel Pump
4. Drive Fork
5. Gasket
6. Elbow (2)
7. Coupling
8. Nipple
9. Plug (2)
10. Fuel Pump Shaft
11. Governor
Housing
4-6
TM 08780B-20
4-4. FUEL SUPPLY PUMP REPAIR
THIS TASK COVERS: a. Disassembly

c. Assembly

Condition Condition
MK48 TM 08780B-20 Fuel pump removed
(para 4-3).
Special Tools
Fuel pump tool set J1508-D
Materials/Parts
Adhesive-sealant, silicone (item 5, Appendix D)
Grease (item 21, Appendix D)
Engine oil (item 35, Appendix D)
Gasket (NSN 5330-00-599-5577) item 11
Oil seal (2) (NSN 5330-01-083-3063) items 15 and 16
a. Disassembly
(1) Mount fuel pump assembly (1) in a holding fixture (2).
1. Fuel Pump Assembly

2. Holding Fixture (Tool)
(2) Remove eight capscrews (3) and separate cover (4) from body (5).
(3) Remove drive shaft (6), drive gear (7) and gear retaining ball (8) as an
assembly.
NOTE
Do not remove drive gear (7) from drive shaft unless damaged. If drive shaft assembly is not
damaged, go to step (7).
(4) Place drive shaft (6) in a press with square end of shaft towards press bed.
4-7
TM 08780B-20
CAUTION
DO NOT PRESS SQUARE END OF DRIVE SHAFT THROUGH GEAR. SEAL CONTACT
AREA COULD BE DAMAGED.
NOTE
Gear retaining ball (8) is small. Be careful not to lose it.
(5) Press drive shaft (6) just far enough to remove gear retaining ball (8).
(6) Turn drive shaft (6) so square end is away from press. Press drive shaft
(6) off drive gear (7).
CAUTION
DO NOT REMOVE GEAR FROM DRIVEN SHAFT. DRIVEN GEAR AND SHAFT
ASSEMBLY (9) IS SERVICED ONLY AS AN ASSEMBLY.
(7) Remove driven gear and shaft assembly (9) from body (5).
(8) Remove plug (10) and gasket (11). Discard gasket (11).
(9) Remove spring (12), pin (13) and relief valve (14).
NOTE
Do not remove oil seals (15 and 16) unless damaged or leaking.
(10) Clamp body (5) in soft-jawed vise.
CAUTION
OBSERVE POSITION OF OIL SEAL LIPS FOR ASSEMBLY. INCORRECT POSITION

OF SEAL LIPS WOULD RESULT IN FUEL LEAKAGE.
(11) Using a hammer and a drift pin, remove two oil seals (15 and 16). Discard
oil seals (15 and 16).
(2) Check gear teeth for scoring, chipping or wear. Check slot in drive gear
(7) for wear.
4-8
TM 08780B-20
(3) Inspect drive shafts (6 and 9) for scoring or wear. Driven gear and shaft
assembly (9) is replaced as an assembly only.
(4) Check mating surfaces of cover (4) and body (5) for scratches or wear
around area where gears contact.
(5) Check relief valve (14) for score marks.
(6) Inspect reducer bushing (17) in cover (4) for wear.
3. Capscrew (8)
4. Cover
5. Body
6. Drive Shaft
7. Drive Gear
8. Gear Retaining Ball
9. Driven Gear And Shaft Assembly
10. Plug
11. Gasket
12. Spring
13. Pin
14. Relief Valve
15. Inner Oil Seal
16. Outer Oil Seal
17. Reducer Bushing
4-9
TM 08780B-20
c. Assembly
(1) Grease lips of new oil seals (15 and 16).
(2) Place inner oil seal (15) on seal installer (18) so that inner seal lip (19)
faces towards body (5).
(3) Support body (5) on wooden blocks.
(4) Insert seal installer (18) into body (5) and install inner oil seal (15).
5. Body
15. Inner Oil Seal
18. Seal Installer (Tool)
19. Inner Seal Lip
(5) Install installer adaptor (20) on seal installer (18) so that short end of
installer adaptor (20) is away from installer handle.
(6) Place outer oil seal (16) on seal installer (18) so that outer seat lip (21)
faces towards installer adaptor (20).
(7) Insert seal installer (18) into body (5) and drive the seal in until installer
adaptor (20) makes contact with body (5).
4-10
TM 08780B-20
5. Body
16. Outer Oil Seal
18. Seal Installer (Tool)
20. Installer Adaptor (Tool)
21. Outer Seal Lip
5. Body
10. Plug
11. Gasket
12. Spring
13. Pin
14. Relief Valve
22. Relief Valve Port
(8) Clamp body (5) in a soft-jawed vise so that relief valve port (22) is facing
up.
(9) Lubricate outside diameter of relief valve (14) with clean engine oil.
Insert relief valve (14) into body (5) so the valve’s hollow end is up.
(10) Insert spring (12) into relief valve (14) and insert pin (13) into spring (12).
4-11
TM 08780B-20
(11) Install plug (10) and new gasket (11). Torque plug (10) to 18-22 foot-
pounds (24-30 N*m).
NOTE
If gear was not removed from shaft, go to step (15).
(12) Install gear (7) on end of shaft (6) which is not squared. Slot in gear must
face the plain end of shaft.
(13) Press gear (7) beyond ball notch on shaft (6).
6. Shaft
7. Gear
(14) Place gear retaining ball (8) in notch and press gear (7) back until end of
slot contacts ball.
(15) Lubricate shaft (6) with clean engine oil. Insert the square end of shaft (6)
into the opening on the gear side of body (5).
NOTE
If a service replacement gear is used, the slot must face toward cover.
(16) Install driven gear and shaft assembly (9) i n body (5).
(17) Lubricate gears (7 and 9) and shafts (6 and 9) with clean engine oil.
CAUTION
WHEN APPLYING SEALANT TO COVER, MAKE SURE NO SEALANT IS APPLIED TO

CONTACT AREA OF GEARS. EXCESSIVE SEALANT CAN DAMAGE INTERNAL
PARTS.
(18) Apply thin coat of adhesive sealant to mating surface of cover (4).
(19) Install cover (4) on body (5) so that dowel pins in body align with proper
holes in cover (4).
4-12
TM 08780B-20
(20) Install eight capscrews (3). Tighten capscrews (3) alternately and evenly.
(21) After assembly, rotate shaft (6) by hand, checking that parts rotate freely.
If shaft does not rotate freely, attempt to free it by tapping a corner of the pump. If shaft still
sticks, disassemble pump and recheck the parts.
NOTE
If pump will not be installed immediately, place plastic shipping plugs in inlet and outlet
openings.
END OF TASK
NOTE
TM 08780B-20 Install fuel pump (para 4-3).
Check coolant level (para 6-3).
3. Capscrew (8)
4. Cover
5. Body
6. Drive Shaft
7. Drive Gear
8. Gear Retaining Ball
9. Driven Gear and
Shaft Assembly
4-13
TM 08780B-20
4-5. HAND PRIMING PUMP REPLACEMENT

c. Installation
INITIAL SETUP General Safety Instructions

Do not smoke or use open flame. Fuel
Applicable Configurations is flammable and may explode. Keep
MK48 fire extinguisher within reach.
Materials/Parts
Oil, Fuel (item 28, Appendix D)
a. Removal
(1) Loosen nut (1).
(2) Place a drain pan below handle assembly(2). Pull handle assembly (2)
from barrel (3).
(3) Remove nut (4).
(4) Push barrel (3) through and away from bracket (5).
(5) Loosen fittings (6 and 7).
(6) Tag and remove hoses (8 and 9).
(7) Remove two elbows (10 and 11).
(8) Remove washer (12) and nut (13).
4-14
TM 08780B-20
c. Installation
NOTE
To install a new priming pump, nut (4), handle assembly (2) and nut (1) must be removed
from barrel (3).
(1) Install nut (13) and washer (12) onto barrel (3) two inches (5.08 cm) from
handle end.
(2) Coat threads of elbows (10 and 11) with pipe sealant and install into barrel
(3).
(3) Connect hoses (8 and 9) to elbows (10 and 11). Tighten fittings (6 and 7)
securely.
(4) Insert barrel (3) through hole in bracket (5).
(5) Install nut (4). Tighten nut (4) securely.
(6) Lubricate O-rings (14) with clean fuel.
(7) Carefully install handle assembly (2) into barrel (3).
(8) Tighten nut (1) securely.
END OF TEST
NOTE
TM 08780B-10 Prime fuel
system (para 2-13).
Run engine and check

for leaks (para 2-13).
4-15
TM 08780B-20
1. Nut
2. Handle Assembly
3. Barrel
4. Nut
5. Bracket
6. Fitting
7. Fitting
8. Hose
9. Hose
10. Elbow
11. Elbow
12. Washer
13. Nut
14. O-Ring (2)
4-16
TM 08780B-20
4-6. AIR CLEANER ASSEMBLY REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Locknut (2) (1600460) item 8
Locknut (7) (MS51922-1) items 5.3, 10.1,11 and 14
Lockwasher (2) (MS35338-45) item 34
a. Removal
(1) Loosen clamp (1) on air inlet duct (2).
(2) Loosen clamp (3) on hose (4) at check valve assembly (5) and remove
hose(4).
NOTE
Perform steps (3) and (4) on LVSA1 series vehicles only.
(3) Remove four capscrews (5.1) from right, left and rear sides of weather-
hood (5.2).
(4) Remove two locknuts (5.3) and capscrews (5.4) from tabs of weatherhood
(5.2). Remove weatherhood (5.2). Discard locknuts (5.3).
NOTE
Mounting hardware for the LVSA1 worklight bracket has changed from capscrews,
lockwashers and hex nuts to flanged type capscrews and locknuts. When repairing a non-A1
vehicle, use the new style flanged mounting hardware to replace the old style hardware. Refer
to TM 08780B-24P for correct part identification.
(5) Remove two capscrews (6), locknuts (8), worklight (9) and bracket (10).
Discard locknuts (8).
(6) Remove two locknuts (10.1) capscrews (10.2), washers (10.3) and bracket
(10.4). Discard locknuts (10.1).
(7) Remove two locknuts (11) and capscrews (12). Discard locknuts (11).
4-17
TM 08780B-20
1. Clamp
2. Air Inlet Duct
3. Clamp
4. Hose
5. Check Valve Assembly
5.1. Capscrew (4)*
5.2. Weatherhood*
5.3. Locknut (2)*
5.4. Capscrew (2)*
6. Capscrew (2)
7. Deleted
8. Locknut (2)
9. Worklight
10. Bracket
10.1. Locknut (2)
10.2. Capscrew (2)
10.3. Washer (2)
10.4. Bracket
11. Locknut (2)
12. Capscrew (2)
*LVSA1 Series Vehicles Only
4-18
TM 08780B-20
(8) Remove capscrew (13) and locknut (14) from hanger (15). Discard
locknut (14).
(9) Remove capscrew (16), nut (17) and bracket (18) from air cleaner (19).
(10) Remove four capscrews (20) and flanged nuts (21) from air cleaner
brackets (22). Remove air cleaner (19).
(11) Remove capscrew (23) and nut (24) to remove clamp (25).
(12) Loosen clamp (26) at air inlet housing (27) and remove hose (28).
13. Capscrew
14. Locknut
15. Hanger
16. Capscrew (2)
17. Nut (2)
18. Bracket
19. Air Cleaner
20. Capscrew (4)
21. Flanged Nut (4)
22. Air Cleaner Bracket (2)
23. Capscrew
24. Nut
25. Clamp
26. Clamp
27. Air Inlet Housing
28. Hose
4-19
TM 08780B-20
(13) Loosen two clamps (29 and 30). Remove check valve assembly (31).
(14) Remove two elbows (32).
(15) Remove two capscrews (33), lockwashers(34), nuts (35) and bracket (36).
c. Installation
(1) Install bracket (36), two capscrews (33), new lockwashers (34) and nuts
(35). Tighten capscrews (33) and nuts (35) securely.
(2) Coat elbows (32) with pipe sealant and install. Tighten securely.
(3) Install check valve assembly (31) and two clamps (29 and 30). Tighten
clamps (29 and 30) securely.
(4) Align air cleaner (19) with holes in brackets (22) and install four
capscrews (20) and flanged nuts (21). Tighten capscrews (20) and flanged nuts (21) securely.
(5) Install hose (28) and clamp (26) at air inlet housing (27). Tighten clamp
(26) securely.
(6) Install bracket (18), two capscrews (16) and nuts (17) at the third hole
from the end of air cleaner (19). Tighten capscrews (16) securely.
(7) Position clamp (25) and install capscrew (23) and nut (24). Tighten
capscrew (23) and nut (24) securely.
(8) Install hanger (15), capscrew (13) and locknut (14). Tighten capscrew
(13) and locknut (14) securely.
(9) Install two capscrews (12) and new locknuts (11). Tighten locknuts (11)
securely.
4-20
TM 08780B-20
29. Clamp
30. Clamp
32. Elbow (2)
33. Capscrew (2)
34. Lockwasher (2)
35. Nut (2)
36. Bracket
4-21
TM 08780B-20
1. Clamp
2. Air Inlet Duct
3. Clamp
4. Hose
5.1. Capscrew (4)*
5.2. Weatherhood*
5.3. Locknut (4)*
5.4. Capscrew (2)*
6. Capscrew (2)
7. Deleted
8. Locknut (2)
9. Worklight
10. Bracket
10.1. Locknut (2)
10.2. Capscrew (2)
10.3. Washer (2)
10.4. Bracket
11. Locknut (2)
12. Capscrew (2)
13. Capscrew
14. Locknut
15. Hanger
16. Capscrew (2)
17. Nut (2)
18. Bracket
19. Air Cleaner
20. Capscrew (4)
21. Flanged Nut (4)
22. Air Cleaner Bracket (2)
23. Capscrew
24. Nut
25. Clamp
26. Clamp
27. Air Inlet Housing
28. Hose
4-22
TM 08780B-20
(10) Install bracket (10.4) and two washers(10.3), capscrews (10.2) and new
locknuts (10.1). Tighten locknuts (10.1) securely.
(11) Install worklight (9), bracket (10), two capscrews (6) and new locknuts
(8). Tighten locknuts (8) securely.
NOTE
Perform steps (12) and (13) for LVSA1 series vehicles only.
(12) Install weatherhood (5.2) using two capscrews (5.4) and new locknuts
(5.3). Tighten locknuts (5.3) securely.
(13) Install four capscrews (5.1) in right, left and rear sides of weatherhood
(5.2). Tighten capscrews (5.1) securely.
(14) Install hose (4) and clamp (3) on check valve assembly (5). Tighten clamp
(3) securely.
(15) Install air inlet duct (2) on air cleaner (19) and tighten clamp (1).
END OF TASK
4-23
TM 08780B-20
4-7. AIR CLEANER ELEMENT REPLACEMENT

c. Assembly
INITIAL SETUP
Applicable Configurations Equipment

MK48 Condition Condition
TM Description
TM 08780B-20 Weatherhood
Materials/Parts removed (para 4-6
Primary filter element (124210) item 11 LVSA1 series
Secondary filter element (C-60238) item 15 vehicles only).
a. Disassembly
(1) Remove capscrew (1) and nut (2) from each side of super clone (3).
Position super clone (3) out of the way.
(2) Remove two capscrews (4) and two nuts (5) from each end of two
clamping straps (6). Remove two clamping straps (6).
(3) Remove two capscrews (7) and nuts (8) from each side of sealing frame
(9). Remove sealing frame (9) and worklight bracket (10).
(4) Remove primary filter element (11) from plenum pan (12). Discard
primary filter element (11).
(5) Loosen four capscrews (13) and nuts (14) at each corner of secondary
filter element (15).
(6) Swing each holding tab (16) away from secondary filter element (15).
(7) Remove and discard secondary filter element (15).
(1) Clean plenum pan (12) and super clone (3).
4-24
TM 08780B-20
c. Assembly
(1) Install new secondary filter element (15).
(2) Swing holding tabs (16) over secondary filter element (15) so that
secondary filter element (15) is secured in plenum pan (12).
(3) Tighten four capscrews (13) and nuts (14) securely.
(4) Install new primary filter element (11) with open side of primary filter
element (11) facing away from locating strap (17).
NOTE
When tightening capscrews (7), lightly tap sealing frame (9) to insure it is fully seated.
(5) Install sealing frame (9) on primary filter element (11). Align holes in
sealing frame (9) with plenum pan (12) and install four capscrews (7), worklight bracket (10) and
nuts (8). Tighten capscrews (7) and nuts (8) securely.
(6) Install two clamping straps (6). Install two capscrews (4) and two nuts (5)
on each end of clamping straps (6). Tighten capscrews (4) and nuts (5) securely.
(7) Install super clone (3), two capscrews (1) and nuts (2) on sealing frame
(9). Tighten two capscrews (1) and nuts (2) securely.
NOTE
TM 08780B-20 Install weatherhood
(para 4-6 LVSA1 series vehicles only).
4-25
TM 08780B-20
1. Capscrew (2)
2. Nut (2)
3. Super Clone
4. Capscrew (4)
5. Nut
6. Clamping Strap (2)
7. Capscrew (4)
8. Nut (4)
9. Sealing Frame
10. Work Light Bracket
11. Primary Filter Element
12. Plenum Pan
13. Capscrew (4)
14. Nut (4)
15. Secondary Filter Element
16. Holding Tab (4)
17. Locating Strap
END OF TASK
4-26
TM 08780B-20
4-8. AIR RESTRICTION INDICATOR REPLACEMENT

c. Installation
INITIAL SETUP Materials/Parts

MK48
a. Removal
(1) Unscrew air restriction indicator (1) from elbow (2).
(2) Remove elbow (2) from mounting flange (3).
NOTE
If mounting flange (3) must be removed, remove dashboard (4). This will allow access to nuts
(5) and lockwashers (6). Refer to paragraph 7-11 of this manual.
(3) Loosen fitting (7) and remove vacuum line (8).
(4) Remove two capscrews (9), nuts (5) and lockwashers (6). Discard
lockwashers (6).
(5) Pull mounting flange (3) away from dashboard (4).
(6) Remove adapter (10) from mounting flange (3).
c. Installation
(1) Install adapter (10) into mounting flange (3). Tighten securely.
(2) Install vacuum line (8) onto adapter (10). Tighten fitting (7) securely.
(3) Install mounting flange (3), two capscrews (9), new lockwashers (6) and
nuts (5). Tighten capscrews (9) and nuts (5) securely.
4-27
TM 08780B-20
(4) Install elbow (2) onto mounting flange (3). Tighten elbow (2) securely.
(5) Install air restriction indicator (1). Tighten air restriction indicator (1) by
hand.
END Of TASK
NOTE
TM 08780B-20 Install dashboard
(4) if removed (para 7-11).
1. Air Restriction Indicator

2. Elbow
3. Mounting Flange
4. Dashboard
5. Nut (2)
6. Lockwasher (2)
7. Fitting
8. Vacuum Line
9. Capscrew (2)
10. Adapter
4-28
TM 08780B-20
4-9. INTAKE DUCTING REPLACEMENT

c. Installation

Lockwasher (MS35338-44) item 9
Applicable Configurations Lockwasher (2) (MS35338-45) item 18
MK48
a. Removal
(1) Loosen clamp (1) and remove hose (2).
(2) Loosen fitting (3) and remove hose (4).
(3) Loosen clamp (5) at the turbocharger (6).
(4) Remove capscrew (7), nut (8) and lockwasher (9) from hanger (10) behind
air cleaner assembly (11). Discard lockwasher (9).
(5) Loosen clamp (12) at air cleaner assembly (11). Pull rubber elbow (13)
away from air cleaner assembly (11).
(6) Pull intake ducting (14) free from air cleaner assembly (11) and
turbocharger (6).
1. Clamp 8. Nut
2. Hose 9. Lockwasher
3. Fitting 10. Hanger
4. Hose 11. Air Cleaner Assembly
5. Clamp 12. Clamp
6. Turbocharger 13. Rubber Elbow
7. Capscrew 14. Intake Ducting
4-29
TM 08780B-20
NOTE
Two clamps (15) may be used.
(7) Loosen clamp (15) and separate rubber elbow (13) from pipe (16).
(8) Remove two nuts (17), lockwashers (18), washers (19), clamp (20) and
bracket (10). Discard lockwashers (18).
(9) Loosen clamp (21) and separate reducer elbow (22) from pipe (16).
(10) Loosen clamp (23) and separate tube (24) from reducer elbow (22).
(11) Loosen clamp (25) and separate reducer elbow (26) from tube (24).
(12) Slide clamp (12) off of elbow (13).
10. Hanger
12. Clamp
13. Rubber Elbow
14. Intake Ducting
15. Clamp
16. Pipe
17. Nut (2)
18. Lockwasher (2)
19. Washer (2)
20. Clamp
21. Clamp
22. Reducer Elbow
23. Clamp
24. Tube
25. Clamp
26. Reducer Elbow
4-30
TM 08780B-20
c. Installation
NOTE
Assemble parts of intake ducting(14) as shown for proper installation.
(1) Install reducer elbow (26) and clamp (25) on tube (24). Tighten clamp
(25) securely. Slide clamp (23) onto reducer elbow (22).
(2) Install reducer elbow (22) and clamp (23) on tube (24). Tighten clamp
(23) securely.
(3) Install pipe (16) and clamp (21) on reducer elbow (22). Tighten clamp
(21) securely.
(4) Install clamp (20) with hanger (10), two washers (19), new lockwashers
(18) and two nuts (17). Tighten nuts (17) securely.
(5) Install rubber elbow (13) and clamp (15) on pipe (16). Tighten clamp (15)
securely.
(6) Slide clamp (12) onto rubber elbow (13).
4-31
TM 08780B-20
10. Hanger
12. Clamp
13. Rubber Elbow
14. Intake Ducting
15. Clamp
16. Pipe
17. Nut (2)
18. Lockwasher (2)
19. Washer (2)
20. Clamp
21. Clamp
22. Reducer Elbow
23. Clamp
24. Tube
25. Clamp
26. Reducer Elbow
1. Clamp
2. Hose
3. Fitting
4. Hose
5. Clamp
6. Turbocharger
7. Capscrew
8. Nut
9. Lockwasher
10. Hanger
11. Air Cleaner Assembly
12. Clamp
13. Rubber Elbow
14 Intake Ducting
16. Pipe
27. Reducer Elbow
4-32
TM 08780B-20
CAUTION
TO PREVENT PARTS DAMAGE, POSITION INTAKE DUCTING (14) AWAY FROM THE
AIR COMPRESSOR AND COOLANT PIPES.
(7) Install intake ducting (14). Position reducer elbow (27) and clamp (5) on
turbocharger (6). Tighten clamp (5) securely.
(8) Position rubber elbow (13) and clamp (12) on air cleaner assembly (11).
Tighten clamp (12) securely.
(9) Install hose (2) and clamp (1) on pipe (16). Tighten clamp (1) securely.
(10) Install hose (4) on pipe (16). Tighten fitting (3) securely.
(11) Install hanger (10) to air cleaner assembly (11) and secure with capscrew
(7), new lockwasher (9) and nut (8). Tighten capscrew (7) and nut (8) securely.
(12) Torque two nuts (17) to 15 foot-pounds (20 N*m).
END OF TASK
4-33
TM 08780B-20
4-10. LEFT FUEL TANK REPLACEMENT

b. Removal
c. Cleaning/Inspection
d. Installation

Applicable Configurations flammable and may explode. Keep
Materials/Parts
Cable tie (66182AX) item 16.1
Locknut (2) (1437220) item 23
Locknut (4) (MS51943-39) Items 17 and 20
Lockwasher (351AX) item 27
a. Draining
NOTE
A siphon pump can be used to drain fuel, if available.
(1) Close valve (1) and (1.1) at left fuel tank (2) and right fuel tank (2.1) on
crossover hose (3).
NOTE
Fuel tank capacity is 75 gallons. Make certain container used to catch fuel is large enough.
(2) Remove capscrew (4), lockwasher (5), washer (5.1) and clamp (6).
Discard lockwasher (5).
(3) Place containers large enough to hold entire contents of left fuel tank (2)
near valve (1).
1. Valve
1.1. Valve
2. Left Fuel Tank
2.1. Right Fuel Tank
3. Crossover Hose
4. Capscrew
5. Lockwasher
5.1. Washer
6. Clamp
4-34
TM 08780B-20
(4) Loosen fitting (9) at right fuel tank (2.1). Remove crossover hose (3) and
place inside container. Open valve (1) at left fuel tank (2).
(5) Allow entire contents of left fuel tank (2) to drain.
(6) Connect fitting (9) to right fuel tank (2.1). Tighten securely.
1. Valve
2. Left Fuel Tank
9. Fitting
4-35
TM 08780B-20
b. Removal
(1) Loosen fitting (8) and allow crossover hose (3) to hang loose.
(2) Remove adapter (10), valve (1), nipple (11), elbow (12) and nipple (13).
NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Disassembly steps are the same for old and new vehicles, except that the
nipple (13) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct
parts identification.
(3) Remove hose (14), check valve (15) and adapter (16).
NOTE
Perform step (4) for LVSA1 series vehicles only.
(4) Cut cable tie (16.1) and remove vent line (16.2) and vent valve (16.3).
(5) Remove two locknuts (17) from hold down straps (18) at radiator support
(19). Discard locknuts (17).
(6) Remove two locknuts (20) from hold down straps (18) under fender (21).
(7) Remove two hold down straps (18) and two hold down strap liners (22).
NOTE
(8) Remove two locknuts (23) and capscrews (24) from grab handle (25).
(9) Remove capscrew (26), lockwasher (27), washer (28) and grab handle
(25). Discard lockwasher (27).
4-36
TM 08780B-20
1. Valve 17. Locknut (2)

2. Left Fuel Tank 18. Hold Down Strap (2)
3. Crossover Hose 19. Radiator Support
8. Fitting 20. Locknut (2)
10. Adapter 21. Fender
11. Nipple 22. Hold Down Strap Liner (2)
12. Elbow 23. Locknut (2)
13. Nipple 24. Capscrew (2)*
14. Hose 25. Grab Handle*
15. Check Valve 26. Capscrew
16. Adapter 27. Lockwasher
16.1. Cable Tie* 28. Washer
16.2. Vent Line*
16.3. Vent Valve* *LVSA1 Series Vehicles Only
4-37
TM 08780B-20
(10) With help from assistant, remove left fuel tank (2). Tip left fuel tank (2)
up to drain any remaining fuel.
(11) Remove pipe plug (23).
(12) Remove five screws (24), cover (25) and gasket (26). Discard gasket (26).
(13) Remove fuel tank cap (27) with strainer (28) and retainer (29).
(2) Inspect hold down strap liners (22) for wear. Replace if worn.

2. Left Fuel Tank
23. Pipe Plug
24. Screw (5)
25. Cover
26. Gasket
27. Fuel Tank Cap
28. Strainer
29. Retainer
30. Pipe Plug
31. Pipe Plug
4-38
TM 08780B-20
d. Installation
CAUTION
TO PREVENT CONTAMINATION OF FUEL SYSTEM, DO NOT COAT FIRST TWO

THREADS OF ANY FITTING WITH PIPE SEALANT.
NOTE
Apply pipe sealant to threads on all fittings, elbows, adapters and pipe plugs.
(1) Install pipe plugs (30 and 31) into left fuel tank (2). Tighten securely.
(2) Install new gasket (26), cover (25) and five screws (24). Tighten screws
(24) securely.
(3) Install and tighten pipe plug (23).
(4) Install retainer (29), strainer (28) and fuel tank cap (27).
2. Left Fuel Tank

23. Pipe Plug
24. Screw (5)
25. Cover
26. Gasket
27. Fuel Tank Cap
28. Strainer
29. Retainer
30. Pipe Plug
31. Pipe Plug
4-39
TM 08780B-20
(5) With help from assistant, lift left fuel tank (2) into place on fender (21).
(6) Place hold down straps (18) on left fuel tank (2). Make sure two hold
down strap liners (22) are in place.
(7) Install new locknuts (17 and 20) onto hold down straps (18). Tighten
locknuts (17 and 20) securely
NOTE
old and new vehicles. Assembly steps are the same for old and new vehicles, except that the
(8) Install nipple (13) and elbow (12) into left fuel tank (2). Tighten securely.
(9) Install nipple (11), valve (1) and adapter (10) into left fuel tank (2) and
tighten securely.
(10) Connect crossover hose (3) and tighten fitting (8) securely.
(11) Install clamp (6) using capscrew (4), new lockwasher (5) and washer (5.1).
Torque capscrew (4) to 8 foot-pounds (11 N*m).
(12) Install adapter (16) and tighten securely.
(13) Install check valve (15). Tighten securely.
(14) Connect hose (14) to check valve (15).
NOTE
Perform steps (15 thru 18) for LVSA1 series vehicles only.
(15) Install vent valve (16.3). Tighten securely.
(16) Connect vent line (16.2) to barbed nozzle of vent valve (16.3) and secure
with cable tie (16.1).
(17) Install grab handle (25) with two capscrews (24) and new locknuts (23).
Tighten securely.
(18) Install new lockwasher (27), washer (28) and capscrew (26) in grab handle
(25). Tighten securely.
END OF TASK
4-40
TM 08780B-20
NOTE
TM 08780B-10 Fill fuel tanks and
prime fuel system (para 2-13).
Run engine and check for leaks

(para 2-13).
1. Valve 12. Elbow 20. Locknut (2)

2. Left Fuel Tank 13. Nipple 21. Fender
3. Crossover Hose 14. Hose 22. Hold Down Strap
4. Capscrew 15. Check Valve Liner (2)
5. Lockwasher 16. Adapter 23. Locknut (2)*
5.1. Washer 16.1. Cable Tie* 24. Capscrew (2)*
6. Clamp 16.2. Vent Line* 25. Grab Handle*
8. Fitting 16.3. Vent Valve* 26. Capscrew
10. Adapter 17. Locknut (2) 27. Lockwasher
11. Nipple 18. Hold Down Strap (2) 28. Washer
* LVSA1 Series Vehicles Only
4-41
TM 08780B-20
4-11. RIGHT FUEL TANK REPLACEMENT

b. Removal
d. Installation

Condition Condition
MK48 TM 08780B-20 Fuel level sending
unit removed (para
Materials/Parts 7-40).
Cable tie (66182AX) item 19.1
Lockwasher (MS35338-45) item 5 General Safety Instructions
Locknut (4) (MS51943-39) items 20 and 23 Do not smoke or use open flame. Fuel is
Locknut (2) (1437220) item 19.4 flammable and may explode. Keep fire
Lockwasher (351AX) item 19.9 extinguisher within reach.
a. Draining
NOTE
A siphon pump can be used to drain fuel, if available.
(1) Close valve (1) and (1.1) at left fuel tank (2) and right fuel tank (2.1) on
crossover hose (3).
NOTE
Fuel tank capacity is 75 gallons. Make certain container used to catch fuel is large enough.
(2) Remove capscrew (4), lockwasher (5), washer (5.1) and clamp (6).
(3) Place container large enough to hold entire contents of right fuel tank (2.1)
near valve (1).
(4) Loosen fitting (8), remove crossover hose (3) from valve (1) and place
crossover hose (3) inside container. Open valve (1.1).
(5) Allow entire contents of right fuel tank (2.1) to drain.
4-42
TM 08780B-20
1. Valve
1.1. Valve
2. Left Fuel Tank
3. Crossover Hose
4. Capscrew
5. Lockwasher
5.1. Washer
6. Clamp
8. Fitting
4-43
TM 08780B-20
b. Removal
NOTE
nipple (10.1) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct
(1) Remove adapter (10), valve (1.1) and nipple (10.1).
(5) Remove hose (17), check valve (18) and adapter (19).
NOTE
Perform steps (6 through 8) for LVSA1 series vehicles only.
(6) Cut cable tie (19.1) and remove vent line (19.2) and vent valve (19.3).
(7) Remove two locknuts (19.4) and capscrews (19.5) from grab handle
(8) Remove capscrew (19.7), washer (19.8), lockwasher (19.9) and grab
handle (19.6). Discard lockwasher (19.9).
(9) Remove two locknuts (20) from hold down straps (21) at radiator support
(10) Remove two locknuts (23) from hold down straps (21) under fender (24).
Discard locknuts (23). Remove two hold down straps (21). If damaged, remove and discard two
hold down strap liners (25).
(11) With help from assistant, remove right fuel tank (2.1). Tip right fuel tank
(2.1) up to drain any remaining fuel.
4-44
TM 08780B-20
1.1. Valve 19.2. Vent Line*

2.1. Right Fuel Tank 19.3. Vent Valve*
10. Adapter 19.4. Locknut (2)*
10.1. Nipple 19.5. Capscrew (2)*
11. Fitting 19.6. Grab Handle*
12. Hose 19.7. Capscrew
13. Fitting 19.8. Washer
14. Hose 19.9. Lockwasher
15. Fitting 20. Locknut (2)
16. Hose 21. Hold Down Strap (2)
17. Hose 22. Radiator Support
18. Check Valve 23. Locknut (2)
19. Adapter 24. Fender
19.1. Cable Tie* 25. Hold Down Strap Liner (2)
4-45
TM 08780B-20
NOTE
nipples (28 and 31) are not required on LVSA1 series vehicles. Refer to TM 08780B-24P for
correct parts identification.
(12) Remove adapter (26), check valve (27), nipple (28), elbow (29),
reducer(30) and nipple (31).
(13) Remove adapters (32 and 33), tee (34) and nipple (35).
NOTE
(14) Remove tee (36) and nipple (37).
(16) Remove fuel tank cap (40), strainer (41) and retainer (42).
4-46
TM 08780B-20
26. Adapter 35. Nipple

27. Check Valve 36. Tee
28. Nipple 37. Nipple
29. Elbow 38. Pipe Plug
30. Reducer 39. Pipe Plug
31. Nipple 40. Fuel Tank Cap
32. Adapter 41. Strainer
33. Adapter 42. Retainer
34. Tee
4-47
TM 08780B-20
d. Installation
CAUTION
TO PREVENT CONTAMINATION OF FUEL SYSTEM, DO NOT COAT FIRST TWO

THREADS OF ANY FITTING WITH PIPE SEALANT.
NOTE
Apply pipe sealant to threads on all fittings, elbows, adapters and pipe plugs.
(1) Install pipe plugs (38 and 39) into right fuel tank (7). Tighten securely.
(2) Install retainer (42), strainer (41) and fuel tank cap (40).
NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have. changed to a larger diameter for
old and new vehicles. Assembly steps are the same for old and new vehicles, except that the
nipples (28 and 31) are not required on LVSA1 series vehicles. Refer to TM 08780B-24P for
correct parts identification
(3) Install nipple (31), reducer (30) and elbow (29). Tighten securely.
NOTE
old and new vehicles. Assembly steps are the same for old and new vehicles, except that nipple
(37) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct parts
identification.
(4) Install nipple (28), check valve (27) and adapter (26). Tighten securely.
(5) Install nipple (37), tee (36), nipple (35) and tee (34). Tighten securely.
(6) Install nipple (45) and tee (34). Tighten securely.
(7) Install adapters (32 and 33).
(8) With help from assistant, lift right fuel tank (2.1) into place on fender (24).
4-48
TM 08780B-20

27. Check Valve 36. Tee
28. Nipple 37. Nipple
29. Elbow 38. Pipe Plug
30. Reducer 39. Pipe Plug
31. Nipple 40. Fuel Tank Cap
32. Adapter 41. Strainer
33. Adapter 42. Retainer
34. Tee
4-49
TM 08780B-20
(9) If removed, install two hold down strap liners (25). Place two hold down
straps (21) on right fuel tank (2.1).
(10) Install four new locknuts (20 and 23) onto hold down straps (21). Tighten
locknuts (20 and 23) securely.
(11) Install adapter (19) and tighten securely.
(12) Install check valve (18) and tighten securely. Connect hose (17) to check
valve (18).
NOTE
(13) Install vent valve (19.3) and tighten securely. Connect hose (19.2) to
barbed nozzle of vent valve (19.3) and secure with cable tie (19.1).
(14) Connect hose (16) to adapter (26). Tighten fitting (15) securely.
NOTE
old and new vehicles. Assembly steps are the same for old and new vehicles, except that nipple
(10.1) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct parts
identification.
(15) Install nipple (10.1), valve (1.1) and adapter (10). Tighten securely.
(16) Connect crossover hose (3) to adapter (10). Tighten fitting (9) securely.
NOTE
Perform steps (17 and 18) for LVSA1 series vehicles only.
(17) Install grab handle (19.6) with two capscrews (19.5) and new
locknuts(19.4). Tighten locknuts (19.4) securely.
(18) Install washer (19.8), lockwasher (19.9) and capscrew (19.7) in grab
handle (19.6). Tighten capscrew (19.7) securely.
(19) Install clamp (6) using capscrew (4), new lockwasher (5) and washer (5.1).
Tighten capscrew (4) to 8 foot-pounds (11 N*m).
4-50
TM 08780B-20
1. Valve
3. Crossover Hose
4. Capscrew
5. Lockwasher
5.1. Washer
6. Clamp
8. Fitting
(20) Install crossover hose (3) to valve (1). Tighten fitting (8) securely. Place
valve (1) in open position.
END OF TASK
NOTE
TM 08780B-10 Fill fuel tanks and
prime fuel system (para 2-13).
Run engine and check for

leaks (para 2-13).
TM 08780B-20 Install fuel level sending

unit (para 7-40).
4-51
TM 08780B-20
1.1. Valve 19.3. Vent Valve*

2.1. Right Fuel Tank 19.4. Locknut (2)*
10. Adapter 19.5. Capscrew (2)*
10.1. Nipple 19.6 Capscrew*
12. Hose 19.8. Washer*
13. Fitting 19.9. Lockwasher*
14. Hose 20. Locknut (2)
15. Fitting 21. Hold Down Strap (2)
16. Hose 22. Radiator Support
17. Hose 23. Locknut (2)
18. Check Valve 24. Fender
19. Adapter 25. Hold Down Strap Liner (2)
19.1. Cable Tie*
19.2. Hose* *LVSA1 Series Vehicles Only
4-52
TM 08780B-20
4-12. FUEL LINE, VENT, AND FITTING REPLACEMENT

d. Installation
INITIAL SETUP
Applicable Configurations Do not smoke or use open flame. Fuel is
MK48 flammable and may explode. Keep fire
extinguisher within reach.
Materials/Parts
Cable tie (AR) (MS3367-1-9)
Cable tie (2) (66182AX) item 4.1
a. Removal
NOTE
• The following procedures describe service of all fuel lines and fittings shown.
• Tag or mark all fuel lines to ensure proper installation.
• If fuel line is under pressure crack or open line to bleed off pressure. Use a cloth or
container to catch run-off fuel. Dispose of fuel properly.
• Fuel lines and fittings on LVSA1 series vehicles are larger than fuel lines and fittings
on non-A1 vehicles. Repair procedures are identical for LVSA1 and non-A1 vehicles.
Refer to TM 08780B-24P for correct parts identification.
(1) Use proper size line wrench to remove fuel lines (1) as necessary.
(2) Remove fittings (2) as necessary.
(3) Remove check valves (3) as necessary.
(4) Remove vent lines (4) as necessary.
NOTE
(5) Cut cable ties (4.1) and remove vent line (4.2) as necessary.
(6) Remove vent valve (4.3).
(7) Remove cable ties as necessary.
4-53
TM 08780B-20
(2) Inspect all hoses for cuts, cracks, breaks or bends.
(3) Inspect elbows, fittings and tubing for stripped threads, cracks or breaks.
(4) Inspect check valves for proper operation. Air or fluid must be able to
pass in one direction.
c. Installation
NOTE
Apply proper sealant to all fitting threads before installing.
(1) Install vent lines (4) or as necessary.
(2) Install check valves (3) as necessary.
NOTE
(3) Install vent valve (4.3) as necessary.
(4) Install vent line (4.2) as necessary and secure with cable tie (4.1).
(5) Install fittings (2) as necessary.
(6) Install fuel lines (1) as necessary.
(7) Install nylon ties to secure hoses in place.
END OF TASK
NOTE
TM 08780B-10 Prime fuel system
(para 2-13).

4-54
TM 08780B-20
1. Fuel Lines
2. Fittings
3. Check Valves
4. Vent Line
4.1. Cable Tie (2)*
4.1. Vent Line*
4.2. Vent Valve*
4-55
TM 08780B-20
4-13. SHUTDOWN SOLENOID REPLACEMENT

b. Cleaning/Installation
c. Installation
d. Adjustment

Condition Condition
MK48 TM 08780B-20 Batteries
disconnected
Materials/Parts (para 7-45).
Lockwasher (7) (MS35338-44) items 6, 20,23,25 and 31 Engine access panel
Copper washer (MS51092-1) item 26 removed (para 18-15).
Personnel Required General Safety Instructions

1 MOS 3521 To prevent personal injury, make sure
1 Assistant batteries are disconnected before working
on electrical components.
a. Removal
(1) Remove two flange nuts (1). Tag and remove four wires (2, 3, 4 and 4.1).
(2) Remove two nuts (5), lockwashers (6), washers (7) and capscrews (8)
from bracket (9). Discard lockwashers (6).
(3) Remove nut (10), two star washers (10.1), wire (4) and capscrew (10.2).
Discard star washers (10.1).
1 Flange Nut 8. Capscrew (2)
2. Wire (No. 019) 9. Bracket
3. Wire (No. 817) 10. Nut
4. Wire Ground 10.1. Star Washer (2)
4.1. Wire (718) 10.2. Capscrew
5. Nut (2) 11. Governor Control Lever
6. Lockwasher (2) 12. Shaft
7. Washer (2)
4-56
TM 08780B-20
NOTE
Locate engine serial number. Engines prior to 8VF 98256 use a short style mounting bracket
(13). Engines after that serial number use a long style mounting bracket (13) and spacer (17).
(4) Remove nut (14), lockwasher (15), washers (16), spacer (17) if used and
capscrew (18). Discard lockwasher (15).
(5) Remove capscrew (19) and lockwasher (20) from governor control lever
(11). Remove governor control lever (11). Discard lockwasher (20).
(6) Remove shutdown solenoid (21).
(7) Remove two capscrews (22), lockwashers (23) and bracket (9). Discard
lockwashers (23).
(8) Remove capscrew (24), lockwashers (25), bracket (13), copper washer
(26) or nut (27) if used. Discard lockwashers (25) and copper washer (26).
(9) Remove capscrew (28) and nut (29) from governor control lever (11).
(10) Remove nut (30), lockwasher (31), washer (32), bracket clip (33), washer
(34) and nut (35) from shutdown solenoid (21). Discard lockwasher (31).
9. Bracket
11. Governor Control Lever
12. Shaft
13. Bracket
14. Nut
15. Lockwasher
16. Washer
17. Spacer
18. Capscrew
19. Capscrew
20. Lockwasher
21. Shutdown Solenoid
22. Capscrew (2)
23. Lockwasher (2)
24. Capscrew
25. Lockwasher
26. Copper Washer
27. Nut
28. Capscrew
29. Nut
30. Nut
31. Lockwasher
32. Washer
33. Bracket Clip
34. Washer
35. Nut
4-57
TM 08780B-20
(2) Inspect wires (2, 3, 4 and 4.1) and connections.
c. Installation
(1) Install nut (35), washer (34), bracket clip (33), washer (32), lockwasher
(31) and nut (30) onto shutdown solenoid (21). Leave nuts (30 and 35) fingertight for
adjustment.
(2) Install bracket (13), with a new copper washer (26), new lockwashers (25),
capscrew (24) and nut (27). Tighten.
(3) Install bracket (9), two capscrews (22) and new lockwashers (23). Tighten
capscrews (22) securely.
(4) Install capscrew (18) with spacer (17) if used, through brackets (9 and 13).
Install washers (16), new lockwasher (15) and nut (14). Tighten nut (14) securely.
(5) Install control lever (11), new lockwasher (20) and capscrew (19).
(6) Align marks on governor control lever (11) and shaft (12) and tighten
capscrew (19) securely.
(7) Align hole in bracket clip (33) with hole in governor control lever (11).
Install capscrew (28) and nut (29). Tighten capscrew (28) and nut (29) securely.
(8) Align holes in shutdown solenoid (21) with holes in bracket (9). Install
shutdown solenoid (21) with bracket clip (33) facing governor control lever (11). Install ground
wire (4), two new star washers (10.1), capscrew (10.2) and nut (10). Tighten capscrew (10.2)
and nut (10) securely.
(8.1) Install two capscrews (8), washers (7), lockwashers (6) and nuts (5).
Tighten capscrews (8) and nuts (5) securely.
(9) Loosen nuts (30 and 35) on shutdown solenoid (21).
4-58
TM 08780B-20
9. Bracket 23. Lockwasher (2)

11. Governor Control Lever 24. Capscrew
12. Shaft 25. Lockwasher
13. Bracket 26. Copper Washer
14. Nut 27. Nut
15. Lockwasher 28. Capscrew
16. Washer 29. Nut
17. Spacer 30. Nut
18. Capscrew 31. Lockwasher
19. Capscrew 32. Washer
20. Lockwasher 33. Bracket Clip
21. Shutdown Solenoid 34. Washer
22. Capscrew (2) 35. Nut
4-59
TM 08780B-20
(10) Install wires (2, 3, 4 and 4.1) in their marked locations.
(11) Install two flange nuts (1). Tighten nuts (1) securely.
(12) Connect batteries. Refer to paragraph 7-41.
d. Adjustment
(1) Have assistant position governor control lever (11) in no fuel position and
push shaft (36) in all the way. Tighten nut (30) until snug. Tighten nuts (30 and 35) securely.
NOTE
Make sure shaft (36) does not bind when operated. Adjust mounting bolts as required to
prevent binding.
(2) Check operation of shutdown solenoid (21). If shutdown solenoid will

not stop engine, back off nut (35) and tighten nut (30) until properly adjusted.
END OF TASK
NOTE
TM 08780B-20 Install engine access
panel (para 18-15).
1. Flange Nut
2. Wire (No. 019)
3. Wire (No. 817)
4. Wire Ground
4.1. Wire (No. 718)
5. Nut (2)
6. Lockwasher (2)
7. Washer (2)
8. Capscrew
9. Bracket
10.1. Star Washer (2)
10.2. Capscrew
11. Governor Control Lever
12. Shaft
21. Shutdown Solenoid
30. Nut
33. Bracket Clip
35. Nut
36. Shaft
4-60
TM 08780B-20
4-14. SHUTDOWN SOLENOID REPLACEMENT (LVSA1 SERIES VEHICLES ONLY)

c. Installation

Condition Condition
MK48A1 TM 08780B-20 Batteries
disconnected
Materials/Parts (para 7-46)
Lockwasher (7) (MS35338-44) items 2, 6, 29 and 34
Copper washer (MS51092-1) item 36 Engine access panel
Lockwasher (P/N 351 AX) item 12 removed (para 18-15)
Locknut (2) (P/N 25003FX) item 17 and 22
Locknut (P/N 112556A) item 24 General Safety Instructions
Compound, Corrosion preventive (item 11.1 To prevent personal injury, make sure
Appendix D) batteries are disconnected before working
a. Removal
(1) Remove nut (1), Lockwasher (2) and washer (3) from shaft (4). Discard
lockwasher (2).
(2) Remove two nuts (5), lockwashers (6), three washers (7) and two screws
(8) from solenoid (9) and plate (10). Discard lockwashers (6).
NOTE
Tag and mark wires before removal.
(3) Remove capscrew (11), lockwasher (12), flat washer (13) and ground wire
(14). Discard Lockwasher (12).
4-61
TM 08780B-20
1. Nut 5. Nut (2) 9. Solenoid 13. Flat Washer

2. Lockwasher 6. Lockwasher (2) 10. Plate 14. Ground Wire
3. Washer 7. Washer (3) 11. Capscrew
4. Shaft 8. Screw (2) 12. Lockwasher
(4) Remove two nuts (15), three wires (16) and ground wire (17).
NOTE
Screw (22) may need to be loosened to remove locknut (18).
(5) Remove locknut (18). Pull up on shutdown link (19) and remove bracket
(20) and stop lever (21) from screw (22). Discard locknut (18).
(6) Remove locknut (23), two washers (24) and screw (22). Discard locknut
(23).
(7) Remove locknut (25) and shutdown link (19) from shutdown cable (26).
Discard locknut (25).
(8) Loosen two nuts (27) and remove shutdown cable (26) from cable bracket
(28).
NOTE
Crossover tube may need to be loosened to remove screw (29).
(9) Remove screw (29), lockwasher (30) and plate (10). Discard lockwasher
(30).
(10) Remove two nuts (31), lockwashers (32), washers (33), screws (34) and
cable bracket (28). Discard lockwashers (32).
(11) Remove solenoid (9).
4-62
TM 08780B-20
NOTE
Matchmark stop lever and stop lever shaft.
(12) Loosen screw (35) and remove stop lever (21).
NOTE
Note location of ties prior to removal to ensure proper installation.
(13) Remove screw (36), copper washer (37) and bracket (38). Discard copper
washer (37).
9. Solenoid 22. Screw 31. Nut (2)

10. Plate 23. Locknut 32. Lockwasher (2)
15. Nut (2) 24. Washer (2) 33. Washer (2)
16. Wire (3) 25. Locknut 34. Screw (2)
17. Ground Wire 26. Shutdown Cable 35. Screw
18. Locknut 27. Nut (2) 36. Screw
19. Shutdown Link 28. Cable Bracket 37. Copper Washer
20. Bracket 29. Screw 38. Bracket
21. Stop Lever 30. Lockwasher
4-63
TM 08780B-20
26. Shutdown Cable

39. Nut
40. Handle
41. Nut
(14) Remove three ties connecting shutdown cable (26) to cab and transmission
shift cable.
(15) Loosen nut (41) and unscrew handle (40) from shutdown cable (26).
(16) Remove nuts (39 and 41) and pull shutdown cable (26) downward through
opening in cab.
(2) Inspect wires (14, 16 and 17) and connections.
c. Installation
(1) Route shutdown cable (26) upward through opening in cab. Secure using
nuts (39 and 41).
(2) Screw handle (40) on shutdown cable (26) and tighten nut (39).
(3) Secure shutdown cable (25) to transmission shift cable and cab with ties in
positions noted during removal.
(4) Install bracket (38), new copper washer (37) and screw (36).
(5) Align matchmarks and install stop lever (21).
(6) Tighten screw (35).
4-64
TM 08780B-20
(7) Position solenoid (9) on plate (10).
(8) Install cable bracket (28) with two screws (34), washers (33), new
lockwashers (32) and nuts (31).
(9) Install plate (10) with screw (29) and new lockwasher (30).
(10) Install shutdown cable (26) on cable bracket (28) and tighten two nuts
(27).
(11) Install shutdown link (19) on shutdown cable (26) with new locknut (25).
Do not tighten locknut (25).
(12) Install bracket (20) on screw (22).
(13) Install screw (22) in shutdown link (19) with two washers (24) and new
locknut(23). Tighten new locknut (23) to provide 0.03 in. (0.76 mm) clearance above and below
shutdown link (19).
(14) Install stop lever (21) and bracket (20) on screw (22) with new locknut
(18). Tighten new locknut (18) to provide 0.03 in. (0.76 mm) clearance above and below
bracket (20).
(15) Adjust locknut (25) until shutdown link (19) has approximately 0.38 in.
(9.65 mm) free play in slot before shutdown link contacts screw (22). Tighten locknuts.
(16) Install ground wire (17), three wires (16) and nuts (15).
4-65
TM 08780B-20
9. Solenoid
10. Plate
15. Nut (2)
16. Wire (3)
17. Ground Wire
18. Locknut
19. Shutdown Link
20. Bracket
21. Stop Lever
22. Screw
23. Locknut
24. Washer (2)
25. Locknut
26. Shutdown Cable
27. Nut (2)
28. Cable Bracket
29. Screw
30. Lockwasher
31. Nut (2)
32. Lockwasher (2)
33. Washer (2)
34. Screw (2)
35. Screw
36. Screw
37. Copper Washer
38. Bracket
1. Nut
2. Lockwasher
3. Washer
4. Shaft
5. Nut (2)
6. Lockwasher (2)
7. Washer (2)
8. Screw (2)
9. Solenoid
10. Plate
11. Capscrew
12. Lockwasher
13. Flat Washer
14. Ground Wire
20. Bracket
42. Nut
4-66
TM 08780B-20
(17) Install capscrew (11), new lockwasher (12), flat washer (13) and ground
wire (14).
(18) Coat capscrew (11) at ground wire (14) with corrosion preventive
compound.
(19) Install two screws (8), three washers (7), two new lockwashers (6) and
nuts (5) on solenoid (9) and plate (10).
(20) Install washer (3), new lockwasher (2) and nut (1) on shaft (4) finger tight
and take slack out of bracket (19).
(21) Tighten nuts (42) and (1) against bracket (20).
d. Adjustment
(1) Hold stop lever (1) in run position.
(2) Adjust nut (2) to touch bracket (3).
(3) Tighten nuts (2 and 4) against bracket (3).
(4) Move stop lever (1) to stop position; if it binds, loosen mounting bolts and
re-align solenoid (5).
(5) Move stop lever (1); if lever binds with shutdown link (6), loosen locknut
(7) until lever moves freely within slot of shutdown link.
END OF TASK
NOTE
TM 08780B-20 Install engine access
panel (para 18-15).
Connect batteries
(para 7-46).
4-67
TM 08780B-20
1. Stop Lever
2. Nut
3. Bracket
4. Nut
5. Solenoid
6. Shutdown Link
7. Locknut
4-68
TM 08780B-20
4-15. THROTTLE CONTROL SOLENOID REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Exhaust crossover
tube removed (para
Gasket (731740-002) item 1.3 TM 08780B-10 Air system
drained (para 3-5).
a. Removal
(1) Unplug boot connector (1).
NOTE
(2) Loosen screw (1.1) and remove connector (1.2) and gasket (1.3). Discard
gasket (1.3).
(3) Loosen fitting (2). Tag and remove air line (3).
(5) Remove capscrew (6), washer (7) and bracket (11) from throttle control
wire (8).
(6) Remove capscrew (9), washer (10), solenoid (12) from transmission (13).
(7) Remove two capscrews (6 and 9), washers (7 and 10), bracket (11) and
throttle control solenoid (12.1) from transmission (13).
(8) Remove two screws (14) and lockwashers (15) from throttle control
solenoid (12) or (12.1). Remove bracket (11) and throttle control solenoid (12 or 12.1). Discard
lockwashers (15).
(9) Remove two elbows (16) from throttle control solenoid (12 or 12.1).
4-69
TM 08780B-20
(2) Inspect parts for damage. Refer to paragraph 2-12.
c. Installation
(1) Coat two elbows (16) with pipe sealant and install on throttle control
solenoid (12 or 12.1). Tighten elbows (16) securely.
(2) Install bracket (11), two screws (14) and new lockwashers (15) on throttle
control solenoid (12 or 12.1). Tighten screws (14) securely.
(3) Install throttle control solenoid (12), bracket (11), wire (8), two capscrews
(6 and 9) and washers (7 and 10) on transmission (13). Tighten capscrews (6 and 9) securely.
NOTE
(4) Install throttle control solenoid (12.1), bracket (11), two capscrews (6 and
9) and washers (7 and 10) on transmission (13). Tighten capscrews(6 and 9) securely.
(5) Install air line (5) in tagged location. Tighten fitting (4) securely.
(7) Reconnect boot connector (1).
(8) Install new gasket (1 .3) on connector (1.2) and reconnect. Tighten screw
(1.1) securely.
END OF TASK
4-70
TM 08780B-20
NOTE
TM 08780B-20 Install exhaust
crossover tube
(para 5-4).
TM 08780B-10 Start and run

engine (para 2-13).
Check to make sure

engine speed increases when
winch is operated.
1. Boot Connector
1.1. Screw*
1.2. Connector*
1.3. Gasket*
2. Fitting
3. Air Line
4. Fitting
5. Air Line
6. Capscrew
7. Washer
8. Wire
9. Capscrew
10. Washer
11. Bracket
12. Throttle Control Solenoid
12.1. Throttle Control Solenoid
13. Transmission
14. Screw (2)
15. Lockwasher (2)
16. Elbow (2)
4-71
TM 08780B-20
4-16. THROTTLE CYLINDER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-10 Air system drained
(para 3-5).
Materials/Parts
Pipe sealant (item 48, Appendix D) TM 08780B-20 Access panel
Lockwasher (7) (MS35338-44) removed
items 10, 14 and 20 (para 18-15, item 9).
a. Removal
(1) Loosen fittings (1, 2 and 3). Tag and remove air lines (4, 5 and 6).
(2) Line mark throttle lever (7) and shaft (8).
(3) Remove two capscrews (9), lockwashers (10) and nuts (11) from throttle
lever (7). Discard lockwashers (10).
(4) Remove two capscrews (12), nuts (13), lockwashers (14) and washers (15)
from throttle cylinder (16) and bracket (17). Discard lockwashers (14).
(5) Remove throttle cylinder (16).
(6) Remove throttle lever (7) and spring (18).
(7) Remove three capscrews (19), lockwashers (20) and bracket (17). Discard
lockwashers (20).
(8) Remove check valve (21) from throttle cylinder (16).
(9) Remove tee (22) and adapter (23) from check valve (21).
(10) Remove elbow (24).
4-72
TM 08780B-20
c. Installation
NOTE
Coat all pipe threads with pipe sealant during installation.
(1) Install elbow (24), tee (22) and adapter (23) into check valve (21).
Tighten elbow (24), tee (22) and adapter (23) securely.
(2) Thread check valve (21) into throttle cylinder (16). Tighten check valve
(21) securely.
(3) Install bracket (17) with three capscrews(19) and new lockwashers (20).
Tighten capscrews (19) securely.
(4) Install throttle lever (7) onto shaft (8).
(5) Install throttle cylinder (16) with rod (25) in throttle lever (7).
(6) Install two capscrews (12), new lockwashers (14), washers (15) and
nuts(13). Tighten capscrews (12) and nuts (13) securely.
(7) Install two capscrews (9), new lockwashers (10) and nuts (11) into throttle
lever (7). Align throttle lever (7) and shaft (8) with line marks. Tighten capscrews (9) securely.
(8) Install spring (18).
(9) Install air lines (4, 5 and 6) in their tagged locations. Tighten fittings (1, 2
and 3) securely.
END OF TASK
NOTE
LI 2320-12/9 Lubricate throttle
LO 9-2320-297-12 cylinder.
TM 08780B-20 Install access panel

(para 18-15, item 9).
TM 08780B-10 Run engine to build air

pressure. Check system for
leaks (para 2-13).
4-73
TM 08780B-20
1. Fitting 14. Lockwasher (2)

2. Fitting 15. Washer (2)
3. Fitting 16. Throttle Cylinder
4. Air Line 17. bracket
5. Air Line 18. Spring
6. Air Line 19. Capscrew (3)
7. Throttle Lever 21. Check Valve
9. Capscrew (2) 22. Tee
11. Wit (2) 23. Adapter
12. Capscrew (2) 24. Elbow
13. Nut (2) 25. Rod
4-74
TM 08780B-20
4-17. THROTTLE CYLINDER REPAIR

c. Assembly
INITIAL SETUP References

LI 2320-12/9
MK48
Equipment
Adhesive (item 3, Appendix D) TM Description
Grease (item 22, Appendix D) TM 08780B-20 Throttle
Silicone lubricant (item 26, Appendix D) cylinder removed
Soap solution (item 54, Appendix D) (para 4-16).
Repair kit (117612)
a. Disassembly
(1) Remove eight screws (1) and cover (2) from rear of throttle cylinder (3).
Discard eight screws (1).
(2) Install an Allen wrench (4) into piston (5) to prevent piston (5) from
turning.
(3) Place a wrench (6) on flats of rod end assembly (7). Remove rod end
assembly (7). Discard rod end assembly (7).
(4) Push piston (5) out of throttle cylinder (3).
1. Screw (8)
2. Cover
3. Throttle Cylinder
4. Allen Wrench
5. Piston
6. Wrench
7. Rod End Assembly
4-75
TM 08780B-20
(5) Remove and discard spring (8).
(6) Remove U-cup (9) and wear ring (10) from piston (5). Discard U-cup (9)
and wear ring (10).
(7) Remove and discard shell (11) and O-ring (12).
(8) Remove dust boot (13). Remove alignment spacer (14) from dust boot
(13). Discard dust boot (13).
(9) Remove two capscrews (15), nuts (16), washers (17) and lockwashers
(18). Remove throttle cylinder (3) from bracket (19). Discard lockwashers (18).
3. Throttle Cylinder 14. Alignment Spacer

5. Piston 15. Capscrew (2)
8. Spring 16. Nut (2)
9. U-Cup 17. Washer (2)
10. Wear Ring 18. Lockwasher (2)
11. Shell 19. Bracket
12. O-Ring
13. Dust Boot
4-76
TM 08780B-20
c. Assembly
(1) Install throttle cylinder (3) on bracket (19), using two capscrews (15),
washers (17), new lockwashers (18) and nuts (16). Tighten capscrews (15) and nuts (16)
securely.
(2) Install new shell (11) into throttle cylinder (3).
(3) Lightly coat new O-ring (12) with silicone lubricant. Carefully push
O-ring (12) into position around shell (11).
(4) Thoroughly coat new wear ring (10) with silicone lubricant. Carefully
install wear ring (10) onto piston (5).
(5) Thoroughly coat new U-cup (9) with silicone lubricant. Carefully install
U-cup (9) onto piston (5). Make certain open end of U-cup (9) faces away from wear ring (10).
(6) Install spring (8) onto piston (5).
(7) Install piston (5) and spring (8) into throttle cylinder (3).
(8) Install alignment spacer (14) on new dust boot (13) as shown.
(9) Install new dust boot (13) on throttle cylinder (3).
3. Throttle Cylinder 11. Shell 16. Nut (2)

5. Piston 12. O-Ring 17. Washer (2)
8. Spring 13. Dust Boot 18. Lockwasher (2)
9. U-Cup 14. Alignment Spacer 19. Bracket
10. Wear Ring 15. Capscrew (2)
4-77
TM 08780B-20
1. Screw (8)
2. Cover
3. Throttle Cylinder
4. Allen Wrench
5. Piston
7. Rod End Assembly
(10) Apply adhesive to threads on piston (5). Install new rod end assembly (7)
on piston (5).
(11) Secure piston (5) with an Allen wrench (4). Torque rod end assembly (7)
to 110-120 inch-pounds (2.71 N*m).
(12) Remove Allen wrench (4) from piston (5).
(13) Install cover (2) and eight new screws (1) following torque pattern.
Torque screws (1) to 24 inch-pounds (2.71 N*m).
(14) Lubricate rod end assembly (7). Refer to LI 2320-12/9, LO 9-2320-297-

12.
(15) Install throttle cylinder (3). Refer to paragraph 4-16.
Torque Pattern
END OF TASK
4-78
TM 08780B-20
4-18. FUEL/WATER SEPARATOR SERVICE

c. Assembly

Applicable Configurations flammable and may explode. Keep fire
MK48 extinguisher within reach.
Materials/Parts
O-ring (11350) item 3
Gaskets (2) (NSN 5330-01-046-1990) items 4 and 15
Filter element (2020) item 7
Filter element (2020SMOR) item 7 (LVSA1 Series Vehicles Only)
a. Disassembly
(1) Remove lid (1) by turning tee handle (2) counterclockwise. Remove and
discard O-ring (3) and gasket (4).
(2) Open drain valve (5) and drain fuel from fuel/water separator (6). Refer to
paragraph 4-19 of this manual.
(3) Remove filter element (7) from fuel/water separator (6) by turning filter
element (7). Discard filter element.
(4) Remove drain valve (5) from bowl (8 or 8.1).
(1) Flush fuel/water separator (6) with clean diesel fuel.
(2) If bowl (8) has large build up of sludge, remove bowl as follows:
(a) Remove four screws (9) and bowl retainer (10).
(b) Lower bowl (8). Tag and remove two wires (11 and 12) from two
terminals (13 and 14).
(c) Remove bowl (8) and gasket (15). Discard gasket (15).
(d) Clean bowl (8) with clean diesel fuel.
4-79
TM 08780B-20
NOTE
Perform steps (3) for LVSA1 series vehicles only.
(3) If bowl (8.1) has large build up of sludge, remove bowl as follows:
(a) Remove four screws (9) and bowl retainer (10).
(b) Remove bowl (8.1) and gasket (15). Discard gasket (15).
(c) Clean bowl (8.1) with clean diesel fuel.
c. Assembly
(1) If removed, install bowl (8) as follows:
(a) Coat new gasket (15) with clean diesel fuel. Install gasket (15)
into base (16).
(b) Connect two wires (11 and 12) to two terminals (13 and 14) inside
bowl (8).
(c) Install bowl retainer (10) using four screws (9). Torque screws (9)
to 40 inch-pounds (3.4 N*m).
NOTE
Perform steps (2) for LVSA1 series vehicles only.
(2) If removed, install bowl (8.1) as follows:
(a) Coat new gasket (15) with clean diesel fuel. Install gasket (15)
into base (16).
(b) Install bowl (8.1) and bowl retainer(10) using four screws (9).
Torque screws (9) to 40 inch-pounds (3.4 N*m).
(c) Install drain valve (5) into bowl (8.1).
(3) Install drain valve (5) into bowl (8).
(4) Install new filter element (7) into fuel/water separator (6).
4-80
TM 08780B-20
(5) Prime fuel/water separator (6) by filling fuel/water separator with clean
diesel fuel.
(6) Coat new O-ring (3) and new gasket (4) with clean diesel fuel. Install lid
(1) and gasket (4) using tee handle (2) and O-ring (3). Tighten tee handle (2) securely.
END OF TASK
NOTE
(para 2-13).
Start engine and

check for fuel leaks (para 2-13).
1. Lid 9. Screw (4)

2. Tee Handle 10. Bowl Retainer
3. O-Ring 11. Wire
4. Gasket 12. Wire
5. Drain Valve 13. Terminal
6. Fuel/Water Separator 14. Terminal
7. Filter Element 15. Gasket
8. Bowl 16. Base
8.1. Bowl*
4-81
TM 08780B-20
4-19. FUEL/WATER SEPARATOR REPLACEMENT

b. Removal
d. Installation

MOS 3521
Applicable Configurations 1 Assistant
MK48
Materials/Parts General Safety Instructions

Pipe sealant (item 48, Appendix D) Do not smoke or use open flame. Fuel is
Lockwasher (4) (MS35338-46) item 28 flammable and may explode. Keep fire
Lockwasher (3) (351AX1) item 28.2 extinguisher within reach.
Star washer (2) (1397020) item 28.5
Locknut (2) (11841) item 41.1 To prevent personal injury, make sure
Corrosion preventive compound (item 11.1, batteries are disconnected before working on
Appendix D) electrical components.
a. Draining
(1) Loosen fitting (1) on fuel line (2). Remove fuel line (2) from right fuel
tank (3).
(2) Attach a hose (4) to drain cock (5) on bottom of fuel/water separator (6) or
(6.1).
(3) Place free end of hose (4) in a container large enough to hold contents of
fuel/water separator (6) or (6.1).
NOTE
Tee handle (7) may have to be loosened to aid draining.
(4) Unscrew drain cock (5) until fuel begins to flow.
(5) Allow all fuel in fuel/water separator (6) or (6.1) to drain.
(6) Remove hose (4) and close drain cock(5).
b. Removal
(1) Tag and unplug two wires (8 and 9) from fuel/water separator (6).
4-82
TM 08780B-20
NOTE
Perform step (2) on LVSA1 series vehicles only.
(2) Cut wire (9.1) at butt connector (9.2).
(3) Loosen fitting (10). Tag and remove hose (11) from elbow (12).
(5) Disconnect plug (16).
(6) Loosen fitting (17). Tag and remove hose (14) from adapter (18).
NOTE
Have assistant hold fuel/water separator (6) or (6.1) during removal.
(9) Remove four capscrews (25), washers (26), nuts (27) and lockwashers
(28). Discard lockwashers (28).
NOTE
(10) Remove three nuts (28.1), lockwashers (28.2), six washers (28.3) and
three capscrews (28.4). Discard lockwashers (28.2).
(11) Remove nut (28.1), two star washers (28.5), terminal (28.6) and capscrew
(28.4). Discard star washer (28.5).
(12) Remove fuel/water separator (6) or (6.1) from bracket (29).
4-83
TM 08780B-20
1. Fitting 11. Hose 24. Elbow

2. Fuel Line 12. Elbow 25. Capscrew (4)
3. Right Fuel Tank 13. Fitting 26. Washer (4)
4. Hose 14. Hose 27. Nut (4)
5. Drain Cock 15. Elbow 28. Lockwasher (4)
6. Fuel/Water Separator 16. Plug 28.1. Nut (4)
6.1. Fuel/Water Separator* 17. Fitting 28.2. Lockwasher (3)
7. Tee Handle 18. Adapter 28.3. Washer (6)*
8. Wire 19. Fitting 28.4. Capscrew (4)*
9. Wire 20. Hose 28.5. Star Washer (2)*
9.1. Wire* 21. Elbow 28.6. Terminal*
9.2. Butt Connector* 22. Fitting 29. Bracket
10. Fitting 23. Hose
4-84
TM 08780B-20
(13) Remove elbow (12 and 15).
NOTE
Fittings on LVSA1 fuel/water separator have changed from a reducer bushing, nipple, tee,
nipple and adapter to adapter, street tee and hex nipple. When repairing non-A1 vehicles, use
new style hardware to replace old style hardware. Refer to TM 08780B-24P for correct parts
identification.
(14) Remove pressure switch (30), hex nipple (32), street tee (33) and adapter
(35).
(15) Remove elbows (21 and 24).
NOTE
Fittings on LVSA1 fuel/water separator have changed from an adapter, reducer fitting, cross,
nipple and adapter to an adapter, cross, hex nipple and adapter. When repairing non-A1
vehicles, use new style hardware to replace old style hardware. Refer to TM 08780B-24P for
(16) Remove adapter (37), cross (38), hex nipple (39) and adapter (40).
(17) Remove tee handle (7) and two clamps (41).
NOTE
(18) Remove tee handle (7).
(19) Remove two locknuts (41.1), washers (41.2), capscrews (41.3), clamps
d. Installation
NOTE
Coat threads of all fuel fittings and connections with pipe sealant.
(1) Install two clamps (41) and tee handle (7).
4-85
TM 08780B-20
NOTE
(2) Install two clamps (41.4) using two capscrews (41.3), washer (41.2) and
new locknuts (41.1). Tighten locknuts (41.1) securely.
(3) Install tee handle (7). Torque tee handle (7) to 80 - 90 inch-pounds (9.04 -
10.17 N*m).
(4) Install adapter (40), hex nipple (39), (38) and adapter (37). Tighten all
parts securely.
(5) Install elbows (21 and 24). Tighten securely.
(6) Install adapter (35), street tee (33) and pressure switch (30). Tighten all
parts securely.
(7) Install elbows (12 and 15). Tighten securely.
(8) Install fuel/water separator (6) to bracket (29) with four capscrews (25),
washers and nuts (26), new lockwashers (28), (27). Tighten capscrews (25) and nuts (27)
securely.
NOTE
Perform steps (9) thru (11) on LVSA1 series vehicles only.
(9) Install fuel/water separator (6.1) to bracket (29) with three capscrews
(28.4), six washers (28.3) three new lockwashers (28.2) and nuts (28.1). Tighten nuts (28.1)
securely.
(10) Install capscrew (28.4), terminal (28.6), two new star washers (28.5) and
nut (28.1). Tighten securely.
(11) Apply corrosion preventive compound at terminal (28.6).
(12) Install hose (23) in tagged location on elbow (24). Tighten fitting (22)
securely.
securely.
(14) Install hose (14) in tagged location on adapter (18). Tighten fitting (17)
securely.
(15) Connect plug (16).
4-86
TM 08780B-20
securely.
securely.
(18) Install two wires (8 and 9) in tagged locations.
NOTE
• Refer to paragraph 7-48 in this manual for proper installation of butt connectors.
• Perform step (19) on LVSA1 series vehicles only.
(19) Connect wire (9.1) with butt connector (9.2).
(20) Install fuel line (2) on right fuel tank (3). Tighten fitting (1) securely.
END OF TASK
NOTE
TM 08780B-20 Service fuel/water
separator (para 4-18).

(para 2-13).
Start engine and

4-87
TM 08780B-20
6. Fuel/Water Separator 16. Plug 28. Lockwasher (4) 34. Deleted

6.1. Fuel/Water Separator 17. Fitting 28.1. Nut (4) 35. Adapter
7. Tee Handle 18. Adapter 28.2. Lockwasher (3) 36. Deleted
8. Wire 19. Fitting 28.3. Washer (6)* 37. Adapter
9. Wire 20. Hose 28.4. Capscrew (4) 38. Cross
9.1. Wire* 21. Elbow 28.5. Star Washer (2)* 39. Hex Nipple
9.2. Butt Connector* 22. Fitting 28.6. Terminal* 40. Adapter
10. Fitting 23. Hose 29. Bracket 41. Clamp (2)
11. Hose 24. Elbow 30. Pressure Switch 41.1. Locknut (2)*
12. Elbow 25. Capscrew (4) 31. Deleted 41.2. Washer (2)*
13. Fitting 26. Washer (4) 32. Hex Nipple 41.3. Capscrew (2)*
14. Hose 27. Nut (4) 33. Street Tee 41.4. Clamp (2)’*
15. Elbow
4-88
TM 08780B-20
4-20. FUEL/WATER SEPARATOR REPAIR

c. Assembly

Condition Condition
MK48 TM 08780B-20 Fuel/water separator
Materials/Parts
O-ring (11350) item 2 General Safety Instructions
Gasket (2) (NSN 5330-01-046-1990) items 4 To prevent personal injury, make sure
and 17 batteries are disconnected before
Check ball gasket (NSN 5330-01-147-2520) working on electrical components.
item 23
Bowl gasket (11007) item 26 and 34
Check ball gasket (11028) item 30
Adhesive (item 3, Appendix D)
a. Disassembly
NOTE
Steps (1) through (7) can be used for both LVS and LVSA1 series vehicles.
(1) Remove tee handle (1) by turning counterclockwise.
(2) Remove and discard O-ring (2) from tee handle (1).
(3) Remove lid (3). Remove and discard gasket (4).
(4) Remove filter element (5) from housing (6 or 32) by turning filter element
(5).
NOTE
Drain valves on LVSA1 vehicles have changed from an adapter, O-ring and valve to a drain
valve assembly. When repairing non-A1 vehicles, use new style hardware to replace the old
style hardware. Refer to TM 08780B-24P for correct parts identification.
(5) Remove drain valve assembly (7).
(6) Remove four screws (10) from bowl retainer (11). Remove bowl retainer
(11).
4-89
TM 08780B-20
NOTE
Perform steps (7 through 10) only when repairing a non-A1 series vehicle. Perform steps (12
through 19) only when repairing an LVSA1 series vehicle.
(7) Lift bowl (12). Tag and remove two wires (13 and 14) from terminals (15
and 16).
(8) Remove bowl (12) and gasket (17). Discard gasket (17).
(9) Remove heater disc (18) by passing two wires (13 and 14) through baffle
(19) and base (20).
(10) Remove turbine (21), baffle (19), check ball (22) and check ball gasket
(23). Discard check ball gasket (23).
(11) Remove bowl (24) from base (25).
(12) Remove bowl gasket (26) from base (25). Discard bowl gasket (26).
(13) Unscrew turbine (27) and remove check ball (28) from base (25).
(14) Remove baffle (29) and check ball gasket (30) from base (25). Discard
check ball gasket (30).
(15) Remove heater (31) from housing (32).
NOTE
Match mark housing and base.
(16) Remove heater feed wire (33) from base (25).
(17) Install housing (32) in a soft jawed vise.
(18) Remove housing (32) and gasket (34) from base (25). Discard gasket
(34).
(19) Remove return tube (35) from base (25).
(3) Inspect bowl (12 and 24) for cracks.
4-90
TM 08780B-20
(4) Inspect heater disc wires (13, 14 and 33) for cracks or fraying.
1. Tee Handle 11. Bowl Retainer 20. Base 29. Baffle*

2. O-Ring 12. Bowl 21. Turbine 30. Check Ball Gasket*
3. Lid 13. Wire 22. Check Ball 31. Heater*
4. Gasket 14. Wire 23. Gasket 32. Housing*
5. Filter Element 15. Terminal 24. Bowl* 33. Heater Feed Wire*
6. Housing 16. Terminal 25. Base* 34. Gasket*
7. Drain Valve 17. Gasket 26. Bowl Gasket* 35. Return Tube*
Assembly 18. Heater Disc 27. Turbine*
10. Screw (4) 19. Baffle 28. Check Ball*
4-91
TM 08780B-20
c. Assembly
NOTE
Perform steps (1) through (5) only for non-A1 series vehicles. Perform steps (6) thru (13) only
for LVSA1 series vehicles.
(1) Install baffle (19), turbine (21), check ball (22) and new check ball gasket
(23).
(2) Install heater disc (18) by passing two wires (13 and 14) through base (20)
and baffle (19).
(3) Coat new bowl gasket (17) with clean diesel fuel. Install gasket (17) into
base (20).
(4) Connect two wires (13 and 14) to terminals (15 and 16) on inside of bowl
(12).
(5) Install bowl (12) using bowl retainer (11) and four screws (10). Torque
screws (10) to 40 inch-pounds (4.51 N*m).
(6) Coat threads of return tube (35) with adhesive. Install return tube (35) in
base (25). Torque return tube (35) to (9) 180-200 inch pounds (20.34-22.57 N*m).
(7) Lubricate new gasket (34) with diesel fuel. Install O-ring (2) onto tee
handle (1).
NOTE
Align match marks made prior to removal.
(8) Install housing (32) in base (25).
(9) Install heater (31) in housing (32).
(10 Install heater feed wire (33) in base (25).
NOTE
Install check ball gasket (30), so side marked TOP is against base (25).
(11) Coat new check bail gasket (30) with clean diesel fuel. Install check ball
gasket (30) and baffle (29) on base (25).
(12) Install check ball (28) and turbine (27) on base (25). Torque turbine (27)
20-25 inch pounds (2.26-2.85 N*m).
4-92
TM 08780B-20
(13) Install bowl (24) using bowl retainer (11) and four screws (10). Torque
screws (10) to 55-65 inch-pounds (6.25-7.35 N*m).
NOTE
Steps (14) through (18) can be used for both non-A1 and LVSA1 fuel/water separators.
(14) Install drain valve assembly (7), Torque drain valve assembly (7) to 30-35
inch pounds (3.39-3.96 N*m).
(15) Install filter element (5) into housing (6 or 32).
(16) Coat new gasket (4) with clean diesel fuel. Install gasket (4) and lid (3)
onto housing (6 or 32).
(17) Coat new O-ring (2) with clean diesel fuel and install in base (25).
(18) Install tee handle (1). Tighten securely.
END OF TASK
NOTE
TM 08780B-20 Install fuel/water
separator (para 4-19).
4-93
TM 08780B-20
1. Tee Handle 11. Bowl Retainer 20. Base 29. Baffle*

2. O-Ring 12. Bowl 21. Turbine 30. Check Ball Gasket*
3. Lid 13. Wire 22. Check Ball 31. Heater*
4. Gasket 14. Wire 23. Gasket 32. Housing*
5. Filter Element 15. Terminal 24. Bowl* 33. Heater Feed Wire*
6. Housing 16. Terminal 25. Base* 34. Gasket*
7. Drain Valve 17. Gasket 26. Bowl Gasket* 35. Return Tube*
Assembly 18. Heater Disc 27. Turbine*
10. Screw (4) 19. Baffle 28. Check Ball*
4-94
TM 08780B-20
4-21. SECONDARY FUEL FILTER AND ADAPTER REPLACEMENT

c. Installation

Applicable Configurations flammable and may explode. Keep
Materials/Parts
Pine sealant (item 48, Appendix D)
Filter element (23518482) item 1
a. Removal
(1) Using a filter wrench, turn filter element (1) counterclockwise and remove
it. Discard filter element (1).
(2) Tag, remove and plug three fuel lines (2, 3 and 4).
(3) Remove three 90 degree elbows (5, 6 and 7).
(4) Remove two nuts (8), washers (9), lockwashers (10) and capscrews (11).
(5) Remove filter adapter (12) from vehicle.
c. Installation
(1) Install filter adapter (12) using two nuts (8), washers (9), new lockwashers (10)
and capscrews (11).
NOTE
Apply sealant to threads of pipe three 90 degree elbows (5, 6 and 7) before installing.
4-95
TM 08780B-20
(2) Install three 90 degree elbows (5, 6 and 7).
(3) Install three fuel lines (2, 3 and 4).
(4) Fill new filter element (1) with clean diesel fuel.
(5) Install and hand tighten filter element (1). Using filter wrench, turn filter
an additional 2/3 turns clockwise.
END OF TASK
NOTE
TM 08780B-10 Prime fuel
system (para 2-13).

4-96
TM 08780B-20
1. Filter Element 8. Nut (2)

2. Fuel Line (No. 262) 9. Washer (2)
3. Fuel Line (No. 263) 10. Lockwasher (2)
4. Fuel Line (No. 264) 11. Capscrew (2)
5. 90 Degree Elbow 12. Filter Adapter
6. 90 Degree Elbow
7. 90 Degree Elbow
4-97
TM 08780B-20
4-22. ETHER STARTING AID REPLACEMENT
THIS TASK COVERS: a. Fuel Cylinder Replacement

b. Valve and Mounting Bracket Removal
d. Installation

TM 08780B-10
MK48
Materials/Parts To prevent fire or explosion, do not smoke
Lockwasher (6) (MS35338-45) item 13, 16 and 21 or use open flame when near fuel cylinder.
Avoid breathing fumes from fuel cylinder.
a. Fuel Cylinder Replacement
(1) Unscrew two wing nuts (1) securing cylinder clamp (2).
(2) Remove cylinder clamp (2).
(3) Unscrew fuel cylinder (3). Discard fuel cylinder (3) if empty.
(4) Remove shipping cap (4) from fuel cylinder (3).
(5) Screw new fuel cylinder (3) into valve (8). Hand tighten new fuel cylinder
(3) securely.
(6) Install cylinder clamp (2).
(7) Install two wing nuts (1). Hand tighten wing nuts (1) securely.
(8) Check for proper operation of fuel cylinder (3), temperature permitting.
Refer to TM 08780B-10.
b. Valve and Mounting Bracket Removal
(1) Remove fuel cylinder (3). Refer to section a, above.
(3) Loosen fitting (6) and remove tube (7) from valve (8).
(4) Remove two capscrews (9), clamp (10) and valve (8).
4-98
TM 08780B-20
(5) Remove two capscrews (11), nuts (12) and lockwashers (13). Remove
(6) Remove two nuts (15) and lockwashers (16) behind plate (17). Remove
bracket (18), two studs (19), nuts (20) and lockwashers (21). Discard lockwashers (16 and 21).
NOTE
If atomizer (22) and tube (7) will be replaced, follow steps (7) thru (9).
(7) Loosen fitting (23) and remove tube (7) from atomizer (22).
1. Wing Nut (2)

2. Cylinder Clamp
3. Fuel Cylinder
4. Shipping Cap
5. Plug
6. Fitting
7. Tube
8. Valve
9. Capscrew (2)
10. Clamp
11. Capscrew (2)
12. Nut (2)
13. Lockwasher (2)
14. Bracket
15. Nut (2)
16. Lockwasher (2)
17. Plate
18. Bracket
19. Stud (2)
20. Nut (2)
21. Lockwasher (2)
(8) Remove atomizer (22) from blower inlet housing (24).
(9) Remove ties as needed to free tube (7) from wiring harness. Remove tube
(7).
7. Tube
22. Atomizer
23. Fitting
24. Blower Inlet Housing
4-99
TM 08780B-20
d. Installation
(1) Install bracket (14), two capscrews (11), new lockwashers (13) and nuts
(12). Tighten capscrews (11) and nuts (12) securely.
(2) Install valve (8), clamp (10) and two capscrews (9). Tighten two
capscrews (9) securely.
(3) Install two nuts (20) and new lockwashers (21) on studs (19).
(4) Install bracket (18), two studs (19), new lockwashers (16) and nuts (15).
Tighten nuts (15 and 20) securely.
(5) If removed, install fitting (23), atomizer (22) and tube (7) at blower inlet
housing (24). Tighten fitting (23) and atomizer (22) securely. Route tube (7) along wiring
harness and replace ties as needed.
(6) Install tube (7) and fitting on valve (8). Tighten fitting (6) securely.
(7) Install plug (5).
(8) Install fuel cylinder (3). Refer to section a, above.
END Of TASK
4-100
TM 08780B-20
4-23. THROTTLE TREADLE VALVE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-10 Drain air tanks
(para 3-5).
Materials/Parts
Pipe Sealant (item 48, Appendix D)
Lockwasher (7) (MS35338-45) items 2 and 10
NOTE
Removal, Cleaning/Inspection and Installation instructions are applicable to LVSA1 and non-
A1 vehicles.
a. Removal
(1) Remove four capscrews (1) and lockwashers (2) from bracket (3). Discard
lockwashers (2).
(2) Pull throttle treadle valve (4) down for access to air lines (5 and 6).
NOTE
Fittings (7 and 8) of air lines (5 and 6) are parts of compression fittings. Tube supports of
compression fittings may stay with air lines or with the fittings (as shown). If damaged, refer
to paragraph 13-23 for compression fitting replacement.
(5) Remove throttle treadle valve (4) and bracket (3).
4-101
TM 08780B-20
1. Capscrew (4) 5. Airline

2. Lockwasher (4) 6. Airline
3. Bracket 7. Fitting
4. Throttle 8. Fitting
5. Treadle Valve
(6) Remove three capscrews (9), lockwashers (10), nuts (11) and throttle
treadle valve (4) from bracket (3). Discard lockwashers (10).
(7) Remove two fittings (12 and 13) from throttle treadle valve (4).
c. Installation
(1) Apply pipe sealant to threads on fittings (12 and 13). Install fittings (12
and 13). Tighten fittings (12 and 13) securely.
4-102
TM 08780B-20
NOTE
On non-A1 vehicles, make sure notch (14) in bracket (3) is installed as shown.
(2) Install throttle treadle valve (4) on bracket (3) with three capscrews (9),
new lockwashers (10) and nuts (11). Tighten capscrews (9) and nuts (11) securely.
(5) Position bracket (3). Install four capscrews (1) and new lockwashers (2).
END OF TASK
NOTE
TM 08780B-10 Operate vehicle
(para 2-13) and check throttle treadle
valve for proper operation or leaks.
3. Bracket
4. Throttle Treadle Valve
9. Capscrew (3)
10. Lockwasher (3)
11. Nut (3)
12. Fitting
13. Fitting
14. Notch
4-103/(4-104 blank)
TM 08780B-20
CHAPTER 5
EXHAUST SYSTEM
5-1. OVERVIEW
The following chapter covers replacement procedures for the vehicle’s exhaust system.
a. General. The LVS exhaust system channels the engine’s exhaust away from the
engine and sends it through a muffler. The exhaust system also supplies power for the
turbocharger. The exhaust system consists of the parts listed below.
b. Exhaust Manifolds. The exhaust manifolds are mounted on the engine and direct
exhaust gases from the engine to the rest of the exhaust system.
c. Exhaust Pipe. The exhaust pipes direct exhaust gases to each part of the exhaust
system.
d. Turbocharger. The turbocharger uses exhaust gas as a power supply for the turbo
charging operation.
e. Muffler. The muffler contains baffles that absorb noise created by the engine and
exhaust.
f. Rain Cap. The rain cap prevents rain from entering the muffler and exhaust
system while engine is turned off.
5-1
TM 08780B-20
5-3. MUFFLER/PIPE REPLACEMENT

c. Installation

During normal operation, the exhaust pipes
Applicable Configurations and muffler can become very hot. Be
MK48 careful not to touch these components with
your bare hands. Do not allow your body to
Materials/Parts contact the hot pipes or muffler. Exhaust
Lockwasher (4) (MS35338-48) items 10 and 13 system components may be hot enough
Locknut (MS51922-17) item 21 to cause serious burns.
Lockwasher (7) (MS35338-45) items 24, 28 and 32
a. Removal
(1) Loosen nut (1).
(2) Slide clamp (2) off exhaust pipe (3) onto turbocharger (4).
(3) Remove nut (5) and capscrew (6) from rain cap (7).
(4) Remove rain cap (7) from exhaust elbow (8).
(5) Remove two capscrews (9) and lockwashers (10) from rear mounting plate
from clamp (16). Discard lockwashers (13).
(7) Remove muffler (17) and exhaust pipe (3) from vehicle.
(8) Remove two nuts (18) and washers (19) from clamp (20). Remove
exhaust pipe (3) from muffler (17). Remove clamp (20).
(9) Remove locknut (21) and capscrew (22) from clamp (16). Remove clamp
(16) from muffler (17). Discard locknut (21).
(10) Remove two nuts (23), lockwashers (24) and washers (25) from clamp
(26). Discard lockwashers (24). Remove rear mounting plate (11) and clamp (26) from muffler
(11) Remove exhaust elbow (8) from muffler (17).
5-2
TM 08780B-20
(12) Remove three nuts (27), lockwashers (28) and capscrews (29) from heat
shield (30). Remove heat shield (30) from muffler (17). Discard lockwashers (28).
from each rear muffler mounting biscuits (35). Discard lockwashers (32).
(14) Remove four nuts (36), 10 washers (37), four springs (38), plate (39) and
two capscrews (40) from mounting bracket (41).
(15) Remove two nuts (42), lockwashers (43), clamp (44) and elbow (45).
(16) Separate ball joint (46) and flange (47).
5-3
TM 08780B-20
1. Nut
2. Clamp
3. Exhaust Pipe
4. Turbocharger
5. Nut
6. Capscrew
7. Rain Cap
8. Exhaust Elbow
9. Capscrew (2)
10. Lockwasher (2)
11. Rear Mounting Plate
12. Nut (2)
13. Lockwasher (2)
14. Washer (2)
15. Capscrew (2)
16. Clamp
17. Muffler
18. Nut (2) 37. Washer (10)
19. Washer (2) 38. Spring (4)
20. Clamp 39. Plate
21. Locknut 40. Capscrew (2)
22. Capscrew 41. Mounting Bracket
23. Nut (2) 42. Nut (2)
24. Lockwasher (2) 43. Lockwasher (2)
25. Washer (2) 29. Capscrew (3) 33. Washer (2) 44. Clamp
26. Clamp 30. Heat Shield 34. Capscrew (2) 45. Elbow
27. Nut (3) 31. Nut (2) 35. Mounting Biscuits 46. Ball Joint
28. Lockwasher (3) 32. Lockwasher (2) 36. Nut (4) 47. Flange
5-4
TM 08780B-20
(3) Inspect muffler (17) for cracks or holes.
c. Installation
(1) Install two capscrews (40), 10 washers (37), four springs (38), plate (39)
and four nuts (36) to mounting bracket (41).
(2) Install two rear muffler mounting biscuits (35) using four capscrews (34),
washers (33), new lockwashers (32) and nuts (31).
(3) Install clamp (16) onto muffler (17) using capscrew (22) and new locknut
(21). Finger tighten locknut (21).
(4) Install clamp (26) onto muffler (17) using rear mounting plate (11), new
lockwashers (24), two washers (25) and nuts (23). Finger tighten nuts (23).
(5) Slide ball joint (46) and flange (47) together.
(6) Install elbow (45) into ball joint (46) with clamp (44), new lockwashers
(43) and nuts(42). Tighten nuts (42) securely.
(7) Install exhaust pipe (3) onto turbocharger (4) as shown.
(8) Slide clamp (2) onto exhaust pipe (3). Tighten nut (1) securely.
(9) Install muffler (17) onto exhaust pipe (3). Install clamp (20) onto muffler
(17) using two washers (19) and two nuts (18). Tighten nuts (18) securely.
(10) Install two capscrews (15), washers (14), new lockwashers (13) and nuts
(12) into clamp (16) and plate (39). Tighten nuts (12) securely.
(11) Install exhaust elbow (8) into muffler (17) as shown. Tighten two nuts
(23) securely.
(12) Install two capscrews (9) and new lockwashers (10) into two mounting
biscuits (35). Tighten capscrews (9) securely.
5-5
TM 08780B-20
(13) Install rain cap (7) onto exhaust elbow (8). Install nut (5) and capscrew
(6). Tighten nut (5) securely.
(14) Install heat shield (30) using three capscrews (29), new lockwashers (28)
and nuts (27).
END OF TASK
NOTE
TM 08780B-10 Start engine
(para 2-13) and check
for exhaust leaks.
5-6
TM 08780B-20
1. Nut
2. Clamp
3. Exhaust Pipe
4. Turbocharger
5. Nut
6. Capscrew
7. Rain Cap
8. Exhaust Elbow
9. Capscrew (2)
10. Lockwasher (2)
11. Rear Mounting Plate
12. Nut (2)
13. Lockwasher (2)
14. Washer (2)
15. Capscrew (2)
16. Clamp
17. Muffler
18. Nut (2) 37. Washer (10)
19. Washer (2) 38. Spring (4)
20. Clamp 39. Plate
22. Capscrew 41. Mounting Bracket
23. Nut (2) 42. Nut (2)
25. Washer (2) 29. Capscrew (3) 33. Washer (2) 44. Clamp
26. Clamp 30. Heat Shield 34. Capscrew (2) 45. Elbow
27. Nut (3) 31. Nut (2) 35. Mounting Biscuits 46. Ball Joint
28. Lockwasher (3) 32. Lockwasher (2) 36. Nut (4) 47. Flange
5-7
TM 08780B-20
5-4. EXHAUST CROSSOVER TUBE MAINTENANCE

b. Installation

Condition Condition
opened (para 2-1).
During normal operation, the exhaust pipes and
muffler can become very hot. Be careful not to
touch these components with your bare hands. Do
not allow your body to contact the hot pipes or
muffler. Exhaust system components may be hot
enough to cause serious burns.
a. Removal
NOTE
The crossover tube has changed to a new design with a thermal wrap instead of a blanket.
When repairing a non-A1 vehicle, use new style tube to replace old style tube. Refer to TM
08780B-24P for correct parts identification.
(1) Loosen clamp (1) on left exhaust manifold (2). Slide clamp (1) back and
out of the way.
NOTE
Support crossover tube (3) or thermal wrapped crossover tube (3.1), while removing clamp (4).
(2) Loosen clamp (4) on turbo charger adapter (5). Slide clamp (4) back and
remove crossover tube (3).
NOTE
Perform step (3) on LSVA1 series vehicles only.
(3) Loosen clamp (4) on turbo charger adapter (5). Slide clamp (4) back and
remove thermal-wrapped crossover tube (3.1).
(4) Remove clamps (1 and 4) from crossover tube (3).
NOTE
(5) Remove clamps (1 and 4) from thermal-wrapped crossover tube (3.1).
5-8
TM 08780B-20
(6) Cut lockwire (6). Remove two clamps (7 and 8) and blanket (9). Discard
lockwire (6), clamps (7 and 8) and blanket (9).
b. Installation
(1) Slide clamps (1 and 4) onto thermal wrapped crossover tube (3.1).
(2) Position thermal wrapped crossover tube (3.1) on left exhaust manifold (2)
and install clamp (1). Position thermal wrapped crossover tube (3.1) on turbocharger adapter (5).
Install clamp (4). Tighten clamps (1 and 4) securely.
END OF TASK
NOTE
TM 08780B-10 Start engine (park 2-13) and check for
exhaust leaks.
Close engine access door (para 2-1).
5-9
TM 08780B-20
1. Clamp
2. Left Exhaust Manifold
3. Crossover Tube
3.1. Thermal-Wrapped Crossover
Tube
4. Clamp
5. Turbo charger Adapter
6. Lockwire
7. Clamp
8. Clamp
9. Blanket
5-10
TM 08780B-20
CHAPTER 6
COOLING SYSTEM
6-1. OVERVIEW
The following chapter covers maintenance and replacement procedures for the vehicle’s cooling
system.
6-2. COOLING SYSTEM DESCRIPTION
a. General. The LVS has a pressure type cooling system. It has a radiator, mounted
in a horizontal position, above and toward the rear of the engine. Two thermostats, one for each
cylinder bank, regulate the flow of coolant through two pipes that are connected to the radiator.
The radiator expansion tank has a pressure fill cap, a coolant level sight glass and a deaeration
system with vent lines that release trapped air from the engine. A transmission oil cooler and a
hydraulic oil cooler are mounted directly above the radiator. Cooling air is drawn downward
through the radiator by a hydraulically- driven, thermostatically-controlled fan mounted beneath
the radiator. Coolant is circulated by a centrifugal type, gear-driven pump that is mounted on the
front of the engine.
b. Radiator. A device that circulates coolant through fins and baffles that readily
conduct heat, causing rapid dissipation of heat into the surrounding air.
c. Radiator Cap. Closes off filler opening and keeps system under pressure, up to a
maximum of 7 psi (48.26 kPa).
d. Coolant Filter. Removes dirt and foreign particles from coolant.
e. Thermostats. Shut off coolant flow to radiator until temperature reaches 180
degrees. Coolant is then directed through the radiator inlet hose to the radiator.
f. Hydraulic Oil Cooler. A device that circulates hydraulic oil through finned tubing
that readily conducts heat, causing rapid dissipation of heat into the surrounding air.
g. Transmission Oil Cooler. A device that circulates transmission oil through finned
tubing that readily conducts heat, causing rapid dissipation of heat into the surrounding air.
h. Hydraulic Fan. Hydraulic oil drives fan once coolant temperature reaches 180
degrees.
6-1
TM 08780B-20
1. Radiator 5. Hydraulic Oil Cooler

2. Radiator Cap 6. Transmission Oil Cooler
3. Coolant Filter 7. Hydraulic Fan
4. Thermostats (2)
6-2
TM 08780B-20
6-3. RADIATOR SERVICE
THIS TASK COVERS: a. Draining Radiator

b. Filling Radiator

Use extreme care to avoid being burned
Applicable Configurations when working on any part of the cooling
MK48 system. Wear gloves to protect hands if you
must work on a hot system.
Materials/Parts
Coolant (item 8, Appendix D)
References
LI 2320-12/9
LO 9-2320-297-12
a. Draining Radiator
(1) Push down on radiator cap (1) and turn one half turn counterclockwise to
release pressure.
(2) Once pressure is released, turn radiator cap (1) an additional half turn and
remove radiator cap (1).
NOTE
Use funnel to direct flow of coolant from drain cocks into drain pan.
(3) Turn drain cock (2) counterclockwise to open. Drain coolant (3) into
drain pan (4).
(4) Turn drain cock (5) counterclockwise to open. Drain coolant (3) into
drain pan (4).
(5) Turn drain cocks (2 and 5) clockwise to close when radiator (10) is empty
or when coolant is at proper level.
(6) To drain coolant from engine block, open four drain cocks (6, 7, 8 and 9)
by turning counterclockwise.
(7) Turn drain cocks (6, 7, 8 and 9) clockwise to close, after block is drained.
b. Filling Radiator
(1) Make sure all six drain cocks (6 thru 9) and (2 and 5) are closed.
6-3
TM 08780B-20
(2) Fill radiator (10) to one inch (25.40 mm) below filler neck (11) with
permanent antifreeze. Refer to LI 2320-12/9, LO 9-2320-297-12.
(3) Install radiator cap (1) by turning clockwise.
END OF TASK
NOTE
1. Radiator Cap
2. Drain Cock
3. Coolant
4. Catch Pan
5. Drain Cock
6. Drain Cock
7. Drain Cock
8. Drain Cock
9. Drain Cock
10. Radiator
11. Filler Neck
6-4
TM 08780B-20
6-4. RADIATOR GRILLE AND GRATE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Grab handles
Materials/Parts (LVSA1 series
Locknut (11) (MS51858-5) item 2 vehicles only).
Lockwasher (6) (MS35338-46) item 6 Personnel Required
(LVSA1 series vehicles only) 1 MOS 3521
Lockwasher (10) (MS35338-44) item 12 1 Assistant

when working on any part of the cooling
system. Wear gloves to protect hands if you
a. Removal
(1) While assistant holds engine cover (1), remove 11 locknuts (2) and screws
(3) from engine cover hinge (4). Remove engine cover (1) from vehicle. Discard locknuts (2).
(2) Remove eight capscrews (5), lockwashers (6) and washers (7) from
radiator grille hold down (8). Discard lockwashers (6).
NOTE
(3) Remove six capscrews (5), lockwashers (6) and washers (7.1) from
radiator grille hold down (8). Discard lockwashers (6).
(4) With assistant, lift radiator grille (9) off radiator assembly (10).
(5) Remove ten capscrews (11), lockwashers (12), washers (13) and grate
6-5
TM 08780B-20
c. Installation
(1) Install ten capscrews (11), new lockwashers (12) and washers (13) to
secure grate (14).
(2) With assistant, place radiator grille (9) over radiator assembly (10).
NOTE
(3) Install six washers (7.1), new lockwashers (6) and capscrews (5.1) on
radiator grille hold down (8).
(4) Install eight capscrews (5), new lockwashers (6) and washers (7) on
radiator grille hold down (8).
(5) Install engine cover (1) using 11 screws (3) and new locknuts (2).
END OF TASK
NOTE
TM 08780B-20 Install grab handles
(para 18-21) (LVSA1
series vehicles only).
6-6
TM 08780B-20
1. Engine Cover
2. Locknut (11)
3. Screw (11)
4. Engine Cover Hinge
5. Capscrew (8)
5. Capscrew (6)*
6. Lockwasher (8)
6. Lockwasher (6)*
7. Washer(8)
7. Washer (6)*
8. Radiator Grille Hold Down
9. Radiator Grille
10. Radiator Assembly
11. Capscrew (10)
12. Lockwasher (10)
13. Washer (10)
14. Grate
6-7
TM 08780B-20
6-5. COOLANT FILTER AND ADAPTER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Fill radiator to
proper level if drained
Coolant (item 8, Appendix D)
Oil (item 37, Appendix D) TM 08780B-10 Start engine (Check
Pipe sealant (item 48, Appendix D) for leaks (para 2-13).
Filter (PFC-24A) item 3
Capscrew (2) (MS16208-136) item 7 General Safety Instructions
Lockwasher (2) (MS35338-50) item 9 Use extreme care to avoid being burned
References
TM 08780B-10
a. Removal
(1) Close two valves (1 and 2) by turning clockwise.
(2) Use filter wrench to turn filter (3) counterclockwise. Remove filter (3)
and discard.
NOTE
Hose clamps (4) have changed from a worm type clamp to a constant torque “Breeze” type
clamp. When repairing a non-A1 vehicle, use the new style constant torque clamp to replace
the old style clamp. Refer to TM 08780B-24P for correct parts identification.
(3) Loosen two hose clamps (4). Remove two hoses (5 and 6). Plug two
hoses (5 and 6) with 5/8 X 1 capscrews. Tighten clamps (4) securely.
(4) Remove two capscrews (8), lockwashers (9), bracket (10) and filter
adapter (11) from engine block (12). Discard lockwashers (9).
(5) Remove three capscrews (13) and nuts (14) from bracket (10) and filter
adapter (11).
6-8
TM 08780B-20
(6) Remove valve (2) from filter adapter (11).
NOTE
Fittings for LVSA1 series vehicles have changed from a nipple and elbow to a street elbow.
When repairing a non-A1 vehicle, use the new style fittings to replace the old style fittings.
(7) Remove street elbow (16) and valve (1) from filter adapter (11).
c. Installation
NOTE
Apply pipe sealant to street elbow and two valves before installing.
(1) Install street elbow (16) and valve (1) into filter adapter (11).
(2) Install valve (2) into filter adapter (11).
(3) Install bracket (10) onto filter adapter (11) using three capscrews (13) and
nuts (14).
(4) Install bracket (10) and filter adapter (11) onto engine block (12) using
two capscrews (8) and new lockwashers (9).
(5) Coat filter seal (17) on new filter (3) with clean engine oil.
(6) Install filter (3) onto filter adapter (11). Turn filter a quarter turn after
filter seal (17) contacts filter adapter (11).
(7) Loosen two clamps (4). Remove two capscrews (7) from two hoses (5 and
6). Install two hoses (5 and 6). Torque hose clamps (4) to 40 inch-pounds (4.51 N*m).
(8) Open two valves (1 and 2) by turning handles counterclockwise.
END OF TASK
6-9
TM 08780B-20
NOTE
TM 08780B-20 Fill radiator to
proper level if drained (para 6-3).
TM 08780B-10 Start engine (Check

6-10
TM 08780B-20
6-6. THERMOSTAT AND HOUSING REPLACEMENT

c. Installation

Condition Condition
open (para 2-1).
Materials/Parts
Anti-freeze (item 8, Appendix D) TM 08780B-20 Engine access panels
Gasket, right (NSN 5350-01-058-8267) item 25 removed (para 18-15).
Seal (2) (NSN 5330-00-961-9806) item 27
Gasket, left (NSN 5330-00-781-7117) item 31 Coolant drained (para
Gasket, left (NSN 5330-00-973-1415) item 37 6-3).
Gasket, right (NSN 5330-00-915-2835) item 42
Lockwasher (5) (MS35338-47) item 23 Cooling system
Lockwasher (10) (MS35338-46) items 29, 36, and 40 switch removed (para
7-9).
Temperature sending
units disconnected
(para 7-39).
Shutdown solenoid
removed (para 4-13
or 4-14 for LVSA1
Series Vehicles only).

a. Removal
NOTE
Hose clamps (1, 2, 15 and 17) have changed from a “worm” type clamp to a constant torque
“Breeze” type clamp. When repairing a non-A1 vehicle, use the new style constant torque
clamp to replace the old style clamp. Refer to TM 08780B-24P for correct part identification.
(1) Loosen two hose clamps (1 and 2) and remove two upper radiator hoses (3
and 4).
6-11
TM 08780B-20
(2) Remove two capscrews (5 and 6) on lifting bracket (7). Remove lifting
bracket (7).
(3) Loosen four hose clamps (8) on by-pass tube (9). Slide two hoses (10) to
clear thermostat housings (11 and 12).
(4) Remove by-pass tube (9).
(5) Loosen two hose clamps (13) on hose (14). Slide hose (14) to clear upper
left thermostat housing (11).
(6) Loosen hose clamp (15). Tag and remove hose (16).
(7) Loosen hose clamp (17). Tag and remove hose (18).
1. Hose Clamp
2. Hose Clamp
3. Upper Radiator Hose
5. Capscrew
6. Capscrew
7. Lifting Bracket
8. Hose Clamp (4)
9. By-Pass Tube
10. Hose (2)
11. Upper Left
Thermostat Housing
12. Upper Right
Thermostat Housing
13. Hose Clamp (2)
14. Hose
15. Hose Clamp
16. Hose
17. Hose Clamp
18. Hose
6-12
TM 08780B-20
(8) Loosen two hose clamps (19) on hose (20). Slide hose (20) to clear upper
right thermostat housing (12).
NOTE
If thermostat housings must be replaced, go to step (15).
(9) Remove four capscrews (21), capscrew (22) and five lockwashers (23) on
upper right thermostat housing (12). Discard lockwashers (23).
(10) Separate upper right thermostat housing (12) from lower right thermostat
housing (24). Remove and discard gasket (25).
(11) Remove thermostat (26) from upper right thermostat housing (12).
Remove and discard seal (27).
(12) Remove four capscrews (28) and lockwashers (29) on upper left
thermostat housing (11). Discard lockwasher (29).
(13) Separate upper left thermostat housing (11) from lower left thermostat
housing (30). Remove and discard gasket (31).
(14) Remove thermostat (26) from upper left thermostat housing (11). Remove
and discard seal (27).
(15) Remove three capscrews (32, 33 and 34),washer (35) and three
lockwashers (36). Discard lockwashers (36).
(16) Remove lower left thermostat housing (30)and lower left thermostat
housing gasket (37). Discard lower left thermostat housing gasket (37).
(17) If necessary, tag and remove two fuel lines (38). Refer to paragraph 4-12.
(18) Remove three capscrews (39) and lockwashers (40). Discard lockwashers
(40). Loosen capscrew (41).
(19) Remove lower right thermostat housing (24) and gasket (42). Discard
gasket (42).
(2) Clean all mating surfaces.
6-13
TM 08780B-20
(3) Inspect thermostat housings (12 and 24, 11 and 30) for cracks.
(4) Inspect threads for nicks and burrs.
c. Installation
(1) If removed, install lower right thermostat housing (24) using three
capscrews (39), capscrew (41), new lockwashers (40) and new gasket (42). Tighten capscrews
(39 and 41) securely.
(2) If removed, install two fuel lines (38).
(3) If removed, install lower left thermostat housing (30) using three
capscrews (32, 33 and 34), new lockwashers (36), washer (35) and new lower left thermostat
housing gasket (37). Tighten capscrews (32, 33 and 34) securely.
(4) Install new seal (27), lip facing up, into upper right thermostat housing
(12).
(5) Install new thermostat (26) into upper right thermostat housing (12) spring
facing down.
(6) Install new gasket (25) on upper right thermostat housing (12).
(7) Install upper right thermostat housing (12) onto lower right thermostat
housing (24) using four capscrews (21), capscrew (22), and five new lockwashers (23). Torque
capscrews (21 and 22) to 30-35 foot-pounds(41-47 N*m).
(8) Install new seal (27), with lip facing up, into upper left thermostat housing
(11).
(9) Install new thermostat (26) into upper left thermostat housing (11), spring
facing down.
(10) Install new gasket (31) on upper left thermostat housing (11).
(11) Install upper left thermostat housing (11) on lower left thermostat housing
(30) using four capscrews (28) and new lockwashers (29). Torque capscrews to 30-35 foot-
pounds (41-47 N*m).
(12) Install hose (20) onto water pump (42). Tighten hose clamps (19)
securely.
6-14
TM 08780B-20
11. Upper Left 25. Gasket (Right) 35. Washer

Thermostat Housing 26. Thermostat (2) 36. Lockwasher (3)
12. Upper Right 27. Seal (2) 37. Lower Left Thermostat
Thermostat Housing 28. Capscrew (4) Housing Gasket
19. Hose Clamp (2) 29. Lockwasher (4) 38. Fuel Line (2)
20. Hose 30. Lower Left 39. Capscrew (3)
21. Capscrew (4) Thermostat Housing 40. Lockwasher (3)
22. Capscrew 31. Gasket (Left) 41. Capscrew
23. Lockwasher (5) 32. Capscrew 42. Gasket (Right)
24. Lower Right 33. Capscrew
Thermostat Housing 34. Capscrew
6-15
TM 08780B-20
(13) Install by-pass tube (9). Slide two hoses (10) onto thermostat housings
(11 and 12). Tighten four hose clamps (8) securely.
(14) Install lifting bracket (7) using capscrews (5 and 6). Torque capscrew (5)
on lifting bracket (7) to 71-75 foot-pounds (96-102 N*m). Torque capscrew (6) on lifting
bracket (7) to 137-147 foot-pounds (186-200 N*m).
(15) Slide hose clamps (15 and 17) over hoses (18 and 16) and install onto
elbow (43). Tighten hose clamps (17 and 15) to 40 inch-pounds (4.5 N*m).
(16) Slide hose (14) onto upper left thermostat housing (11). Tighten two hose
clamps (13) securely.
(17) Install two upper radiator hoses (3 and 4). Tighten two hose clamps (1
and 2) to 100 inch-pounds (11 N*m).
END OF TASK
NOTE
TM 08780B-20 Install throttle shut
down solenoid (para 4-13).
Connect temperature
sending unit (para
7-39).
Cooling system switch installed

(para 7-9).
Fill coolant (para 6-3).
Install engine access panels (18-15).

check for leaks. (para 2-13).
Close engine access

door (para 2-1).
6-16
TM 08780B-20
5. Capscrew
6. Capscrew
7. Lifting Bracket
8. Hose Clamp (4)
9. By-Pass Tube
10. Hose (2)
6-17
TM 08780B-20
1. Hose Clamp
2. Hose Clamp
11. Upper Left
Thermostat Housing
12. Upper Right
Thermostat Housing
13. Hose Clamp (2)
14. Hose
15. Hose Clamp
16. Hose
17. Hose Clamp
18. Hose
43. Elbow
6-18
TM 08780B-20
6-7. COOLING SYSTEM HOSE AND TUBE REPLACEMENT
THIS TASK COVERS: a. Lower Hose and Tube Removal

b. Upper Hose and Tube Removal
d. Upper Hose and Tube Installation
e. Lower Hose and Tube Installation

Condition Condition
MK48 TM 08780B-20 Side access panels
Materials/Parts
Nylon ties (6) (MS3367-1-9) item 10 Cooling system
Lockwasher (7) (MS35338-45) items 13, 23 and 32 drained (para 6-3).

References Use extreme care to avoid being burned
TM 08780B-10 when working on any part of the cooling
a. Lower Hose and Tube Removal
NOTE
clamp to replace the old style clamp. Refer to TM 08780B-24P for correct part identification.
(1) Loosen two hose clamps (1). Slide hose (2) down onto tube (3) to clear
radiator (4).
(2) Loosen two hose clamps (5). Remove tube (3), hose (2) and elbow (6).
(3) Remove hose (2) and elbow (6) from tube (3). Remove four clamps (1
and 5) from hose (2) and elbow (6).
(4) Loosen two hose clamps (7) from hose (8). Slide hose (8) onto tube (9).
(5) Note location of nylon ties (10) for installation. Remove nylon ties (10) as
required.
(6) Remove three clamps (11) by removing capscrews (12) and lockwashers
(13). Discard lockwashers (13). Remove hose (9).
6-19
TM 08780B-20
(7) Loosen two hose clamps (14). Slide hose (15) onto tube (16).
(8) Remove nylon ties (10) as required.
(9) Remove tube (16) and hose (15). Remove hose (15) and two hose clamps
(14) from tube (16).
1. Hose Clamp (2) 10. Nylon Ties

2. Hose 11. Clamp (3)
3. Tube 12. Capscrew (3)
4. Radiator 13. Lockwasher (3)
5. Hose Clamp (2) 14. Hose Clamp (2)
6. Elbow 15. Hose
7. Hose Clamp (2) 16. Tube
8. Hose
9. Tube
6-20
TM 08780B-20
b. Upper Hose and Tube Removal
NOTE
clamp to replace the old style clamp. Refer to TM 08780B-24P for correct parts identification.
(1) Loosen two hose clamps (17). Slide hose (18) onto left tube (19).
(2) Loosen two hose clamps (20). Cut nylon ties (10) as required.
(3) Remove clamp (21) by removing two nuts (22) and lockwashers (23) from
(4) Remove left tube (19) and elbow (25). Remove elbow (25) and two hose
clamps (20) from left tube (19).
(5) Loosen two hose clamps (26). Slide hose (27) onto right tube (28).
(6) Loosen two hose clamps (29).
(7) Remove nylon ties (10) as required.
(8) Remove clamp (30) by removing two nuts (31) and lockwashers (32).
(9) Remove right tube (28), hose (27) and elbow (33).
(10) Remove hose (27), two hose clamps (26), elbow (33) and two hose clamps
(29) from right tube (28).
d. Upper Hose and Tube Installation
(1) Install two hose clamps (26) on hose (27) and two hose clamps (29) onto
elbow (33).
(2) Slide elbow (33) and hose (27) on right tube (28).
6-21
TM 08780B-20
(3) Install right tube (28) by sliding hose (27) onto radiator (4) and elbow (33)
onto right thermostat housing (34).
(4) Install clamp (30) using two nuts (31) and new lockwashers (32).
(5) Install nylon ties (10) as required.
(6) Install two hose clamps (20), elbow (25) and two hose clamps (17) onto
hose (18).
(7) Slide hose (18) and elbow (25) onto left tube (19).
(8) Install left tube (19) by sliding hose (18) onto radiator (4) and elbow (25)
onto left thermostat housing (35).
(9) Install clamp (21) onto bracket (24), with two new lockwashers (23) and
nuts (22).
(10) Install nylon ties (10) as required. Tighten eight clamps (17, 20, 26 and
29) to 100 inch-pounds (11 N*m).
6-22
TM 08780B-20
4. Radiator 27. Hose

10. Nylon Tie 28. Right Tube
18. Hose 30. Clamp
19. Left Tube 31. Nut (2)
20. Hose Clamp (2) 32. Lockwasher (2)
21. Clamp 33. Elbow
22. Nut (2) 34. Right Thermostat
23. Lockwasher (2) Housing
24. Bracket 35. Left Thermostat
25. Elbow Housing
26. Hose Clamp (2)
6-23
TM 08780B-20
e. Lower Hose and Tube Installation
(1) Install two hose clamps (14) onto hose (15) and two hose clamps (7) onto
hose (8).
(2) Slide two hoses (15 and 8) onto tube (16).
(3) Install tube (16) by sliding hose (15) onto water pump (36).
(4) Install tube (9) by sliding hose (8) to rear.
(5) Install three clamps (11) using three capscrews (12) and new lockwashers
(13).
(6) Install two clamps (5) on elbow (6) and two clamps (1) on hose (2).
(7) Slide elbow (6) and hose (2) onto tube (3).
(8) Install tube (3) by sliding elbow (6) onto tube (9) and hose (2) onto
radiator (4).
(9) Install nylon ties (10) as required. Tighten eight clamps (1, 5, 7 and 14) to
100 inch-pounds (11 N*m).
END OF TASK
NOTE
Follow-on Maintenance
TM 08780B-20 Fill cooling system
(para 6-3).
Install side access panels

(para 18-15).

6-24
TM 08780B-20
1. Hose Clamp (2) 10. Nylon Ties

2. Hose 11. Clamp (3)
3. Tube 12. Capscrew (3)
4. Radiator 13. Lockwasher (3)
6. Elbow 15. Hose
7. Hose Clamp (2) 16. Tube
8. Hose 36. Water Pump
9. Tube
6-25
TM 08780B-20
6-8. RADIATOR TESTING
THIS TASK COVERS: a. Preparation for Testing

b. Radiator Testing
c. Radiator Cap Testing

TM 08780B-10
MK48
Test Equipment General Safety Instructions

Cooling Pressure Testing Kit (J-24460-01) Block wheels of truck to prevent
personal injury.
Materials/Parts
Anti-freeze (item 8, Appendix D)
a. Preparation For Testing
(1) Fill radiator (1) to proper level.
(2) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Bring engine
coolant to normal operating temperature. Stop engine.
b. Radiator Testing
WARNING
USE EXTREME CAUTION WHEN WORKING ON COOLING SYSTEM TO PREVENT

BURNS.
(1) While pushing down, slowly turn radiator cap (2) one quarter turn
counterclockwise to relieve built-up pressure.
(2) While pushing down, slowly turn radiator cap (2) an additional one quarter
turn and remove radiator cap (2).
(3) Wipe inside of filler neck and examine lower inside sealing seat for nicks,
cracks, dirt and solder bumps.
(4) Install rubber filler neck plug (3) from pressure test kit (J-2446-01) into
filler neck (4).
(5) Attach pressure tester (5) to filler neck (4).
6-26
TM 08780B-20
1. Radiator
2. Radiator Cap
3. Rubber Filler Neck Plug
4. Filler Neck
5. Pressure Tester
6-27
TM 08780B-20
1. Radiator
5. Pressure Tester
6. Needle
(6) Using pressure tester (5), pressurize cooling system to 10-15 psi (68.95-
103.4 kPa).
(7) Observe gage on pressure tester (5) as follows:
(a) If needle (6) holds steady for two minutes, there is no leak.
(b) If pressure drops slowly, there are small leaks or seepage. Check
radiator, hoses and clamps for leaks.
(c) If pressure drops quickly, there is a large leak. Inspect cooling

system for external leaks.
(d) If pressure drops with no external leaks, check engine

compression. Refer to Direct Support, Third Echelon, Maintenance.
(8) Remove pressure tester (5) and rubber filler neck plug (3) from filler neck
(4).
(9) Install radiator cap (2) onto radiator (1).
c. Radiator Cap Testing
(1) While pushing down, slowly turn radiator cap (2) one quarter turn
counterclockwise to relieve built-up pressure.
(2) While pushing down, turn radiator cap (2) an additional one quarter turn
and remove radiator cap (2).
(3) Install radiator cap (2) onto adapter (7) from pressure tester kit.
(4) Install pressure tester (5) onto adapter (7).
6-28
TM 08780B-20
(5) Using pressure tester (5), pressurize radiator cap (2) until pressure
releases. Radiator cap will release pressure at 6.5-8 psi (44.81-55.16 kPa).
(6) Replace radiator cap (2) if pressure does not build up to 6.5-8 psi (44.81-
55.16 kPa) or if pressure exceeds 8 psi (55.16 kPa).
(7) Remove radiator cap (2) from adapter (7).
(8) Remove adapter (7) from pressure tester (5).
(9) Install radiator cap (2) onto radiator (1).
2. Radiator Cap
5. Pressure Tester
7. Adapter
END OF TASK
6-29/(6-30 blank)
TM 08780B-20
CHAPTER 7
ELECTRICAL SYSTEM
7-1. OVERVIEW
The following chapter covers maintenance and replacement procedures for the vehicle’s
electrical system.
a. General. The LVS electrical system supplies all of the electrical power needed to
operate the MK48 and any trailer (MK14, 15, 16 or 17) connected to it. The complete electrical
system is made up of the following subsystems.
• Power storage and Generating

• Engine Starting and Stopping
• Service Lighting
• Blackout Lighting
• Accessory Lighting
• Instruments
• Warning Lights and Buzzers.
b. Power Storage and Generating. Power storage for the LVS consists of four 12
volt batteries. The four batteries are divided into two sets. The two batteries in each set are
wired in parallel to produce higher amperage. The two sets are then wired in series to produce
24 volts. While the batteries can power all of the systems in the LVS for a limited time, their
primary purpose is to supply power to the engine’s starting system. Once the engine is running,
the generating system provides the electrical power for all of the systems. The engine driven
alternator generates alternating current (AC) which is passed through a set of rectifiers that
change it into direct current (DC). This direct current is used to charge the batteries and is
distributed to the other systems of the LVS. Part of the alternator is a voltage regulator that
samples the amount of direct current being used and adjusts alternator output to fit the needs of
the electrical system.
7-1
TM 08780B-20
c. Engine Starting and Stopping. The engine starting system uses the stored
electrical energy of the batteries to turn the engine over and start it. The master switch is turned
to the ON position to energize the electrical system. When the master switch is turned to the
START position, electrical power is passed through the neutral safety switch to the starter relay.
The starter relay, when energized, draws electrical power directly from the batteries and sends it
to the starter motor solenoid. When the solenoid is energized, the starter motor draws electrical
power from the batteries and turns the engine. To stop the engine, depress the engine stop
switch. This energizes the engine stop solenoid. The solenoid pulls the governor linkage to the
stop position, shutting off fuel to the engine.
d. Service Lighting. The service lighting system includes the headlights, tail lights,
stop lights, clearance marker lights, panel lights, turn signals and emergency flashers. They are
energized by turning the blackout light switch to the stop light or service drive position. The
stop lights, clearance marker lights, panel lights, turn signals and emergency flashers are then
controlled by separate switches located in the cab.
7-2
TM 08780B-20
e. Blackout Lighting. The blackout lighting system includes the front blackout
marker lights, the rear blackout marker lights, the blackout stop lights and the panel lights. They
are energized by turning the blackout light switch to either the blackout marker position or the
blackout drive position. The blackout stop lights and the panel lights are then controlled by other
switches located in the cab.
f. Accessory Lighting. The accessory lighting system includes the dome light, map
light, beacon light and worklights. These are energized by turning the blackout light switch to
the stop light position or the service drive position. The dome light, map light, beacon light and
worklights are then controlled by separate switches in the cab. The worklights have switches
built into the light assemblies themselves.
7-3
TM 08780B-20
g. Instruments. The instrument system includes all gauges that give the operator
information. The speedometer and tachometer receive signals from two transducers. One is
mounted on the transfer case, the other is on the top rear of the engine. Both of these transducers
act as generators to convert rotational motion into a pulsed electrical signal that the gauges turn
into a reading the operator can understand. The fuel gauge, oil pressure gauge, water
temperature gauge, hydraulic oil temperature gauge and transmission oil temperature gauge all
receive electrical signals from sending units. These sending units monitor fluid level, pressure
and temperature and send this information to the gauges. The gauges display the information in
a way the operator can understand.
7-4
TM 08780B-20
h. Warning Lights and Buzzers. The warning lights and buzzers in the cab are
activated by automatic switches located in different systems of the LVS. These include low air
pressure, low oil pressure, low hydraulic oil level, high water temperature, suspension lock struts
and ABS. When one or more of these switches are activated, they energize the proper light
and/or buzzer, informing the operator of a specific problem.
7-5
TM 08780B-20
7-3. ALTERNATOR CIRCUIT BREAKER AND DIODE REPLACEMENT

c. Installation

Condition Condition
disconnected
(para 7-45 or 7-46
for LVSA1 series
Materials/Parts vehicles only).
Star washer (MS35335-61) item 2
Star washer (MS35335-42) item 6 General Safety Instructions
Lockwasher (2) (MS35338-45) item 9 To prevent personal injury, make sure
Locknut (2) (1437220) item 12 battery cables are disconnected before
working on electrical components.
a. Removal
NOTE
• Tag all wires before removal to insure proper installation.
• If diode does not have to be replaced, go to step (4).
(1) Remove nut (1), star washer (2) and wire (3) from diode (4).
(2) Remove nut (5), star washer (6) and washer (7) from diode (4). Discard
star washer (6).
(3) Remove diode (4).
NOTE
If circuit breaker does not have to be replaced, go to section b, CLEANING/INSPECTION.
(4) Remove two capscrews (8), two lockwashers (9) and wires (3, 10 and 11).
NOTE
Mounting hardware for LVSA1 alternator circuit breakers has changed from a capscrew,
lockwasher and hex nut, to a flanged capscrew and locknut. When repairing a non-A1
vehicle, use the new style flanged mounting hardware to replace the old style hardware. Refer
to TM 08780B-24P for correct parts identification.
7-6
TM 08780B-20
(6) Remove circuit breaker (15).
(2) Inspect diode mounting hole for corrosion. Diode must have a clean
mounting surface for proper grounding.
c. Installation
NOTE
If diode was not removed, go to step (4).
(1) Install diode (4) into mounting plate (16).
(2) Install washer (7), new star washer (6) and nut (5). Tighten securely.
(3) Install wire (3), new star washer (2) and nut (1). Tighten securely.
(4) Install circuit breaker (15) onto mounting plate (16).
(5) Install two capscrews (14) and new locknuts (12). Tighten locknuts
securely.
(6) Install three wires (3, 10 and 11) onto circuit breaker (15).
(7) Install two new lockwashers (9) and capscrews (8). Tighten capscrews (8)
securely.
END OF TASK
7-7
TM 08780B-20
NOTE
TM 08780B-20 Connect batteries
(para 7-45 or 7-46 for
LVSA1 series vehicles only).
TM 08780B-10 Run engine and

check for proper
voltage (para 2-13).
1. Nut
2. Star Washer
3. Wire (No. 279)
4. Diode
5. Nut
6. Star Washer
7. Washer
8. Capscrew (2)
9. Lockwasher (2)
10. Wire (No. 278)
11. Wire (No. 833)
12. Locknut (2)
13. Deleted
14. Capscrew (2)
15. Circuit Breaker
16. Mounting Bracket
7-8
TM 08780B-20
7-4. ALTERNATOR REPLACEMENT

c. Installation

Condition Condition
disconnected (para
Materials/Parts 7-45 or 7-46 for
Lockwasher (MS35338-43) item 2 LVSA1 series
Lockwasher (MS35338-45) item 7 vehicles only).
Lockwasher (10) (MS35338-46) items 17, 24, Exhaust crossover
27, 30 and 33 tube removed (para
Gasket (101051) item 21 5-4).
Gasket (5330-01-088-5984) item 35
To prevent personal injury, make sure
batteries are disconnected before working on
electrical components.
a. Removal
NOTE
Tag all wires before removal to insure proper installation.
(1) Remove nut (1), lockwasher (2), wire (3) and wire (4) from negative
terminal (5). Discard lockwasher (2). Reinstall nut (1) on negative terminal (5) finger tight.
(2) Remove nut (6), lockwasher (7), wire (8) and wire (9) from positive
terminal (10). Discard lockwasher (7). Reinstall nut (6) on positive terminal (10) finger tight.
(3) Remove nut (11), star washer (12) and wire (13) from ignition (IGN)
terminal (14) of regulator (15). Reinstall nut (11) on ignition (IGN) terminal (14) finger tight.
Discard star washer (12).
(4) Remove three capscrews (16), lockwashers (17) and washers (18).
(5) Remove alternator (19), drive coupling (20) and gasket (21). Discard
gasket (21).
7-9
TM 08780B-20
1. Nut
2. Lockwasher
3. Wire (No. 815)
4. Wire (No. 128)
5. Negative Terminal
6. Nut
7. Lockwasher
8. Wire (No. 820)
9. Wire (No. 278)
10. Positive Terminal
11. Nut
12. Star Washer
13. Wire (No. 831)
14. Ignition Terminal
15. Regulator
16. Capscrew (3)
17. Lockwasher (3)
18. Washer (3)
19. Alternator
20. Drive Coupling
21. Gasket
7-10
TM 08780B-20
NOTE
If adapter (22) does not have to be replaced, go to task b, Cleaning/ Inspection.
(6) Mark adapter (22) and flywheel housing for location during assembly.
Remove nut (23), lockwasher (24), bracket (25), capscrew (26), lockwasher (27) and spacer (28).
Discard lockwashers (24 and 27).
(7) Remove three capscrews (29), lockwashers (30) and spacers (31). Discard
lockwashers (30).
(8) Remove two nuts (32), lockwashers (33) and spacers (34). Discard
lockwashers (33).
(9) Remove adapter (22) and gasket (35). Discard gasket (35).
(10) If damaged, remove two studs (36).
c. Installation
(1) If removed, install two studs (36).
NOTE
If adapter (22) was not removed, go to step (5).
(2) Install new gasket (35) and adapter (22).
(3) Install two spacers (34), new lockwashers (33) and nuts (32). Torque nuts
(32) to 28 foot-pounds (38 N*m).
(4) Install three spacers (31), new lockwashers (30) and capscrews (29).
Torque capscrews (29) to 28 foot-pounds (38 N*m).
(5) Install spacer (28), new lockwasher (27), capscrew (26), bracket (25), new
lockwasher (24) and nut (23). Torque nut (23) to 35 foot-pounds (47 N*m).
7-11
TM 08780B-20
22. Adapter
23. Nut
24. Lockwasher
25. Bracket
26. Capscrew
27. Lockwasher
28. Spacer
29. Capscrew (3)
30. Lockwasher (3)
31. Spacer (3)
32. Nut (2)
33. Lockwasher (2)
34. Spacer (2)
35. Gasket
36. Stud (2)
7-12
TM 08780B-20
WARNING
ALTERNATOR IS HEAVY. USE CARE WHEN INSTALLING TO PREVENT PERSONAL

INJURY.
(6) Install new gasket (21), drive coupling (20) and alternator (19).
(7) Install three washers (18), new lockwashers (17) and capscrews (16).
Torque capscrews (16) to 35 foot-pounds (47 N*m).
(8) Remove nut (11) from ignition (IGN) terminal (14) of regulator (15).
Install wire (13), new star washer (12) and nut (11) on IGN terminal (14). Tighten nut (11)
securely.
CAUTION
OBSERVE POLARITY MARKINGS TO PREVENT DAMAGE TO ALTERNATOR.
(9) Remove nuts (6 and 1) from positive and negative terminals (10 and 5).
(10) Install wires (9 and 8), new lockwasher (7) and nut (6) on positive
terminal (10). Tighten nut (6) securely.
(11) Install wires (4 and 3), new lockwasher (2) and nut (1) on negative
terminal (5). Tighten nut (1) securely.
END OF TASK
NOTE
TM 08780B-20 Install exhaust pipe
at rear of alternator
(para 5-4).
Connect batteries
(para 7-45 or 7-46 for LVSA1

check for proper voltage
(para 2-13).
7-13
TM 08780B-20
1. Nut 12. Star Washer

2. Lockwasher 13. Wire (No. 831)
3. Wire (No. 815) 14. Ignition Terminal
4. Wire (No. 128) 15. Regulator
5. Negative Terminal 16. Capscrew (3)
6. Nut 17. Lockwasher (3)
7. Lockwasher 18. Washer (3)
8. Wire (No. 820) 19. Alternator
9. Wire (No. 278) 20. Drive Coupling
10. Positive Terminal 21. Gasket
11. Nut
7-14
TM 08780B-20
7-5. VOLTAGE REGULATOR MAINTENANCE

b. Adjustment
c. Installation

Condition Condition
disconnected
Lockwasher (4) (MS35338-43) item 5 General Safety Instructions
Gasket (NSN 5330-01-145-0725) item 8 To prevent personal injury, make sure
battery cables are disconnected before
a. Removal
(1) Remove nut (1), star washer (2) and ignition lead (3). Discard star washer
(2).
(2) Remove four capscrews (4) and lockwashers (5) from alternator (6).
(3) Carefully pull up on regulator (7) and remove.
(4) Remove gasket (8) and discard.
b. Adjustment
(1) Remove screw (9).
(2) Install screw (9) in one of three holes (10, 11 or 12) for voltage required.
(a) LO (10) position will give 26.9-27.5 volts.
(b) MIDDLE (11) position will give 27.8-28.2 volts.
(c) HI (12) position will give 28.5-29.1 volts.
c. Installation
(1) Install new gasket (8) on alternator (6).
7-15
TM 08780B-20
(2) Install regulator (7) on alternator (6) using four capscrews (4) with new
lockwashers (5).
(3) Tighten capscrews (4) securely.
(4) Install ignition lead (3), new star washer (2) and nut (1). Tighten nut
securely.
END OF TASK
NOTE
(para 7-45).

check for proper
voltage (para 2-13).
7-16
TM 08780B-20
1. Nut
2. Star Washer
3. Ignition Lead
4. Capscrews (4)
5. Lockwashers (4)
6. Alternator
7. Regulator
8. Gasket
9. Screw
10. Hole
11. Hole
12. Hole
7-17
TM 08780B-20
7-6. STARTER SOLENOID REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Battery box removed
(para 7-45).
References
TM 08780B-10
a. Removal
NOTE
Tag all wires to insure proper installation.
(1) Remove nut (1) from terminal (2). Remove wire (3) from terminal (2).
(2) Remove nut (4) from terminal (5). Remove battery cable (6) and three
wires (7, 8 and 9) from terminal (5).
(3) Remove nut (10) from terminal (11). Remove two wires (12 and 13) from
terminal (11).
(4) Remove nut (14) from starter stud (15). Loosen clamp (16).
(5) Remove four capscrews (17). Remove starter solenoid (18) from starter
(19).
(6) Remove nut (20) and bracket (21) from starter solenoid (18).
(3) Replace all pans failing inspection.
7-18
TM 08780B-20
c. Installation
(1) Install bracket (21) and nut (20) onto starter solenoid (18). Tighten nut
(20) securely.
(2) Position starter solenoid (18) onto starter. Make sure bracket (21) goes
onto stud (15).
(3) Install four capscrews (17) and nut (14). Tighten four capscrews (17) and
nut (14) securely. Tighten clamp (16) securely.
(4) Install two wires (12 and 13) onto terminal (11) using nut (10). Tighten
nut (10) securely.
(5) Install three wires (7, 8 and 9) and battery cable (6) onto terminal (5) using
nut (4). Tighten nut (4) securely.
(6) Install wire (3) onto terminal (2) using nut(1). Tighten nut (1) securely.
END OF TASK
NOTE
(para 7-45).
TM 08780B-10 Check operation of

starter (para 2-13).
7-19
TM 08780B-20
1. Nut
2. Terminal
3. Wire
4. Nut
5. Terminal
6. Battery Cable
7. Wire (No. 046)
8. Wire (No. 838)
9. Wire (N0. 818)
10. Nut
11. Terminal
12. Wire (No. 045)
13. Wire (No. 816)
14. Nut
15. Starter Stud
16. Clamp
17. Capscrew (4)
18. Starter Solenoid
19. Starter
20. Nut
21. Bracket
7-20
TM 08780B-20
7-7. STARTER REPLACEMENT

c. Installation

Condition Condition
(para 7-45).
Materials/Parts
Star washer (3) (MS45904-84) items 4, 17 and 20 General Safety Instructions
Lockwasher (4) (MS35338-46) items 25 and 34 To prevent personal injury, make sure
Lockwasher (3) (MS35338-50) item 30 batteries are disconnected before working on
Gasket (NSN 5330-00-980-1546) item 37 electrical components.
Personnel Required
MOS 3521
1 Assistant
a. Removal
(1) Disconnect rear flange (1) of nose box propeller shaft (2). Refer to
paragraph 10-3.
NOTE
(2) Remove nut (3), star washer (4), wire (5), wire (6), wire (7) and ground
strap (8) from ground terminal (9). Discard star washer (4).
(3) Remove nut (10), battery cable (11), wire (12), wire (13) and wire (14)
from starter positive terminal (15).
(4) Remove nut (16), star washer (17) and wire (7) from solenoid ground
terminal (18). Discard star washer (17).
(5) Remove nut (19), star washer (20), wire (21) and wire (22) from solenoid
positive terminal (23). Discard star washer (20).
(6) Remove two capscrews (24), lockwashers (25) and nuts (26) from
mounting bracket (27). Discard lockwashers (25).
7-21
TM 08780B-20
1. Rear Flange 21. Wire (No. 045)

2. Propeller Shaft 22. Wire (No. 816)
3. Nut 23. Solenoid Positive Terminal
4. Star Washer 24. Capscrew (2)
5. Wire (No. 819) 25. Lockwasher (2)
6. Wire (No. 138) 26. Nut (2)
7. Wire (No. 128) 27. Mounting Bracket
8. Ground Strap (No. 148)
9. Ground Terminal
10. Nut
11. Battery Cable (No. 139)
12. Wire (No. 046)
13. Wire (No. 833)
14. Wire (No. 818)
16. Nut
17. Star Washer (No. 10)
18. Solenoid Ground Terminal
19. Nut
20. Star Washer (No. 10)
7-22
TM 08780B-20
28. Starter
(7) Wrap lifting sling around starter (28) and have assistant hold from above.
(30).
(9) Use lifting sling to remove starter (28). Remove two spacers (31).
(10) Remove three capscrews (32) and mounting bracket (27).
(11) Reinstall three capscrews (32).
(12) If damaged, remove two capscrews (33), lockwashers (34), washers (35)
and bracket (36). Discard lockwashers (34).
c. Installation
(1) Remove three capscrews (32).
(2) Install mounting bracket (27) and three capscrews (32). Tighten securely.
(3) If removed, install bracket (36), two washers (35), new lockwashers (34)
and capscrews (33). Tighten securely.
7-23
TM 08780B-20
(4) Have assistant raise starter (28) into position. Install starter (28), new
gasket (37) and two spacers (31).
(5) Install three new lockwashers (30) and capscrews (29). Torque capscrews
(29) to 95-105 foot-pounds (129-143 N*m).
(6) Install two new lockwashers (25), capscrews (24) and nuts (26). Tighten
securely.
(7) Install wire (22), wire (21), new star washer (20) and nut (19) onto
solenoid positive terminal (23). Tighten securely.
(8) Install wire (7), new star washer (17) and nut (16) onto solenoid ground
terminal (18). Tighten securely.
(9) Install wire (14), wire (13), wire (12), battery cable (11) and nut (10) onto
starter solenoid positive terminal (15). Tighten securely.
(10) Install ground strap (8), wire (7), wire (6), wire (5), new star washer (4)
and nut (3) onto starter ground terminal (9). Tighten securely.
(11) Install rear flange (1) of nosebox propeller shaft (2). Refer to paragraph
10-3.
END OF TASK
NOTE
TM 08780B-20 Install battery box
(para 7-45).
TM 08780B-10 Start engine to check operation

of starter (para 2- 13).
7-24
TM 08780B-20
1 Rear Flange 20. Star Washer (No. 10)

2. Propeller Shaft 21. Wire (No. 045)
3. Nut 22. Wire (No. 816)
4. Star Washer 23. Solenoid Positive
5. Wire (No. 819) Terminal
6. Wire (No. 138) 24. Capscrew (2)
8. Ground Strap (No. 148) 26. Nut (2)
9. Ground Terminal 27. Mounting Bracket
10. Nut 28. Starter
11. Battery Cable (No. 139) 29. Capscrew (3)
13. Wire (No. 833) 31. Spacer (2)
14. Wire (No. 818) 32. Capscrew (3)
15. Positive Terminal 33. Capscrew (2)
16. Nut 34. Lockwasher (2)
17. Star Washer (No. 10) 35. Washer (2)
18. Solenoid Ground Terminal 36. Bracket
19. Nut 37. Gasket
7-25
TM 08780B-20
7-8. STARTER RELAY REPLACEMENT

c. Installation

Condition Condition
(para 7-45).
Materials/Parts
Star washer (MS45904-68) item 10 General Safety Instructions
Lockwasher (MS45815-48) item 11 To prevent personal injury, make sure
batteries are disconnected before working
a. Removal
NOTE
(1) Remove two nuts (1) and two wires (2 and 3) from top of starter relay (4).
(2) Remove two nuts (5) and three wires (6, 7 and 8) from sides of starter
relay (4).
(3) Remove two nuts (9), star washer (10), lockwasher (11), capscrews (12),
wire (3), washer (13) and starter relay (4). Discard star washer (10) and lockwasher (11).
(2) Inspect surface where starter relay will be mounted and remove any
corrosion.
c. Installation
(1) Place starter relay (4) in position and install wire (3), washer (13) and two
capscrews (12).
7-26
TM 08780B-20
(2) Install new star washer (10), lockwasher (11) and two nuts (9). Tighten
nuts securely.
(3) Install three wires (8, 7 and 6) and two nuts (5) onto sides of starter relay
(4). Tighten nuts securely.
(4) Install two wires (2 and 3) and nuts (1) onto top of starter relay (4).
Tighten nuts securely.
END OF TASK
NOTE
TM 08780B-20 Install battery box
(para 7-45).
TM 08780B-10 Start engine to check

starter circuit (para 2-13).
7-27
TM 08780B-20
1. Nut (2)
2. Wire (No. 021)
3. Wire (No. 196)
4. Starter Relay
5. Nut (2)
6. Wire (No. 045)
7. Wire (No. 046)
8. Wire (No 430)
9. Nut (2)
10. Star Washer
11. Lockwasher
12. Capscrew (2)
13. Washer
7-28
TM 08780B-20
7-9. COOLING SYSTEM SWITCH REPLACEMENT

c. Installation

Condition Condition
disconnected
Lockwasher (MS35338-45) item 7 Engine access covers
removed (para 18-15,
items 14 and 16).
Coolant drained to a
level below switches
(para 6-3).


a. Removal
NOTE
(1) For fan switch (1), remove two screws (2), wires (3) and washers (4).
(2) For high temperature switch (5), remove nut (6), lockwasher (7), two
wires (8 and 9) and washer (10). Discard lockwasher (7).
(3) Remove switch (1 or 5).
(4) Remove reducer (11).
7-29
TM 08780B-20
(2) Inspect parts for cracks, breaks or damage. Refer to paragraph 2-12.
(3) Repair or replace all parts failing inspection.
c. Installation
(1) Coat threads with pipe sealant and install reducer (11) and switch (1 or 5).
(2) For high temperature switch (5), install washer (10), two wires (8 and 9),
new lockwasher (7) and nut (6). Torque nut (6) to maximum of nine inch-pounds (1.01 N*m).
(3) For fan switch (1), install two washers (4), wires (3) and screws (2).
Tighten screws (2) securely.
END OF TASK
NOTE
TM 08780B-20 Install access engine
covers (para 18-15,
items 14 and 16).
Connect batteries (para 7-45).
Fill coolant to proper level (para 6-3).

7-30
TM 08780B-20
1. Fan Switch
2. Screw (2)
3. Wire (2) (No. 718)
4. Washer (2)
5. High Temperature Switch
6. Nut
7. Lockwasher
8. Wire (No. 032)
9. Wire (No. 147)
10. Washer
11. Reducer
7-31
TM 08780B-20
7-10. OIL PRESSURE SWITCH REPLACEMENT

c. Installation

Condition Condition
Disconnected
a. Removal
NOTE
(1) Remove two screws (1) and wires (2) from oil pressure switch (3).
(2) Remove oil pressure switch (3).
(3) For low oil pressure switch (4), remove wire (5).
(4) Remove low oil pressure switch (4).
c. Installation
(1) Apply pipe sealant to threads and install switches (3 and 4).
(2) For low oil pressure switch (4), install wire (5).
7-32
TM 08780B-20
(3) For oil pressure (3) switch install two wires (2) and screws (1). Tighten
screws (1) securely.
END OF TASK
NOTE
(para 7-45).

1. Screw (2)
2. Wire (2) (No. 522)
3. Oil Pressure Switch
4. Low Oil Pressure Switch
5. Wire (No. 147)
7-33
TM 08780B-20
7-11. INSTRUMENT PANEL ASSEMBLY REPLACEMENT

c. Installation

Condition Condition
Disconnected
(para 7-45).

Drain all pressure from air system to prevent
personal injury. To prevent personal injury,
make sure batteries are disconnected before
a. Removal
(1) Remove six screws (1) and move instrument panel (2) away from dash (3).
Lean instrument panel (2) against steering wheel.
NOTE
Tag air lines (4 and 5) before removal to insure proper installation.
(2) Disconnect two air lines (4 and 5).
(3) Disconnect plug (6) from socket (7).
(4) Unscrew and disconnect harness plug (8).
(5) Remove instrument panel assembly (2) from truck.
c. Installation
(1) Position instrument panel (2) between dash (3) and steering wheel.
7-34
TM 08780B-20
(2) Connect harness plug (8).
(3) Connect plug (6) to socket (7).
(4) Connect two-air lines (4 and 5) to air pressure gauge (9). Tighten
securely.
(5) Install instrument panel (2) using six screws (1). Tighten securely.
END OF TASK
NOTE
(para 7-45).
TM 08780B-10 Start engine

(para 2-13).
Check all gauges for proper

reading (para 2-13).
1. Screw (5)
2. Instrument Panel
3. Dash
4. Air Line (No. 041)
6. Plug
7. Socket
8. Harness Plug
9. Air Pressure Gauge
7-35
TM 08780B-20
7-12. INSTRUMENT PANEL HARNESS REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Instrument panel
Materials/Parts
Star washer (10) (MS35333-71) items 13, 17, 28,
31, 34, 48, 50 and 68
a. Removal
NOTE
(1) Remove two light sockets (1 and 2) from oil pressure gauge (3) and fuel
gauge (4).
(2) Remove two light sockets (5 and 6) from instrument panel (7).
(3) Remove wire (8) from oil pressure gauge (3).
(4) Remove wire (9) from oil pressure gauge (3). Remove jumper wire (10)
from oil pressure gauge (3) and fuel gauge (4).
(5) Remove wire (11) from fuel gauge (4).
(6) Remove nut (12), star washer (13) and jumper wires (14 and 15) from oil
pressure gauge (3). Discard star washer (13).
(7) Remove nut (16), star washer (17) and jumper wires (18 and 15) from fuel
gauge (4). Discard star washer (17).
(8) Remove two light sockets (19 and 20) from water temperature gauge (21)
and transmission temperature gauge (22).
(9) Remove wires (23 and 24) from water temperature gauge (21).
(10) Remove wire (25) from transmission temperature gauge (22). Remove
jumper wire (26) from water temperature gauge (21) and transmission temperature gauge (22).
7-36
TM 08780B-20
(11) Remove nut (27), star washer (28) and wire (29) from water temperature
gauge (21). Discard star washer (28).
(12) Remove nut (30), star washer (31), wire (32) and jumper wire (14) from
water temperature gauge (21). Discard star washer (31).
(13) Remove nut (33), star washer (34), jumper wire (18) and jumper wire (35)
from transmission temperature gauge (22). Discard star washer (34).
1. Light Socket
2. Light Socket
3. Oil Pressure Gauge
4. Fuel Gauge
5. Light Socket
6. Light Socket
7. Instrument Panel
8. Wire (No. 113)
9. Wire (No. 076)
10. Jumper Wire (No. 076)
11. Wire (No. 318)
12. Nut
13. Star Washer
16. Nut
17. Star Washer
14. Jumper Wire (No 435)
18. Jumper Wire (No 435)
19. Light Socket
20. Light Socket
21. Water Temperature Gauge
22. Transmission
Temperature Gauge
23. Wire (No. 320)
24. Wire (No. 076)
25. Wire (No. 422)
27. Nut
28. Star Washer
29. Wire (No. 435)
30. Nut
31. Star Washer
32. Wire (No 435)
33. Nut
34. Star Washer
7-37
TM 08780B-20
(14) Remove three light sockets (36, 37 and 38) from air pressure gauge (39),
voltmeter (40) and hydraulic temperature gauge (41).
(15) Remove two wires (42 and 43) from voltmeter (40).
(16) Remove three wires (44, 45 and 46), nut (47), star washer (48) and jumper
wire (35) from hydraulic temperature gauge (41). Discard star washer (48).

36. Light Socket
37. Light Socket
38. Light Socket
40. Voltmeter
41. Hydraulic Temperature Gauge
42. Wire (No. 232)
43. Wire (No. 076)
44. Wire (No. 126)
45. Wire (No. 435)
46. Wire (No. 076)
47. Nut
48. Star Washer
7-38
TM 08780B-20
(17) Remove nut (49), star washer (50), three wires (51, 52 and 53) and light
socket (54) from tachometer (55). Discard star washer (50).
(18) Loosen four screws (56) and remove five wires (57 thru 61) from
tachometer terminal block (62).
(19) Remove two light sockets (63 and 64) from instrument panel (7).
(20) Remove six wires (65) from junction block (66).
7. Instrument Panel 58. Wire (No. 808)

49. Nut 59. Wire (No. 518)
50. Star Washer 60. Wire (No. 108)
51. Wire (No. 435) 61. Wire (No. 522)
52. Wire (No. 435) 62. Tachometer
53. Wire (No. 435) Terminal Block
54. Light Socket 63. Light Socket
55. Tachometer 64. Light Socket
56. Screw (4) 65. Wire (6) (No. 076)
57. Wire (No. 076) 66. Junction Box
7-39
TM 08780B-20
(21) Remove nut (67), star washer (68), jumper wire (69), three wires (70, 71
and 72) and light socket (73) from speedometer (74). Discard star washer (68).
(22) Loosen four screws (75) remove three wires (76, 77 and 78) and jumper
wire (69) from speedometer terminal block (79).
(23) Remove light socket (80) from instrument panel (7).
(24) Remove six wires (81 thru 86) from buzzer (87).
(25) Remove nut (88) and washer (89) from harness connector (90). Remove
wiring harness (91) from instrument panel (7).
NOTE
• The new wiring harness does not include light sockets. Save old light sockets for
installation onto new harness.
• When removing light sockets, cut wires as close to the butt connector as possible.
• Tag all light sockets to aid in installation.
(26) Remove two light sockets (1 and 2) from wire (92). Remove black lead of
two light sockets (5 and 6) from wire (93). Remove white lead of light socket (5) from wire
(94). Remove white lead of light socket (6) from wire (95).
7-40
TM 08780B-20
79. Speedometer Terminal

7. Instrument Panel Block
67. Nut 80. Light Socket
69. Jumper Wire (No. 520) 82. Wire (No. 076)
70. Wire (No. 435) 83. Wire (No. 120)
71. Wire (No. 435) 84. Wire (No. 120)
72. Wire (No. 435) 85. Wire (No. 032)
73. Light Socket 86. Wire (No. 032)
74. Speedometer 87. Buzzer
75. Screw (4) 88. Nut
76. Wire (No. 076) 89. Washer
77. Wire (No. 519) 90. Connector
78. Wire (No. 519) 91. Wiring Harness
7-41
TM 08780B-20
(27) Remove two light sockets (19 and 20) from wire (96). Remove two light
sockets (36 and 37) from wire (97). Remove light socket (38) from wire (98).
(28) Remove two light sockets (53 and 72) from wire (99). Remove light
socket (63) from wire (100). Remove light socket (64) from wire (101). Remove light socket
(80) from wire (102).
c. Installation
NOTE
Refer to paragraph 7-48 in this manual for proper installation of butt connectors to new
harness and old light sockets.
(1) Connect light socket (80) to wire (102). Connect light socket (64) to wire
(101). Connect light socket (63) to wire (100). Connect the red leads of light sockets (53 and
72) to wire (99).
(2) Connect light socket (38) to wire (98). Connect two light sockets (36 and
37) to wire (97). Connect two light sockets (19 and 20) to wire (96).
(3) Connect white lead of light socket (6) to wire (95). Connect white lead of
light socket (5) to wire (94). Connect black leads of light sockets (5 and 6) to wire (93).
Connect two lights sockets (1 and 2) to wire (92).
7-42
TM 08780B-20
1. Light Socket 80. Light Socket

2. Light Socket 92. Wire (No 052)
19. Light Socket 95. Wire (N0. 120)
64. Light Socket 102. Wire (N0. 002)
72. Light Socket
7-43
TM 08780B-20
79. Speedometer Terminal

7. Instrument Panel Block
67. Nut 80. Light Socket
70. Wire (No. 435) 83. Wire (No. 120)
71. Wire (No. 435) 84. Wire (No. 120)
72. Wire (No. 435) 85. Wire (No. 032)
74. Speedometer 87. Buzzer
75. Screw (4) 88. Nut
76. Wire (No. 076) 89. Washer
77. Wire (No. 519) 90. Harness Connector
78. wire (No. 519) 91. Wiring Harness
(4) Install wiring harness (91) onto instrument panel (7) using washer (89)
and nut (88) on harness connector (90). Tighten nut (88) securely.
(5) Connect six wires (81 thru 86) to buzzer (87).
(6) Install light socket (80) into instrument panel (7).
(7) Connect three wires (76, 77 and 78) and jumper wire (69) to speedometer
terminal block (79). Tighten four screws (75) securely.
(8) Connect three wires (72, 71 and 70) and jumper wire (69), new star
washer (68), nut (67) and light socket (73) onto speedometer (74).
(9) Connect six wires (65) to junction block (66).
7-44
TM 08780B-20
(10) Install two light sockets (63 and 64) into instrument panel (7).
(11) Connect five wires (57 thru 61) to tachometer terminal block (62).
Tighten four screws (56) securely.
(12) Connect three wires (53, 52 and 51), new star washer (50) and nut (49) to
tachometer (55). Tighten nut (49) securely.
(13) Install light socket (54) into tachometer (55).
7. Instrument Panel 49. Nut

51. Wire (No. 435) 60. Wire (No. 108)
52. Wire (No. 435) 61. Wire (No. 522)
53. Wire (No. 435) 62. Tachometer
54. Light Socket Terminal Block
55. Tachometer 63. Light Socket
56. Screw (4) 64. Light Socket
57. Wire (No. 076) 65. Wire (6) (No. 076)
58. Wire (No. 808) 66. Junction Box
7-45
TM 08780B-20
(14) Connect wires (44, 45 and 46), jumper wire (35), new star washer (48) and
nut (47) to hydraulic temperature gauge (41).
(15) Connect two wires (42 and 43) to voltmeter (40).
(16) Install three light sockets (36, 37 and 38) onto air pressure gauge (39),
voltmeter (40) and hydraulic temperature gauge (41).

36. Light Socket
37. Light Socket
38. Light Socket
40. Voltmeter
41. Hydraulic Temperature Gauge
42. Wire (No. 232)
43. Wire (No. 076)
44. Wire (No. 126)
45. Wire (No. 435)
46. Wire (No. 076)
47. Nut
48. Star Washer
7-46
TM 08780B-20
(17) Connect jumper wires (35 and 103), new star washer (34) and nut (33) to
transmission temperature gauge (22). Tighten nut (33) securely.
(18) Connect jumper wire (14), wire (32), new star washer (31) and nut (30) to
water temperature gauge (21). Tighten nut (30) securely.
(19) Connect wire (29), new star washer (28) and nut (27) to water temperature
gauge (21). Tighten nut (27) securely.
(20) Connect jumper wire (26) between transmission temperature gauge (22)
and water temperature gauge (21).
(21) Connect wire (25) to transmission temperature gauge (22).
(22) Connect two wires (23 and 24) to water temperature gauge (21).
(23) Install light sockets (19 and 20) into water temperature gauge (21) and
transmission temperature gauge (22),
fuel gauge (4). Tighten nut (16) securely.
oil pressure gauge (3). Tighten nut (12) securely.
(26) Connect wire (11) to fuel gauge (4).
(27) Connect jumper wire (10) between fuel gauge (4) and oil pressure gauge
(3).
(28) Connect wire (9) to oil pressure gauge (3).
(30) Install two light sockets (5 and 6) into instrument panel (7).
(31) Install two light sockets (1 and 2) into oil pressure gauge (3) and fuel
gauge (4).
END OF TASK
7-47
TM 08780B-20
NOTE
TM 08780B-20 Install instrument panel
(para. 7-11).
TM 08780B-10 Check all gauges and lights

for proper operation
(para 2-13 and 2-14).
1. Light Socket
2. Light Socket
4. Fuel Gauge
5. Light Socket
6. Light Socket
7. Instrument Panel
8. Wire (No. 113)
9. Wire (No. 076)
11. Wire (No. 318)
12. Nut
13. Star Washer
16. Nut
17. Star Washer
7-48
TM 08780B-20

16. Nut
17. Star Washer
19. Light Socket
20. Light Socket
22. Transmission
Temperature Gauge
23. Wire (No. 320)
24. Wire (No. 076)
25. Wire (No. 422)
27. Nut
28. Star Washer
29. Wire (No. 435)
30. Nut
31. Star Washer
32. Wire (No. 435)
33 Nut
34. Star Washer
7-49
TM 08780B-20
7-13. INSTRUMENT PANEL HARNESS REPLACEMENT (LVSA1 SERIES

VEHICLES ONLY)

c. Installation

Condition Condition
MK48A1 TM 08780B-20 Instrument panel
Materials/ Parts
Star washer (6) (MS35333-38) items 9, 14,
17, 20 and 90
Star washer (4) (MS35333-39) items 49, 55, 58 and 92
Star washer (L051275) item 87
a. Removal
NOTE
• New wire harness does not come with light bulbs, save old bulbs for reuse or install
new bulbs. Refer to TM 08780B-24P for correct parts identification.
(1) Remove two light sockets (1 and 2) from oil pressure gauge (3) and fuel
gauge (4).
(2) Remove two light sockets (5 and 6).
(3) Remove wire (7) from oil pressure gauge (3).
(4) Remove two nuts (8), star washers (9) and jumper wire (10) from water
temperature gauge (11) and oil pressure gauge (3). Discard star washers (9).
(5) Remove wire (12) from water temperature gauge (11).
(6) Remove nut (13), star washer (14) and jumper wire (15) from fuel gauge
(4). Discard star washer (14).
(7) Remove nut (16), star washer (17) and jumper wire (18) from fuel gauge
7-50
TM 08780B-20
(8) Remove nut (19), star washer (20) and jumper wire (18) from transmission
oil temperature gauge (21). Discard star washer (20).
(9) Remove light sockets (22 and 23) from transmission oil temperature gauge
(21) and water temperature gauge (11).
(10) Remove light sockets (24, 25 and 26) from air pressure gauge (27), battery
gauge (28) and hydraulic oil temperature gauge (29).
(11) Remove two wires (30 and 31) from fuel gauge (4).
(12) Remove three wires (31, 32 and 33) from transmission oil temperature
gauge (21).
(13) Remove three wires (34, 35 and 36) from water temperature gauge (11).
(14) Remove two wires (37 and 38) from battery gauge (28).
(15) Remove three wires (39, 40 and 41) from hydraulic oil temperature gauge
(29).
(16) Remove light socket (42) from right turn signal indicator (43).
(17) Remove light socket (44) from high beam indicator (45).
(18) Remove light socket (46) from left turn signal indicator (47).
7-51
TM 08780B-20
1. Light Socket 12. Jumper Wire (No. 435)
(Wire No. 052) 13. Nut
2. Light Socket 14. Star Washer
(Wire No. 052) 15. Jumper Wire (No. 435)
3. Oil Pressure Gauge 16. Nut
4. Fuel Gauge 17. Star Washer
5. Light Socket 18. Jumper Wire (No. 435)
(Wire Nos. 076/032) 19. Nut
6. Light Socket 20. Star Washer
(Wire Nos. 076/120) 21. Transmission Oil
7. Wire (No. 13) Temperature Gauge
8. Nut (2) 22. Light Socket (Wire No. 052)
9. Star Washer (2) 23. Light Socket (Wire No. 052)
11. Water Temperature
Gauge
24. Light Socket (Wire No. 052)

28. Battery Gauge
29. Hydraulic Oil Temperature Gauge
30. Wire (No. 318)
31. Wire (No. 076)
32. Wire (No. 422)
33. Wire (No. 076)
35. Wire (No. 320)
36. Wire (No. 076)
37. Wire (No. 232)
38. Wire (No. 076)
39. Wire (No. 435)
40. Wire (No. 808)
41. Wire (No. 754)
43. Right Turn Signal Indicator
45. High Beam Indicator
47. Left Turn Signal Indicator
7-52
TM 08780B-20
(19) Remove nut (48), star washer (49) and three wires (50, 51 and 52) from
tachometer (53). Discard star washer (49).
(20) Remove nut (54), star washer (55) and wire (56) from tachometer (53).
(21) Remove nut (57), star washer (58) and two wires (59 and 60) from
speedometer (61). Discard star washer (58).
(22) Remove two wires (62 and 63) from alarm (64).
48. Nut
49. Star Washer
51. Wire (Nos. 232/435)
52. Wire (No. 435)
53. Tachometer
54. Nut
55. Star Washer
56. Wire (Nos. 435/435)
57. Nut
58. Star Washer
60. Wire (No. 435)
61. Speedometer
62. Wire (No. 033)
63. Wire (Nos. 076/079)
64. Alarm
7-53
TM 08780B-20
(23) Remove three wires (65, 66 and 67) from rectifier (68).
(24) Loosen screws (69) and remove five wires (70, 71, 72, 73 and 74) from
terminal block (75).
(25) Loosen screws (76) and remove three wires (77, 78 and 79) from terminal
block (80).
65. Wire (Nos. 032/032)

66. Wire (No. 033)
67. Wire (Nos. 120/120)
68. Rectifier
69. Screw
70. Wire (No. 076)
71. Wire (No. 08)
72. Wire (No. 108)
73. Wire (No. 518)
74. Wire (No. 522)
75. Terminal Block
76. Screw
77. Wire (No. 076)
78. Wire (No. 519)
79. Wire (No. 519)
80. Terminal Block
7-54
TM 08780B-20
(26) Cut wire (81) from two light sockets (82) and (83) at butt connector (84).
(27) If required, remove fitting (85), nut (86), star washer (87) and jumper wire
(88) from air pressure gauge (27). Discard star washer (87).
(28) If required, remove nut (89), star washer (90) and jumper wire (88) from
water temperature gauge (11). Discard star washer (90).
(29) If required, remove nut (91), star washer (92) and wire (93) from
speedometer (61). Discard star washer (92).
(30) Remove nut (94) and washer (95) from harness connector (96). Remove
wiring harness (97) from instrument panel (98).

61. Speedometer
81. Wire (No. 052)
82. Light Socket
83. Light Socket
84. Butt Connector
85. Fitting
86. Nut
87 Star Washer 93. Jumper Wire (No. 435)
88. Jumper Wire (No. 435) 94. Nut
89. Nut 95. Washer
90. Star Washer 96. Harness Connector
91. Nut 97. Wiring Harness
92. Star Washer 98. Instrument Panel
7-55
TM 08780B-20
c. Installation
NOTE
Refer to paragraph 7-48 in this manual for proper installation of butt connectors to new
harness.
(1) Position wiring harness (97) in instrument panel (98).
(2) Install nut (94) and washer (95) on harness connector (96). Tighten
securely.
(3) If required, install wire (93) on speedometer (61) with new star washer
(92) and nut (91). Tighten securely.
(4) If required, install jumper wire (88) on water temperature gauge (11) with
new star washer (90) and nut (89). Tighten securely.
(5) If required, install jumper wire (88) on air pressure gauge (27) with new
star washer (87) and nut (86). Tighten securely.
(6) Apply pipe sealant to threads of fitting (85) and install on air pressure
gauge (27). Tighten securely.
7-56
TM 08780B-20

61. Speedometer
85. Fitting
86. Nut
87. Star Washer
89. Nut
90. Star Washer
91. Nut
92. Star Washer
94. Nut
95. Washer
96. Harness Connector
97. Wiring Harness
98. Instrument Panel
7-57
TM 08780B-20
(7) Connect two light sockets (83 and 82) to wire (81) with butt connector
(84).
(8) Connect three wires (77, 78 and 79) to speedometer terminal block (80).
(9) Connect five wires (70 through 74) to tachometer terminal block (75).
(10) Connect three wires (65, 66 and 67) to rectifier (68).
(11) Connect two wires (62 and 63) to alarm (64).
(12) Connect two wires (59 and 60) to speedometer (61) with new star washer
(58) and nut (57). Tighten securely.
(13) Connect wire (56) to tachometer (53) with new star washer (55) and nut
(14) Connect three wires (50, 51 and 52) to tachometer (53) with new star
washer (49) and nut (48). Tighten securely.
7-58
TM 08780B-20
48. Nut 66 Wire (No. 033)

49. Star Washer 67. Wire (Nos. 120/120)
50. Jumper Wire (No. 435) 68. Rectifier
51. Wire (Nos. 232/435) 69. Screw
52. Wire (No. 435) 70. Wire (No. 076)
53. Tachometer 71. Wire (No. 808)
54. Nut 72. Wire (No. 108)
56. Wire (Nos. 435/435) 74. Wire (No. 522)
57. Nut 75. Terminal Block
58. Star Washer 76. Screw
60. Wire (No. 435) 78. Wire (No. 519)
61. Speedometer 79. Wire (No. 519)
62. Wire (No. 033) 80. Terminal Block
63. Wire (Nos. 076/079) 81. Wire (No. 052)
64. Alarm 82. Light Socket
65. Wire (Nos. 032/032) 83. Light Socket
66. Wire (No. 033) 84. Butt Connector
7-59
TM 08780B-20
(15) Install light socket (46) into left turn signal indicator (47).
(16) Install light socket (44) into high beam indicator (45).
(17) Install light socket (42) into right turn signal indicator (43).
(18) Connect three wires (39, 40 and 41) to hydraulic oil temperature gauge
(29).
(19) Connect two wires (37 and 38) to battery gauge (28).
(20) Connect three wires (34, 35 and 36) to water temperature gauge (11).
(21) Connect three wires (31, 32 and 33) to transmission oil temperature gauge
(21).
(22) Connect two wires (30 and 31) to fuel gauge (4).
7-60
TM 08780B-20
4. Fuel Gauge
21. Transmission Oil Temperature Gauge
28. Battery Gauge
29. Hydraulic Oil Temperature Gauge
31. Wire (No. 076)
32. Wire (No. 422)
33. Wire (No. 076)
35. Wire (No. 320)
36. Wire (No. 076)
37. Wire (No. 232)
38. Wire (No. 076)
39. Wire (No. 435)
40. Wire (No. 808)
41. Wire (No. 754)
43. Right Turn Signal Indicator
45. High Beam Indicator
47. Left Turn Signal Indicator
7-61
TM 08780B-20
(23) Install light sockets (24, 25 and 26) into air pressure gauge (27), battery
gauge (28) and hydraulic oil temperature gauge (29).
(24) Install light sockets (22 and 23) into transmission oil temperature gauge
(21) and water temperature gauge (11).
(25) Connect jumper wire (18) to transmission oil temperature gauge (21) with
new star washer (20) and nut (19). Tighten securely.

19. Nut
20. Star Washer
21. Transmission Oil Temperature
Gauge
28. Battery Gauge
7-62
TM 08780B-20
(26) Connect jumper wire (18) to fuel gauge (4) with new star washer (17) and
nut (16). Tighten securely.
(27) Connect jumper wire (15) to fuel gauge (4) with new star washer (14) and
nut (13). Tighten securely.
(28) Connect wire (12) to water temperature gauge (11).
(29) Connect jumper wire (10) to water temperature gauge (11) and oil
pressure gauge (3) with two new star washers (9) and nuts (8). Tighten securely.
(31) Install two light sockets (5 and 6).
(32) Install two light sockets (1 and 2) into oil pressure gauge (3) and fuel
gauge (4).
END OF TASK
NOTE
TM 08780B-20 Install instrument panel
(para 7-11).
TM 08780B-10 Check all gauges and

lights for proper
operation
(para 2-13 and 2-14).
7-63
TM 08780B-20

4. Fuel Gauge
5. Light Socket (Wire Nos. 076/032)
6. Light Socket (Wire Nos. 076/120)
7. Wire (No. 113)
8. Nut (2)
9. Star Washer (2)
11. Water Temperature gauge
13. Nut
14. Star Washer
16. Nut
17. Star Washer
7-64
TM 08780B-20
7-14. CIRCUIT BREAKER REPLACEMENT

c. Installation

Condition Condition
TM Description
Applicable Configurations TM 08780B-20 Batteries
MK48 disconnected
(para 7-45).
Materials/Parts
Star washer (2) (MS4590460) item 21 Access cover in cab
removed (para 18-15),
item 14.

a. Removal
NOTE
• Circuit breakers (1 thru 13) may have as many as six wires on one terminal. Be sure to
tag all wires before removal to insure proper installation.
(1) Remove two nuts (14) and wires (15) from terminals (16 and 17).
(2) If used, remove nut (18), wires (15) and bus bar (19) from adjoining
circuit breaker.
(3) For circuit breaker (13), remove two screws (20) and discard star washers
(21).
(4) Pry up on circuit breaker (1 thru 12) until it releases from mounting strip
(22).
(2) Inspect wires for corrosion, breaks or missing insulation.
7-65
TM 08780B-20
(3) Repair or replace any wire failing inspection.
c. Installation
(1) Install circuit breaker (1 thru 12) into mounting strip (22).
(2) For circuit breaker (13), install into position and secure using two new star
washers (21) and screws (20). Tighten screws (20) securely.
(3) If removed, install bus bar (19), wires (15) and nut (18) on adjoining
circuit breaker (1 thru 12). Tighten nut (18) securely.
(4) Install wires (15) onto terminals (16 and 17) as tagged.
(5) Install nuts (14) and tighten securely.
END OF TASK
NOTE
(para 7-45).
Install access cover

(para 18-15), item 14.
7-66
TM 08780B-20
Typical Circuit Breaker Service
1. Circuit Breaker
2. Circuit Breaker
3. Circuit Breaker
4. Circuit Breaker
5. Circuit Breaker
6. Circuit Breaker
7. Circuit Breaker
8. Circuit Breaker
9. Circuit Breaker
10. Circuit Breaker
11. Circuit Breaker
12. Circuit Breaker
13. Circuit Breaker
14. Nut (2)
15. Wire (AR)
16. Terminal
17. Terminal
18. Nut
19. Bus Bar
20. Screw (2)
21. Star Washer (2)
22. Mounting Strip
7-67
TM 08780B-20
7-15. TOGGLE SWITCH REPLACEMENT

c. Installation

Condition Condition
Disconnected
(para 7-45).
Access panels
removed as needed
(para 18-15).

a. Removal
NOTE
This procedure works for all toggle switches used on the MK48.
(1) Remove nut (1) from toggle switch (2).
(2) Remove toggle switch (2) from panel (3).
NOTE
(3) Remove washer (4) and nut (5).
(4) Remove screws (6) and wires (7).
(1) Clean all parts, as needed. Refer to paragraph 2-11.
(2) Inspect wire connections for damage, wear or corrosion.
7-68
TM 08780B-20
c. Installation
(1) Install wires (7) using screws (6). Tighten screws (6) securely.
(2) Install nut (5) and washer (4) on toggle switch (2).
(3) Install toggle switch (2) into panel (3). Adjust nut (5) to allow nut (1) to
be installed.
(4) Install and tighten nut (1).
END OF TASK
NOTE
TM 08780B-20 Install access panels,
if removed (para 18-15).
TM 08780B-10 Check operation of switch (para 2-13).
1. Nut
2. Toggle Switch
3. Panel
4. Washer
5. Nut
6. Screw (2 or 3)
7. Wires
7-69
TM 08780B-20
7-16. STEERING SELECTOR SWITCH REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Star washer (2) (MS35333-72) item 2
a. Removal
(1) Remove two screws (1), star washers (2) and wires (3). Discard star
washers (2).
(2) Remove nut (4) and nut (5).
(3) Remove steering selector switch (6) from bracket (7).
(4) Remove nut (8) and nut (9) from steering selector switch (6).
(2) Inspect all parts for damage.
c. Installation
(1) Install nut (9) and nut (8) onto steering selector switch (6).
(2) Install steering selector switch (6) into bracket (7).
(3) Loosely install nut (5) and nut (4) onto steering selector switch (6).
(4) Pull handle (10) of steering/ auxiliary valve (11) all the way out.
(5) Adjust steering selector switch (6) so that shaft (12) of steering selector
switch (6) is touching shaft (13) of steering/ auxiliary valve (11).
7-70
TM 08780B-20
(6) Secure in place by tightening nut (5) and nut (9) securely.
(7) Tighten nut (4) and nut (8) securely.
(8) Install two wires (3), new star washers (2) and screws (1).
END OF TASK
1. Screw (2)
2. Star Washer (2)
3. Wire (2) (No. 843)
4. Nut
5. Nut
6. Steering Selector Switch
7. Bracket
8. Nut
9. Nut
10. Handle
11. Steering/Auxiliary Valve
12. Shaft
13. Shaft
7-71
TM 08780B-20
7-17. TURN SIGNAL SWITCH AND FLASHER REPLACEMENT

c. Installation

Condition Condition
disconnected
Locknut (MS21083-N3) item 4.2 Instrument panel open
(para 7-11).

NOTE
Some LVS models use a new style turn signal flasher that is mounted in a different way than
the old style flasher. Do steps (2.1) and (2.2) if flasher is new style.
a. Removal
(1) Remove four screws (1) and panel (2).
(2) Remove flasher (3) from clip (4).
(3) Remove three screws (4.1), locknut (4.2), screw (4.3) and panel (4.4).
(4) Allow flasher (4.5) and ground wire (4.6) to hang.
NOTE
• Remove nylon ties, as needed. Note location for proper installation.
(5) Unplug five wires (5) coming from turn signal switch (6) to wiring
harness.
(6) Measure two inches (5.08 cm) from flasher plug (7) and cut wire (8).
7-72
TM 08780B-20
(7) Remove nut (9), lockwasher (10), clamp (11) and capscrew (12). Discard
lockwasher (10).
(8) Unscrew clamp (13) from around steering column (14) and remove turn
signal switch (6) and flasher (3).
(9) Remove flasher (3) from flasher plug (7).
c. Installation
(1) Position turn signal switch (6) onto steering column (14) as shown.
(2) Tighten clamp (13) securely.
(3) Install wires (5) into clamp (11), using capscrew (12), new lockwasher
(10) and nut (9). Tighten nut (9) securely.
(4) Plug five wires (5) into wiring harness.
(5) Connect wire (8) using a butt connector. Refer to paragraph 7-48.
(6) Install nylon ties at locations noted during removal.
(7) Install flasher (3) into flasher plug (7).
NOTE
If flasher is new style, do step (10).
(8) Install flasher (3) into clip (4) on panel (2)
(9) Install panel (2) using four screws (1).
(10) Install flasher (4.5), ground wire (4.6) and panel (4.4) using three screws
(4.1), screw (4.3) and new locknut (4.2)
END OF TASK
7-73
TM 08780B-20
NOTE
TM 08780B-20 Install instrument
panel (para 7-11).
TM 08780B-10 Check for proper operation

of turn signal switch (para 2-1).
1. Screw (4) 5. Wire (5)

2. Panel 6. Turn Signal Switch
3. Flasher 7. Flasher Plug
4. Clip 8. Wire (No. 080)
4.1. Screw (3) 9. Nut
4.2. Locknut 10. Lockwasher
4.3. Screw 11. Clamp
4.4. Panel 12. Capscrew
4.5. Flasher 13. Clamp
4.6. Ground Wire 14. Steering Column
(No. 435)
7-74
TM 08780B-20
7-18. TURN SIGNAL SWITCH AND FLASHER REPLACEMENT (LVSA1 SERIES

VEHICLES ONLY)

c. Installation

Condition Condition
disconnected
Locknut (2) (1600460) item 1
Lockwasher (353AX) item 7 Instrument panel
Corrosion preventive compound (item 11.1, partially removed
Appendix D) for access (para 7-11).

a. Removal
NOTE
• Remove nylon ties as needed. Note location for proper installation.
• Note location of harness routing for proper installation.
(2) Unscrew flasher connector (3) and remove flasher (4).
NOTE
Remove additional terminals as necessary. Note locations for proper installation.
(3) Remove nut (5), terminal (6) and lockwasher (7). Discard lockwasher (7).
(4) Unscrew signal connector (8) from turn signal switch assembly (9).
(5) Loosen clamp screw (10) and disconnect clamp (11). Remove pads (12)
and turn signal switch assembly (9) from steering column (13).
(6) Remove nut (14) and wire clamp (15) from harness (16).
7-75
TM 08780B-20
(7) Disconnect weather pack terminal (17) and remove harness (16).
c. Installation
(1) Connect signal connector (8) into turn signal switch assembly (9).
(2) Position turn signal switch assembly (9) and pads (12) on steering column
(13). Connect clamp (11) and tighten clamp screw (10) securely.
(3) Install flasher (4) using two capscrews(2) and new locknuts (1). Tighten
locknuts (1) securely.
(4) Route harness (16) as noted during removal. Connect weather pack
terminal (17).
(5) Secure harness (16) on steering column (13) using wire clamp (15) and nut
NOTE
Install additional terminals as necessary in noted locations.
(6) Install new lockwasher (7), terminal (6) and nut (5). Apply corrosion
preventive compound at terminal (6).
(7) Connect flasher connector (3) into flasher (4).
(8) Install nylon ties as necessary at locations noted during removal.
END OF TASK
7-76
TM 08780B-20
NOTE
panel (para 7-11).
Connect batteries
(para 7-46).
TM 08780B-10 Check for proper

operation of turn
signal switch (para 2-1).
1. Locknut (2)
2. Capscrew (2)
3. Flasher Connector (MC29)
4. Flasher
5. Nut
6. Terminal (1435)
7. Lockwasher
8. Signal Connector (MC28)
9. Turn Signal Switch Assembly
10. Clamp Screw
11. Clamp
12. Pad (2)
13. Steering Column
14. Nut
15. Wire Clamp
16. Harness
17. Weather Pack Terminal (MC30)
7-77
TM 08780B-20
7-19. SPEEDOMETER/TACHOMETER REPLACEMENT

c. Installation

Condition Condition
disconnected
Materials/Parts (para 7-45 or 7-46
Lockwasher (2) (MS35338-43) item 8 on LVSA1 series
vehicles only).
Instrument panel
open (para 7-11).

a. Removal
NOTE
Tag all wires for location before removal for use during installation.
(1) Loosen four screws (1) and remove wires (2).
(2) Remove nut (3) and washer (4).
(3) Remove wires (5).
(4) Remove light socket (6).
(5) Remove two nuts (7) and two lockwashers (8). Discard lockwashers (8).
(6) Remove mounting bracket (9) and gauge (10) from instrument panel (11).
7-78
TM 08780B-20
c. Installation
(1) Place gauge (10) in position and install mounting bracket (9).
(2) Install two new lockwashers (8) and two nuts (7). Tighten nuts securely.
(3) Install wires (5), washer (4) and nut (3). Tighten nut securely.
(4) Install four wires (2) and tighten screws (1) securely.
(5) Install light socket (6).
END OF TASK
NOTE
panel (para 7-11).
Connect batteries
(para 7-45 or 7-46 on

gauges (para 2-13).
7-79
TM 08780B-20
1. Screw (4)
2. Wire (4)
3. Nut
4. Washer
5. Wire (Air)
6. Light Socket
7. Nut (2)
8. Lockwasher (2)
9. Mounting Bracket
10. Gauge
11. Instrument Panel
7-80
TM 08780B-20
7-20. ELECTRICAL GAUGE REPLACEMENT

c. Installation

Condition Condition
disconnected (para
Materials/Parts 7-45 or 7-46 on
Star washer (1) (MS35333-73) item 5 LVSA1 series
Lockwasher (2) (MS35338-43) item 8 vehicles only).
Instrument panel open

(para 7-11).

a. Removal
NOTE
Tag all wires before removing for use during installation.
(1) Remove light socket (1) from gauge (2).
(2) Disconnect wires (3).
(3) Remove nut (4), star washer (5) and wire or wires (6). Discard star washer
(5).
(4) Remove two nuts (7) and lockwashers (8). Discard lockwashers (8).
(5) Remove mounting bracket (9) and gauge (2).
7-81
TM 08780B-20
c. Installation
(1) Place gauge (2) in position and install mounting bracket (9).
(2) Install two new lockwashers (8) and nuts (7). Tighten securely.
(3) If needed, install wire or wires (6), new star washer (5) and nut (4).
Tighten securely.
(4) Install wires (3).
(5) Install light socket (1).
END OF TASK
NOTE
panel (para 7-11).
Connect batteries (para 7-45

or 7-46 on LVSA1 series
vehicles only).
TM 08780B-10 Check operation of gauges

(para 2-13).
7-82
TM 08780B-20
1. Light Socket
2. Gauge
3. Wires (A/R)
4. Nut
5. Star Washer
8. Wire (A/R)
7. Nut (2)
8. Lockwasher (2)
9. Mounting Bracket
7-83
TM 08780B-20
7-21. MAGNETIC SWITCH REPLACEMENT

c. Installation

Condition Condition
disconnected
Access cover
removed (para
18-15, item 14)

a. Removal
NOTE
(1) Remove two nuts (1) and wires (2 and 3).
(2) Remove two nuts (4) and wires (5 and 6).
(3) Remove two capscrews (7), star washers (8) and wire (5). Discard star
washers (8).
(4) Remove magnetic switch (9).
(2) Inspect wires for damage or missing insulation.
(3) Repair or replace as needed.
7-84
TM 08780B-20
c. Installation
(1) Position magnetic switch (9) in place.
(2) Install wire (5), two new star washers (8) and capscrews (7). Tighten
securely.
(3) Install wires (5 and 6) and two nuts (4). Tighten securely.
(4) Install wires (2 and 3) and two nuts (1). Tighten securely.
END OF TASK
NOTE
(para 18-15, item 14).
1. Nut (2)
2. Wire (No. 835)
3. Wire (No. 836)
4. Nut (2)
5. Wire (No. 196)
6. Wire (No. 837)
7. Capscrew (2)
8. Star Washer (2)
9. Magnetic Switch
7-85
TM 08780B-20
7-22. ETHER START SWITCH REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Disconnect batteries
(para 7-45).
Materials/Parts
Star washer (2) (MS35333-73) item 6 Instrument panel open
(para 7-11).

a. Removal
NOTE
(1) Remove rubber boot (1) and knurled nut(2).
(2) Pull ether start switch (3) out of dash panel (4).
(3) Remove two screws (5), star washers (6) and wires (7 and 8). Discard star
washers (6).
(2) Inspect wires for damage or missing insulation.
(3) Repair or replace all parts as needed.
c. Installation
(1) Install wires (7 and 8) using two new star washers (6) and screws (5).
Tighten securely.
(2) Install ether start switch (3) through dash panel (4).
7-86
TM 08780B-20
(3) Install knurled nut (2).
(4) If any depth adjustment of ether start switch (3) is needed, remove nut (2),
adjust nut (9) and reinstall knurled nut (2).
(5) Tighten knurled nut (2) securely.
(6) Install rubber boot (1).
END OF TASK
NOTE
panel (para 7-11).

ether start system, temperature
permitting (para 2-13).
1. Rubber Boot
2. Knurled Nut
3. Ether Start Switch
4. Dash Panel
5. Screw (2)
6. Star Washer (2)
7. Wire (No. 036)
8. Wire (No. 036)
9. Adjustment Nut
7-87
TM 08780B-20
7-23. IGNITION SWITCH REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Disconnect batteries
(para 7-45).
Materials/Parts
Lockwasher (M535338-43) item 2 General Safety Instructions
a. Removal
(1) Remove screw (1), lockwasher (2) and knob (3). Discard lockwasher (2).
(2) Remove knurled nut (4) and push ignition switch (5) through dash panel
(6).
(3) Pull ignition switch (5) down below dash panel (6) for easy access to
wiring on rear of ignition switch (5).
NOTE
(4) Remove five screws (7) and five retainers (8).
(5) Remove wires (9, 10, 11, 12 and 13).
(1) Clean all parts as needed. Refer to paragraph 2-11.
(2) Inspect wires for damaged or missing insulation.
c. Installation
(1) Install wires (9, 10, 11, 12 and 13) using five screws (7) and retainers (8).
Tighten securely.
7-88
TM 08780B-20
(2) Install ignition switch (5) into dash panel (6).
(3) Install knurled nut (4), knob (3), new lockwasher (2) and screw (1).
Tighten securely.
END OF TASK
NOTE
(para 7-45).
TM 08780B-10 Start engine to

check operation of
ignition switch. (para
2-13).
1. Screw
2. Lockwasher
3. Knob
4. Knurled Nut
5. Ignition Switch
6. Dash Panel
7. Screw (5)
8. Retainers (5)
9. Wire (No. 830)
10. Wire (No. 431)
11. Wire (No. 640)
12. Wire (No. 436)
13. Wire (No. 075)
7-89
TM 08780B-20
7-24. MASTER LIGHT SWITCH REPLACEMENT

c. Installation

Condition Condition
disconnected
Locknut (4) (MS51858-5) item 7 Remove access cover
(para 18-15, item 14).

a. Removal
(1) Remove three screws (1), lockwashers (2), levers (3) and washers (4).
(2) Unscrew and remove cannon plug (5).
(3) Remove four screws (6) and locknuts (7). Discard locknuts (7).
(4) Remove master light switch (8).
c. Installation
(1) Install cannon plug (5) onto master light switch (8). Tighten securely.
(2) Install master light switch (8) using four screws (6) and new locknuts (7).
Tighten securely.
7-90
TM 08780B-20
(3) Install three washers (4), levers (3), new lockwashers (2) and screws (1).
Tighten securely.
END OF TASK
NOTE
(para 18-15, item 14).

light switch (para 2-14).
1. Screw (3)
2. Lockwasher (3)
3. Lever (3)
4. Washer (3)
5. Cannon Plug
6 Screw (4)
7. Locknut (4)
8. Master Light Switch
7-91
TM 08780B-20
7-25. STOP LIGHT SWITCH REPLACEMENT

c. Installation

Condition Condition
(para 3-5).
Materials/Parts
Pipe sealant (item 48, Appendix D) TM 08780B-20 Batteries
disconnected
(para 7-45).
Remove access panels

as needed (para
18-15).
General Safety instructions

a. Removal
NOTE
This procedure will work for all stop light switches (1, 2, 3 or 4) on all valves (5, 6 or 7).
(1) Remove two nuts (8).
NOTE
• Tag all wires (9) before removal to insure proper installation.
• There may be up to three wires (9) on each terminal.
(2) Remove wires (9) and washers (10).
(3) Unscrew and remove switch (1, 2, 3 or 4).
7-92
TM 08780B-20
c. Installation
(1) Apply pipe sealant to threads of stop light switch (1, 2, 3 or 4) and install
into valve (5, 6 or 7).
(2) Install two washers (10) and two wires (9) at each switch.
(3) Install two nuts (8) at each switch.
END OF TASK
NOTE
TM 08780B-20 Install access panel,
if removed (para 18-15).
TM 08780B-10 Operate foot and hand brakes

to make sure stop lights work
(para 2-13).
7-93
TM 08780B-20
1 Stop Light Switch

2. Stop Light Switch
5. Treadle Brake Valve
6. Hand Control Valve
7. Quick Release Valve
8. Nut
9. Wire
10. Washer
7-94
TM 08780B-20
7-26. NEUTRAL SAFETY SWITCH MAINTENANCE

c. Installation

Condition Condition
disconnected (para
Test Equipment 7-45 or 7-46 on
Multimeter, URM-106 LVSA1 series
vehicles only).
Materials/Parts
Electrical tape (item 55, Appendix D) Access panel next to
Nylon tie (MS3367-4-9) shifter removed from
Cotter pin (MS24665-132) item 9 inside cab (para
Male butt connector (2) (NSN 5940-00-549-2815) item 18 18-15, item 4).
Star washer (P/N WS-516) item 11.1
Block wheels of truck to prevent personal
injury.
a. Removal
(1) Remove nylon tie (1) and electrical tape holding wires (2, 3 and 4) to shift
cable (5).
(2) Tag wires (2, 3 and 4) for identification and disconnect.
(3) Remove four capscrews (6) and flat washers (7) from rubber boot (8).
(4) Slide rubber boot (8) down and back out of the way.
7-95
TM 08780B-20
1. Nylon Tie
2. Wire (No. 436)
3. Wire (No. 021)
4. Wire (No. 052)
5. Shift Cable
6. Capscrew (4)
7. Flat Washer (4)
8. Rubber Boot
(5) Remove cotter pin (9) and washer (10) from neutral safety switch (16).
Discard cotter pin (9).
(6) Remove nut (11), star washer (11.1), washer (12), spacer (13) and
capscrew (14) attaching neutral safety switch (16). Discard star washer(11.1).
(7) Remove neutral safety switch (16) from shift lever bracket (17).
8. Rubber Boot
9. Cotter Pin
10. Washer
11. Nut
11.1. Star Washer
12. Washer
13. Spacer
14. Capscrew
16. Neutral Safety Switch
17. Shift Lever Bracket
7-96
TM 08780B-20
c. Installation
(1) Install a male butt connector (18) onto green wire (19) and white wire
(20). Refer to paragraph 7-48 in this manual.
(2) Cut off red wire (21) and black wire (22) one inch from neutral safety
switch (16).
(3) Position neutral safety switch (16) onto shift lever bracket (17).
(4) Install capscrew (14), spacer (13), washer (12), new star washer (11.1) and
nut (11) finger tight.
(5) Install plunger (23) into shift lever (24).
(6) Install washer (10) and new cotter pin (9).
(7) Using ohmmeter, connect leads to green (19) and white (20) wires from
neutral safety switch (16).
(8) Make sure shift lever (24) is in neutral position and slide neutral safety
switch (16) back and forth until a reading of ‘0’ shows on the ohmmeter.

8. Rubber Boot
9. Cotter Pin
10. Washer
11. Nut
11.1. Star Washer
12. Washer
13. Spacer
14. Capscrew
17. Shift Lever Bracket
18. Male Butt Connector (2)
19. Green Wire
20. White Wire
21. Red Wire
22. Black Wire
23. Plunger
24. Shift Lever
7-97
TM 08780B-20
(10) Slide rubber boot (8) into position, up over wires (2, 3 and 4).
(11) Install capscrews (6) with fiat washers (7).
(12) Plug wires (2, 3 and 4) into connectors as marked.
(13) Wrap connectors with electrical tape and secure with nylon tie (1).
END OF TASK
NOTE
TM 08780B-20 Install access

panel in cab (para 18-15, item 4).
Connect batteries
(para 7-45 or 7-46 on
TM 08780B-10 Start engine (para 2-13).

Make sure engine starts in neutral
range only.
1. Nylon Tie
2. Wire (No. 436)
3. Wire (No. 021)
4. Wire (No. 052)
6. Capscrew (4)
7. Flat Washer (4)
8. Rubber Boot
7-98
TM 08780B-20
7-27. Hl IDLE NEUTRAL SWITCH REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Remove vehicle step
(para 18-7).
Materials/Parts
Sealant (item 48, Appendix D) Remove access panel
(para 18-15, item 27).
a. Removal
(1) Cut and remove nylon tie (1). Discard nylon tie (1).
(3) Unscrew and remove neutral switch (3).
c. Installation
(1) Coat threads with sealant and install neutral switch (3). Tighten securely.
(2) Connect plug (2) and install new nylon tie (1).
END OF TASK
NOTE
(para 18-15, item 27).
Install vehicle step (para 18-7).
7-99
TM 08780B-20
1. Nylon Tie
2. Plug
3. Neutral Switch
7-100
TM 08780B-20
7-28. RELAY REPLACEMENT

c. Installation

Condition Condition
Disconnected
Access panel removed
(para 18-15, item 14).

a. Removal
(1) Remove plug (1) from relay (2).
(2) Remove capscrew (3) and star washer (4). Remove ground wire (5) if
used. Discard star washer (4).
(3) Remove relay (2).
c. Installation
(1) Position relay (2) and install ground wire (5), new star washer (4) and
capscrew (3). Tighten securely.
END OF TASK
7-101
TM 08780B-20
NOTE
(para 18-15, item 14).
Connect batteries
(para 7-45).
1. Plug
2. Relay
3. Capscrew
4. Star Washer
5. Ground Wire
7-102
TM 08780B-20
7-29. DASHBOARD WARNING AND/OR INDICATOR LIGHT REPLACEMENT

c. Installation

Condition Condition
disconnected
Star washer (M535333-81) item 6
Access cover(s)
removed as needed
(para 18-15).
Instrument panel

a. Removal
NOTE
This procedure will work for all warning and indicator lights.
(1) Remove socket (1) from rear of lens assembly (2).
(2) Remove bulb (3) from socket (1).
(3) Remove rubber shield (4) from front of lens assembly (2).
(4) Remove nut (5), lens assembly (2) and discard star washer (6).
7-103
TM 08780B-20
c. Installation
(1) Install new star washer (6) onto lens assembly (2) and install into panel
(7).
(2) Install nut (5) and tighten securely.
(3) Install lens (4) into front of lens assembly (2).
(4) Install bulb (3) into socket (1) and install into rear of lens assembly (2).
END OF TASK
NOTE
TM 08780B-20 Install access panel(s)
(para 18-15).
Install instrument panel (7-11).
TM 08780B-10 Check for proper operation

of lights (para 2-13).
1. Socket
2. Lens Assembly
3. Bulb
4. Rubber Shield
5. Nut
6. Star Washer
7. Panel
7-104
TM 08780B-20
7-30. HEADLIGHT MAINTENANCE

c. Installation
d. Adjustment

Locknut (4) (MS51922-9) item 3
Applicable Configurations Lockwasher (6) (MS35337-25)
MK48 items 20 and 27
Locknut (MS21083-N3) item 12.1
References
TM 08780B-10
a. Removal
(1) Remove four capscrews (1), washers (2), locknuts (3) and headlight guard
(2) Loosen three screws (5) and remove bezel (6).
(3) Tag and disconnect three wires (7, 8 and 9) from headlight housing (10).
(4) Remove headlight (11).
NOTE
• If headlight (11) is all that is being replaced, go to installation, step (9).
• Some LVS models use a new style turn signal flasher that is mounted with the shield
(13) mounting hardware. Do step 6 if a new style turn signal flasher is present.
(5) If left headlight housing (10) is being removed, remove four screws (12)
and shield (13).
(6) If left headlight housing (10) is being removed, remove three screws (12),
locknut (12.1), screw (12.2) and shield (13). Discard lockout (12.1).
(7) If right headlight housing (10) is being removed, remove four screws (14)
and shield (15).
(8) Carefully pull spring (16) forward and out of retaining hole (17).
(9) Remove adjusting ring (18).
7-105
TM 08780B-20
(10) Remove three nuts (19), lockwashers (20) and washers (21). Discard
lockwashers (20).
(11) Tag and remove three wires (22, 23 and 24) from headlight housing (10).
(12) Remove headlight housing (10) and gasket (25). Discard gasket (25).
(13) If needed, remove three nuts (26), lockwashers (27) and rubber mounts
(2) Inspect all parts for damaged. Refer to paragraph 2-12.
c. Installation
(1) If removed, install three rubber mounts (28), new lockwashers (27) and
nuts (26). Tighten securely.
(2) Install new gasket (25).
(3) Install three wires (22, 23 and 24) onto back of headlight housing (10).
(4) Install headlight housing (10) onto rubber mounts (28).
(5) Install three washers (21), new lockwashers (20) and nuts (19). Tighten
securely.
(6) Install adjusting ring (18).
(7) Install spring (16) into retaining hole (17).
(8) Install three wires (7, 8 and 9) from headlight (11) to headlight housing
(10).
(9) Install headlight (11) into adjusting ring (18). Make sure alignment lugs
(29) are properly seated.
(10) Install bezel (6) onto headlight (11) and tighten three screws (5). Make
sure adjustment screw holes (30) line up with adjustment screws (31).
7-106
TM 08780B-20
(11) Install headlight guard (4), four capscrews (1), washers (2) and new
locknuts (3). Tighten securely.
NOTE
Only new style turn signal flasher uses locknut (12.1) and screw (12.2) as mounting hardware.
(12) Install shields (13 or 15) with four screws (12 or 14), screw (12.1) and
new locknut (12.2) if removed.
1. Capscrew (4) 16. Spring

2. Washer (4) 17. Retaining Hole
3. Locknut (4) 18. Adjusting Ring
4. Headlight Guard 19. Nut (3)
5. Screw (3) 20. Lockwasher (3)
6. Bezel 21. Washer (3)
7. Wire (No. 017) 22. Wire (No. 007)
8. Wire (No. 018) 23. Wire (No. 006)
9. Wire (No. 091) 24. Wire (No. 091)
10. Headlight Housing 25. Gasket
11. Headlight 26. Nut (3)
12. Screw (4) 27. Lockwasher (3)
12.1. Screw 28. Rubber Mount (3)
12.2. Locknut 29. Alignment Lug (3)
13. Shield 30. Adjustment Screw Holes
14. Screw (4) 31. Adjustment Screw (2)
15. Shield
7-107
TM 08780B-20
d. Adjustment
NOTE
• MK48 must be connected to a trailer for proper adjustment.
• Make sure truck is unloaded and tires are properly inflated.
(1) Park truck on a level surface 18 inches (45.7 cm) from a flat vertical
surface (such as a wall).
(2) Draw two vertical lines (32) even with the outside edges of the skid plate
(33).
(3) Measure inward nine inches (22.8 cm) from each vertical line (32) and
draw two more vertical lines (34).
(4) Measure up 61 inches (154.9 cm) from the ground and draw a horizontal
line (35) which crosses both lines (34).
(5) Measure four inches (10.2 cm) outward in all four directions (up, down,
left and right) from point where lines (34 and 35) cross.
(6) Using these points, draw two eight inch (20.4 cm) squares (36), as shown.
32. Vertical Line (2)

33. Skid Plate
34. Vertical Line (2)
35. Horizontal Line
36. Square (2)
7-108
TM 08780B-20
(7) Turn headlight (11) ON, low beam. Refer to paragraph 2-13 (TM
08780B-10).
(8) If the light from the headlights (11) are centered in squares (36), the
headlights (11) are properly adjusted. If not, adjust as follows.
(9) Use top adjusting screw (31) to move light up or down.
(10) Use side adjusting screw (31) to move light left or right.
(11) Once proper adjustment is obtained, turn headlights (11) OFF.
11. Headlight
31. Adjustment Screws
END OF TASK
7-109
TM 08780B-20
7-31. CLEARANCE LIGHT REPLACEMENT

c. Installation
INITIAL SETUP
Materials/Parts
Retainer (2) (MS51857-2) item 5
Nut with captive lockwasher (4) (1571850) item 12
Compound, corrosion preventive (item 11.1 , Appendix D)
Compound, anti-corrosion conductive (item 11.2, Appendix D)
a. Removal
(1) Disconnect wire (1) at plug (2).
(2) Remove two screws (3) and lens housing (4).
(3) Remove two push-on retainers (5) and lens (6) from lens housing (4).
Discard retainers (5).
(4) Remove bulb (7) from socket (8).
(5) Remove screw (9) and socket (8).
NOTE
• If lens (6), bulb (7) or socket (8) are the only items being replaced, go to
INSTALLATION, step (4).
• Some bases (13) are installed with only two screws (10) and nuts with captive
lockwasher (12).
• On clearance lights with ground terminals, mark location of ground terminal to ensure
proper installation.
• Mounting hardware for LVSA1 clearance lights has changed from screw, washer and
locknut to a screw and nut with captive lockwasher. When repairing non-A1 vehicles,
use new style hardware to replace old style hardware. Refer to TM 08780B-24P for
(6) Remove four screws (10) and nuts with captive lockwasher (12). Discard
nuts with captive lockwasher (12).
7-110
TM 08780B-20
NOTE
Perform steps (7) and (8) on clearance lights with ground wires.
(7) Remove two screws (10), nuts with captive lockwasher (12) and terminal
(11). Discard nuts with captive lockwasher (12).
(8) Remove screw (10) and nut with captive lockwasher (12). Discard nut
with captive lockwasher (12).
(9) Remove base (13) and gasket (14).
c. Installation
(1) Install gasket (14) and base (13) onto truck.
(2) Install four screws (10) and new nuts with captive lockwasher (12).
NOTE
Perform steps (3) thru (5) on clearance lights with ground terminals.
(3) Install four screws (10) and new nuts with captive lockwasher (12).
(4) Install terminal (11) using screw (10) and new nut with captive
lockwasher(12) in marked location.
(5) Apply corrosion preventive compound to terminal (11) at nut with captive
lockwasher (12).
(6) Install socket (8) and screw (9).
(7) Coat interior of socket (8) with anti-corrosion conductive compound and
install bulb (7) into socket (8).
(8) Install lens (6) into lens housing (4) and secure using two new push-on
retainers (5).
(9) Install lens housing (4) onto base (14).
7-111
TM 08780B-20
(10) Install two screws (3).
(11) Connect wire (1) at plug (2).
END OF TASK
NOTE
clearance lights (para
2-14).
1. Wire
2. Plug
3. Screw (2)
4. Lens Housing
5. Push-On Retainer (2)
6. Lens
7. Bulb
8. Socket
9. Screw
10. Screw (4)
11. Terminal (No. 1435)
12. Nut With Captive
Lockwasher (4)
13. Base
14. Gasket
7-112
TM 08780B-20
7-32. CLEARANCE LIGHT MOUNTING BRACKET REPLACEMENT

c. Installation

Condition Condition
disconnected
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) While assistant holds clearance light mounting bracket (1), remove six
screws(2) and six star washers (3). Discard star washers (3).
(2) Unplug electrical connector (4) and remove clearance light mounting
bracket(1).
(3) Remove clearance lights. Refer to paragraph 7-31.
c. Installation
(1) Install clearance lights. Refer to paragraph 7-31.
(2) While assistant holds clearance light mounting bracket (1), plug electrical
connector (4) together.
7-113
TM 08780B-20
(3) Align holes in clearance light mounting bracket (1) and install six new star
washers (3) and six screws (2). Tighten screws (2) securely.
END OF TASK
1. Mounting Bracket
2. Screws (6)
3. Star Washer (6)
4. Connector
7-114
TM 08780B-20
7-33. DOME LIGHT REPLACEMENT

c. Installation
INITIAL SETUP
MK48
a. Removal
(1) Remove two screws (1) from lens (2).
(2) Turn bulb (3) counterclockwise and remove from socket fixture (4).
(3) If bulb (3) is all that is being replaced, go to INSTALLATION, step (3).
(4) Remove four screws (5) from dome light base (6).
(5) Unplug wire and remove dome light base (6).
(6) Remove two flanged capscrews (7) and remove dome light bracket (8).
(2) Inspect all parts-Refer to paragraph 2-12.
c. Installation
(1) Install light bracket (8) with two flanged capscrews (7). Tighten securely.
(2) Install base (6) with four head screws (5). Connect wire. Tighten
securely.
(3) Install bulb (3) in socket fixture (4) and turn clockwise.
(4) Install lens (2) with two screws (1). Tighten securely.
END OF TASK
7-115
TM 08780B-20
NOTE
TM 08780B-10 Check dome light
for proper operation (para 2-14).
1. Phillips Head Screw (2)

2. Lens
3. Bulb
4. Socket Fixture
5. Phillips Head Screw (4)
6. Dome Light Base
7. Flanged Capscrew (2)
8. Dome Light Bracket
7-116
TM 08780B-20
7-34. FRONT COMPOSITE LIGHT REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 For left composite
light only, treadle
Materials/Parts valve partially
Locknut (4) (MS51922-9) item 1 removed for access
Gasket (5330-00-463-0200) item 7 to mounting
Star washer (2) (MS35335-63) item 17 capscrews and
Compound, anti-corrosion conductive (item 11.2, Appendix D) wiring (para 13-14).
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Remove four locknuts (1), washers (2) and capscrews (3).
(2) Remove headlight grille (4).
(3) Loosen five screws (5), remove light door (6) and gasket (7). Discard
gasket (7).
(4) Remove parking lamp (8), signal lamp (9) or blackout marker lamp (10),
as needed.
NOTE
If parking lamp (8), signal lamp (9) or blackout marker lamp (10) are all that is being
replaced, go to INSTALLATION section, step (5).
(5) Tag and disconnect three wires (12, 13 and 14) at plugs (15).
(6) Remove two capscrews (16) and star washers (17). Discard star
washers(17).
(7) Remove light body (11).
7-117
TM 08780B-20
1. Locknut (4) 10. Blackout

2. Washer (4) Marker Lamp
3. Capscrew (4) 11. Light Body
4. Headlight Grille 12. Wire (No. 491)
5. Screw (5) 13. Wire (No. 460/461)
6. Light Door 14. Wire (No. 020)
7. Gasket 15. Plug (3)
8. Parking Lamp 16. Capscrew (2)
9. Signal Lamp 17. Star Washer (2)
7-118
TM 08780B-20
1. Locknut (4) 10. Blackout

2. Washer (4) Marker Lamp
3. Capscrew (4) 11. Light Body
4. Headlight Grille 12. Wire (No. 491)
5. Screw (5) 13. Wire (No. 460/461)
6. Light Door 14. Wire (No. 020)
7. Gasket 15. Plug (3)
8. Parking Lamp 16. Capscrew (2)
9. Signal Lamp 17. Star Washer (2)
c. Installation
(1) If removed, thread three wires (12, 13 and 14) through hole (18) and
position light body (11) into place.
(2) Install two new star washers (17) and capscrews (16). Tighten securely.
(3) For left composite light, connect three plugs (15). Wire (12) goes to wire
(19), wire (13) goes to wire (20), wire (14) goes to wire (21).
16. Capscrew (2)

17. Star Washer (2)
18. Hole
19. Wire (No. 491)
20. Wire (No. 002)
21. Wire (No. 680)
22. Wire (No. 001)
7-119
TM 08780B-20
(4) For right composite light, connect three plugs (15). Wire (12) goes to wire
(19), wire (13) goes to wire (22), wire (14) goes to wire (21).
(5) If removed, coat interior of lamp socket with anti-corrosion conductive

compound and install parking lamp (8), signal lamp (9) or blackout marker lamp (10), as needed.
(6) Install new gasket (7) and light door (6).
(7) Tighten five screws (5) securely.
(8) Place headlight grille (4) in position and install four capscrews (3),
washers (2) and new locknuts (1). Tighten securely.
END OF TASK
NOTE
TM 08780B-20 If partially removed,
install brake treadle
valve (para 13-14).
TM 08780B-10 Check composite

lights for proper
operation (para 2-14).
16. Capscrew (2)

17. Star Washer (2)
18. Hole
19. Wire (No. 492)
21. Wire (No. 680)
22. Wire (No. 001)
Right Side
7-120
TM 08780B-20
7-35. MAP LIGHT REPLACEMENT

c. Installation

Condition Condition
disconnected
Locknut (MS51922-17) item 7
References To prevent personal injury, make sure
TM 08780B-10 batteries are disconnected before working on
a. Removal
(1) Turn lens (1) counterclockwise one quarter turn and remove.
(2) Remove bulb (2).
NOTE
If bulb (2) is all that is being replaced, go to INSTALLATION section, step (5).
(3) Remove two screws (3) and nuts (4).
(4) Remove base (5) and gasket (6).
(5) Remove locknut (7), capscrew (8) and bracket (9). Discard locknut (7).
(6) Remove screw (10) from toggle switch (11) and remove wire (12).
c. Installation
(1) Install wire (12) onto toggle switch (11) using screw (10).
7-121
TM 08780B-20
(2) Install bracket (9) using capscrew (8) and new locknut (7). Tighten
locknut (7) securely.
(3) Install gasket (6) and base (5).
(4) Install two screws (3) and nuts (4). Tighten securely.
(5) Install bulb (2) and lens (1).
END OF TASK
NOTE
(para 7-45).
Install access panel (para 18-15).
TM 08780B-10 Check map light

7-122
TM 08780B-20
1. Lens
2. Bulb
3. Screw (2)
4. Nut (2)
5. Base
6. Gasket
7. Locknut
8. Capscrew
9. Bracket
10. Screw
11. Switch
12. Wire (No 413)
7-123
TM 08780B-20
7-36. REAR COMPOSITE LIGHT REPLACEMENT

c. Installation

Gasket (NSN 5330-00-462-0907) item 3
Applicable Configurations Lockwasher (2) (351AX) item 14
MK14 Compound, corrosion preventive (item 11.1,
MK15 Appendix D)
MK16 Compound, anti-corrosion conductive (item
MK17 11.2, Appendix D)
a. Removal
NOTE
If entire assembly will be replaced, go to step (3).
(1) Loosen six screws (1) and remove light door (2) and gasket (3). Discard
gasket (3).
(2) If tail light lamp (4), stop light lamp (5); blackout stop lamp (6) or
blackout marker lamp (7) must be replaced, push in and turn counterclockwise to remove.
NOTE
If any or all of lamps (4, 5, 6 and 7) are all being replaced, go to the INSTALLATION section
and perform steps (1), (2) and (3) only.
(3) Tag and disconnect four wires (8, 9, 10 and 11) at plugs (12).
(4) Remove two capscrews (13) and lockwashers (14). Discard lockwashers
(14).
NOTE
(5) Remove two capscrews (13), lockwashers (14), washer (14.1) and terminal
(14.2). Discard lockwashers(14).
(6) Remove light body (15).
7-124
TM 08780B-20
c. Installation
NOTE
If entire assembly, is to be installed, go to step (4).
(1) If removed, coat interior of lamp socket with anti-corrosion conductive

compound and install tail light lamp (4), stop light lamp (5), blackout stop lamp (6) and blackout
marker lamp (7) by pushing lamp into lamp socket and turning clockwise.
(2) Install new gasket (3) and light door (2) onto light body (15).
(3) Tighten six screws (1).
(4) Position light body (15) and install two new lockwashers (14) and
capscrews (13).
NOTE
(5) Position light body (15) and install terminal (14.2), washer (14.1), two
new lockwashers (14) and capscrews (13).
(6) Apply corrosion preventive compound to ground connection at washer

(14.1).
(7) Connect four wires (8, 9, 10 and 11) at plugs (12).
END OF TASK
NOTE
TM 08780B-10 Check composite
lights for proper operation
(para 2-14).
7-125
TM 08780B-20
1. Screw (6)
2. Light Door
3. Gasket
4. Tail Light Lamp
5. Stop Light Lamp
6. Blackout Stop Lamp
7. Blackout Marker Lamp
8. Wire (No. 8/21)
9. Wire (No. 3/22 or 4/22)
10. Wire (No. 678/23)
11. Wire (No. 680/24)
12. Plug (4)
13. Capscrew (2)
14. Lockwasher (2)
14.1 Washer*
14.2 Terminal (No. 1435)*
15. Light Body
7-126
TM 08780B-20
7-37. WORKLIGHT REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

MK48
a. Removal
(1) Unscrew and remove plug (1).
(2) Remove retaining pin (2) and worklight (3) from bracket (4).
b. Disassembly
(1) Carefully insert a flat-tipped tool between sealed beam (5) and rubber
housing (6).
(2) Pry gently and remove sealed beam (5).
(3) Remove two screws (7) and star washers (8). Discard star washers (8).
(4) Remove two wires (9).
(2) Inspect parts for damage.
d. Assembly
(1) Install two wires (9) using two new star washers (8) and screws (7).
Tighten securely.
(2) Install sealed beam (5) into rubber housing (6).
7-127
TM 08780B-20
e. Installation
(1) Position worklight (3) in bracket (4) and install retaining pin (2).
(2) Install plug (1) and tighten securely.
END OF TASK
NOTE
TM 08780B-10 Check worklight for
1. Plug
2. Retaining Pin
3. Work Light
4. Bracket
5. Sealed Beam
6. Rubber Housing
7. Screw (2)
8. Star Washer (2)
9. Wire (2) (No. 040)
7-128
TM 08780B-20
7-38. BEACON LIGHT REPLACEMENT

c. Installation

Condition Condition
disconnected
Star washer (5) (MS35333-60) items 13, 17 and 19
Gasket (D-80056) item 20 General Safety Instructions
To prevent personal- injury, make sure
a. Removal
(1) Remove screw (1), clamp (2) and lens (3).
(2) Remove strobe light tube (4).
NOTE
If strobe light tube (4) is the only item being replaced, go to INSTALLATION, steps (8) and
(9).
(3) Remove clip (5) and three screws (6).
(4) Lift power supply (7) and disconnect plug (8).
(5) Remove power supply (7).
NOTE
If power supply (7) is all that is being replaced, go to INSTALLATION, steps (6) thru (9).
(6) Remove insulator (9).
(7) Cut wire (10) about three inches above clip (11).
(8) Remove three nuts (12), star washers (13) and screws (14). Discard star
washers (13).
(9) Lift base (15) and remove nut (16), star washer (17), screw (18) and star
washer (19). Discard star washers (17 and 19).
7-129
TM 08780B-20
(10) Remove base (15) and gasket (20). Discard gasket (20).
c. Installation
(1) Install new gasket (20) onto mounting plate (21).
(2) Thread wire (10) through hole in mounting plate (21) and install wire (22),
new star washer (19), screw (18), screw (18), new star washer (17) and nut (16). Tighten
securely.
(3) Install base (15) onto gasket (20).
(4) Install three new star washers (13), screws (14) and nuts (12). Tighten
securely.
(5) Splice the two ends of wire (10) together where cut during disassembly.
(6) Reconnect plug (8).
(7) Make sure insulator (9) is between transistor (23) and base (15). Then
install power supply (7) onto base (15).
(8) Install clip (5) and three screws (6). Tighten screws (6) securely.
(9) Install strobe light tube (4).
(10) Install lens (3), clamp (2) and screw (1). Tighten securely.
END OF TASK
7-130
TM 08780B-20
NOTE
(para 7-45).
TM 08780B-10 Check beacon light

1. Screw
2. Clamp
3. Lens
4. Strobe Light Tube
5. Clip
6. Screw (3)
7. Power Supply
8. Plug
9. Insulator
10. Wire (No. 029)
11. Clip
12. Nut (3)
13. Star Washer (3)
14. Screw (3)
15. Base
16. Nut
17. Star Washer
18. Screw
19. Star Washer
20. Gasket
21. Mounting Plate
22. Wire (Ground)
23. Transistor
7-131
TM 08780B-20
7-39. SENDING UNIT REPLACEMENT
THIS TASK COVERS: a. Temperature Sending Unit Removal

b. Oil Pressure Sending Unit Removal
d. Oil Pressure Sending Unit Installation
e. Temperature Sending Unit Installation

Condition Condition
MK48 TM 08780B-20 Access panels
Materials/Parts removed as needed

Pipe sealant (item 48, Appendix D) (para 18-15).
Coolant drained to a
level below coolant
sending units, if
needed (para 6-3).

Use extreme care to avoid being
burned when working on any part of the
cooling system. Wear gloves to protect
hands if you must work on a hot system.

a. Temperature Sending Unit Removal
(1) To remove temperature sending unit (1), remove nut (2), lockwasher (3)
and wire(4). Discard lockwasher (3).
(2) Unscrew and remove temperature sending unit (1).
b. Oil Pressure Sending Unit Removal
(1) To remove oil pressure sending unit (5), remove nut (6), lockwasher (7)
and wire (8). Discard lockwasher (7).
(2) Unscrew and remove sending unit (5).
7-132
TM 08780B-20
d. Oil Pressure Sending Unit Installation
(1) Apply pipe sealant to threads of oil pressure sending unit (5) and install.
Tighten securely.
(2) Install wire (8), new lockwasher (7) and nut (6). Tighten nut (6) securely.
e. Temperature Sending Unit Installation
(1) Apply pipe sealant to threads of temperature sending unit (1) and install.
Tighten securely.
(2) Install wire (4), new lockwasher (3) and nut (2). Tighten securely.
END OF TASK
NOTE
TM 08780B-20 Refill engine coolant,
as needed (para 6-3).
Install access panels as

needed (para 18-15).
7-133
TM 08780B-20
1. Temperature Sending Unit

2. Nut
3. Lockwasher
4. Wire (No. 320)
5. Oil Pressure
Sending Unit
6. Nut
7. Lockwasher
8. Wire (No. 113)
7-134
TM 08780B-20
7-40. FUEL LEVEL SENDING UNIT REPLACEMENT

c. Installation

Condition Condition
disconnected
Gasket (NSN 5330-01-163-7432) item 12 General Safety Instructions
Do not smoke or use open flame.
Fuel is flammable and may explode. Keep
fire extinguisher within reach.

a. Removal
(1) Remove nut (1) and lockwasher (2) from positive terminal (3) on top of
fuel level sending unit (4). Discard lockwasher (2).
(2) Tag and remove wire (5) from positive terminal (3) on fuel level sending
unit (4).
(3) Remove screw (6) and washer (7).
(4) Tag and remove ground wire (8).
(5) Remove remaining four screws (9).
(6) Pull fuel level sending unit (4) up and work float (10) out through opening
in fuel tank (11).
7-135
TM 08780B-20
c. Installation
(1) Slide new gasket (12) over float (10) and onto fuel level sending unit (4).
CAUTION
TO PREVENT EQUIPMENT DAMAGE, FUEL LEVEL SENDING UNIT (4) MUST BE

HELD IN POSITION WITH FLOAT (10) POINTING TOWARDS THE FRONT OF THE
VEHICLE.
(2) Carefully insert float (10) through opening in fuel tank (11) so float (10)
points toward the front of vehicle.
(3) Align holes in gasket (12), fuel tank (11) and fuel level sending unit (4).
(4) Install four screws (9).
(5) Install ground wire (8), screw (6) and washer (7) in tagged location.
(6) Tighten five screws (6 and 9) securely.
(7) Install wire (5) on positive terminal (3).
(8) Install new lockwasher (2) and nut (1). Tighten nut (1) securely.
END OF TASK
NOTE
(para 7-45).
TM 08780B-10 Check fuel gauge for

proper reading (para
2-13).
7-136
TM 08780B-20
1. Nut
2. Lockwasher
4. Fuel Level Sending Unit
5. Wire
6. Screw
7. Washer
8. Ground Wire
9. Screws (4)
10. Float
11. Fuel Tank
12. Gasket
Right Fuel Tank
7-137
TM 08780B-20
7-41. BUZZER WARNING SYSTEM REPLACEMENT

c. Installation

Condition Condition
disconnected
Locknut (2) (MS51922-1) item 7 LVSA1 series
Locknut (1571860) item 18 vehicles only).
Locknut (2) (114356A) item 21
Instrument panel
partially removed for
access (para 7-11),
step (1).

a. Removal
NOTE
Perform steps (4 through 8) only when repairing an LVSA1 series vehicle.
(1) Tag and remove six wires (1, 2, 3, 4, 5 and 6).
(2) Remove two locknuts (7), washers (8) and screws (9). Discard locknuts
(7).
(3) Remove buzzer (10).
(4) Tag and remove two wires (11 and 12).
(5) Remove knurled nut (13) and buzzer (14).
(6) Tag and remove three wires (15, 16 and 17).
(7) Remove locknut (18), screw (19) and rectifier (20). Discard locknut (18).
7-138
TM 08780B-20
(8) Remove two locknuts (21), screws (22), washers (23) and bracket (24).
c. Installation
NOTE
Perform steps (4 through 11) only when repairing an LVSA1 series vehicle.
(1) Install buzzer (10).
(2) Install two screws (9), washers (8) and new locknuts (7). Tighten
securely.
(3) Install six wires (6, 5, 4, 3, 2 and 1).
(4) Install bracket (24).
(5) Install two screws (22), washers (23) and two new locknuts (21). Tighten
securely.
(6) Install rectifier (20) onto bracket (24).
(7) Install screw (19) and new locknut (18). Tighten securely.
(8) Install three wires (15, 16 and 17).
(9) Install buzzer (14) onto bracket (24).
(10) Install knurled nut (13) onto buzzer(14).
(11) Install two wires (11 and 12).
END OF TASK
7-139
TM 08780B-20
NOTE
panel (para 7-11), step (5).
Connect batteries
(para 7-45 or 7-46 LVSA1
TM 08780B-10 Check buzzer for

proper operation (para 2-13).
1. Wire (No. 079) 10. Buzzer 19. Screw*

2. Wire (No. 076) 11. Wire (No. 033) * 20. Rectifier*
3. Wire (No. 120) 12. Wire (No. 076/079)* 21. Locknut (2)*
4. Wire (No. 120) 13. Nut* 22. Screw (2)*
5. Wire (No. 032) 14. Buzzer* 23. Washer (2)*
6. Wire (No. 032) 15. Wire (No. 120/120)* 24. Bracket*
7. Locknut (2) 16. Wire (No. 032/032)*
8. Washer (2) 17. Wire (No. 033)*
9. Screw (2) 18. Locknut*
7-140
TM 08780B-20
7-42. ALARM REPLACEMENT

c. Installation

Condition Condition
disconnected
(para 7-45).
Instrument panel
partially removed for
access (para 7-11),
step (1).

a. Removal
NOTE
(1) Remove two screws (1) and wires (2 and 3).
(2) Unscrew knurled nut (4) and remove alarm (5).
(1) Clean all parts. Refer to paragraph 2-11 in this manual.
(2) Inspect parts for damage. Repair or replace as needed.
c. Installation
(1) Install alarm (5) and knurled nut (4). Tighten securely.
(2) Install wire (3) and one screw (1) to negative terminal (6).
7-141
TM 08780B-20
(3) Install wire (2) and one screw (1) to positive terminal (7). Tighten screws
(1) securely.
END Of TASK
NOTE
panel (para 7-11),
step (5).
TM 08780B-10 Check alarm for

1. Screw (2)
2. Wire (No. 525)
3. Wire (No. 033)
4. Knurled Nut
5. Alarm
6. Negative Terminal
7-142
TM 08780B-20
7-43. LOW AIR PRESSURE SWITCH REPLACEMENT

c. Installation

Condition Condition
(para 3-5).
Materials/Parts
Pipe sealant (item 48, Appendix D) General Safety Instructions
To prevent personal injury, drain all
pressure from the air system.
a. Removal
(1) To determine which switch is bad, refer to paragraph 2-7 in this manual
(troubleshooting).
NOTE
Replacement procedure is the same for both switches.
(2) Tag and remove wire (1) from switch (2).
(3) Remove switch (2) from brake treadle valve (3).
c. Installation
(1) Coat threads (4) of switch (2) with pipe sealant.
(2) Install switch (2) on brake treadle valve (3)and tighten securely.
(3) Install wire (1) on switch (2).
END OF TASK
7-143
TM 08780B-20
NOTE
TM 08780B-10 Start engine, build
air pressure and
1. Wire (No. 005 or No. 009)

2. Switch (2)
3. Brake Treadle Valve
4. Threads
7-144
TM 08780B-20
7-44. FUEL RESTRICTION SENSOR REPLACEMENT

c. Installation

Do not smoke or use open flame.
Applicable Configurations Fuel is flammable and may explode. Keep
Materials/Parts
a. Removal
(2) Disconnect fuel line (2).
(3) Remove fuel restriction sensor (3).
(4) Remove elbow (4) and nipple (5) from fuel restriction sensor (3).
(1) Clean all parts. Refer to paragraph 2-11 in this manual.
c. Installation
(1) Coat threads with sealant and install nipple (5) in LO side of fuel
restriction sensor (3) and elbow (4) in HI side.
(2) Coat threads of nipple (5) with sealant and install fuel restriction sensor
(3).
(3) Install fuel line (2) onto elbow (4).
7-145
TM 08780B-20
1. Plug
2. Fuel Line
3. Fuel Restriction Sensor
4. Elbow
5. Nipple
END OF TASK
7-146
TM 08780B-20
7-45. BATTERY AND BATTERY BOX REPLACEMENT

c. Assembly
d. Installation

When servicing battery cables, do
Applicable Configurations not wear watches, rings or other jewelry.
MK48 They could short out battery terminals. Do
not smoke or use open flame around
Materials/Parts batteries. Batteries may explode
Corrosion preventive compound (item 11, from a spark.
Appendix D)
Locknut (14) (MS51922-7) items 2, 5, 8, 17,
24, 28 and 33
a. Removal
WARNING
• WHEN SERVICING BATTERIES OR CABLES, DO NOT WEAR WATCHES,

RINGS OR OTHER JEWELRY. THEY COULD SHORT OUT BATTERY
TERMINALS. DO NOT SMOKE OR USE OPEN FLAME AROUND BATTERIES.
BATTERIES MAY EXPLODE FROM A SPARK.
• WHENEVER DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT

GROUND TERMINAL FIRST. WHEN RECONNECTING, ALWAYS CONNECT
GROUND CABLES LAST.
• TO PREVENT ARCING AND PERSONAL INJURY, DO NOT ALLOW TOOLS TO

CONTACT BATTERY BOX OR OTHER BATTERY TERMINALS WHEN
REMOVING OR INSTALLING CABLES.
(1) Remove battery box cover (1).
(2) Remove locknut (2) from negative battery stud (3). Remove negative
battery cable (4). Discard locknut (2).
(3) Remove locknut (5) from positive battery stud (6). Remove positive
battery cable (7 ). Discard locknut (5 ).
7-147
TM 08780B-20
(4) Remove locknut (8) from negative battery stud (9). Remove cable (10)
from negative battery studs (3 and 9). Remove two wires (11 and 12) from negative battery stud
(3). Discard locknut (8).
(5) Remove capscrew (13) and lockwasher (14) from slave connector (15).
Remove cable (16) from negative battery stud (9). Discard lockwasher (14).
(6) Remove locknut (17) from positive battery stud (18). Remove cable (19)
from positive battery studs (6 and 18). Remove wire (20) from positive battery stud (6). Discard
locknut (17).
(7) Remove capscrew (21) and lockwasher (22) from slave connector (15).
Remove cable (23) from positive battery stud (18). Discard lockwasher (22).
(8) Remove two locknuts (24) from negative battery stud (25) and positive
battery stud (26). Remove cable (27). Discard locknuts (24).
(9) Remove two locknuts (28) from negative battery stud (29) and positive
battery stud (30). Remove cable (31) from negative battery studs (25 and 29). Remove cable
(32) from positive battery studs (26 and 30). Discard locknuts (28).
7-148
TM 08780B-20
1. Battery Box Cover

2. Locknut
3. Negative Battery Stud
4. Negative Battery Cable
5. Locknut
6. Positive Battery Stud
7. Positive Battery Cable
8. Locknut
10. Cable
11. Wire (821/813)
12. Wire (Ground)
13. Capscrew
14. Lockwasher
15. Slave Connector
16. Cable
17. Locknut
19. Cable
20. Wire (814/822)
21. Capscrew
22. Lockwasher
23. Cable
24. Locknut (2)
27. Cable
28. Locknut (2)
31. Cable
32. Cable
7-149
TM 08780B-20
(10) Remove four locknuts (33) from battery hold down capscrews (34).
Remove battery hold-down frame (35). Discard locknuts (33).
(11) Remove four batteries (36).
(12) Slide four battery hold down capscrews (34) out of brackets (37).
(13) Remove six nuts (38), lockwashers (39) and capscrews (40). Remove two
brackets (37) from battery box (41). Remove battery box (41) from vehicle. Discard
lockwashers (39).
(2) Clean all corrosion from batteries and cables.
(3) Inspect cables for cracks and missing or damaged insulation.
(4) If damaged, remove protective covering (42) from cable (23).
33. Locknut (4)

34. Battery Hold Down
Capscrew (4)
35. Hold Down Frame
36. Battery (4)
37. Bracket (2)
38. Nut (6)
39. Lockwasher (6)
40. Capscrew (6)
41. Battery Box
7-150
TM 08780B-20
c. Assembly
(1) If cable is to be replaced, measure old cable, including the part that is
inside the terminal (43).
(2) Cut new cable (44) to the same length as old cable.
(3) Remove one inch (2.5 cm) of insulation (45) from both ends of new cable
(44).
(4) Install new terminal (43) on end of new cable (44) and crimp into place.
Repeat on opposite end of new cable (44).
(5) If replacing cable (23), replace protective covering (42).
23. Cable
42. Protective Covering
43. Terminal
44. New Cable
45. Insulation
7-151
TM 08780B-20
33. Locknut (4)

34. Battery Hold Down
Capscrew (4)
35. Hold Down Frame
36. Battery (4)
37. Bracket (2)
38. Nut (6)
39. Lockwasher (6)
40. Capscrew (6)
41. Battery Box
d. Installation
(1) Position battery box (41) on vehicle. Install two brackets (37) inside
battery box (41). Install six capscrews (40), new lockwashers (39) and nuts (38). Tighten nuts
(38) securely.
(2) Slide four battery hold-down capscrews (34) into brackets (37).
(3) Install four batteries (36). Position positive battery studs (6, 18, 26 and
30) facing toward front of vehicle.
(4) Install hold-down frame (35) onto batteries (36). Install four battery hold
down capscrews (34) into hold-down frame (35).
(5) Install four new locknuts (33) onto battery hold down capscrews (34).
Tighten locknuts (33) securely.
(6) Install cable (31) onto negative battery studs (25 and 29). Install cable
(32) onto positive battery studs (26 and 30).
(7) Install cable (27) onto both positive battery stud (26) and negative battery
stud (25).
(8) Install two new locknuts (24) onto positive battery stud (26) and negative
battery stud (25). Torque locknuts (28) to 15 foot-pounds (20.34 N*m).
7-152
TM 08780B-20
(9) Install one new locknut (28) onto each battery stud (30 and 29). Torque
locknuts (28) to 15 foot-pounds (20.34 N*m).
(10) Install cable (23) onto slave connector (15) using capscrew (21) and new
lockwasher (22). Install cable (23) onto positive battery stud (18).
(11) Install wire (20) onto positive battery stud (6). Install cable (19) onto
positive battery studs (6 and 18).
(12) Install positive battery cable (7) onto positive battery stud (6). Install two
new locknuts (5 and 17) onto positive battery studs (6 and 18). Torque locknuts (5 and 17) to 15
foot-pounds (20.34 N*m).
(13) Install cable (16) onto slave connector (15) using capscrew (13) and new
lockwasher (14). Install cable (16) onto negative battery stud (9).
(14) Install wires (11 and 12) on negative battery stud (3). Install cable (10)
onto negative battery studs (3 and 9).
(15) Connect negative battery cable onto negative battery stud (3). Install two
new locknuts (2 and 8) and torque locknuts (2 and 8) to 15 foot-pounds (20.34 N*m).
(15) Connect negative battery cable (4) onto negative battery stud (3). Install
two new locknuts (2 and 8) and torque locknuts (2 and 8) to 15 foot-pounds (20.34 N*m).
(16) Coat battery terminals with corrosion (4) preventive compound.
(17) Install battery box cover (1).
END OF TASK
7-153
TM 08780B-20
1. Battery Box Cover

2. Locknut
5. Locknut
8. Locknut
10. Cable
11. Wire (No. 821/813)
12. Wire (Ground)
13. Capscrew
14. Lockwasher
15. Slave Connector
16. Cable
17. Locknut
19. Cable
20. Wire (No. 814/822)
21. Capscrew
22. Lockwasher
23. Cable
24. Locknut (2)
27. Cable
28. Locknut (2)
31. Cable
32. Cable
7-154
TM 08780B-20
7-46. BATTERY AND BATTERY BOX REPLACEMENT (LVSA1 SERIES VEHICLES

ONLY)

c. Installation

When servicing battery cables, do not
Applicable Configurations wear watches, rings or jewelry. They could
MK48A1 short out battery terminals. Do not smoke
or use open flame around batteries.
Materials/Parts Batteries may explode from a spark.
Corrosion preventive compound (item 11,
Appendix D)
Lockwasher (8) (P/N 351AX) items 22, 31, 37, 45,
53, 61, 67 and 76
Locknut (6) (1600460) items 84 and 87
a. Removal
WARNING
• WHEN SERVICING BATTERIES OR CABLES, DO NOT WEAR WATCHES,

RINGS OR OTHER JEWELRY. THEY COULD SHORT OUT BATTERY
TERMINALS. DO NOT SMOKE OR USE OPEN FLAME AROUND BATTERIES.
BATTERIES MAY EXPLODE FROM A SPARK.
• WHENEVER DISCONNECTING BATTERY CABLES, ALWAYS DISCONNECT

GROUND TERMINAL FIRST. WHEN RECONNECTING, ALWAYS CONNECT
GROUND CABLES LAST.
• TO PREVENT ARCING AND PERSONAL INJURY, DO NOT ALLOW TOOLS TO

CONTACT BATTERY BOX OR OTHER BATTERY TERMINALS WHEN
REMOVING OR INSTALLING CABLES.
(1) Remove battery box cover (1).
7-155
TM 08780B-20
NOTE
Tag and mark all cables, wires and terminals prior to removal.
(2) Loosen nut (2) and remove terminal (3) from battery post (4).
(3) Loosen nut (5) and remove terminal (6) from battery post (7).
(4) Remove four nuts (8), lockwashers (9), eight washers (10), two brackets
(11) and four hold-down hooks (12).
(5) Loosen nut (13) and remove terminal (14) from battery post 15.
(6) Repeat step (5) for terminals (16, 17, 18, 19 and 20).
7-156
TM 08780B-20
2. Nut 12. Hold-Down

3. Terminal Hook (4)
4. Battery Post 13. Nut
5. Nut 14. Terminal
6. Terminal 15. Battery Post
7. Battery Post 16. Terminal
8. Nut (4) 17. Terminal
9. Lockwasher (4) 18. Terminal
10. Washer (8) 19. Terminal
11. Bracket (2) 20. Terminal
7-157
TM 08780B-20
(7) Remove nut (21), lockwasher (22), washer (23), two cables (24 and 25),
wire (26), washer (27) and capscrew(28) from terminal (6). Discard lockwasher (22).
(8) Remove nut (5) and capscrew (29) from terminal (6).
(9) Remove nut (30), lockwasher (31), washer (32), cable (24), washer (33)
and capscrew (34) from terminal (3). Discard lockwasher (31).
washer (48) and capscrew (49) from terminal (18). Discard lockwasher (45).
(21) Remove nut (75), lockwasher (76), washer (77), wire (78), cable (70),
7-158
TM 08780B-20
2. Nut 30. Nut 50. Nut 70. Cable (137)

3. Terminal 31. Lockwasher 51. Capscrew 71. Washer
5. Nut 32. Washer 52. Nut 72. Capscrew
6. Terminal 33. Washer 53. Lockwasher 73. Nut
13. Nut 34. Capscrew 54. Washer 74. Capscrew
14. Terminal 35. Capscrew 55. Cable (137) 75. Nut
16. Terminal 36. Nut 56. Washer 76. Lockwasher
17. Terminal 37. Lockwasher 57. Capscrew 77. Washer
18. Terminal 38. Washer 58. Nut 78. Wire (822/814)
19. Terminal 39. Cable (137) 59. Capscrew 79. Washer
20. Terminal 40. Washer 60. Nut 80. Capscrew
21. Nut 41. Capscrew 61. Lockwasher 81. Nut
22. Lockwasher 42. Nut 62. Washer 82. Capscrew
23. Washer 43. Capscrew 63. Washer
24. Cable (137) 44. Nut 64. Capscrew
25. Cable (138) 45. Lockwasher 65. Capscrew
26. Wire (821/813) 46. Washer 66. Nut
27. Washer 47. Cable (137) 67. Lockwasher
28. Capscrew 48. Washer 68. Washer
29. Capscrew 49. Capscrew 69. Cable (139)
7-159
TM 08780B-20
(23) Remove four batteries (83).
(24) Remove four locknuts (84), washers (85) and capscrews (86). Discard
locknuts (84).
(25) Remove two locknuts (87), four washers (88) and two capscrews (89).
Remove battery box (90) from vehicle. Discard locknuts (87).
83. Battery (4) 87. Locknut (2)

84. Locknut (4) 88. Washer (4)
85. Washer (4) 89. Capscrew (2)
86. Capscrew (4) 90. Battery Box
(2) Clean all corrosion from batteries and cables.
c. Installation
(1) Position battery box (90) on vehicle and install two capscrews (89), four
washers (88) and two new locknuts (87). Tighten locknuts (87) securely.
(2) Install four capscrews (86), four washers (85) and four new locknuts (84).
(3) Position four batteries (83) in battery box (90) with positive battery posts
(+) facing toward front of vehicle.
7-160
TM 08780B-20
(4) Loosely install capscrew (82) and nut (81) on terminal (17).
(5) Install capscrew (80), washer (79), cable (70), wire (78), washer (77), new
lockwasher (76) and nut (75) on terminal (17). Torque nut to 12-16 foot-pounds (16-22 N*m).
(7) Install capscrew (72), washer (71), two cables (70 and 69) washer (68),
new lockwasher (67) and nut (66) on terminal (20). Torque nut to 12-16 foot-pounds (16-22
N*m).
(9) Install capscrew (64), washer (63), cable (55), washer (62), new
(11) Install capscrew (57) washer (56), two cables (47 and 55), washer (54),
new lockwasher (53) and nut (52) on terminal (19). Torque nut to 12-16 foot-pounds (16-22
N*m).
(13) Install capscrew (49) washer (48), two cables (39 and 47), washer (46),
new cable lockwasher (45) and nut (44) on terminal (18). Torque nut to 12-16 foot-pounds
(16-22 N*m).
lockwasher (37) and nut (36), on terminal (16). Torque nut to 12-16 foot-pounds (16-22 N*m).
7-161
TM 08780B-20
13. Nut 43. Capscrew 57. Capscrew 71. Washer

14. Terminal 44. Nut 58. Nut 72. Capscrew
16. Terminal 45. Lockwasher 59. Capscrew 73. Nut
17. Terminal 46. Washer 60. Nut 74. Capscrew
18. Terminal 47. Cable (137) 61. Lockwasher 75. Nut
19. Terminal 48. Washer 62. Washer 76. Lockwasher
20. Terminal 49. Capscrew 63. Washer 77. Washer
36. Nut 50. Nut 64. Capscrew 78. Wire (822/814)
37. Lockwasher 51. Capscrew 65. Capscrew 79. Washer
38. Washer 52. Nut 66. Nut 80. Capscrew
39. Cable (137) 53. Lockwasher 67. Lockwasher 81. Nut
40. Washer 54. Washer 68. Washer 82. Capscrew
41. Capscrew 55. Cable (137) 69. Cable (139)
42. Nut 56. Washer 70. Cable (137)
7-162
TM 08780B-20
(16) Loosely install capscrew (35) and nut(2) on terminal (3).
(19) Install capscrew (28), washer (27), wire (26), two cables (24 and 25),
washer (23), new lockwasher (22) and nut (21) on terminal (6). Torque nut to 12-16 foot-pounds
(16-22 N*m).
2. Nut 27. Washer

3. Terminal 28. Capscrew
5. Nut 29. Capscrew
6. Terminal 30. Nut
22. Lockwasher 31. Lockwasher
23. Washer 32. Washer
24. Cable (137) 33. Washer
25. Cable (138) 34. Capscrew
26. Wire (821/813) 35. Capscrew
7-163
TM 08780B-20
(20) Install terminal (14) on battery post (15) and tighten nut (13) to 84 - 96
in-lb (9.5- 10.8 N*m).
(21) Repeat step (20) for terminals (16, 17, 18, 19 and 20).
(22) Install four hold-down hooks (12).
(23) Install batteries in battery box (90). Secure batteries as follows:
(a) Loosen four hold-down hook nuts (91) one-half turn.
CAUTION
DO NOT TIGHTEN NUTS (8) GREATER THAN 20 - 25 IN-LB (2.3 - 2.8 N*M). FAILURE
TO COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT.
(b) Install two brackets (11) onto hold-down hooks (12) using eight
washers (10), four new lockwashers (9) and four nuts (8). Torque nuts (8) to 20 - 25 in-lb (2.3 -
2.8 N*m).
(c) Tighten four hold-down hook nuts (91) securely.
(24) Install terminal (6) on battery post (7) and tighten nut (5) to 84 - 96 in-lb
(9.5 - 10.8 N*m).
(25) Install terminal (3) on battery post (4) and tighten nut (2) to 84 - 96 in-lb
(9.5 - 10.8 N*m).
(26) Coat battery terminals with corrosion preventive compound.
(27) Install battery box cover (1).
END OF TASK
7-164
TM 08780B-20
1. Battery Box Cover 12. Hold-Down Hook (4)

2. Nut 13. Nut
3. Terminal 14. Terminal
4. Battery Post 15. Battery Post
5. Nut 16. Terminal
6. Terminal 17. Terminal
7. Battery 18. Terminal
8. Nut (4) 19. Terminal
9. Lockwasher (4) 20. Terminal
10. Washer (8) 90. Battery Box
11. Bracket (2) 91. Hold-Down Hook Nut (4)
7-165
TM 08780B-20
7-47. SLAVE CONNECTOR REPLACEMENT

c. Installation

Condition Condition
disconnected
Corrosion preventive compound (item 11, for LVSA1 series
Appendix D) vehicles only).
Cable Tie (5201 HX) item 0.1
Locknut (4) (MS51858-5) item 6 To prevent personal injury, make sure
Gasket (NSN 5330-01-059-4286) item 10 batteries are disconnected before working on
a. Removal
NOTE
(1) Remove cable tie (0.1) from bellows (0.2). Discard cable tie (0.1).
NOTE
Tag both battery cables to insure proper installation.
(2) Remove two capscrews (1), lockwashers (2), negative battery cable (3)
and positive battery cable (4). Discard lockwashers (2).
(3) Remove bellows (0.2).
(4) Remove four capscrews (5) and locknuts (6). Discard locknuts (6).
(5) Remove insulator (7), cover (8), slave connector (9) and gasket (10).
Discard gasket (10).
7-166
TM 08780B-20
c. Installation
(1) Install cover (8) and new gasket (10) onto connector (9).
(2) Install slave connector (9) into battery box (11).
NOTE
Perform step (3) and (4) on LVSA1 series vehicles only.
(3) Install slave connector (9) into slave bracket (11.1).
(4) Slide bellows (0.2) over battery cables (4 and 3).
(5) Install positive battery cable (4) onto slave connector (9) with capscrew
(1) and new lockwasher (2). Tighten securely.
(6) Install four capscrews (5), making sure one of them goes through eyelet
(12) in cover (8).
(7) Install insulator (7) and four new locknuts (6). Tighten locknuts (6)
securely.
(8) Install negative battery cable (3), lockwasher (2) and capscrew (1).
Tighten securely.
(9) Coat negative battery cable (3) and positive battery cable (4) ends and
slave connector (9) with corrosion preventive compound.
NOTE
• Perform steps (10) and (11) on LVSA1 series vehicles only.
• Ensure that bellows (0.2) fits securely to the back of the slave connector (9).
(10) Secure bellows (0.2) using cable tie (0.1).
(11) Cut 0.25 inch (6.35 mm) diameter drainage hole in bottom of bellows
(0.2).
END OF TASK
7-167
TM 08780B-20
NOTE

(para 7-45 or 7-46
on LVSA1 series vehicles only).
0.1. Cable Tie*

0.2. Bellows*
1. Capscrew (2)
2. Lockwasher (2)
5. Capscrew (4)
6. Locknut (4)
7. Insulator
8. Cover
9. Slave Connector
10. Gasket
11. Battery Box
11.1. Slave Bracket*
12. Eyelet
7-168
TM 08780B-20
7-48. WIRING HARNESS MAINTENANCE
THIS TASK COVERS: a. Solderless Terminal Replacement

b. Wire Splicing Using Butt Connectors
c. Wire Splicing Using Solder Method
d. Male Cable Connector Replacement
e. Female Cable Connector Replacement
f. Deutsch Connector (Plug or Receptacle) Repair or Replacement
g. Cannon Connector (Plug or Receptacle) Repair or Replacement
h. Type II Connector Repair or Replacement(LVSA1 Series
Vehicles Only)
i. Hirschman Connector Repair or Replacement (LVSA1 Series
Vehicles Only)

Solder (item 52, Appendix D)
Special Tools Heat Shrink tubing (NSN 5970-01-161-8031)
Deutsch crimping tool (HDT-48-00) Adhesive-sealant, silicone (item 5, Appendix D)
Extraction tool (NSN 5120-04-158-4707) Adhesive (item 2.1, Appendix D)
Weather pack crimper (item 92, Alcohol (item 6, Appendix D)
Appendix G)
Terminal remover, weather pack (item 91,
Appendix G)
a. Solderless Terminal Replacement

CAUTION
TERMINALS COME IN DIFFERENT STYLES AND SIZES. TO PREVENT EQUIPMENT

DAMAGE, BE SURE TO USE ONLY THE EXACT REPLACEMENTS. DO NOT
ATTEMPT TO MODIFY TERMINAL TO FIT.
(1) Remove old terminal (1) and trim end of wire (2) as needed to make an
undamaged end.
NOTE
If trimming causes wire to become too short, refer to splicing sections (b and c) of this
paragraph.
(2) Remove insulation (3) from end of wire (2) equal to the length of
dimension A.
(3) Install new terminal (1) over bare end of wire (2). Make sure all strands of
wire (2) are inside of terminal (1).
(4) Crimp new terminal (1) firmly in place.
7-169
TM 08780B-20
1. Terminal
2. Wire
3. Insulation
b. Wire Splicing Using Butt Connectors
NOTE
• Wherever possible, use solder method of wire splicing. Refer to section c of this
paragraph.
• If repairing a broken wire, perform steps (1) thru (4) only. If section of wire is being
replaced, perform steps (5) thru (11).
(1) Remove damaged piece of wire (4).
CAUTION
TO PREVENT EQUIPMENT DAMAGE, ALWAYS USE PROPER GAUGE WIRE AND
PROPER SIZE BUTT CONNECTORS.
(2) Remove insulation (5) from both ends of wire (4) equal to the length of
dimension A.
(3) Install butt connector (6) over bare ends of wire (4) and crimp firmly at
both ends.
(4) Inspect splice and make sure no bare wire (4) is visible.
(5) If a section of wire (4) is being replaced, install two butt connectors (6),
one onto each bare end of wire (4).
(6) Crimp one end of both butt connectors (6) firmly in place over wire (4).
(7) Measure the distance between the two open ends of the two butt
connectors (6).
(8) Cut a section of new wire (7) one inch (2.54 cm) longer than the distance
measured in step (7).
7-170
TM 08780B-20
(9) Remove insulation (5) from both ends of new wire (7), equal to dimension
A.
(10) Install bare ends of new wire (7) into butt connectors (6) and crimp firmly
in place.
(11) Inspect splice and make sure no bare wire (4 or 7) is visible.
Repairing Broken Wire
4. Wire
5. Insulation
6. Butt Connector
Replacing Section Of Damaged Wire 7. New Wire
c. Wire Splicing Using Solder Method
NOTE
• This method makes a stronger and more permanent repair. Use this method whenever
possible.
• If repairing a broken wire, perform steps (1) thru (7) only. If a section of wire is being
replaced, perform steps (8) thru (13).
(1) If needed, remove broken wire (8).
(2) Remove .75 inch (1.9 cm) of insulation (9) from both ends of wire (8).
(3) Slide a three inch (7.62 cm) piece of proper size heat shrink tubing (10)
over one end of wire (8).
(4) Twist the two bare ends of wire (8) together and solder. Make sure solder
flows evenly onto both ends of wire (8).
7-171
TM 08780B-20
WARNING
TO PREVENT PERSONAL INJURY, ALLOW SOLDER JOINT TO COOL BEFORE

HANDLING.
(5) Slide heat shrink tubing (10) over solder joint.
(6) Make sure solder joint is centered in heat shrink tubing (10).
WARNING
TO PREVENT PERSONAL INJURY, NEVER USE AN OPEN FLAME TO APPLY HEAT

TO HEAT SHRINK TUBING.
CAUTION
DO NOT OVERHEAT THE HEAT SHRINK TUBING. IT WILL SPLIT OR MELT AND
HAVE TO BE REPLACED.
(7) Heat the heat shrink tubing (10) with a heat gun (11). Allow heat shrink
tubing (10) to shrink until tight on solder joint and insulation of wire (8).
WARNING
TO PREVENT PERSONAL INJURY, ALLOW HEAT SHRINK TUBING TO COOL

BEFORE HANDLING.
(8) If replacing a section of wire (8), measure distance between ends of wire
(8).
CAUTION
ALWAYS USE WIRE OF THE SAME GAUGE AS THE WIRE BEING REPAIRED. USE
OF WIRE OF A SMALLER GAUGE WILL CAUSE EQUIPMENT DAMAGE AND/OR
FAILURE.
(9) Cut a section of new wire (12) two inches (5.08 cm) longer than the
distance measured in step (8).
(10) Remove .75 inch (1.9 cm) of insulation (9) from both ends of new wire
(12).
(11) Slide two, three inch (7.62 cm) pieces of heat shrink tubing (10) over ends
of wire (8).
7-172
TM 08780B-20
(12) Twist the bare ends of wires (8) and new wire (12) together and solder.
Make sure solder flows evenly onto both wires (8) of each joint.
WARNING
TO PREVENT PERSONAL INJURY, ALLOW SOLDER JOINT TO COOL BEFORE

HANDLING.
(13) Repeat steps (5) thru (7) for both solder joints.
Repairing Broken Wire

8. Wire
9. Insulation
10. Heat Shrink Tubing
11. Heat Gun
12. New Wire
Replacing Section of Damaged Wire
7-173
TM 08780B-20
d. Male Cable Connector Replacement
(1) If needed, remove old contact (13).
(2) Trim end of wire (14) as needed to make an undamaged end.
NOTE
paragraph.
(3) Install outer shell (15) over end of wire (14).
(4) Remove .375 inch (1.0 cm) of insulation (16) from end of wire (14).
(5) Install contact (13) over bare end of wire (14).
(6) Crimp contact (13) firmly in place.
(7) Install C-washer (17) onto wire (14).
(8) Slide outer shell (15) over C-washer (17) and contact (13).
(9) Make sure no bare wire is visible outside of outer shell (15).
e. Female Cable Connector Replacement
(1) If needed, remove old contact (18).
(2) Trim end of wire (19) as needed to make an undamaged end.
NOTE
paragraph.
(3) Install outer shell (20) over end of wire (19).
(4) Remove .25 inch (6.4 mm) of insulation (21) from end of wire (19).
(5) Install sleeve (22) over end of wire (19).
(6) Install contact (18) over bare end of wire (19).
(7) Crimp contact (18) firmly in place.
(8) Slide outer shell (20) over sleeve (22) and contact (18).
7-174
TM 08780B-20
(9) Make sure no bare wire (19) shows outside of outer shell (20).
13. Contact
14. Wire
15. Outer Shell
16. Insulation
17. C-Washer
18. Contact
19. Wire
20. Outer Shell
21. Insulation
22. Sleeve
f. Deutsch Connector (Plug or Receptacle) Repair or Replacement
(1) Disconnect plug (23) from receptacle (24). If needed, remove receptacle
(24) from mounting surface.
NOTE
• Some plugs and receptacles may use adhesive to make them more water tight. If plug
or receptacle has adhesive on it and no heat gun is available, go to step (2). If plug or
receptacle has adhesive on it and a heat gun is available, go to step (3). If plug or
receptacle has no adhesive on it, go to step (4).
• Contact removal from plug or receptacle is the same.
(2) Using a sharp instrument, carefully remove all adhesive from back of plug
(23) or receptacle (24) and wire (27).
(3) Using heat gun (11) carefully heat adhesive on back of plug (23) or receptacle
(24) until adhesive can be removed.
7-175
TM 08780B-20
(4) To remove a contact (25) from plug (23), position rear of plug (23)
towards you.
(5) Snap correct size extractor tool (26) over wire (27) being removed.
(6) Slide extractor tool (26) along wire (27) into rear of plug (23) until it
engages contact (25) and resistance is felt.
(7) Remove contact (25), extractor tool (26) and wire (27) from plug (23), all
at the same time.
(8) If contact (25) is being replaced, cut it from end of wire (27).
(9) If plug (23) or receptacle (24) is being replaced, tag and remove all
contacts (25). Refer to steps (4) thru (7).
23. Plug
24. Receptacle
25. Contact
26. Extractor Tool
27. Wire
25. Contact
26. Extractor Tool
27. Wire
28. Insulation
29. Selector Knob
30. Crimping Tool
31. Locknut
32. Adjusting Screw
33. Cover
34. Handle (2)
35. Handle Stop
7-176
TM 08780B-20
(10) To install a new contact (25), remove .25 inch (6.4 mm) of insulation (28)
from end of wire (27).
(11) Raise selector knob (29) on crimping tool (30) and rotate until arrow is
aligned with wire gauge being crimped.
(12) Loosen locknut (31) and turn adjusting screw (32) in until it stops.
(13) Insert new contact (25) into crimping tool (30) and turn adjusting screw
(32) out until contact (25) is flush with cover (33).
(14) Tighten locknut (31) and insert bare end of wire (27) into contact (25).
(15) Make sure contact (25) is centered. Then close handles (34) until one
handle (34) touches handle stop (35).
(16) Release handles (34), remove and inspect crimped contact (25). Make
sure all strands of wire (27) are inside contact (25).
NOTE
Crimping tool must be readjusted for each type and/or size contact.
(17) To insert contact(s) (25) into plug (23), position plug (23) with rear toward
you.
(18) Insert contact(s) (25) into plug (23) and push until contact (25) stops.
(19) Pull on wire (27) to confirm that contact (25) is locked in place.
(20) Repeat steps (15) thru (17) as many times as needed until all contacts (25)
are installed.
(21) Install sealing plugs (36) into any unused holes in plug (23) and receptacle
(24).
NOTE
• If plug and receptacle had adhesive on it and a heat gun is not available, perform steps
(22) and (23), then continue with step (25).
• If plug and receptacle had adhesive on it and a heat gun is available, perform steps
(22) and (24), then continue with step (25).
• If plug and receptacle did not have adhesive on it, go to step (25).
(22) Clean back of plug (23), receptacle (24) and wires (27) with alcohol and
allow to dry.
7-177
TM 08780B-20
(23) Apply silicone sealant to seal back of plug (23), receptacle (24) and wires
(27). Cover all parts fully.
WARNING
TO PREVENT PERSONAL INJURY, ALLOW ADHESIVE TO COOL BEFORE

HANDLING.
(24) Using heat gun (11), apply adhesive to back of plug (23), receptacle (24)
and wires (27). Cover all parts fully.
(25) If receptacle (24) was repaired or replaced, install it on mounting surface.
(26) Connect plug (23) to receptacle (24).
23. Plug
24. Receptacle
25. Contact
26. Extractor Tool
27. Wire
36. Sealing Plug
g. Cannon Connector (Plug or Receptacle) Repair or Replacement
(1) To remove contacts (37), separate boot (38) from body (39) and slide out
of the way.
(2) Using insertion tool (40), push contact (37) and wire (41) to rear of body
(39).
(3) If body (39) is being replaced, tag and remove all contacts (37). Refer to
steps (1) and (2) above.
(4) If contact (37) is being replaced, cut it from wire (41).
(5) Remove 1/4 inch (6.3 mm) of insulation (42) from wire (41).
(6) Insert new contact (37) into crimping tool (43).
(7) Install bare end of wire (41) into contact (37) and crimp firmly into place.
7-178
TM 08780B-20
(8) Remove wire (41) and contact (37) from crimping tool (43).
(9) To install contact (37), first install boot (38) onto wire (41) if removed.
(10) Install insertion tool (40) onto wire (41) and contact (37).
(11) Using insertion tool (40), install contact (37) and wire (41) into rear of
body (39).
(12) After contact (37) locks in place, remove insertion tool (40).
(13) If body (39) is being replaced, repeat steps (9) thru (12) until all contacts
(37) have been installed.
(14) Slide boot (38) all the way onto body (39).
37. Contact
38. Boot
39. Body
40. Insertion Tool
41. Wire
43. Crimping Tool
7-179
TM 08780B-20
37. Contact
38. Boot
39. Body
40. Insertion Tool
41. Wire
42. Insulation
h. Type II Connector Repair or Replacement (LVSA1 Series Vehicles Only)
NOTE
• Connector is removed by gently prying up on clip and pulling on connector.
• All Type II connectors are repaired the same way. Number of wires in connector may
vary.
• Both halves of connector are repaired the same way.
(1) Disconnect connector (44).
(2) Unlatch and open two secondary locks (45) on connector (44).
44. Connector
45. Lock
7-180
TM 08780B-20
WARNING
TIP OF REMOVAL TOOL IS VERY SHARP. USE CAUTION WHEN USING TOOL.
FAILURE TO COMPLY MAY RESULT IN INJURY TO PERSONNEL.
(3) Insert removal tool into cavity (46) on connection (44) until seated.
(4) Pull wire (47) back through connector (44) and remove tool.
NOTE
• Perform step (5) only if old terminal is still attached to wire.
• Make cut directly behind damaged terminal.
(5) Cut terminal (48) and wire seal (49) from wire (47). Discard terminal (48)
and seal (49).
(6) Insert wire (47) through new wire seal (49).
44. Connector
46. Cavity
47. Wire
48. Terminal
49. Seal
(7) Strip end of wire (47) leaving 1/4 in. (0.64 cm) of bare wire.
(8) Insert new terminal (48) in locating hole of crimp tool using proper hole
according to the gauge of wire (47).
7-181
TM 08780B-20
(9) Slide seal (49) down to end of insulation (50) on wire (47).
NOTE
Wire and seal should be positioned so larger wings of terminal will crimp around seal and
smaller wings will crimp around exposed bare wire.
(10) Position wire (47) on terminal (48).
(11) Press handles of crimp tool together until ratchet releases and crimp is
complete.
(12) Push new terminal (48) and wire (47) through connector (44) until seated.
(13) Close two secondary locks (45) on connector (44).
(14) Connect connector (44).
i. Hirschman Connector Repair or Replacement
(1) If present, remove and discard gasket (50) from connector (51).
(2) Remove screw (52) from connector (51).
(3) Loosen cord grip nut (53).
7-182
TM 08780B-20
NOTE
• Note position of insert (54), diode(57) and cable (55) ends prior to removal to ensure
proper installation.
• Not all connectors will have a diode (57).
(4) Remove insert (54) and cable (55) from connector (51).
(5) Loosen two screws (56) and remove cable (55) ends and diode (57) from
insert (54).
(6) Remove cable (55) from connector (51).
(7) Check diode (57) for continuity in one direction only. Discard diode (57)
if no continuity is found or if continuity is found in both directions (diode has shorted).
(8) Install cable (55) in connector (51).
NOTE
Diode (57) is installed with stripe on diode facing the screw in the number one terminal.
(9) Install diode (57) and cable (55) ends in insert (54) and tighten two screws
(56).
(10) Snap insert (54) into connector (51).
(11) Tighten cord grip nut (53).
(12) Install screw (52) in connector (51).
(13) If removed, install new gasket (50) on connector (51).
END OF TASK
50. Gasket
51. Connector
52. Screw
53. Cord Grip Nut
54. Insert
55. Cable
56. Screw (2)
57. Diode
7-183
TM 08780B-20
7-49. OPTIC RIBBON LIGHT SOURCE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Remove heater access
panel (para 18-15),
item 3.
a. Removal
(1) Unplug socket (1) and remove bulb (2).
(2) Pry clip up and pull out three optic ribbons (3, 4 and 5).
(3) Unclip light source (6) from dash panel (7).
(4) Remove clip (8) from light source (6).
(3) Inspect bulb (2) for broken filament.
c. Installation
(1) Install clip (8) into light source (6).
(2) Install bulb (2) into socket (1).
(3) Install socket (1) into light source (6).
(4) Plug three optic ribbons (3, 4 and 5) into light source (6).
(5) Clip light source (6) to dash panel (7).
END OF TASK
7-184
TM 08780B-20
NOTE
TM 08780B-20 Install heater
access panel (para 18-15), item 3.
TM 08780B-10 Check dash lights for

1. Socket
2. Bulb
3. Optic Ribbon
4. Optic Ribbon
5. Optic Ribbon
6. Light Source
7. Dash Panel
8. Clip
7-185
TM 08780B-20
7-50. OPTIC RIBBON REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Access panels
removed as
needed (para
18-15), item 3.
a. Removal
(1) Unplug optic ribbon (1) from light source (2).
NOTE
Before removing optic ribbon (1), tag each panel opening to insure correct installation.
(2) Depress tab (3) on back of title appliqué (4) and remove from clip (5).
(3) Repeat step (2) for all title appliqués (4) of optic ribbon (1).
(4) If any clip (5) needs to be replaced, remove from panel (6).
c. Installation
(1) If removed, install clips (5) into panel (6).
(2) Install all title appliqués (4) into clips (5).
(3) Plug optic ribbon (1) into light source (2).
END OF TASK
7-186
TM 08780B-20
NOTE
panels removed (para 18-15), item 3.
TM 08780B-10 Check dash lights for

for proper operation(para 2-14).
1. Optic Ribbon
2. Light Source
3. Tab
4. Title Appliqué
5. Clip
6. Panel
7-187
TM 08780B-20
7-51. RESISTOR REPLACEMENT

c. Installation

Condition Condition
disconnected
(para 7-45).

(para 18-15), item 14.
General Safety instructions

a. Removal
(1) Unplug two wires (1 and 2).
(2) Remove two screws (3).
(3) Remove resistor (4).
c. Installation
(1) Place resistor (4) in position.
(2) Install two screws (3). Tighten securely.
(3) Plug in two wires (2 and 1) into connectors (5).
END OF TASK
7-188
TM 08780B-20
NOTE
panel (para 18-15), item 14.
TM 08780B-10 Check dash board

lights for proper operation (para 2-1).
1. Wire (No. 677)

2. Wire (No. 677)
3. Screw (2)
4. Resistor
5. Connector (2)
7-189
TM 08780B-20
7-52. DIMMER SWITCH REPLACEMENT

c. Installation

Condition Condition
disconnected
Lockwasher (2) (MS35338-44) item 2 on LVSA1 series
Lockwasher (2333HX) item 14 vehicles only).

a. Removal
(1) Remove two capscrews (1) and lockwashers (2). Discard lockwashers(2).
(2) Remove dimmer switch (3) from mounting plate (4).
NOTE
Tag all wires before removing for location during installation.
(3) Remove three screws (5 and 13), two retainers (6), lockwasher (14) and
wires (7, 8, 9, 10, 11 and 12). Discard lockwasher (14).
(2) Inspect wiring and capscrews for damage.
c. Installation
(1) Install wires (7, 8, 9, 10, 11 and 12) in locations shown, using two
retainers (6), new lockwasher (14) and three screws (5 and 13).
(2) Install dimmer switch (3) into mounting plate (4).
7-190
TM 08780B-20
(3) Install two new lockwashers (2) and capscrews (1). Tighten securely.
END OF TASK
NOTE
(para 7-45 or 7-46
on LVSA1 series
vehicles only).
TM 08780B-10 Check dimmer

switch operation
(para 2-1).
1. Capscrew (2)
2. Lockwasher (2)
3. Dimmer Switch
4. Mounting Plate
5. Screw (2)
6. Retainer (2)
7. Wire (No. 006)
8. Wire (No. 18/006)
9. Wire (No. 017)
10. Wire (No. 17/007)
11. Wire (No. 018)
12. Wire (No. 17-007)
13. Screw
14. Lockwasher.
7-191
TM 08780B-20
7-53. ELECTRICAL CONTROL UNIT (ECU) POWER CABLE REPLACEMENT

(FPU) (ABS MODIFIED VEHICLES ONLY)

c. Installation

Condition Condition
MK48/MK48A1 TM 08780B-20 Batteries
disconnected
Tie Straps (102679AA) item 4 for LVSA1 series
Star washer ( ) item 9 vehicles only).

a. Removal
(1) Open support clip (1) by inserting screwdriver into clip slot and prying
forward.
(2) Pull ABS wiring harness (2) straight out from ECU (3).
1. Support Clip
2. ABS Wiring
Harness
3. Electronic Control
Unit
7-192
TM 08780B-20
(3) Cut tie strap holding sensor cables (blue and yellow) to brake chamber air
lines. Disconnect (blue and yellow) sensor cables from sensor cable (4).
4. Antilock Brake
System Sensor Lead
(4) Unscrew nut (5) and star washer (6) from DDU Test connector (7). DDU
Test Connector (7) will drop down from electronic service panel in cab. Discard star washer.
5. Nut
6. Star Washer
7. DDU Test Connector
(5) Disconnect red lead (8) from CB #4 (9).
(6) Disconnect black leads (10) and purple leads (11) from ABS warning
lights (12).
7-193
TM 08780B-20
(7) Disconnect yellow leads (13) from CB #9 (14).
(8) Disconnect orange and brown leads from ECU relay assembly (15).
(9) Disconnect white lead (16) from ground (17).
(10) Remove harness (2) by routing leads/cable through electrical service

panel.
8 9
13
15 2. ABS Wiring Harness
8. Red Lead
16 14 9. CB #6
10. Black Lead
17 11. Purple Lead
12. ABS Warning Light
11 13. Yellow Lead
12 14. CD #9
10
15. ECU Relay Assembly
2 16. White Lead
18 17. Ground
18. Diagnostic Cable
(2) Clean corrosion from all cables and connectors.
c. Installation
(1) Route leads/cables or harness (2) through electrical service panel.
(2) Connect white lead (16) to ground (17).
(3) Connect orange and brown leads to ECU relay assembly (15).
(4) Connect yellow lead (13) to CB #9 (14).
(5) Connect black leads (10) and purple leads (11) to ABS warning lights
(12).
7-194
TM 08780B-20
(6) Connect read lead (8) to CB #4 (9).
8 9
15 8. Red Lead
16 9. CB #4
14
10. Black Lead
11. Purple Lead
17 12. ABS Warning Light
13. Yellow Lead
11 14. CB #9
10 12 15. ECU Relay Assembly
16. White Lead
2 17. Ground
18 18. Diagnostic Cable
(7) Route DDU Test connector (7) up through bottom of electrical service
panel. Secure DDU Test connector (7) to electrical service panel with new star washer and nut.
5. Nut
6. Star Washer
(8) Route ABS sensor leads along air lines going to brake chamber air lines.
Connect sensor leads (blue and yellow) to sensor leads (4). Secure sensor leads with new double
wrap tie straps as required.
7-195
TM 08780B-20
4. Antilock Brake
System Sensor Lead
(9) Connect ABS wiring harness (2) to ECU (3) listening for two “clicks” as
the latch falls into place.
(10) Close the support clip (1) and lock into place. Band should completely
cover the enlarged portion of the wiring harness.
1. Support Clip
2. ABS Wiring Harness
3. Electronic Control Unit
END OF TASK
NOTE
TM 08780B-20 Connect batteries (para 7-45 or 7-46
Install access panel (para 18-15) item 14
7-196
TM 08780B-20
7-54. ELECTRICAL CONTROL UNIT (ECU) POWER CABLE REPLACEMENT

(RBU) (ABS MODIFIED VEHICLES ONLY)

c. Installation

Condition Condition
MK14, MK15, MK16, MK17 TM 08780B-20 Batteries
disconnected
Tie Straps (102679AA) item 4 for LVSA1 series
Star washer ( ) item 9 vehicles only).

(para 18-15, item 14)

a. Removal
(1) Open support clip (1) by inserting screwdriver into clip slot and prying
forward.
(2) Pull ABS wiring harness (2) straight out from ECU (3).
1. Support Clip
2. ABS Wiring
Harness
3. Electronic Control
Unit
7-197
TM 08780B-20
(3) Cut tie straps holding sensor (blue and yellow) cable to brake chamber air
lines. Disconnect (blue and yellow) sensor cable from sensor cable (4).
4. Antilock Brake System

Sensor Lead
(4) Unscrew nut (5) and star washer (6) from connector (7). Push connector
(7) through RBU frame chassis connector panel, air and electrical.
5,6
5. Nut
6. Star Washer
(5) Cut tie straps holding DDU connector cable (18) to RBU frame.
(6) Disconnect red lead (8) from CB #6 (9).
(7) Disconnect black leads (10) and purple leads (11) from ABS warning
lights (12).
(8) Disconnect yellow leads (13) from CB #9 (14).
(9) Disconnect orange and brown leads from ECU relay assembly (15).
7-198
TM 08780B-20
(10) Disconnect white lead (16) from ground (17).
(11) Remove EDU wiring harness (2) by routing leads and cables from RBU
and FPU.
8 9
13
15
8. Red Lead
16
14 9. CB #4
10. Black Lead
11. Purple Lead
17 12. ABS Warning Light
13. Yellow Lead
11 14. CB #9
12 15. ECU Relay Assembly
10
16. White Lead
2 17. Ground
18 18. Diagnostic Cable
c. Installation
(1) Route leads and cables of ECU wiring harness (2) through RBU and FPU.
(2) Connect white lead (16) to ground (17).
(3) Connect orange and brown leads to ECU relay assembly (15).
(4) Connect yellow lead (13) to CB #9 (14).
(5) Connect black leads (10) and purple leads (11) to connector on ABS
warning lights (12).
7-199
TM 08780B-20
(6) Connect red lead (8) to CB #6 (12).
8 9
13
15

14
8. Red Lead
9. CB #4
17 10. Black Lead
11. Purple Lead
11
13. Yellow Lead
12 14. CB #9
10
15. ECU Relay Assembly
2 16. White Lead
18 17. Ground
18. Diagnostic Cable
(7) Push connector (7) through hole in RBU frame. Secure connector (7) to
frame with star washer (6) and nut (5).
5,6
5. Nut
6. Star Washer
7. ABS Connector
(8) Secure DDU connector cable (18) to RBU frame with tie straps.
(9) Connect sensor (blue and yellow) cables to sensor cable. Secure sensor
cables (4) to brake chamber air lines with double tie wraps.
7-200
TM 08780B-20
4. Antilock Brake System

Sensor Lead
(10) Connect ABS wiring harness (2) to ECU (3) listening for two “clicks” as
the latches fall into place.
(11) Close the support clip (1) and lock into place. Band should completely
cover the enlarged portion of the ABS wiring harness.
1. Support Clip
3. Electronic Control Unit
END OF TASK
NOTE
TM 08780B-20 Connect batteries (para 7-45 or 7-46
Install access panel (para 18-15) item 14
7-201
TM 08780B-20
7-55. ELECTRICAL CONTROL UNIT (ECU) RELAY ASSEMBLY REPLACEMENT

(ABS MODIFIED VEHICLES ONLY)

c. Installation

Condition Condition
disconnected
(para 7-45 or 7-46
for LVSA1 series
vehicles only).

(para 18-15, item 14)

a. Removal
(1) Cut black wire (2) from ECU relay assembly (1) to retarder circuit 712.
(2) Remove white wire (3) from CB #9.
(3) Disconnect two brown wires (5) connecting ECU relay assembly (1) to
power cable (7).
(4) Disconnect two orange wires (6) connecting ECU relay assembly (1) to
power cable (7).
(5) Remove two screws holding ECU relay assembly (1) to electronic control
panel. Remove ECU relay assembly.
7-202
TM 08780B-20
1. ECU Relay
Assembly
2. Black Wire
3. White Wire
4. CB #9
5. Brown Wire
6. Orange Wire
7. Power Cables
c. Installation
(1) Attach ECU relay assembly (1) to electronic control panel with two
screws.
(2) Connect two orange wires (6) from power cable (7) to ECU relay
assembly (1).
(3) Connect two brown wires (5) from power cable (7) to ECU relay assembly
(1).
(4) Connect white wire (3) to CB #9 (4).
(5) Splice black wire (2) from ECU relay assembly (1) to black wire from
retarder circuit. Refer to paragraph 7-48 of this manual.
7-203
TM 08780B-20
1. ECU Relay
Assembly
2. Black Wire
3. White Wire
4. CB #9
5. Brown Wire
6. Orange Wire
7. Power Cables
END OF TASK
NOTE
(para 7-45 or 7-46
on LVSA1 series
vehicles only).
Install access panel

(para 18-15) item 14
7-204
TM 08780B-20
7-56. ANTILOCKING BRAKE SYSTEM (ABS) WARNING LIGHT REPLACEMENT

(ABS MODIFIED VEHICLES ONLY)

c. Installation

Condition Condition
disconnected
(para 7-45 or 7-46
for LVSA1 series
vehicles only).

(para 18-15, item 14)

a. Removal
NOTE
Each ABS warning light is removed in the same manner.
(1) Disconnect black lead (1) and purple lead (2) from ABS warning light.
(2) Disconnect number 4 wire (3) from CB #9.
(3) Disconnect number 3 wire (5) from ground (6).
(4) Remove two screws (7) from ABS warning light assembly (8) and top of
electrical panel.
(5) Remove ABS warning light assembly (8) from top of electrical panel.
7-205
TM 08780B-20
c. Installation
(1) Thread wires of ABS warning light assembly (8) through hole in top of
electrical panel. Ensure two holes in ABS warning light assembly are aligned with holes in
electrical panel.
(2) Attach ABS warning light assembly (8) to top of electrical panel with two
screws (7). Tighten screws.
(3) Connect #3 wire (5) to ground (6).
(4) Connect #4 wire (3) to CB #9 (4).
(5) Connect black lead (1) and purple lead (2) to ABS warning light.
1. Black Lead
2. Purple Lead
3. #4 Wire
4. CB #9
5. #3 Wire
6. Ground
7-206
TM 08780B-20
7. Screw (2)
Assembly
END OF TASK
NOTE
(para 7-45 or 7-46
on LVSA1 series
vehicles only).
Install access panel

(para 18-15) item 14
7-207/(7-208 blank)
TM 08780B-20
CHAPTER 8
TRANSMISSION
8-1. OVERVIEW. This chapter provides information authorized for Second Echelon
Maintenance level mechanics. The following chapter covers principles of operation,
maintenance, repair and replacement procedures for the vehicle’s transmission.
a. General. This truck uses an HT 740-D automatic transmission. This model has
four forward speeds and one reverse speed. In forward range, the transmission will start in first
gear and automatically upshift at the proper speeds thru all gears. This transmission also uses an
automatic lockup clutch to mechanically lock the engine output the transmission input. The
name plate is located on the right rear side of the transmission. The name plate shows serial, part
and model numbers.
b. Shift Control. A cab mounted shift control uses a neutral start switch to prevent
starting the engine with the transmission in any position except neutral. The shift control is
connected to the transmission through a cable.
c. Governor. The governor is driven by a gear on the output shaft of the

transmission. The governor changes oil pressure depending on the speed of the output shaft.
d. Modulator Actuator. An air operated modulator actuator is located on the left side
of the transmission. The modulator actuator controls a modulator valve inside the transmission.
The modulator valve changes oil pressure depending on throttle position.
8-1
TM 08780B-20
e. Transmission Lockup Switch. The transmission lockup switch is located on the

bottom of the transmission. This switch senses when the lockup clutch, inside the transmission,
is engaged.
f. Lockup Solenoid Valve. This electrically controlled valve senses operation of the
engine brake and controls the transmission’s lockup clutch.
8-2
TM 08780B-20
g. Transmission Oil Cooler. A transmission oil cooler is mounted on top the

engine’s radiator. Oil flows from the transmission to the oil cooler. The oil is then cooled as the
air is moved past the oil cooler by the engine fan. The cool oil then flows back to the
transmission. A gauge on the dash allows the operator to monitor transmission oil temperature.
h. Transmission Filters. The transmission oil is cleaned by two filters. A spin-on

type filter is mounted on the right fender of the front power unit. This filter requires periodic
maintenance. A mesh screen type filter is used inside the transmission. This filter is serviced
less frequently. Refer to LI 2320-1219, LO 9-2320-297-12 for service intervals.
8-3
TM 08780B-20
8-3. TRANSMISSION OIL CHANGE AND SPIN-ON FILTER REPLACEMENT

b. Filter Removal
d. Filter Installation
e. Filling and Checking
INITIAL SETUP
Applicable Configurations General Safety Instructions

MK48 Block wheels of truck to prevent personal
injury.
Materials/Parts
Oil filter (25010335) item 4
References
LI 2320-12/9
LO 9-2320-297-12
a. Draining
CAUTION
• OIL MUST BE HANDLED IN CLEAN CONTAINERS TO PREVENT DIRT FROM

ENTERING THE TRANSMISSION.
• CONTAINERS THAT HAVE BEEN USED FOR ANTIFREEZE OR ENGINE

COOLANT SOLUTION MUST NOT BE USED FOR TRANSMISSION OIL.
• CLEAN AROUND OIL FILLER TUBE BEFORE REMOVING DIPSTICK. LAY

DIPSTICK IN A CLEAN PLACE WHILE FILLING TRANSMISSION.
(1) For change intervals, refer to lubrication order (LI 2320-12/9,

LO 9-2320-297-12).
(2) Place drain pan below drain plug (1).
NOTE
Transmission should be at operating temperature 160-220° F(71-105° C) when oil is drained.
This will let oil drain faster.
(3) Remove drain plug (1) and washer (2) from rear of oil pan (3). Let oil
drain.
8-4
TM 08780B-20
1. Drain Plug
2. Washer
3. Oil pan
b. Filter Removal
(1) Place drain pan under transmission oil filter (4).
(2) Remove oil filter (4). Discard oil filter (4).
(3) Install drain plug (1) and washer (2) after draining is complete.
4. Oil Filter
5. Oil Seal Ring
6. Oil Filter Base
8-5
TM 08780B-20
d. Filter Installation
CAUTION
TO PREVENT LEAKS, OIL FILTER (4) MUST BE TIGHTENED ONE FULL TURN
AFTER CONTACTING OIL FILTER BASE (6). DISREGARD ANY CONFLICTING
INSTRUCTIONS PRINTED ON REPLACEMENT OIL FILTER (4).
(1) Put a light coat of oil on oil seal ring (5).
(2) Install new oil filter (4).
(3) Tighten filter (4) one full turn after oil seal ring (5) contacts oil filter base
(6).
e. Filling and Checking
(1) Remove dipstick and pour oil through filler tube until oil level is at bottom
of cold run band on dipstick. For type of oil, refer to lubrication order (LI 2320-1219,
LO 9-2320-297-12).
WARNING
• SET PARKING BRAKE BEFORE CHECKING TRANSMISSION FLUID.
• FRONT AND REAR FRAMES PIVOT. STAY CLEAR OF CENTER HINGE AREA
WHILE ENGINE IS RUNNING.
CAUTION
• OIL LEVEL RISES AS TEMPERATURE INCREASES. DO NOT FILL ABOVE

COLD RUN BAND BEFORE TRANSMISSION HAS REACHED NORMAL
OPERATING TEMPERATURE. OVERFILLING CAUSES OVERHEATING AND
IRREGULAR SHIFT PATTERNS.
• CHECK OIL LEVEL SEVERAL TIMES TO OBTAIN AN ACCURATE READING.
(2) Check oil while vehicle is on level ground.
8-6
TM 08780B-20
(3) Start engine and shift transmission thru all drive ranges for about one
minute.
(4) Shift transmission into neutral.
(5) Cold oil check (cold run band), with 26 quarts of oil, engine idling and oil
temperature between 60°-120° F (15.5°-48.8° C) the oil should register in the cold run band.
This indicates a sufficient amount of oil to operate the transmission.
(6) Hot oil check (hot run band), with engine idling and oil temperature
between 160°-200° F (71.1°-93° C), oil should register in the hot run band. This indicates a
sufficient amount of oil to operate the transmission. If oil level registers on or below the bottom
of the hot run band, add oil to bring oil level up to middle of the hot run band.
END OF TASK
8-7
TM 08780B-20
8-4. SHIFT CONTROL REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Skid plate grille
removed (para
Cotter pin (MS24665-281) item 1
Locknut (2) (DF503) item 5 Neutral safety switch
removed (pare 7-24).
Shift tower lamp

removed (para 8-5.1).

injury.
a. Removal
(1) Remove cotter pin (1), washer (2) and cable anchor (3) from shift lever
bracket (4). Discard cotter pin (1).
(2) Remove two locknuts (5) and capscrews (6). Remove clamp (7). Discard
locknuts (5).
(3) Remove four screws with captive lockwashers (8) from shift control unit
(10).
(4) Remove shift control unit (10) from mounting surface (11).
8-8
TM 08780B-20
c. Installation
(1) Install shift control unit (10) on mounting surface (11).
(2) Install four screws with captive lockwashers (8). Tighten screws (8)
securely.
(3) Place cable (12) on bracket angle (13). Install clamp (7) over cable (12)
and secure to bracket angle (13) with two capscrews (6) and nuts (5). Tighten nuts (5) securely.
(4) Install cable anchor (3) in shift lever bracket (4) and secure with washer
(2) and new cotter pin (1).
END OF TASK
NOTE
TM 08780B-20 Install neutral safety switch (para 7-24).
Install skid plate grille (para 18-17).
Install shift tower lamp (para 8-6).
8-9
TM 08780B-20
8-10
TM 08780B-20
8-5. SHIFT CONTROL REPAIR

c. Assembly

Condition Condition
MK48 TM 08780B-20 Shift control
removed (para 8-4).
Materials/Parts
Locknut (4) (MS20364-1032A) item 9
a. Disassembly
(1) Remove two capscrews (1) and two star washers (2) from cable mounting
strap (3). Discard star washers (2).
(2) Remove two capscrews (4) and locknuts (5). Remove bracket angle(6).
(3) Loosen capscrew (7) and remove shift lever assembly (8).
(4) Remove four locknuts (9) and remove gate plate assembly (10), washers
(10.1) and lens (11). Discard locknuts (9).
c. Assembly
(1) Install lens (11), washers (10.1) and gate plate assembly (10). Install four
new locknuts (9) and torque to 20 inch-pounds (2.26 N*m).
(2) Install shift lever assembly (8) and torque capscrew (7) to 100 inch-
pounds (11.20 N*m).
8-11
TM 08780B-20
(3) Install bracket angle (6), two capscrews (4) and two new locknuts (5).
Torque locknuts (5) to 85 inch-pounds (9.60 N*m).
(4) Install cable mounting strap (3), two new star washers (2) and two
capscrews (1). Torque capscrews (1) to 85 inch-pounds (9.60 N*m).
END OF TASK
NOTE
TM 08780B-20 Install shift control (para 8-4).
TM 08780B-10 Check shifter for proper

1. Capscrew 7. Capscrew
2. Star Washer (2) 8. Shift Lever Assembly
3. Cable Mounting Strap 9. Locknut (4)
4. Capscrew (2) 10. Gate Plate Assembly
5. Locknut (2) 10.1. Washer (4)
6. Bracket Angle 11. Lens
8-12
TM 08780B-20
8-6. SHIFT TOWER LAMP REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Rubber boot
mounting capscrews
Materials/Parts removed (para 7-24).
Bulb (1822) item 4
injury.
a. Removal
(1) Pull rubber boot (1) down and out of the way.
(2) Remove light socket (2) from shift tower (3) by pulling down.
(3) Turn bulb (4)counterclockwise and remove bulb (4) from light socket (2).
(1) Clean all parts. Refer to paragraph 2-11
c. Installation
(1) Install bulb (4) in light socket (2) and turn clockwise.
(2) Install light socket (2) in shift tower (3).
(3) Reposition rubber boot (1).
END OF TASK
8-13
TM 08780B-20
NOTE
TM 08780B-20 Install rubber boot mounting
capscrews (para 7-24).
1. Rubber Boot
2. Light Socket
3. Shift Tower
4. Bulb
8-14
TM 08780B-20
8-7. SHIFT CABLE MAINTENANCE

c. Installation/Adjustment

Condition Condition
disconnected (para
Materials/Parts 7-45 or 7-46 on
Electrical tape (item 55, appendix D) LVSA1 series
Nylon tie (MS3367-4-9) item 2 vehicles only).
Cotter pin (2) (MS24665-281) items 10 and 21
Locknut (2) (MS51922-1) items 14 and 19 General Safety Instructions
Lockwasher (MS35338-44) item 25 Block wheels of truck to prevent personal
injury. To prevent personal injury, make
sure batteries are disconnected before
a. Removal
(1) Place transmission shifter (1) in neutral.
(2) Remove nylon tie (2) and electrical tape holding wires (3, 4 and 5) to shift
cable (6). Discard nylon tie (2).
(3) Tag wires (3, 4 and 5) for identification and disconnect.
(4) Remove four capscrews (7) with washers (8).
(5) Slide rubber boot (9) down and back out of the way.
8-15
TM 08780B-20
1. Transmission Shifter 6. Shift Cable

2. Nylon Tie 7. Capscrew (4)
3. Wire (No. 021) 8. Washer (4)
4. Wire (No. 436) 9. Rubber Boot
5. Wire (No. 052)
6. Shift Cable 13. Shift Lever Bracket

9. Rubber Boot 14 Locknut (2)
10. Cotter Pin 15 Capscrew (2)
11. Washer 16. Clamp
12. Cable Anchor 17. Jam Nut
(6) Remove cotter pin (10), washer (11) and cable anchor (12) from shift lever
bracket (13). Discard cotter pin (10).
8-16
TM 08780B-20
(7) Remove two locknuts (14) from two capscrews (15) and remove clamp
(8) Remove cable anchor (12) from shift cable (6).
(9) Remove jam nut (17) from shift cable(6).
(10) Remove rubber boot (9) from shift cable (6).
(11) Remove two capscrews (18), locknuts (19) and clamp (20) at transmission
end of shift cable (6). Discard locknuts (19).
(12) Remove cotter pin (21) and washer (22) at cable anchor (23) and remove
shift cable (6). Remove cable anchor (23) and jam nut (17). Discard cotter pin (21).
(13) Remove capscrew (24), lockwasher (25), clip (26) and washer (27).
24. Capscrew
25. Lockwasher
26. Clip
27. Washer
(14) Cut nylon ties (2) around shift cable (6). Discard nylon ties (2).
(15) Remove shift cable (6).
2. Nylon Tie
6. Shift Cable
17. Jam Nut
18. Capscrew (2)
19. Locknut (2)
20. Clamp
21. Cotter Pin
22. Washer
23. Cable Anchor
8-17
TM 08780B-20
(16) Remove two capscrews (28), bracket (29) and spacers (30) if damaged.
c. Installation/Adjustment
NOTE
Make sure jam nuts (17) are on both ends of new shift cable (6).
(1) Install bracket (29) with two spacers (30) and capscrews (28). Torque
capscrews (28) to 10-13 foot-pounds (14-18 N*m).
(2) Install jam nuts (17) and cable anchors (12 and 23) on the ends of shift
cable (6).
(3) Install washer (22) and new cotter pin (21) to connect shift cable (6) to
transmission shift lever (31).
(4) Lock jam nut (17) on shift cable (6) against cable anchor (23).
(5) Install two new locknuts (19) and two capscrews (18) to secure clamp (20)
to shift cable (6).
(6) Push shift lever (31) all of the way to the rear of the transmission.
(7) Click shift lever (31) forward one step to put transmission in neutral.
(8) Make sure transmission shifter (1) is in the neutral position.
(9) Install shift selector end of shift cable (6) through rubber boot (9).
(10) Install two capscrews (15) and two new locknuts (14) to secure clamp (16)
to shift cable (6).
(11) Install cable anchor (12) on end of shift cable (6).
(12) Adjust cable anchor (12) to fit in hole on shift lever bracket (13). Lock
jam nut (17) against cable anchor (12).
(13) Install washer (11) and new cotter pin (10) on cable anchor (12).
8-18
TM 08780B-20
6. Shift Cable 22. Washer

17. Jam Nut 23. Cable Anchor
18. Capscrew (2) 28. Capscrew (2)
19. Locknut (2) 29. Bracket
20. Clamp 30. Spacer (2)
21. Cotter Pin 31. Shift Lever
6. Shift Cable 13. Shift Lever Bracket

9. Rubber Boot 14. Locknut (2)
10. Cotter Pin 15. Capscrew (2)
11. Washer 16. Clamp
12. Cable Anchor 17. Jam Nut
8-19
TM 08780B-20
(14) Install rubber boot (9) over shift lever bracket (13). Install and tighten
four capscrews (7) and washers (8).
(15) Connect three wires (3, 4 and 5).
(16) Wrap shift cable (6) and wires (3, 4 and 5) with electrical insulation tape.
(17) Wrap new nylon ties (2) around shift cable (6) to secure in place.
(18) Install clip (26), washer (27), new lockwasher (25) and capscrew (24).
Tighten capscrew (24) securely.
(19) Check operation of transmission shifter (1).
24. Capscrew
25. Lockwasher
26. Clip
27. Washer
END OF TASK
NOTE
TM 08780B-20 Install skid plate grille (para 18-17).
Connect batteries (para 7-45 or

7-46) on LVSA1 series vehicles
only).
TM 08780B-10 Check shift control for proper

8-20
TM 08780B-20
1. Transmission Shifter 6. Shift Cable

2. Nylon Tie 7. Capscrew (4)
3. Wire (No. 021) 8. Washer (4)
4. Wire (No. 436) 9. Rubber Boot
5. Wire (No. 052)
8-21
TM 08780B-20
8-8. TRANSMISSION LOCKUP SWITCH REPLACEMENT

c. Installation
INITIAL SETUP

injury.
Materials/Parts
1/4” NPT plug (NSN 4730-00-198-5053)
References
TM 08780B-10
a. Removal
(1) Separate boot (1) from transmission lockup switch (2).
NOTE
Be prepared to insert 1/4 inch pipe plug immediately after removing transmission lockup
switch to prevent excess loss of transmission oil.
(2) Remove transmission lockup switch (2) from transmission (3).
(3) Install plug (4) immediately after removing transmission lockup switch (2)
to prevent oil loss.
c. Installation
(1) Lightly coat threads of transmission lockup switch (2) with pipe sealant.
NOTE
Be prepared to insert transmission lockup switch (2) immediately after removing 1/4 inch plug
(4) to prevent excessive loss of transmission oil.
8-22
TM 08780B-20
(2) Remove plug (4). Install transmission lockup switch (2). Tighten
securely.
(3) Remove excess transmission oil from transmission lockup switch (2) with
a clean rag.
(4) Connect boot (1) to transmission lockup switch (2).
END OF TASK
NOTE
TM 08780B-10 Check transmission oil level (para 2-12).
Check engine brake for proper operation

(para 2-13).
1. Boot
2. Transmission
Lockup Switch
3. Transmission
4. Pipe Plug
8-23
TM 08780B-20
8-9. TRANSMISSION LOCKUP SOLENOID VALVE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Remove access
panel, (para 18-14),
Materials/Parts item 27.
Star washer (MS35333-74) item 12 Block wheels of truck to prevent personal
injury.
a. Removal
(1) Disconnect wire (1).
(2) Tag and remove two hoses (2 and 3). Tie ends of hoses (2 and 3) above
transmission (4) to prevent loss of transmission oil.
(3) Remove locknut (5), capscrew (6), washer (7) and lockup solenoid valve
assembly (8). Discard locknut (5).
(4) Remove two nuts (9), lockwashers (10), capscrew (11), one star washer
(12) and wire (13) from solenoid valve (14). Remove bracket (15). Discard lockwashers (10)
and star washer (11).
(5) Remove adapter (16) and elbow (17) from solenoid valve (14).
(6) If hoses (2 and 3) must be replaced, drain transmission oil. Refer to

paragraph 8-3.
(7) Remove two hoses (2 and 3) from elbows (18 and 19).
(8) Remove elbows (18 and 19) from transmission if damaged.
8-24
TM 08780B-20
c. Installation
(1) Install elbows (18 and 19) into transmission (4), if removed.
(2) Connect hoses (2 and 3) to elbows (18 and 19) if removed.
(3) Install elbow (17) and adapter (16) securely into lockup solenoid valve
(14). Make sure elbow (17) faces down.
(4) Attach lockup solenoid valve (14) and wire (13) to bracket (15) using two
capscrews (11), new lockwashers (10), new star washer (12) and nuts (9). Tighten nuts (9)
securely.
(5) Mount bracket (15) on transmission (4) using capscrew (6), washer (7) and
new locknut (5). Tighten locknut (5) securely.
(6) Connect hose (3) to elbow (17). Tighten securely.
(7) Connect hose (2) to adapter (16). Tighten securely.
(8) Connect wire (1).
(9) Fill transmission (4) with oil, if drained. Refer to paragraph 8-3 of this
manual.
END OF TASK
NOTE
TM 08780B-20 Install access panel,
(para 18-15), item 27.
TM 08780B-10 Check engine brake for

Check lockup clutch in transmission

8-25
TM 08780B-20
1. Wire 10. Lockwasher (2)

2. Hose 11. Capscrew (2)
3. Hose 12. Star Washer
4. Transmission 13. Wire
5. Locknut 14. Solenoid Valve
6. Capscrew 15. Bracket
7. Washer 16. Adapter
8. Lockup Solenoid Valve 17. Elbow
Assembly 18 Elbow
9. Nut (2) 19 Elbow
8-26
TM 08780B-20
8-10. GOVERNOR REPLACEMENT

c. Installation
INITIAL SETUP

MK48 Block wheels of truck to prevent
personal injury.
Materials/Parts
Gasket (NSN 5330-00-001-1984) item 3
a. Removal
(1) Remove four capscrews (1), cover (2) and gasket (3). Discard gasket (3).
(2) Carefully turn governor assembly (4) clockwise and remove from
transmission.
c. Installation
(1) Install governor assembly (4) into port (5), by turning counterclockwise.
(2) Install new gasket (3) and cover (2) with four capscrews (1).
(3) Torque capscrews (1) to 10-13 foot-pounds (14-17 N*m).
END OF TASK
NOTE
TM 08780B-10 Check transmission for proper
shifting (para 2-1).
8-27
TM 08780B-20
1. Capscrew (4)
2. Cover
3. Gasket
4. Governor Assembly
5. Port
8-28
TM 08780B-20
8-11. MODULATOR VALVE REPLACEMENT

c. Installation
INITIAL SETUP

personal injury.
Materials/Parts
Seal ring (118233) item 5
a. Removal
(1) Disconnect hose (1) from modulator valve (2).
(2) Remove capscrew (3),bracket (4), modulator valve (2) and seal ring (5).
Discard seal ring (5).
c. Installation
(1) Install new seal ring (5), modulator valve (2), bracket (4) and capscrew
(3).
(2) Torque capscrew (3) to 8-10 foot-pounds (10.8-13.6 N*m).
(3) Connect hose (1) to modulator valve (2).
END OF TASK
NOTE
TM 08780B-10 Check transmission for proper
shifting (para 2-1).
8-29
TM 08780B-20
1. Hose
2. Modulator Valve
3. Capscrew
4. Bracket
5. Seal Ring
8-30
TM 08780B-20
8-12. OIL FILTER BRACKET REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Spin-on oil filter
removed (para 8-3).
Materials/Parts
References
TM 08780B-10
LI 2320-12/9
LO 9-2320-297-12
a. Removal
(1) Remove two oil lines (1) from oil filter base (2).
(2) Remove four capscrews (3), four nuts (4) and four lockwashers (5).
(3) Remove filter base (2).
(5) Remove wire (9) and lockwasher (10) from capscrew (6). Discard
lockwasher (10).
(6) Remove two capscrews (11), two nuts (12), two lockwashers (13) and
spacer (14). Discard lockwashers (13).
(7) Remove bracket (15).
8-31
TM 08780B-20
c. Installation
(1) Install bracket (15) and secure with four capscrews (6), wire (9), new
lockwasher (10), four new lockwashers (8) and nuts (7). Tighten nuts (7) securely.
(2) Install two capscrews (11), new lockwashers (13), nuts (12) and spacer
(14) into bracket (15). Tighten nuts (12) securely.
(3) Install oil filter base (2) and secure with four capscrews (3), new
lockwashers (5) and nuts (4). Tighten nuts (4) securely.
(4) Connect two oil lines (1) to oil filter base (2). Tighten oil lines (1)
securely.
END OF TASK
NOTE
TM 08780B-20 Install spin-on oil filter (para 8-3).
LI 2320-12/9 Fill transmission with

LO 9-2320-297-12 fluid to proper level.
TM 08780B-10 Start engine and check for

leaks at filter and oil lines (para 2-13).
8-32
TM 08780B-20
1. Oil Line (2) 9. Wire

2. Oil Filter Base 10. Lockwasher
4. Nut (4) 12. Nut (2)
6. Capscrew (4) 14. Spacer
7. Nut (4) 15. Bracket
8. Lockwasher (4)
8-33
TM 08780B-20
8-13. OIL FILTER BRACKET REPLACEMENT (LVSA1 SERIES VEHICLES

ONLY)

c. Installation

Condition Condition
MK48A1 TM 08780B-20 Spin-on filter
removed (para 8-3).
Materials/Parts
Lockwasher (4) (351 AX) item 5 Engine oil sampling
Lockwasher (MS35335-63) item 17 valve bracket
Lockwasher (2) (354AX) item 20 removed (para 3-8).
Locknut (4) (MS17829-6C) item 15
O-ring (2) (3-916) items 11 and 13
References
TM 08780B-10
LI 2320-12/9
LO 9-2320-297-12
a. Removal
NOTE
• Plug hoses after removal to prevent dirt from entering system.
• Place a container to catch oil during hose removal.
(1) Remove two hoses (1) and (2).
(3) Remove filter base (6).
(4) Remove oil sampling valve (7) from reducer (8).
(5) Remove reducer (8), tee (9), adapter (10) and O-ring (11). Discard
O-ring (11).
(6) Remove adapter (12) and O-ring (13). Discard O-ring (13).
8-34
TM 08780B-20
(7) Remove four capscrews (14) and four locknuts (15). Discard
locknuts (15).
(8) Remove wire (16) and lockwasher (17) from capscrew (14). Discard
lockwasher (17).
(9) Remove two capscrews (18), two nuts (19), two lockwashers (20), spacer
(21) and manifold (22). Discard lockwashers (20).
c. Installation
(1) Position bracket (23) on fender (24) and install manifold (22) on bracket
(23) using two capscrews (18), new lockwashers (20) and nuts (19). Tighten nuts (19) securely.
(2) Install wire (16) and new lockwasher (17) on capscrew (14).
(3) Install bracket (23) on fender (24) using four capscrews (14) and new
(4) Install new O-ring (13) and adapter (12). Tighten adapter (12) securely.
NOTE
Apply pipe sealant to all pipe threads before installing.
(5) Install new O-ring (11), adapter (10), tee (9) and reducer (8). Tighten
adapter (10), tee (9) and reducer (8) securely.
(6) Install oil sampling valve (7) on reducer (8). Tighten valve (7) securely.
(7) Install filter base (6) using four capscrews (3), new lockwashers (5) and
nuts (4). Tighten nuts (4) securely.
(8) Install two hoses (2) and (1). Tighten hoses (1 and 2) securely.
END OF TASK
8-35
TM 08780B-20
NOTE
TM 08780B-20 Install spin-on oil filter (para 8-3).
Install engine oil sampling valve

bracket (para 3-8).
LI 2320-12/9 Fill transmission with fluid to proper level.

LO 9-2320-297-12
TM 08780B-10 Start engine and check for leaks at filter and

oil lines (para 2-13).
1. Hose
2. Hose
3. Capscrew (4)
4. Nut (4)
5. Lockwasher (4)
6. Filter Base
8. Reducer
9. Tee
10. Adapter
11. O-Ring
12. Adapter
13. O-Ring
14. Capscrew (4)
15. Locknut (4)
16. Wire
17. Lockwasher
18. Capscrew (2)
19. Nut (2)
20. Lockwasher (2)
21. Spacer
22. Manifold
23. Bracket
24. Fender
8-36
TM 08780B-20
8-14. OIL PAN, GASKET AND INTERNAL FILTER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Shift cable and
bracket removed
Materials/Parts (para 8-7) items
Transmission fluid (item 33, Appendix D) 6 and 29.
Gasket (NSN 5330-01-008-5981) item 7
Filter (NSN TBD) item 9 Clamp removed
Seal ring (NSN 5330-01-049-0547) item 13 (para 9-4) item 18.
References General Safety Instructions

TM 08780B-10 Block wheels of truck to prevent
LI 2320-12/9 personal injury.
LO 9-2320-297-12
a. Removal
CAUTION
KEEP THE REPLACEMENT FILTER IN THE PACKAGE UNTIL READY FOR

INSTALLATION.
NOTE
LVSA1 series vehicles have a new style oil filter and mounting hardware. When repairing a
non-A1 series vehicle, use the new style oil filter and mounting hardware to replace the old
style filter and mounting hardware. Refer to TM 08780B-24P for correct parts identification.
(1) Drain oil into pan by removing drain plug (1) and washer (2).
(3) Remove nut (3) on dipstick tube (4) at transmission oil pan (5).
(4) While holding oil pan (5) up, remove 20 capscrews (6).
(5) Discard gasket (7).
(6) Hold filter (9) and remove capscrew (10) with washer (11).
(7) Remove filter (9) from transmission (8). Discard filter (9).
8-37
TM 08780B-20
(8) Remove two spacers (12).
NOTE
(9) Remove spacer (12.1).
(10) Remove seal ring (13) from oil intake pipe (14).
(11) Discard seal ring (13).
(1) Clean around oil filler tube before removing dipstick.
(2) Keep dipstick in a clean place while filling transmission.
(4) Clean oil pan (5) with mineral spirits or paint thinner.
(5) Clean gasket surfaces (15) with gasket scraper.
c. Installation
(1) Lubricate new seal ring (13) with transmission fluid.
(2) Install seal ring (13) on oil intake pipe (14).
(3) Install new oil filter (9) by inserting the oil intake pipe (14) into the hole in
the bottom of the transmission (8).
(4) Install spacer (12.1), capscrew (10) and washer (11).
8-38
TM 08780B-20
1. Drain Plug 9. Oil Filter

2. Washer 10. Capscrew
3. Nut 11. Washer
4. Dipstick tube 12. Spacer (2)
5. Oil Pan 12.1. Spacer
6. Capscrew (20) 13. Seal Ring
7. Gasket 14. Oil Intake Pipe
8. Transmission 15. Gasket Surface
(5) Torque capscrew (10) to 10-13 foot-pounds (14-18 N*m).
CAUTION
GUARD AGAINST DIRT OR FOREIGN MATERIAL ENTERING TRANSMISSION PAN.
(6) Install new gasket (7) onto oil pan (5).
(7) Guide the oil pan (5) and gasket (7) into place. Secure with four
capscrews(6) at corners of transmission (8).
(8) Install remaining 16 capscrews (6). Do not tighten.
8-39
TM 08780B-20
(9) Starting with center capscrew on each side, torque capscrews (6) to 10-13
foot-pounds (14-18 N*m), working alternate sides until pan is secured with uniform pressure.
(10) Install drain plug (1) with washer (2) at rear of transmission. Torque plug
to 15-20 foot-pounds (20-27 N*m).
(11) Install transmission dipstick tube (4) on oil pan (5) and tighten nut (3).
END OF TASK
NOTE
TM 08780B-20 Install shift cable and bracket
(para 8-5) items 6 and 29.
Install clamp(para 9-4) item 18.
LI 2320-12/9 Fill transmission to proper fluid level.

LO 9-2320-297-12
TM 08780B-10 Start engine and check for leaks

round oil pan gasket (para 2-13).
8-40
TM 08780B-20
8-15. TRANSMISSION COOLER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Radiator grille
and grate removed
Lockwasher (6) (MS35338-46) item 4 Hydraulic oil
cooler removed
References (para 23-10).
TM 08780B-10
LI 2320-12/9
LO 9-2320-297-12
a. Removal
(1) Disconnect two transmission oil lines (1) from transmission oil cooler (2).
(2) Remove six capscrews (3), lockwashers (4) and washers (5). Discard
lockwashers (4).
(3) Remove transmission oil cooler (2) from top of radiator.
(4) Remove two fittings (6 and 7) from oil cooler (2).
c. Installation
(1) Install transmission oil-cooler (2) on top of radiator.
(2) Install six washers (5), new lockwashers (4) and capscrews (3). Tighten
securely.
8-41
TM 08780B-20
(3) Apply pipe sealant to threads and install two fittings (6 and 7) into oil
cooler (2). Tighten securely.
(4) Connect two transmission oil lines (1) on transmission oil cooler (2).
Tighten lines (1) securely.
END OF TASK
NOTE
TM 08780B-20 Install hydraulic oil cooler (para 23-10).
Install radiator grille and grate (para 6-4).
Check hydraulic system oil. Fill to proper

level (para 23-2).
LI 2320-12/9 Check transmission oil. Fill to proper level

LO 9-2320-297-12
TM 08780B-10 Start engine and check for oil leaks

(para 2-13).
1. Transmission Oil Line (2)

2. Transmission Oil Cooler
3. Capscrew(6)
4. Lockwasher(6)
5. Washer (6)
6. Fitting
7. Fitting
8-42
TM 08780B-20
8-16. TRANSMISSION BREATHER REPLACEMENT

c. Installation
INITIAL SETUP

personal injury.
Materials/Parts
a. Removal
CAUTION
USE PROPER WRENCH TO REMOVE OR REPLACE BREATHER. IMPROPER TOOLS

WILL DAMAGE THE BREATHER CAUSING METAL CHIPS TO ENTER THE
TRANSMISSION.
(1) Clean area around breather (1).
(2) Hold reducer (2) with wrench.
(3) Remove breather (1) from reducer (2).
(1) Clean breather (1). Refer to paragraph 2-11.
(2) Inspect breather (1) for damage.
WARNING
COMPRESSED AIR USED FOR CLEANING CAN CREATE AIRBORNE PARTICLES

THAT MAY ENTER THE EYES. PRESSURE WILL NOT EXCEED 30 PSI. EYE
PROTECTION REQUIRED.
(3) Test breather (1) for free air flow with compressed air.
(4) Replace breather (1) if it fails inspection.
8-43
TM 08780B-20
c. Installation
(1) Coat threads of reducer (2) and breather (1) with pipe sealant.
(2) Install reducer (2) and tighten securely.
(3) Install breather (1) into reducer (2) and tighten securely.
1. Breather
2. Reducer
END OF TASK
8-44
TM 08780B-20
CHAPTER 9
TRANSFER CASE
maintenance and replacement procedures for the vehicle’s transfer case.
a. General Description. The transfer case receives power by way of a propeller shaft
from the transmission to the input shaft flange. The input shaft drives both the two-speed shift
shaft and the lubrication pump. The two-speed shift shaft drives the lockable differential. The
differential drives the front output shaft and, through an idler gear, the rear output shaft. The
idler shaft also drives the speedometer transducer.
b. Lubrication Pump. The lubrication pump picks up lubricating oil from the bottom
of the transfer case and distributes it to the top of the transfer case, the front of the two-speed
shift shaft, the rear of the two-speed shift shaft and the declutch housing. This insures proper
lubricant flow to all of the moving parts of the transfer case. The lubrication pump is mounted at
the top rear of the transfer case.
9-1
TM 08780B-20
c. Two-Speed Shift Shaft. The two-speed shift shaft is manually shifted by a shift
cable between the transfer case and the cab of the MK48. By moving the shift handle in the cab,
the driver can select either high range (1-1.165 gear ratio) or low range (1-2.116 gear ratio) to
allow for different terrain and/or traction situations.
d. Locking Differential. The transfer case differential can be shifted from the
unlocked to the locked position by a driver controlled air chamber located on the declutch
housing. The unlocked (normal) position is used when traction is good. In this position the front
output shaft can rotate at a different speed from the rear output shaft. The locked position locks
the differential and makes the front and rear output shafts turn at the same speed.
e. Speedometer Transducer. The speedometer transducer is mounted on the rear of

the transfer case. Its function is to turn the rotation of the idler gear into an electrical signal. The
speedometer uses this signal to determine the vehicle’s speed.
9-2
TM 08780B-20
9-3. TRANSFER CASE OIL CHANGE

c. Filling
INITIAL SETUP

personal injury.
Materials/Parts
References
LI 2320-12/9
LO 9-2320-297-12
a. Draining
NOTE
Make sure lubricant is warm before draining.
(1) Position drain pan under transfer case (1) and remove magnetic drain
plug (2).
(2) Remove lubrication line (3) from strainer (4) and drain.
(3) Remove strainer (4) and fill plug (5).
(1) Clean sealant from all plugs and fittings.
(2) Clean strainer (4) of any deposits.
(3) Inspect threads of plugs and fittings for damage.
(4) Inspect strainer (4) for damage.
NOTE
Angle of installation of strainer (4) is critical.
9-3
TM 08780B-20
c. Filling
(1) Coat threads of magnetic drain plug (2) with pipe sealant. Install magnetic
drain plug (2) and tighten securely.
(1) Install drain plug (2) as shown and tighten securely.
(2) Coat threads of strainer (4) with sealant and install as shown.
(3) Install lubrication line (3) onto strainer (4) and tighten securely.
(4) Fill transfer case (1) with lubricant until oil reaches fill plug hole (6).
Refer to LI 2320-12/9, LO 9-2320-297-12.
(5) Coat threads of fill plug (5) with sealant and install.
END OF TASK
NOTE
TM 08780B-10 Operate vehicle and check for leaks
(para 2-13).
1. Transfer Case
2. Magnetic Drain Plug
3. Lubrication Line
4. Strainer
5. Fill Plug
6. Fill Plug Hole
9-4
TM 08780B-20
9-4. 2-SPEED SHIFT LINKAGE MAINTENANCE

c. Installation
d. Adjustment

Condition Condition
removed (para
Nylon tie (MS3367-4-9) item 10 General Safety Instructions
Lockwasher (MS35338-44) item 12 Block wheels of truck to prevent
Lockwasher (4) (MS35338-45) items 27 and 29 personal injury.
a. Removal
(1) Remove cotter pin (1), clevis pin (2) and clevis (3) from shift lever (4).
(2) Loosen locknut (5) on shift cable (6) and slide from bracket (7).
1. Cotter Pin
2. Clevis Pin
3. Clevis
4. Shift Lever
5. Locknut
6. Shift Cable
7. Bracket
(3) Remove capscrew (8) and clamp (9).
(4) Remove nylon tie (10) and discard.
(5) Remove nut (11), lockwasher (12) and capscrew (13) from bracket (14).
9-5
TM 08780B-20
(6) Remove clamp (15).
(7) Remove capscrew (16), spacer (17) and clamp (18).
(8) Remove cotter pin (19), clevis pin (20) and clevis (21) from shift shaft
(22) on transfer case (23). Discard cotter pin (19).
(9) Loosen locknut (24) and remove shift cable (6).
6. Shift Cable 13. Capscrew 19. Cotter Pin

8. Capscrew 14. Bracket 20. Clevis Pin
9. Clamp 15. Clamp 21. Clevis
10. Nylon Tie 16. Capscrew 22. Shift Shaft
11. Nut 17. Spacer 23. Transfer Case
12. Lockwasher 18. Clamp 24. Locknut
9-6
TM 08780B-20
NOTE
Remove brackets (7 and 25) only if they need replacing.
(10) Remove two capscrews (26), lockwashers (27) and bracket (25). Discard
lockwashers (27).
(11) Remove two nuts (28), lockwashers (29), bracket (7) and two capscrews
c. Installation
NOTE
If brackets (7 and 25) were not removed, go to step (3).
(1) If removed, install bracket (25), two new lockwashers (27) and capscrews
(2) If removed, install two capscrews (30), bracket (7), two new lockwashers
(29) and nuts (28). Tighten securely.
(3) Route shift cable (6) loosely into place.
(4) Install clevis (3), clevis pin (2) and new cotter pin (1) onto shift lever (4).
(5) Seat shift cable (6) into slot in bracket (7) and tighten locknut (5) securely.
9-7
TM 08780B-20
1. Cotter Pin 7. Bracket 25. Bracket

2. Clevis Pin 19. Cotter Pin 26. Capscrew (2)
3. Clevis 20. Clevis Pin 27. Lockwasher (2)
4. Shift Lever 21. Clevis 28. Nut (2)
5. Locknut 22. Shift Shaft 29. Lockwasher (2)
6. Shift Cable 24. Locknut 30. Capscrew (2)
(6) Install clamp (9) around shift cable (6) and install capscrew (8). Tighten
securely.
(7) Install new nylon tie (10) between clamps (9 and 15).
(8) Install clamp (15) around shift cable (6) and install onto bracket (14) using
capscrew (13), new lockwasher (12) and nut (11). Tighten securely.
(9) Install clamp (18) around shift cable (6) and install capscrew (16) and
spacer (17). Torque to 10-13 foot-pounds (13.6-17.6 N*m).
(10) Install clevis (21), clevis pin (20) and new cotter pin (19) onto shift shaft
(22).
(11) Seat shift cable (6) into slot in bracket (25) and tighten locknut (24)
securely.
9-8
TM 08780B-20
6. Shift Cable 11. Nut 15. Clamp

8. Capscrew 12. Lockwasher 16. Capscrew
9. Clamp 13. Capscrew 17. Spacer
10. Nylon Tie 14. Bracket 18. Clamp
d. Adjustment
(1) Position shift lever (4) all the way forward.
(2) Remove cotter pin (19), clevis pin (20) and clevis (21) from shift shaft
(22). Discard cotter pin (19).
(3) Position shift shaft (22) all the way in.
(4) Loosen clevis (21), locknut (24) and turn clevis (21) in or out to obtain
proper length of shift cable (6).
9-9
TM 08780B-20
(5) Tighten clevis (21), locknut (24) and install clevis (21), clevis pin (20) and
new cotter pin (19).
NOTE
If proper adjustment cannot be obtained at transfer case end of cable (6), further adjustment
can be made at shift lever end of cable (6). Repeat steps (1) thru (5) at shift lever end of cable
(6).
END OF TASK
NOTE
TM 08780B-10 Check operation of shift lever (para 2-1).
9-10
TM 08780B-20
4. Shift Lever 21. Clevis

6. Shift Cable 22. Shift Shaft
19. Cotter Pin 24. Locknut
20. Clevis Pin
9-11
TM 08780B-20
9-5. SHIFT LEVER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Access panel
removed, (para
Materials/Parts 18-15), item 4.
Silicone sealant (item 5, Appendix D)
Cotter pin (MS24665-353) item 1 General Safety Instructions
Block wheels of truck to prevent
Personnel Required personal injury.
1 MOS 3521
1 Assistant
a. Removal
(1) Reach through opening in cab access panel to remove cotter pin (1), clevis
pin(2) and clevis (3) from rear of shift lever (4). Discard cotter pin (1).
(2) Have assistant hold nuts (5) and remove three capscrews (6) and nuts (5).
(3) Tilt shift lever (4) outward and remove.
(4) Unscrew and remove shift lever knob (7).
(1) Clean sealer from mating surface of panel in cab.
(2) Inspect capscrews (6) and nuts (5) for damaged threads. Inspect all other
parts. Refer to paragraph 2-12.
c. Installation
(1) Apply silicone sealant to mating surface of shift lever (4) and install
through hole in side panel.
(2) Install three capscrews (6) through shift lever (4) and side panel.
9-12
TM 08780B-20
(3) Have assistant install three nuts (5) onto capscrews (6) and tighten
securely.
(4) Install clevis (3), clevis pin (2) and new cotter pin (1).
(5) Install shift lever knob (7).
END OF TASK
NOTE
TM 08780B-20 Install access panel (para 18-15) item 4.
TM 08780B-10 Check operation of shift lever (para 2-1).
1. Cotter Pin
2. Clevis Pin
3. Clevis
4. Shift Lever
5. Nut (3)
6. Capscrew (3)
7. Shift Lever Knob
9-13
TM 08780B-20
9-6. LUBRICATION LINES AND FITTING REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Transfer case
lubricant drained
Lockwasher (MS35338-46) item 2.2 General Safety Instructions
Nylon tie (A/R) (MS3367-4-9) Block wheels of truck to prevent
personal injury.
a. Removal
(1) Remove nylon ties as necessary.
(2) Disconnect lubrication line (1) and remove strainer (2).
(3) Remove nut (2.1), lockwasher (2.2), washer (2.3), capscrew (2.4) and
cushion clip (2.5). Discard lockwasher (2.2).
(4) Disconnect lubrication line (3) from fitting (4).
(5) Disconnect two lubrication lines (5 and 6) and remove fitting (7).
(6) Disconnect other end of lubrication line (6) and remove.
(7) Remove fitting (8).
(8) Remove capscrew (9) and cushion clip (10).
(9) Disconnect and remove lubrication lines (1, 3 and 5).
(10) Disconnect both ends of lubrication line(11) and remove.
(11) Remove fitting (12), reducer (13) and nipple (14) from lubrication pump
(15).
(13) Remove two fittings (17) from fitting (18).
9-14
TM 08780B-20
(14) Remove fitting (19) from fitting (18).
(15) Remove fitting (18) from lubrication pump (15).
(16) Remove reducer (20) from lubrication pump (15).
(17) Remove nipple (21) from reducer (20) or fitting (18) if damaged.
(2) Inspect fittings for damaged threads or other damage.
(3) Inspect lubrication lines for leaks, damaged ends, chafed areas or other
damage.
(4) Replace any part failing inspection.
9-15
TM 08780B-20
1. Lubrication Line 5. Lubrication Line 14. Nipple

2. Strainer 6. Lubrication Line 15. Lubrication Pump
2.1. Nut 7. Fitting 16. Fitting
2.2. Lockwasher 8. Fitting 17. Fitting (2)
2.3. Washer 9. Capscrew 18. Fitting
2.4. Capscrew 10. Cushion Clip 19. Fitting
2.5. Cushion Clip 11. Lubrication Line 20. Reducer
3. Lubrication Line 12. Fitting 21. Nipple
4. Fitting 13. Reducer
9-16
TM 08780B-20
c. Installation
NOTE
• Apply pipe sealant to threads of fittings, nipples and reducers before installing.
• Tighten all fittings and lines securely as installing.
(1) Install reducer (20) into lubrication pump (15).
(2) Install nipple (21) into reducer (20) if removed.
(3) Install and tighten fitting (18) onto nipple (21).
(4) Install fittings (17 and 19) into fitting (18).
(5) Install fitting (16) into transfer case (22).
(6) Install nipple (14), reducer (13) and fitting (12) into lubrication pump (15).
(7) Install lubrication line (11) onto fittings (16 and 17).
(8) Install one end of lubrication line (1) to fitting (12).
(9) Install one end of lubrication lines (3 and 5) onto fittings (17 and 19).
(10) Install strainer (2) and fittings (7 and 8) into transfer case (22).
(11) Install lubrication line (1) onto strainer (2).
(12) Install cushion clip (10) and capscrew (9). Tighten capscrew (9) securely.
(13) Install lubrication line (3) onto fitting (4).
(14) Install lubrication line (5) onto fitting (7).
(15) Install lubrication line (6) onto fittings (7 and 8).
(16) Install cushion clip (2.5) using capscrew (2.4), washer (2.3), new
lockwasher (2.2) and nut (2.1). Tighten nut securely.
(17) Install nylon ties.
END OF TASK
9-17
TM 08780B-20
NOTE
TM 08780B-20 Fill transfer case with lubricant (para 9-3).
TM 08780B-10 Operate transfer case and check for

leaks (para 2-1).
1. Lubrication Line 5. Lubrication Line 14. Nipple

2. Strainer 6. Lubrication Line 15. Lubrication Pump
2.1. Nut 7. Fitting 16. Fitting
2.2. Lockwasher 8. Fitting 17. Fitting (2)
2.3. Washer 9. Capscrew 18. Fitting
2.4. Capscrew 10. Cushion Clip 19. Fitting
2.5. Cushion Clip 11. Lubrication Line 20. Reducer
3. Lubrication Line 12. Fitting 21. Nipple
4. Fitting 13. Reducer 22. Transfer Case
9-18
TM 08780B-20
9-7. TRANSFER CASE LUBRICATION PUMP REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Lubrication lines
and fittings
Sealant (item 39, Appendix D)
Adhesive (item 3, Appendix D) General Safety Instructions
Lockwasher (4) (MS35338-45) item 7 Block wheels of truck to prevent
Lockwasher (1) (MS35338-44) item 2 personal injury.
a. Removal
(1) Remove capscrew (1), lockwasher (2), washer (3) and move fuel line (4)
and clamp (5) out of the way.
(2) Remove four capscrews (6) and lockwashers (7). Discard

lockwashers (7).
(3) Remove pump (8) from transfer case (9).
(1) Clean mating surface on transfer case of any sealant.
(2) Inspect threads of capscrews (1) for damage. Replace if needed.
(4) Inspect all parts failing inspection.
c. Installation
(1) Apply sealant to mating surface of lubrication pump (8).
(2) Align drive shaft tang (10) with drive plate slot (11) and install pump (8)
onto transfer case (9).
(3) Coat threads of four capscrews (6) with adhesive and install with four new
lockwashers (7). Tighten capscrews (6) to 13 foot-pounds (16.9 N*m).
9-19
TM 08780B-20
(4) Install clamp (5) with washer (3), new lockwasher (2) and capscrew (1).
Tighten capscrew (1) to 8 foot-pounds (10.8 N*m).
END OF TASK
NOTE
TM 08780B-20 Install lubrication fittings and lines
(para 9-6).
TM 08780B-10 Operate transfer case and check for

leaks (para 2-13).
1. Capscrew
2. Lockwasher
3. Washer
4. Fuel Line
5. Clamp (4)
6. Capscrew (4)
7. Lockwasher
8. Pump
9. Transfer Case
10. Drive Shaft Tang
11. Drive Plate Slot
9-20
TM 08780B-20
9-8. TRANSFER CASE BREATHER REPLACEMENT

c. Installation
INITIAL SETUP
MK48

Block wheels of truck to prevent personal injury.
a. Removal
CAUTION
USE PROPER WRENCH TO REMOVE OR REPLACE BREATHER. IMPROPER TOOLS

WILL DAMAGE BREATHER AND CAUSE METAL CHIPS TO ENTER TRANSFER
CASE.
(2) Hold reducer coupler (2) with wrench.
(3) Remove breather (1) from reducer coupler (2).
WARNING

(3) Test breather (1) for free air flow with compressed air.
9-21
TM 08780B-20
c. Installation
(1) Install breather (1) into reducer coupler (2).
(2) Tighten securely.
1. Breather
2. Reducer Coupler
END OF TASK
9-22
TM 08780B-20
9-9. LOCKUP AIR CHAMBER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Exterior access
panel removed
Materials/Parts (para 18-15), item 28.
O-ring (NSN 5330-00-454-0370) item 4 To prevent personal injury, drain all air
Locknut (MS51922-9) item 6 pressure from system. Block wheels of
Lockwasher (2) (MS35338-46) item 9 truck to prevent personal injury.
a. Removal
(1) Tag and remove two air lines (1 and 2).
(2) Remove capnut (3) with O-ring (4) from air chamber (5).
(3) Remove O-ring (4) from capnut (3). Discard O-ring (4).
(4) Remove locknut (6) and washer (7). Discard locknut (6).
(5) Remove two capscrews (8) and lockwashers (9). Discard lockwashers (9).
(6) Remove air chamber (5) from declutch housing (10).
(7) Remove air line fittings (11 and 12) from air chamber (5).
(8) Remove reducer (13) from air chamber (5).
9-23
TM 08780B-20
c. Installation
(1) Make sure shift shaft (14) is pulled all the way out.
(2) Apply silicone sealant to mating surface of air chamber (5) and install over
shift shaft (14).
(3) Install washer (7) and new locknut (6). Tighten securely.
(4) Install two new lockwashers (9) and capscrews (8). Tighten securely.
(5) Install new O-ring (4) onto capnut (3).
(6) Install capnut (3) into air chamber (5). Tighten securely.
(7) Apply pipe sealant to threads of reducer (13) and air line fittings (11 and 12)
and install into air chamber (5).
(8) Install air lines (1 and 2) and tighten securely.
END OF TASK
NOTE
TM 08780B-10 Check transfer case for proper
TM 08780B-20 Install access panel (para 18-15), item 28.
9-24
TM 08780B-20

2. Air Line 9. Lockwasher (2)
3. Capnut 10. Declutch Housing
4. O-Ring 11. Airline Fitting
5. Air Chamber 12. Air Line Fitting
6. Locknut 13. Reducer
7. Washer 14. Shift Shaft
9-25/(9-26 blank)
TM 08780B-20
CHAPTER 10
PROPELLER SHAFTS
maintenance, repair and replacement procedures for the vehicle's propeller shafts.
a. General. Propeller shafts transmit power from the engine to the various drive
train components. Through the use of a combination of universal joints, slip joints and cardan
joint, the power is transmitted at the angles needed to operate the LVS.
b. Construction. All propeller shafts and universal joints are similar. Each shaft has
a tube connecting an end yoke to a slip joint. The slip joint allows changes in length between
connected parts of the drive train. The universal joints consist of a cross type journal, bearing
caps, seals and a lubrication fitting. Universal joints allow transmission of power at different
angles. Due to increased stress, a cardan joint and a pillow block shaft are used at the
articulation joint. A cardan joint is two universal joints and a spacer block used in an area of
extreme angle. Pillow block bearings hold the pillow block shaft to prevent movement. A center
support bearing is used to support long propeller shafts.
10-1
TM 08780B-20
10-3. PROPELLER SHAFTS AND UNIVERSAL JOINT MAINTENANCE

b. Disassembly
d. Assembly
e. Installation

1 MOS 3521
Materials/Parts 1 Assistant
Locknut (NSN 5310-00-051-6048) item 3 General Safety Instructions
Lockwasher (2) (MS35338-48) item 8 Block wheels of truck to prevent
Lockwasher (8) (MS35338-46) item 12 personal injury.
Locknut (NSN 5310-00-051-6048) item 33
Self-locking capscrew (12) (6-73-209) Failure to properly tighten bolt or
items 16.1, 22.1 and 28.1 reuse of self-locking capscrews could
cause the driveshaft to loosen and separate
from the vehicle, which could cause a loss
of control and could result in serious
personal injury or death.
a. Removal
NOTE
• For removal of propeller shafts using companion flanges, follow steps (1) thru (6).
• For removal of propeller shafts using yokes, follow steps (7) thru (12).
• LVSA1 series vehicles have changed mounting hardware for the bearing caps. The
lockstraps are no longer available and the capscrews have been replaced by a self-
locking type. When repairing non-Al vehicles, use the new style hardware to replace
the old style hardware. Refer to TM 08780B-24P for correct part identification.
(1) Support shaft (1) with rope.
(2) On shaft supported by chain (2), remove locknut (3), capscrew (4) and flat
washer (5) from one end of chain (2). Discard locknut (3).
(3) On shafts using single center support bearing (6), remove two nuts (7),
lockwashers (8) and capscrews (9). Discard lockwashers (8).
(4) Matchmark companion flanges (10).
10-2
TM 08780B-20
1. Shaft 7. Nut (2)

2. Chain 8. Lockwasher (2)
4. Capscrew 10. Companion Flange
5. Flat Washer 11. Nut (8)
6. Single Center 12. Lockwasher (8)
Support bearing 13. Capscrew (8)
(5) Remove eight nuts (11), lockwashers (12) and capscrews (13). Discard
lockwashers (12).
(6) Repeat steps (3), (4) and (5) at other end of propeller shaft (1). Remove
shaft (1) from truck.
(7) On shafts using yokes (14) and that have lockstraps (15), bend two
lockstraps (15) away from four capscrews (16). Remove capscrews (16). Discard lockstraps
(15).
(8) On shafts using yokes and that do not have lockstraps, remove four
self-locking capscrews (16.1). Discard self-locking capscrews (16.1).
(9) Remove one bearing cap (17) from yoke (14).
(10) Tap cross (18) down through yoke (14) to remove other bearing cap (19).
NOTE
It may be easier to remove all four bearing caps (17 and 19) to allow removal of shaft (20),
depending on location of cross (18).
10-3
TM 08780B-20
(11) Disconnect shaft (20) from yoke (14) by moving cross (18) to one side.
Then tilt to clear other side.
(12) Repeat steps (7) thru (11) for other end of shaft.
14. Yoke 17. Bearing Cap

15. Lockstrap (2) 18. Cross
16. Capscrew (4) 19. Bearing Cap
16.1. Self-Locking Capscrew (4)* 20. Shaft

b. Disassembly
(1) To remove companion flange (10) on shafts with lockstraps, bend two
lockstraps (21) away from four capscrews (22) on companion flange (10). Remove four
capscrews (22). Discard capscrews (22) and lockstraps (21).
(2) To remove companion flange (10) on shafts without lockstraps, remove

four self-locking capscrews (22.1) on companion flange (10). Discard self-locking capscrews
(22.1).
(3) Remove one bearing cap (23).
(4) Tap cross (24) through companion flange (10) to remove other bearing cap
(25).
(5) Disconnect companion flange (10) from shaft (1) by moving cross (24) to
one side. Then tilt to clear other side.
10-4
TM 08780B-20
(6) To remove cross (24) from end of yoke (26) on shafts with lockstraps,
bend remaining two lockstraps (27) away from four capscrews (28). Discard lockstraps (27).
(7) To remove cross (24) from end yoke (26) without lockstraps (27), remove
four self-locking capscrews (28.1). Discard self-locking capscrews (28.1).
(8) Place end yoke (26) in a soft-jawed vise and remove one bearing cap (29)
from end yoke (26).
1. Shaft 25. Bearing Cap

10. Companion Flange 26. End Yoke
21. Lockstrap (2) 27. Lockstrap (2)
22.1. Self-Locking Capscrew (4)* 28.1. Self-Locking Capscrew (4)*
23. Bearing Cap 29. Bearing Cap
24. Cross 30. Bearing Cap
* LVSA1 SERIES VEHICLES ONLY
(9) Tap cross (24) through end yoke (26) to remove other bearing cap (30).
(10) Remove cross (24) by moving to one side of end yoke (26). Then tilt to
clear other side.
10-5
TM 08780B-20
(12) Before separating propeller shaft, matchmark slip shaft (31) and spline
shaft (32).
(13) Loosen and slide dust cap (33) onto spline shaft (32).
(14) Separate slip shaft (31) from spline shaft (32). Remove dust cap (33) from
spline shaft (32).
31. Slip Shaft 1. Shaft

32. Spline Shaft 10. Companion Flange
33. Dust Cap 34. Locknut
35. Washer
36. Single Center Support
Bearing Assembly
(15) Place shaft (1) with single center support bearing assembly (36) in soft-
jawed vise.
(16) Remove locknut (34) and washer (35). Discard locknut (34).
(17) Remove companion flange (10) from shaft (1).
(18) Remove single center support bearing assembly (36) from shaft (1).
(2) Inspect propeller shafts for bends, dents, broken welds or stripped threads.
(3) Inspect U-joints for pitting, scoring or signs of damage.
(4) Inspect yokes and flanges for cracks, stripped threads and broken or worn
splines.
10-6
TM 08780B-20
(5) Inspect slip shaft (31) and spline shaft (32) for twisted, worn or broken
splines.
d. Assembly
(1) Pack single center bearing support assembly (36) with weatherproof
grease.
(2) Install single center support bearing assembly (36) onto shaft (1).
(3) Install companion flange (10) onto shaft (1).
(4) Install washer (35) and new locknut (34). Torque locknut (34) to 750
foot-pounds (1017 N*m).
(5) Install dust cap (33) onto spline shaft (32).
CAUTION
TO PREVENT DAMAGE DURING OPERATION, MAKE SURE TO ALIGN MARKS ON

SLIP SHAFT AND SPLINE SHAFT.
(6) Install spline shaft (32) into slip shaft (31).
1. Shaft
10. Companion Flange
34. Locknut
35. Washer
36. Single Center Support
Bearing Assembly
NOTE
Make sure lip of dust cap (33) faces spline shaft (32).
(7) Thread dust cap (33) on slip shaft (31). Hand tighten dust cap (33).
10-7
TM 08780B-20
31. Slip Shaft

32. Spline Shaft
33. Dust Cap
(8) Install cross (24) into end yoke (26) by tilting into place.
(9) Tap two bearing caps (29 and 30) into end yoke (26) until flush with end
yoke (26).
(10) Install four self-locking capscrews (28.1). Tighten self-locking capscrews

(28.1) to 38-48 foot-pounds (52-65 N*m)
(11) On shafts with companion flanges (10), install companion flange (10) onto
cross by tilting cross (24) into position.
(12) Install two bearing caps (23 and 25) into companion flange (10).
(13) Install four self-locking capscrews (22.1). Tighten self-locking capscrew

(22.1) to 38-48 foot-pounds (52-65 N*m).
10-8
TM 08780B-20
10. Companion Flange 26. End Yoke

21. Deleted 27. Deleted
22. Deleted 28. Deleted
22.1 Self-Locking Capscrew (4) 28.1. Self-Locking Capscrew (4)
23. Bearing Cap 29. Bearing Cap
24. Cross 30. Bearing Cap
25. Bearing Cap
e. Installation
NOTE
• For installation of propeller shafts using companion flanges, follow steps (1) thru (5).
• For installation of propeller shafts using yokes, follow steps (6) thru (9).
(1) Support shaft (1) with rope.
(2) On shafts with companion flanges (10), align matchmarks. Install eight
capscrews (13), new lockwashers (12) and nuts (11). Tighten nuts (11) to 40-48 foot-pounds
(54-65 N*m).
10-9
TM 08780B-20
CAUTION
TO AVOID PARTS DAMAGE, MAKE SURE COMPANION FLANGES (10) DO NOT BIND
ON ARTICULATION JOINT. MOVE SINGLE CENTER SUPPORT BEARING (6) TO
PREVENT BINDING.
(3) On shaft with single center support bearing (6), install two capscrews (9),
new lockwasher (8) and nuts (7). Tighten locknut (3) securely.
(4) Install chain (2) using capscrew (4), flat washer (5) and locknut (3).
Tighten locknut (3) securely.
1. Shaft 6. Single Center 10. Companion Flange

2. Chain Support Bearing 11. Nut (8)
3. Locknut 7. Nut (2) 12. Lockwasher (8)
4. Capscrew 8. Lockwasher (2) 13. Capscrew (8)
5. Flat Washer 9. Capscrew
10-10
TM 08780B-20
14. Yoke 17. Bearing Cap

15. Deleted 18. Cross
16. Deleted 19. Bearing Cap
16.1. Self-Locking
Capscrew (4)
(6) On shafts using yokes (14), insert cross (18) into yoke by tilting into place.
(7) Tap two bearing caps (17 and 19) into yoke (14) until flush with yoke
(14).
(8) Install four new self-locking capscrews (16.1). Tighten self-locking

capscrews (16.1) to 38-48 foot pounds (52-65 N*m).
END OF TASK
NOTE
LI 2320-12/9 Lubricate propeller shafts.
LO 2320-297-12
TM 08780B-10 Operate vehicle (para 2-13) and check for

drive line noise and vibration.
10-11
TM 08780B-20
10-4. CARDAN JOINT REPAIR

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK48 TM 08780B-10 Wheel turned to
right (para 2-13).
Materials/Parts
Grease (item 22, Appendix D) General Safety Instructions
Lockwasher (8) (MS35338-48) Do not work on truck with engine running.
items 2 and 7 Block wheels of truck to prevent
personal injury.
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
WARNING
• DO NOT WORK ON TRUCK WITH ENGINE RUNNING. SERIOUS INJURY MAY

RESULT.
• TO PREVENT INJURY, BE CAREFUL WHEN LIFTING CARDAN JOINT.
(1) Remove four nuts (1), lockwashers (2) and capscrews (3) from propeller
shaft side of cardan joint (4). Discard lockwashers (2).
(2) Slide slip yoke (5) toward rear of truck.
(3) Have assistant support cardan joint (4) and remove four nuts (6),
lockwashers (7) and capscrews (8). Discard lockwashers (7).
(4) Remove cardan joint (4) from transfer case output yoke (9).
b. Disassembly
(1) Matchmark U-joints (10) to center plate (11).
(2) Remove four capscrews (12) from U-joint (10).
10-12
TM 08780B-20
(3) Remove U-joint (10) from center plate (11).
(4) Remove four capscrews (13) from U-joint (10).
(5) Remove U-joint (10) from center plate (11).
(2) Inspect center plate (11) for cracks, burrs and other signs of wear.
(3) Inspect U-joint crosses for cracks, burrs or other signs of wear.
(4) Inspect U-joint caps (14) for broken needle bearing.
d. Assembly
NOTE
If universal joint is being reused, install it in its original position.
(1) Align matchmarks and install U-joint (10) on center plate (11) with four
capscrews (13). Torque capscrews (13) to 108 foot-pounds (146.5 N*m).
(2) Align matchmarks and install U-joint (10) on center plate (11) with four
capscrews (12). Torque capscrews (12) to 108 foot-pounds (146.5 N*m).
e. Installation
(1) Install cardan joint (4) onto rear transfer case output yoke (9).
(2) Install four 1/2 x 3-1/4 inch capscrews (8), new lockwashers (7) and
nuts (6). Tighten nuts (6) securely.
(3) Slide slip yoke (5) to seat against U-joint (10).
(4) Install four 1/2 x 4 inch capscrews (3), new lockwashers (2) and nuts (1).
Tighten nuts (1) securely.
END OF TASK
10-13
TM 08780B-20
NOTE
LI 2320-12/9 Grease cardan joint.
LO 9-2320-297-12

drive line noise or vibration.
1. Nut (4) 6. Nut (4) 11. Center Plate

2. Lockwasher (4) 7. Lockwasher (4) 12. Capscrew (4)
3. Capscrew (4) (1/2 X 4) 8. Capscrew (4) (1/2 X 3 1/4) 13. Capscrew (4)
4. Cardan Joint 9. Transfer Case Output Yoke 14. U-Joint Cap (8)
5. Slip Yoke 10. U-Joint (2)
10-14
TM 08780B-20
10-5. PILLOW BLOCK BEARING REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK48 TM 08780B-10 Wheels turned to
right (para 2-13).
Materials/Parts
Lockwasher (8) (MS35330-46) item 4 Engine turned
Locknut (NSN 5310-00-051-6048) item 6 off (para 2-13).
Locknut (4) (MS17829-14C) item 13 Transfer case
Packing (NSN 5330-01-162-4813) item 19 in low (para 2-1).
Personnel Required Transfer case

1 MOS 3521 lock-up engaged
1 Assistant (para 2-13).

Do not work on truck with engine running.
a. Removal
(1) Matchmark companion flanges (1 and 2).
(2) Remove eight nuts (3), lockwashers (4), capscrews (5) and companion
flange (2). Discard lockwashers (4).
(3) Remove locknut (6) and washer (7) and discard locknut (6). Remove
companion flange (2).
(4) Remove four nuts (8), lockwashers (9) and capscrews (10). Discard
lockwashers (9).
(5) Slide slip yoke (11) toward rear of vehicle.
(6) Have assistant support shaft assembly (12).
10-15
TM 08780B-20
(7) Remove four locknuts (13), eight washers (14) and four capscrews (15).
(8) Remove shaft assembly (12) and two pillow block spacers (16) from
vehicle.
b. Disassembly
(1) Place shaft assembly (12) in soft-jawed vise.
(2) Unscrew dust cap (17), washer (18) and packing (19) from slip yoke (11)
and slide onto shaft (20).
(3) Matchmark slip yoke (11) to shaft (20).
(4) Remove slip yoke (11). Remove packing (19), washer (18) and dust
cap (17) from shaft (20). Discard packing (19).
(5) Remove two Allen screws (21) from pillow block bearing (22).
1. Companion Flange
2. Companion Flange
3. Nut (8)
4. Lockwasher (8)
5. Capscrew (8)
6. Locknut
7. Washer
8. Nut (4)
9. Lockwasher (4)
10. Capscrew (4)
11. Slip Yoke
12. Shaft Assembly
13. Locknut (4)
14. Washer (8)
15. Capscrew (4)
16. Pillow Block Spacer (2)
17. Dust Cap
18. Washer
19. Packing
20. Shaft
21. Allen Screw (2)
22. Pillow Block
Bearing
10-16
TM 08780B-20
NOTE
It may be necessary to use a press to remove pillow block bearing from shaft.
(6) Tag and remove pillow block bearing (22) from shaft (20).
(7) Remove two Allen screws (23).
(8) Tag and remove pillow block bearing (24).
(9) If damaged, remove grease fittings (25) from pillow block bearings (22
and 24).
(3) Inspect shaft (20) for dents, bends or broken welds.
(4) Inspect splines on shaft (20) for cracks, nicks or burrs.
(5) Inspect slip yoke (11) and companion flanges (1 and 2) for cracks or signs
of wear.
d. Assembly
NOTE
If pillow block bearings are reused, they must be installed in original position.
(1) Place shaft (20) in soft-jawed vise with threaded end up.
(2) Install pillow block bearing (24) with long side of bearing (24) facing up.
(3) Install two Allen screws (23) into pillow block bearing (24). Tighten
Allen screws (23) securely.
(4) Install companion flange (2) onto shaft (20) until seated against pillow
block bearing (24).
(5) Install washer (7) and new locknut (6). Do not tighten.
(6) Place shaft (20) in soft-jawed vise with splined end up.
10-17
TM 08780B-20
(7) Install pillow block bearing (22) on shaft (20) with long side of bearing
(22) facing up.
(8) Install two Allen screws (21) into pillow block bearing (22). Tighten
Allen screws (21) securely.
(9) Slide dust cap (17), washer (18) and new packing (19) onto shaft (20).
(10) Align matchmarks made at disassembly. Install slip yoke (11) onto shaft
(20).
(11) Install new packing (19), washer (18) and dust cap (17) onto slip yoke
(11). Hand tighten dust cap (17).
(12) If removed, install two grease fittings (25) into pillow block bearings (22
and 24).
e. Installation
(1) Install four capscrews (15) with four washers (14) into vehicle, with
threads facing down.
(2) Place two pillow block spacers (16) on top of pillow block bearings (22
and 24). Have assistant hold pillow block spacers (16).
(3) Install shaft assembly (12) and two pillow block spacers (16), with slip
yoke (11) facing transfer case, using four washers(14) and new locknuts (13). Do not tighten
nuts (13) yet.
(4) Slide slip yoke (11) until seated.
(5) Install four capscrews (10), new lockwasher (9) and nuts (8). Tighten nuts
(8) securely.
(6) Torque four locknuts (13) to 400 foot-pounds (542 N*m).
(7) Torque nut (6) to 700-750 foot-pounds (949-1,017 N*m).
(8) Align matchmarks on companion flanges (1 and 2). Install eight

capscrews (5), new lockwashers (4) and nuts (3). Tighten nuts (3) to 40-48 foot-pounds (54.24-
65 N*m).
END OF TASK
10-18
TM 08780B-20
NOTE
LI 2320-12/9 Grease pillow block bearings.
LO 9-2320-297-12

drive line noise or vibration.
1. Companion Flange
2. Companion Flange
3. Nut (8)
4. Lockwasher (8)
5. Capscrew (8)
6. Locknut
7. Washers
8. Nut (4)
9. Lockwasher (4)
10. Capscrew (4)
11. Slip Yoke
12. Shaft Assembly
13. Locknut (4)
14. Washer (8)
15. Capscrew (4)
16. Pillow Block Spacer (2)
17. Dust Cap
18. Washer
19. Packing
20. Shaft
21. Allen Screw (2)
22. Pillow Block Bearing
23. Allen Screw (2)
24. Pillow Block Bearing
25. Grease Fitting (2)
10-19/(10-20 blank)
TM 08780B-20
CHAPTER 11
FRONT AXLE
Maintenance level mechanics. The following chapter covers maintenance and replacement
procedures for the vehicle's front axle.
11-2. NO. 1 AXLE PRINCIPLES OF OPERATION
a. General. The No. 1 axle assembly includes the nose box, inter-axle
differential, axle carrier and two ball and socket assemblies.
b. Nose Box. The nose box acts as a drop box to transmit power from the transfer
case to the inter-axle differential and drive the lubrication pump for the No. 1 axle carrier. The
nose box holds seven pints of lubricant. This lubricant is isolated from the rest of the axle by a
pair of seals on the input shaft.
c. Inter-Axle Differential. The inter-axle differential receives power from the nose
box and distributes it to the No. 1 axle and the No. 2 axle.
d. Axle Carrier. The carrier receives power from the inter-axle differential and,
while acting as a differential, distributes it to the axle shafts. Total lubrication capacity of the
axle carrier is 33 pints.
e. Ball/Socket Assembly. There are two ball and socket assemblies. One is on each
end of the No. 1 axle. They give the LVS the ability to turn right or left. They are connected by
the steering arm to the steering linkage.
11-1
TM 08780B-20
11-3. NO. 1 AXLE OIL CHANGE

c. Filling

LI 2320-12/9
MK48
Materials/Parts Block wheels of truck to prevent
Adhesive (item 3, Appendix D) personal injury.
a. Draining
NOTE
• Make sure lubricant is warm before draining. Lubricant will drain faster.
• When removing magnetic drain plugs (2 and 4) and fill plug (6), look for metal
particles sticking to them. Small amounts of fine particles are normal. Large amounts
or large particles may be signs of future axle or nose box failure. Notify Direct
Support/Intermediate Maintenance (Third Echelon), if large amounts of metal or large
particles exist.
(1) Position drain pan under axle (1) and remove drain plug (2).
(2) Position drain pan under nose box (3) and remove drain plug (4).
(3) Remove fill plugs (5 and 6) from axle (1) and nose box (3).
(4) Remove lubrication line (7) from top of carrier cover (8).
(1) Clean sealant from all threaded parts.
(2) Inspect all threaded parts for damage.
c. Filling
(1) Coat threads of drain plugs (2 and 4) with adhesive and install. Tighten
securely.
11-2
TM 08780B-20
CAUTION
NOSE BOX AND AXLE ARE SEPARATE. BE SURE TO CHECK AXLE AND NOSE BOX
OIL LEVELS SEPARATELY.
(2) Fill nose box (3) with proper lubricant till level with hole for fill plug (6).
(3) Coat threads of fill plug (6) with adhesive and install. Tighten securely.
(4) Fill axle (1) with proper lubricant till level with hole for fill plug (5).
(6) Add two pints (0.94 liter) of axle lubricant through hole for lubrication
line (7) at top of carrier cover (8).
(7) Install lubrication line (7).
END OF TASK
NOTE
TM 08780B-10 Operate vehicle (para 2-13) and check
for leaks.
11-3
TM 08780B-20
1. Axle 5. Fill Plug

2. Drain Plug 6. Fill Plug
3. Nose Box 7. Lubrication Line
4. Drain Plug 8. Carrier Cover
11-4
TM 08780B-20
11-4. FRONT AXLE BREATHER SERVICE

c. Installation
INITIAL SETUP

personal injury.
Materials/Parts
a. Removal
(2) Remove breather (1) from front axle housing (2).
(3) Cover hole to prevent dirt from entering.
c. Installation
(1) Coat breather (1) with pipe sealant.
(2) Install breather (1) into front axle housing(2). Tighten breather (1)
securely.
11-5
TM 08780B-20
1. Breather
2. Front Axle Housing
END OF TASK
11-6
TM 08780B-20
11-5. NOSE BOX BREATHER MAINTENANCE

c. Installation
INITIAL SETUP

personal injury.
Materials/Parts
a. Removal
(1) Clean area around elbow (1).
(2) Remove elbow (1), reducer (2) and breather (3) from nose box (4) as an
assembly.
(3) Place elbow (1) in vise and remove breather (3) while holding reducer (2)
with a wrench.
(4) Remove reducer (2) from elbow (1).
c. Installation
(1) Apply pipe sealant to threads and install reducer (2) into elbow (1).
(2) Apply pipe sealant to threads of breather (3) and install into reducer (2).
(3) Apply pipe sealant to threads of elbow (1) and install into nose box (4).
11-7
TM 08780B-20
1. Elbow
2. Reducer
3. Breather
4. Nose Box
END OF TASK
11-8
TM 08780B-20
11-6. NO. 1 AXLE SHAFT MAINTENANCE

c. Installation

Condition Condition
MK48 TM 08780B-20 Remove wheel and
tire (para 14-5).
Materials/Parts
Grease (item 21, Appendix D) Remove hub and
drum (para 14-4).
Remove brake shoes

(para 13-5).
Remove brake spider

and skein (para 13-8).

injury. Support axle with a jack stand rated
at 10 tons or more.
a. Removal
NOTE
Right and left axle shaft assemblies are repaired the same way.
(1) Turn steering wheel to position axle in the straight ahead position.
(2) Pull axle shaft assembly (1) straight out from axle ball socket (2). Be
careful not to damage oil seal (3).
1. Axle Shaft Assembly

2. Axle Ball Socket
3. Oil Seal
11-9
TM 08780B-20
c. Installation
(1) Polish end of the axle shaft splines (4) to eliminate all nicks and burrs.
(2) Pack inner walls of axle ball socket (2) with grease. Leave hole for axle
shaft assembly (1) to clear.
(3) Coat all polished surfaces of axle assembly (1) with grease and install
through housing oil seal (3). Be careful not to damage oil seal (3) during installation.
(4) Use excess grease to cover cage ring (5).
END OF TASK
NOTE
TM 08780B-20 Install brake spider and skein (para 13-8).
Install brake shoes (para 13-6).
Install hub and drum (para 14-5).
Install wheel and tire (para 14-5).
LI 2320-12/9 Fill axle with lubricant.

LO 9-2320-297-12
TM 08780B-10 Operate vehicle (para 2-13) and check front

axle for leaks.
11-10
TM 08780B-20
1. Axle Shaft Assemblies

2. Axle Ball Socket
3. Oil Seal
4. Splines
5. Cage Ring
11-11/(11-12 blank)
TM 08780B-20
CHAPTER 12
REAR AXLES
procedures for the vehicle's rear axles.
a. General. The No. 2, 3 and 4 axles consist of carrier assemblies that distribute
power to the axle shafts. The No. 3 axle includes an inter-axle differential.
b. Axle Carrier. Each axle carrier acts as a differential, distributing power to the
axle shafts. Each carrier holds 33 pints of lubricant.
c. Inter-Axle Differential. The inter-axle differential is located on the front of the

No. 3 axle and distributes power from the transfer case to the carriers of axles No. 3 and No. 4.
The No. 3 axle holds an additional seven pints of lubricant for the inter-axle differential.
12-1
TM 08780B-20
12-3. NO. 2, 3 AND 4 AXLES OIL CHANGE

c. Filling
INITIAL SETUP

Adhesive (item 3, Appendix D) Block wheels of truck to prevent
personal injury.
References
LI 2320-12/9
LO 9-2320-297-12
a. Draining
NOTE
• Make sure lubricant is warm before draining. Lubricant will drain faster.
• When removing magnetic drain plugs (2 and 4) and fill plug (6), look for metal
particles sticking to them. Small amounts of fine particles are normal. Large amounts
or large particles may be signs of future axle or nose box failure. Notify Direct
Support/Intermediate Maintenance (Third Echelon), if large amounts of metal or large
particles exist.
(1) Position drain pan under axle (1) and remove drain plug (2). Allow
lubricant to drain.
(2) For number 3 axle (1) only, remove magnetic strainer (3) and fill plug (4)
from differential carrier cover (5).
(3) Remove fill plug (6).
(1) Clean sealant from all threaded parts. Refer to paragraph 2-11.
(2) Remove any particles sticking to magnetic parts.
(3) Inspect threaded parts for damage.
12-2
TM 08780B-20
c. Filling
(1) Coat threads of drain plug (2) with adhesive and install. Tighten securely.
(2) For number 3 axle (1), coat threads of magnetic strainer (3) with sealant
and install. Tighten securely.
(3) Fill axle (1) with lubricant until level with hole for fill plug (6). Refer to
LI 2320-12/9, LO 9-2320-297-12.
(4) Temporarily install fill plug (6) finger tight.
(5) Jack up left side of axle (1) until axle wheel end is 12 inches (30.5 cm)
higher than axles normal height from the ground. Leave in this position for five minutes to allow
lubricant to run out to end of axle housing.
(6) Lower axle (1) to ground and remove fill plug (6).
(7) Refill axle (1) with lubricant, approximately .75 quart (.71 L), until level
with hole for fill plug (6).
(8) Temporarily install fill plug (6) finger tight.
(9) Repeat steps (5) through (8) on right side of axle.
(10) Remove fill plug (6) and bring lubricant back to level even with hole for
fill plug (6), approximately .75 quart (.71 L).
(12) For number 3 axle (1) only, add two pints (0.094 liter) of lubricant through
hole for fill plug (4), in top of differential carrier cover. Coat threads of fill plug (4) with
adhesive and install. Tighten securely.
END OF TASK
12-3
TM 08780B-20
NOTE
TM 08780B-10 Operate vehicle and check for leaks
(para 2-13).
1. Axle (No 2, 3 or 4) 2. Drain Plug

3. Magnetic Strainer 4. Fill Plug
5. Differential Carrier Cover 6. Fill Plug
12-4
TM 08780B-20
12-4. AXLE SHAFT REPLACEMENT (NO. 2, 3 AND 4 AXLES)

c. Installation

Condition Condition
Materials/Parts TM Description
Oil (item 38, Appendix D) TM 08780B-20 Cage brake chamber
Gasket (NSN 5330-01-117-1019) item 5 (para 13-12)

injury. Jack wheel of axle shaft to be
changed and support with jack stands.
a. Removal
(1) Remove eight nuts (1) and washers (2) from axle shaft (3).
WARNING
TO PREVENT PERSONAL INJURY WEAR EYE PROTECTION FOR THE FOLLOWING

STEP.
(2) Strike center of axle shaft (3) with a sledgehammer.
(3) Remove eight dowels (4) from shaft (3).
(4) Remove axle shaft (3).
1. Nut (8) 5. Gasket

2. Washer (8) 6. Hub
3. Axle Shaft 7. Studs
4. Dowel (8)
(1) Clean hub (6), axle shaft (3) and dowels (4).
12-5
TM 08780B-20
(2) Inspect threads of studs (7) and nuts (1).
(4) Coat studs (7) with oil.
c. Installation
(1) Install new gasket (5) onto hub (6).
(2) Install axle shaft (3).
(3) Install eight dowels (4), washers (2) and nuts (1).
(4) Torque nuts (1) to 90-120 foot-pounds (127-162 N*m).
END OF TASK
NOTE
TM 08780B-20 Uncage brake chamber (para 13-12).
12-6
TM 08780B-20
12-5. REAR AXLE BREATHER SERVICE

c. Installation
INITIAL SETUP
Materials/Parts

a. Removal
NOTE
Breather location varies on each axle. No. 2 and No. 4 axle breathers are on right side. No. 3
axle breather is on left side.
(1) Clean area before removing breather (1).
(2) Remove breather (1) from axle housing (2).
(3) Cover hole with a shop towel to prevent contamination.
(2) Inspect for damage.
c. Installation
(1) Coat threads of breather (1) with pipe sealant.
(2) Install breather (1) into axle housing (2) and tighten securely.
12-7
TM 08780B-20
1. Breather
2. Axle Housing
END OF TASK
12-8
TM 08780B-20
CHAPTER 13
BRAKES
maintenance and replacement procedures for the vehicle’s brake system.
a. General. The air brake system of the LVS consists of the complete air system and
the brake hardware. It includes the following parts.
b. Air Control Valves. The two air control valves are mounted on the dash panel of
the MK48. The top valve controls the parking brakes. When pulled, it exhausts air pressure
from the spring brake chambers allowing the spring to apply the brakes of the No. 2, 3 and 4
axles. When depressed, it applies air pressure to the spring brake chambers, compressing the
springs and releasing the brakes. The trailer supply control valve is used only when towing a
trailer or another vehicle. It is normally left in the pulled position. When towing a vehicle or
trailer, it is depressed to supply air to the system of the towed vehicle or trailer.
c. Treadle Valves. There are two treadle valves on the MK48. They are in the cab
and they control the throttle and the brakes. The throttle treadle valve controls the engine throttle
cylinder. This cylinder controls fuel flow and engine speed. Depressing this treadle valve
increases engine speed, releasing it decreases engine speed. The brake treadle valve controls air
pressure to the wedge brake air chambers on the number one axle and, through the relay valves,
it also controls the S-cam brake air chambers. Depressing this treadle valve applies the brakes
and releasing it allows the brakes to release.
d. Trailer Brake Hand Control Valve. This valve is located in the cab to the right of
the dash panel and controls the brakes of a vehicle or trailer being towed by the LVS. When the
handle is moved toward the rear of the LVS, the brakes are applied. When the handle is moved
forward, the brakes are released.
13-1
TM 08780B-20
e. Air Shift Chambers. There are three types of air shift chambers on the LVS. The
first type is on the transfer case and is used to lock and unlock the differential. When air
pressure is supplied to the air chamber, it pushes against a diaphragm which in turn moves the
shift shaft inward and locks the differential. When air pressure is exhausted from the chamber, a
spring pushes the diaphragm and shift shaft outward, unlocking the differential. There is only
one air chamber of this type on the LVS MK48. The second type is on the inter-axle
differentials of axles No. 1 and No. 3. They function in the same way, locking or unlocking
these differentials. There are two air chambers of this type on the MK48. The third type is on all
four axles and is used to engage or disengage the controlled traction differentials. They are
different in that they can change the up and down movement of the chamber piston into a left and
right movement. When the air chamber end of the shift shaft is moved away from the center of
the axle, the controlled traction differential is engaged. When it is moved toward the center of
the axle, the differential is disengaged. There are four chambers of this type on the LVS.
f. Air Dryer. The air dryer receives compressed air from the compressor. When the
air enters the air dryer, its speed drops and much of the water and oil in the air falls to the bottom
of the dryer. The air then changes direction 180 degrees and passes through a filter which
removes oil and other contaminants. The air then enters a drying bed of material that removes
most of the water from it. The dry air then moves to a purge area and from there to the quick
build-up tank. When the compressor unloads (stops compressing) the air dryer goes through a
purge cycle to remove water, oil and other material from the air dryer. The air dryer is now
ready for another drying cycle. Only ABS modified vehicles have the Model 1200 dual filter air
dryer.
13-2
TM 08780B-20
g. Air Compressor. The air compressor is mounted on the rear of the engine of the
MK48. It is a single stage, two cylinder compressor with an external governor. The governor
controls a set of valves within the compressor. Below 65 psi (448.2 kPa) the governor allows the
valves to close, causing the compressor to compress air for the system. Above 120 psi (827.4
kPa) the governor holds the valves open and exhausts air without compression.
h. Main Air Reservoir Tanks. There are six main air reservoir tanks on the LVS.
Two are located just under the radiator, with one on each side of the MK48. The other four are
located between the frame rails of the MK14, 15, 16 or 17. They are used to store air pressure
for the brakes, engine, throttle, air horn, windshield wipers, axles and transfer case. The left
main air reservoir has a quick disconnect coupling that will connect an air line for inflating tires
and other items as needed.
i. Quick Build-up Tank. Compressed air from the air dryer is sent directly to the
quick build-up tank. This air reservoir has two functions. The first is to build up usable air
pressure quickly. This is done by the use of a pressure protection valve. This valve holds air
pressure in the tank until internal pressure reaches 74 psi (482.7 kPa). All air pressure above this
is passed on to the main reservoir tanks. The second function is to act as a wet tank to remove
moisture from the compressed air before it is allowed to go to the main reservoirs. A drain valve
in the bottom of the tank allows drainage of trapped moisture when needed.
13-3
TM 08780B-20
j. S-Cam Brake. The LVS has six S-cam brake assemblies, located on the wheel
ends of axles number two, three and four. The Scam brake assemblies are manually adjusted; air
operated and includes a parking brake. When the brake treadle valve in the cab is depressed, air
pressure enters the service brake part of the air chamber. This air pressure pushes against a
diaphragm, forcing the push rod out. The push rod is connected to the slack adjuster. When the
slack adjuster moves, it rotates the S-cam shaft. The S-shaped part of the cam forces the brake
shoes into contact with the brake drums. The friction caused by this contact slows the truck.
These brakes must be inspected and adjusted at the slack adjuster to allow for brake lining wear.
The parking brake part of the air chamber uses a large spring to apply the brake when no air
pressure is present. A switch in the cab controls the air pressure applied to spring brake
diaphragm. When air pressure is applied to this diaphragm, it compresses this spring and
releases the brakes for normal operation.
k. Wedge Brake. The MK48 has two wedge brake assemblies, located on the wheel
ends of the number one axle. Each wedge brake assembly is self-adjusting and air operated.
They do not include a parking brake. When the brake treadle valve in the cab is depressed, air
pressure enters the top of the air chamber. The air pressure pushes against the diaphragm,
moving a push rod toward the brake assembly. This push rod forces the wedge assembly to go
between the brake actuating pistons. These pistons move outwards, pushing the brake shoes into
contact with the brake drums. The friction caused by this contact slows the truck. The brake
actuating pistons contain a self-adjusting system that adjusts the brakes every time they are
applied.
l. Relay Valves. There are four relay valves on the LVS. Two are located on the
inside of the right frame rail of the MK48. Two are located between the frame rails of the MM
4, 15, 16 and 17. The relay valves are used to speed up application or release of the brakes on
the number two, three and four axles.
13-4
TM 08780B-20
13-5
TM 08780B-20
13-3. ANTILOCKING BRAKE SYSTEM (ABS)
a. General. The ABS is an electronic system that monitors and controls wheel speed
during braking. The system works with standard air brake systems. The ABS monitors wheel
speeds at all times and controls braking during wheel lock situations. The system improves
vehicles stability and control by reducing wheel lock during braking.
b. Electronic Control Unit (ECU)/Air Control Valves. An integrated unit that

receives and processes signals from the wheel speed sensors. When the ECU/Valve detects a
wheel lock up, the unit activates the appropriate modulator valve and air pressure is controlled.
c. Sensor. The sensor measures the speed of a toner ring rotating with the vehicle
wheel and produces on output voltage proportional to the wheel.
d. Toner Ring. The toner ring is a machined ring mounted to the machined surface
on the hub of each ABS-monitored wheel.
e. Clip and Sensor Mounting Bracket. The sensor clip and mounting bracket holds
the wheel speed sensor in close proximity to the toner ring.
1. ECU/Air Control
Valve
2. Sensor
3. Toner Ring
4. Clip and Sensor
Mounting Bracket
13-6
TM 08780B-20
13-4. BRAKE INSPECTION AND ADJUSTMENT (NO. 1 AXLE)
THIS TASK COVERS: a. Inspection

b. Adjustment
INITIAL SETUP

personal injury.
References
TM 08780B-10
a. Inspection
NOTE
Clean all mud and dirt from brakes before adjustment.
(1) Inspect brake shoe linings (1) and brake drums (2) for obvious grooves
and uneven wear. If brake shoe linings (1) are worn unevenly and appear to be less than 1/4 inch
(1.59 mm) at thinnest point, replace all brake shoes on that axle. Refer to paragraph 13-6 of this
manual. If brake drums (2) have deep grooves, replace brake drums. Refer to paragraph 14-4 of
this manual.
NOTE
• If the brake shoes on one side of axle need adjustment, other side of axle must be
adjusted.
• Always adjust the brakes on any piece of equipment that is towed behind an LVS at the
same time the LVS brakes are adjusted.
b. Adjustment
WARNING
BLOCK WHEELS TO PREVENT PERSONAL INJURY.
(1) Jack wheel to be adjusted free of ground. Refer to paragraph 3-8 in

TM 08780B-10. Support axle with jack stand rated at 10 tons or more.
(2) Turn star wheel portion (3) of adjusting bolts (4) until brake drum (2) will
not turn. Both star wheels (3) must be turned the same amount.
(3) Back off star wheels (3) equal amounts until 0.020-0.040 inch (0.050-1.00
mm) clearance can be measured between center of brake shoe lining (1) and brake drum (2).
13-7
TM 08780B-20
(4) Turn brake drum (2). A light drag should be felt. If not, readjust or check
for damaged brake parts.
(5) Raise axle and remove jack stand from truck. Lower truck and remove
jack. Refer to paragraph 3-8 in TM 08780B-10.
(6) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Build air system
pressure to 80 psi or more.
(7) Apply and release brakes several times.
(8) Recheck clearance. If clearance is not within specifications, repeat

procedure as necessary.
(9) Repeat steps (1) thru (8) for opposite side.
END OF TASK
1. Brake Shoe Linings (2)

2. Brake Drum (2)
3. Star Wheel (2)
4. Adjusting Bolt (2)
13-8
TM 08780B-20
13-5. BRAKE INSPECTION AND ADJUSTMENT (NO. 2, 3 AND 4 AXLES)
THIS TASK COVERS: a. Inspection

b. Adjustment
INITIAL SETUP

Cotter pin (MS24665-353) item 8 Block wheels of truck to prevent
personal injury.
Personnel Required
1 MOS 3521
1 Assistant
a. Inspection
NOTE
Clean all mud and dirt from brakes before adjustment.
(1) Inspect brake linings (1) and brake drums (2) for obvious grooves and
uneven wear. If brake linings (1) are worn unevenly and appear to be less than 1/4 inch (1.59
mm) at thinnest point, replace all brake shoes on that axle. Refer to paragraph 13-7 of this
manual. If brake drums (2) have deep grooves, replace brake drums. Refer to paragraph 14-4 of
this manual.
NOTE
• If the brake shoes on one side of axle number two, three or four need adjustment, both
sides of all three axles must be adjusted.
• The following procedure must be done with 80-90 psi (552-621 kPa) of air pressure.
(2) Start engine. Refer to paragraph 2-13 of TM 08780B-10.
(3) Build air pressure to at least 80 psi (552 kPa).
(4) Shut down engine.
WARNING
BLOCK WHEELS OF TRUCK TO PREVENT PERSONAL INJURY.
(5) Release parking brake.
13-9
TM 08780B-20
1. Brake Lining
2. Brake Drum
(6) While assistant holds brake treadle valve down measure between center of
yoke pin (3) and chamber bracket (4). Record measurement.
(7) With brake treadle valve released, measure between center of yoke pin (3)
and chamber bracket (4). Record measurement.
(8) Subtract measurement taken in step (7) from measurement taken in step
(6). If the difference is more than two inches (5.08 cm) on any one brake assembly, adjust all
brakes on axles number two, three and four.
NOTE
• LVSA1 series vehicles are equipped with automatic slack adjusters. Automatic and
manual slack adjusters are not interchangeable. If manual slack adjuster on one side
of the No. 2, 3 or 4 axle is replaced with automatic slack adjuster, then both manual
slack adjusters on all three axles must be replaced with automatic slack adjusters.
• Perform steps 9 and 10 on LVSA1 series vehicles only.
(9) Release spring and service brake and check that automatic slack adjuster’s
installation indicator (6) is within slot (7). If slack adjuster fails this inspection, refer to
paragraph 13-10 of this manual.
(10) Remove cotter pin (8) and yoke pin (3). Discard cotter pin (8). Check that yoke
hole and slack adjuster hole remain in alignment. If brake chamber push rod (9) retracts into the
brake chamber, it fails inspection and must be readjusted. Refer to paragraph 13-10 of this
manual. After inspection of automatic slack adjuster, install yoke pin (3) and new cotter pin (8).
13-10
TM 08780B-20
3. Yoke Pin Measurement 6. Installation Indicator*

4. Chamber 7. Slot*
5. Adjusting Screw 8. Cotter Pin
5.1. Adjusting Screw* 9. Push Rod
*LVSA1 SERIES VEHICLES ONLY
b. Adjustment
NOTE
• If the brake shoes on one side of axle number two, three or four need adjustment, both
sides of all three axles must be adjusted.
• Parking brake must be released when adjusting rear brakes.
(1) Release parking brake.
(2) Jack wheel to be adjusted free of the ground. Support axle with a jack
stand rated at 10 tons or more.
13-11
TM 08780B-20
WARNING
BLOCK WHEELS OF TRUCK TO PREVENT PERSONAL INJURY.
(3) Tighten adjusting screw (5) until tire can no longer be turned by hand.
(4) Back out adjusting screw (5) three clicks or 1/4 turn.
NOTE
Perform steps (5) through (7) on LVSA1 series vehicles only.
(5) Rotate the automatic slack adjuster’s adjusting screw (5.1) clockwise until
the brake lining (1) contacts the brake drum (2).
(6) Once brake lining contact is established, back-off adjuster by turning

adjusting screw (5.1) counter-clockwise 1/2 turn.
(7) Use a torque wrench to test tension on slack adjuster’s adjusting screw
(5.1). A minimum of 13 foot-pounds (18 N*m) of torque is necessary to overcome the slack
adjuster’s internal clutch. If torque reading is less than 13 foot-pounds (18 N*m), repeat step 6
as necessary until minimum torque is achieved.
(8) Remove jack stand.
(9) Repeat steps (1) thru (8) until all brakes on axles two, three and four have
been adjusted.
END OF TASK
NOTE
TM 08780B-10 Operate vehicle and check for proper
brake operation (para 2-13).
13-12
TM 08780B-20
13-6. BRAKE SHOE REPLACEMENT (NO. 1 AXLE)

c. Installation

Condition Condition
MK48 TM 08780B-20 Hub and drum
Materials/Parts
Cotter pin (2) (NSN 5315-01-084-1077) item 1 General Safety Instructions
Spring (2) (NSN 5360-01-016-8470) item 4 Brake shoes contain asbestos. Do not use
Return spring (P/N 2258G1333) item 7 compressed air to clean. Compressed air
Return spring (P/N 2258H1334) item 11 can cause airborne particles which may be
inhaled. Wear an approved respirator.
a. Removal
(1) Remove two cotter pins (1) and nuts (2). Discard cotter pins (1).
(2) Remove two washers (3) and springs (4). Discard springs (4).
(3) Remove two brake shoe retainer plates (5).
(4) Back off adjusting bolts (6) to relieve spring pressure.
(5) Pry upper return spring (7) free of bracket (8).
(6) Carefully pry brake shoes (9) away from adjusting bolts (6).
(7) Pull outward until brake shoes (9) are clear of screws (10).
(8) Holding brake shoes (9) up, release upper return spring (7) from
bracket (8).
(9) Remove two brake shoes (9) with return springs (7 and 11).
(10) Lay brake shoes (9) on bench and remove return springs (7 and 11).
Discard return springs (7 and 11).
13-13
TM 08780B-20
WARNING
NEVER USE COMPRESSED AIR WHEN CLEANING BRAKE ASSEMBLY. BRAKE

LININGS CONTAIN ASBESTOS WHICH IS HAZARDOUS TO HEALTH IF INHALED.
WEAR APPROVED RESPIRATOR DURING CLEANING.
(2) Inspect threads on retainer screws (10) and nuts (2).
(3) Inspect adjusting bolt (6) and anchor assemblies (12) for damage.
c. Installation
CAUTION
• DO NOT REUSE SPRINGS OR COTTER PINS. ALWAYS REPLACE WITH NEW

PARTS.
• IF BRAKE SHOES ARE BEING REPLACED, REPLACE ALL SHOES ON THAT

AXLE. MIXING OLD AND NEW WILL CAUSE UNEVEN BRAKING
• LVS BRAKE SHOES ON TRUCKS WITH SERIAL NUMBERS 37141 AND ABOVE
WILL HAVE ASBESTOS AND NON-ASBESTOS BRAKE SHOES. WHEN
REPLACING BRAKE SHOES ON AXLE, MAKE SURE ALL REPLACEMENT
SHOES ON BOTH SIDES ARE ALL ASBESTOS OR ALL NON-ASBESTOS.
MIXING NON-ASBESTOS SHOES AND ASBESTOS SHOES ON AXLE WILL
CAUSE UNEVEN BRAKING.
• DO NOT ALLOW OIL OR GREASE TO GET ON BRAKE SHOES OR DRUM.

BRAKING ACTION WILL BE DANGEROUSLY REDUCED.
(1) Turn two adjusting bolts (6) all the way in.
(2) Install brake shoe (9) on top of adjusting bolt (6) and anchor assembly
(12). Make sure screw (10) comes through triangle opening (13) in brake shoe (9).
(3) Install retainer plate (5), new spring (4), washer (3) and nuts (2) on screw
(10). Do not tighten nut (2).
(4) Install new upper return spring (7) at the top of brake shoe (9). Make sure
upper return spring (7) sits in bracket (8).
13-14
TM 08780B-20
(5) Install new lower return spring (11) at the bottom of brake shoe (9).
(6) While holding remaining brake shoe (9), connect springs (7 and 11).
(7) Pull brake shoe (9) down onto adjusting shoes, bolt (6) and anchor
assembly (12). Make sure screw (10) comes through triangle opening (13) in brake shoe (9).
(8) Install retainer plate (5), spring (4), washer (3) and nut (2).
(9) Tighten both nuts (2) until hole for cotter pin is visible. Install two new
cotter pins (1).
END OF TASK
NOTE
TM 08780B-20 Install hub and drum assembly (para 14-4).
Adjust brakes (para 13-4).
1. Cotter Pin (2) 8. Bracket

2. Nut (2) 9. Brake Shoe (2)
3. Washer (2) 10. Screw (2)
4. Spring (2) 11. Lower Return Spring
5. Retainer Plate (2) 12. Anchor Assembly
6. Adjusting Bolt (2) 13. Triangle Opening
7. Upper Return Spring
13-15
TM 08780B-20
13-7. BRAKE SHOE REPLACEMENT (NO. 2, 3, AND 4 AXLES)

c. Installation

Condition Condition
Special Tools TM Description
Inside caliper set TM 08780B-20 Hub and drum
Materials/Parts
Spring (P /N 2258G1333) item 6 General Safety Instructions
Spring (2) (P/N 2258H1334) item 7 Block wheels of truck to prevent personal
injury. Support axle with jack stand rated at
10 tons or more.
a. Removal
(1) Carefully pry brake shoes (1 and 2) away from S-cam (3) and remove two
rollers (4) and pins (5).
(2) Lift bottom brake shoe (2) and remove spring (6). Discard spring (6).
(3) Remove brake shoes (1 and 2).
(4) Place brake shoes (1 and 2) on floor and remove two springs (7). Discard
springs (7).
WARNING
NEVER USE COMPRESSED AIR WHEN CLEANING BRAKE ASSEMBLY. BRAKE

LININGS CONTAIN ASBESTOS WHICH IS HAZARDOUS TO HEALTH IF INHALED.
WEAR APPROVED RESPIRATOR DURING CLEANING.
(1) Wipe out interior of drum (8) with a dry cloth.
(2) Clean brake spider (9) with a wire brush.
(3) Clean rollers (4) and pins (5). Refer to paragraph 2-11.
(4) Inspect all parts for damage or signs of overheating.
13-16
TM 08780B-20
(5) Measure inside of drum. Maximum inside diameter is 16.614 inches

(42.199 cm).
1. Brake Shoe 6. Spring

2. Brake Shoe 7. Spring (2)
3. S-Cam 8. Drum
4. Roller (2) 9. Brake Spider
5. Pin (2) 10. Anchor Pin
c. Installation
CAUTION
• DO NOT REUSE SPRINGS OR COTTER PINS. ALWAYS REPLACE WITH NEW

PARTS.
• IF BRAKE SHOES ARE BEING REPLACED, REPLACE ALL SHOES ON THAT

AXLE. MIXING OLD AND NEW WILL CAUSE UNEVEN BRAKING
• DO NOT ALLOW OIL OR GREASE TO GET ON BRAKE SHOES OR DRUM.

BRAKING ACTION WILL BE DANGEROUSLY REDUCED.
• LVS BRAKE SHOES ON TRUCKS WITH SERIAL NUMBERS 37141 AND ABOVE
WILL HAVE ASBESTOS AND NON-ASBESTOS BRAKE SHOES. WHEN
REPLACING BRAKE SHOES ON AXLE, MAKE SURE ALL REPLACEMENT
SHOES ON BOTH SIDES ARE ALL ASBESTOS OR ALL NON-ASBESTOS.
MIXING NON-ASBESTOS SHOES AND ASBESTOS SHOES ON AXLE WILL
CAUSE UNEVEN BRAKING.
13-17
TM 08780B-20
(1) Install brake shoe (1) onto anchor pin (10) and S-cam (3).
(2) Install two new springs (7) onto brake shoe (1).
(3) Install brake shoe (2) onto other end of springs (7).
(4) Install new spring (6) into both brake shoes (1 and 2).
(5) Carefully pry each brake shoe (1 and 2) away from S-cam (3) and install
two rollers (4) and pins (5).
END OF TASK
NOTE
TM 08780B-20 Install hub and drum (para 14-3).
13-18
TM 08780B-20
13-8. WEDGE BRAKE MAINTENANCE (NO. 1 AXLE)

c. Assembly

Condition Condition
removed (para 14-4)
Materials/Parts
Grease, aircraft (item 20, Appendix D) Brake shoes
Plunger seal (2) (NSN 5330-01-106-6495) item 11 removed(para 13-6)
Brake chamber
a. Disassembly
(1) Remove wedge assembly (1) from actuating plunger housing (2).
(2) Bend tabs on two locking plates (3) and remove two capscrews (4),
springs (5) and adjusting pawls (6).
(3) Remove two retainers (7) and detent washers (8).
(4) Remove two snaprings (9) from retainers (7).
(5) Remove two adjusting bolts (10), seals (11) and adjusting sleeves (12)
from actuating plunger housing (2).
(6) Turn adjusting bolts (10) into adjusting sleeves (12) until snaprings (13)
can be removed. Remove snaprings (13).
(7) Remove adjusting bolts (10) from adjusting sleeves (12).
(8) Remove two plunger seals (11) from adjusting bolts (10). Discard plunger
seals (11).
(9) Remove two actuating plungers (14) from actuating plunger housing (2).
(10) Bend tabs on two locking plates (15) and remove two capscrews (16).
(11) Tag for installation and remove left and right anchor plunger (17 and 18)
from lower anchor plunger housing (19).
13-19
TM 08780B-20
(2) Inspect adjusting pawls (6) and adjusting sleeves (12) for grooves.
(3) Inspect inside of plunger housings (2 and 19) for wear, pitting or scoring.
(4) Inspect all other parts for wear, cracks, breaks or pitting.
NOTE
If inspection reveals a problem in actuating plunger housing (2), spider (20) may be turned
180 degrees on axle. Anchor plunger housing (19) may then be used as the actuating plunger
housing. Refer to paragraph 13-9 in this manual.
c. Assembly
(1) Coat inside of lower anchor plunger housing (19) with aircraft grease.
NOTE
Left and right anchor plungers may be marked ‘L’ and ‘R’. Be sure to install in same position
as when removed.
(2) Install left and right anchor plungers (17 and 18) into anchor plunger
housing (19). Make sure that slots in plungers (17 and 18) line up with capscrew holes (21) in
lower anchor plunger housing (19).
(3) Install two locking plates (15) on capscrews (16). Install two capscrews
(16) into lower anchor plunger housing (19). Tighten securely. Bend tabs on locking plates (15)
to lock capscrews (16) in place.
(4) Check plungers (17 and 18) for one inch (2.54 mm) free movement in and
out.
(5) Coat inside of actuating plunger housing (2) with aircraft grease.
(6) Apply aircraft grease to two actuating plungers (14) and install into
actuating plunger housing (2).
13-20
TM 08780B-20
1. Wedge Assembly 8. Detent Washer (2) 15. Locking Plate (2)

2. Actuating Plunger 9. Snapring (2) 16. Capscrew (2)
Housing 10. Adjusting Bolt (2) 17. Left Anchor Plunger
3. Locking Plate (2) 11. Plunger Seal (2) 18. Right Anchor Plunger
4. Capscrew (2) 12. Adjusting Sleeve (2) 19. Lower Anchor Plunger
5. Spring (2) 13. Snapring (2) Housing
6. Adjusting Pawl (2) 14. Actuating 20. Spider
7. Retainer (2) Plunger (2) 21. Capscrew Holes
(7) Make sure that slots (22) in actuating plungers (14) line up with capscrew
hole (23) in actuating plunger housing (2).
(8) Install two adjusting pawls (6) and springs (5) into actuating plunger
housing (2). Make sure adjusting pawls (6) go into slots (22) in actuating plungers (14).
(9) Apply aircraft grease to rubber of two plunger seals (11).
(10) Install a new seal (11) onto each adjusting bolt (10). Make sure grooved
side of plunger seals (11) face head of adjusting bolts (10).
(11) Coat threads of adjusting bolts (10) with aircraft grease and install into
adjusting sleeves (12).
13-21
TM 08780B-20
(12) Turn adjusting bolts (10) in until just short of bottoming on plunger seal
(11).
(13) Install two snaprings (13) onto adjusting bolts (10).
(14) Apply aircraft grease to outside of adjusting sleeves (12) and install into
actuating plunger housing (2).
(15) Carefully install seals (11) into actuating plunger housing (2).
(16) Install two locking plates (3) onto capscrews (4). Install two capscrews
(4) into capscrew hole (23). Bend up tab on each locking plate (3) to secure capscrew (4) into
place.
(17) Make sure both plunger seals (11) are fully seated in actuating plunger
housing (2).
(18) Install two detent washers (8), retainers (7) and snaprings (9) on adjusting
bolts (10).
(19) Apply aircraft grease to springs and actuating rollers of wedge assembly
(1) and install wedge assembly (1) into actuating plunger housing (2).
(20) Check plunger engagement by pushing on wedge shaft (24) and watching
retainer (7) movement.
END OF TASK
NOTE
TM 08780B-20 Install brake shoes (para 13-6).
Install brake chamber (para 13-13).
13-22
TM 08780B-20
1. Wedge Assembly 6. Adjusting Pawl (2) 12. Adjusting Sleeve (2)

2. Actuating Plunger 7. Retainer (2) 13. Snapring (2)
Housing 8. Detent Washer (2) 14. Actuating Plunger (2)
3. Locking Plate (2) 9. Snapring (2) 22. Slots
4. Capscrew (2) 10. Adjusting Bolt (2) 23. Capscrew Holes
5. Spring (2) 11. Plunger Seal (2) 24. Wedge Shaft
13-23
TM 08780B-20
13-9. BRAKE SPIDER AND SKEIN REPLACEMENT (NO. 1 AXLE)

c. Installation

Condition Condition
Materials/Parts
Silicone sealant (item 5, Appendix D) Brake shoes
Locknut (12) (MS51943-44) item 1 removed (para 13-6).
Plain washer (9) (MS27183-21) item 12
Hex nut (3) (MS51968-44) item 14 Brake chamber
Sealant (item 45, Appendix D) removed (para 13-17).
Wedge brakes
assembly removed
(para 13-8).
a. Removal
(1) Remove 12 locknuts (1) and washers (2) from studs (3). Discard locknuts
(1).
(2) Remove two capscrews (4), washers (5) and bracket (6).
(3) Remove brake spider (7).
(4) Install wheel bearing locknut (8) onto skein (9). Install capscrew (10) into
wheel bearing locknut (8). Tighten capscrew (10) securely.
CAUTION
BE SURE TO PULL SKEIN STRAIGHT OFF WHEN USING PULLER.
(5) Using a three-jaw puller (11), remove skein (9).
(2) Inspect all parts for cracks, breaks or other damage. Refer to paragraph 2-12.
13-24
TM 08780B-20
c. Installation
(1) Coat back of skein (9) with sealant. Install skein (9) onto studs (3).
CAUTION
USE AT LEAST THREE WASHERS (12) FOR EACH STUD (3) FOR SEATING OF SKEIN
(9). LESS THAN THREE WASHERS (12) COULD RESULT IN STRIPPING OF
THREADS ON STUDS (3).
(2) Seat skein (9) against ball and socket assembly (13). Use three
washers(12) on each of three evenly spaced studs (3). Tighten nuts (14) alternately until skein
(9) is seated.
(3) Remove three nuts (14) and nine washers (12).
(4) Coat back of brake spider (7) with sealant and install onto studs (3).
(4.1) Apply silicone sealant to ends of studs (3).
(5) Install two washers (5), bracket (6) and two capscrews (4). Torque to 180
(6) Install 12 washers (2) and new locknuts (1). Torque locknuts (1) and
capscrews (4) to 125 foot-pounds (168.75 N*m).
END OF TASK
NOTE
TM 08780B-20 Install wedge brake assembly (para 13-8).
Install brake chamber (para 13-13).
13-25
TM 08780B-20
1. Locknut (12) 7. Brake Spider 11. Three-Jaw Puller

2. Washer (12) 8. Wheel Bearing 12. Washer (9)
3. Stud (12) Locknut 13. Ball And Socket
4. Capscrew (2) 9. Skein Assembly
5. Washer (2) 10. Capscrew 14. Nut (3)
6. Bracket
13-26
TM 08780B-20
13-10. CAMSHAFT AND SLACK ADJUSTER REPLACEMENT (NO. 2, 3 AND 4

AXLES)

c. Installation
d. Adjustment (LVSA1 Series Vehicles Only)

Condition Condition
Grease lithium (item 23, Appendix D) TM 08780B-20 Axle shaft
Cotter pin (MS24665-353) item 1 removed (para 12-4).
C-clip (NSN 5365-01-152-4536) item 4
Seal (2) (NSN 5330-01-113-0593) Hub and drum
items 8 and 9 removed (para 14-3).
Bushing (2) (NSN 3120-01-111-7665)
items 10 and 11 Brake shoes
Locknut (TBD) item 7.1 removed (para 13-7).

injury.
a. Removal
NOTE
LVSA1 series vehicles are equipped with automatic slack adjusters. Automatic and manual
slack adjusters are not interchangeable. If manual slack adjuster on one side of the No. 2, 3
or 4 axle is replaced with automatic slack adjuster, then both manual slack adjusters on all
three axles must be replaced with automatic slack adjusters.
(1) Remove cotter pin (1) and clevis pin (2) from manual slack adjuster (3).
NOTE
(2) Rotate adjusting hex (3.1) on automatic slack adjuster (3.2) counter-
clockwise until control arm (3.3) is clear of brake chamber clevis(3.4).
WARNING
C-CLIPS ARE SPRING STEEL AND MAY POP OFF WHEN BEING REMOVED. WEAR
EYE PROTECTION WHEN REMOVING OR INSTALLING C-CLIPS. FAILURE TO DO
SO MAY RESULT IN EYE INJURY TO PERSONNEL.
13-27
TM 08780B-20
NOTE
The number of shim(s) may vary.
(3) Remove C-clip (4) and shims (5) from camshaft (6). Discard C-clip (4).
(4) Remove manual slack adjuster (3) and washer (7).
NOTE
(5) Remove locknut (7.1), washer (7.2), anchor bracket (7.3) and automatic
slack adjuster (3.2).
(6) Remove inner washer (7.4), seal (8), nut (7.5) and anchor bracket (7.3)
from automatic slack adjuster (3.2). Discard seal (8).
(7) Remove camshaft (6).
(8) Remove and discard seal (9).
1. Cotter Pin 4. C-Clip 7.4. Inner Washer*

2. Clevis Pin 5. Shim (A/R) 7.5. Nut*
3. Manual Slack Adjuster 6. Camshaft 8. Seal
3.1. Adjusting Hex* 7. Washer 9. Seal
3.2. Automatic Slack Adjuster* 7.1. Locknut* 10. Bushing
3.3. Control arm* 7.2. Washer* 11. Bushing
3.4. Clevis 7.3. Anchor Bracket* 12. Bracket
13-28
TM 08780B-20
(9) Remove bushings (10 and 11) if needed.
(2) Inspect camshaft (6) for cracks or signs of overheating.
(3) Inspect camshaft to bushing radial clearance. Clearance must not exceed
0.035 inch (0.89 mm). Replace bushings if necessary, then recheck. If clearance is still over
limits, replace camshaft.
(4) Inspect pin (2), shims (5) and washer (7) for damage.
c. Installation
NOTE
Do not reinstall seals, bushings, C-clip or cotter pin if removed. Replace with new parts.
(1) Install new bushings (10 and 11) into bracket (12), if removed.
(2) Install new seals (8 and 9) into bracket (12). Lip on both seals should be
away from brake shoes.
(3) Coat camshaft (6) and bushings (10 and 11) with lithium grease and install
camshaft (6).
(4) Install manual slack adjusters as follows:
(a) Install washer (7) and manual slack adjuster (3).
(b) Adjust camshaft end play to within 0.005-0.025 inch (0.127-0.635

mm), by adding or removing shims (5).
(c) Install new C-clip (4) onto camshaft (6).
(d) Check camshaft (6) for free movement.
(e) Lubricate camshaft (6) at lube fitting until grease comes out by
manual slack adjuster (3), then lubricate manual slack adjuster (3).
(f) Install clevis pin (2) and new cotter pin (1) into manual slack
adjuster (3).
13-29
TM 08780B-20
(5) Install automatic slack adjusters as follows:
NOTE
• LVSA1 series vehicles are equipped with automatic slack adjusters. Automatic and
manual slack adjusters are not interchangeable. If manual slack adjuster on one side
of the No. 2, 3 or 4 axle is replaced with automatic slack adjuster, then both manual
slack adjusters on all three axles must be replaced with automatic slack adjusters.
• Ensure that brake chamber push rod is fully retracted before starting installation.
(a) Install anchor bracket (7.3) loosely using locknut (7.1) and washer
(7.2).
(b) Apply anti-seize type lubricant to spline shaft.
NOTE
Adjust camshaft end play to within 0.005-0.045 inch (0.127-1.143 mm) by adding or removing
shim(s) (5) as necessary.
(c) Install inner washer (7.4), automatic slack adjuster (3.2),

shim(s) (5) and C-clip (4) on the camshaft (6) with the adjusting hex (3.1) pointing away from
the brake chamber.
(d) Rotate adjusting hex (3.1) clockwise until the clevis holes line up
with the corresponding slack adjuster hole.
NOTE
For proper installation, ensure that the installation indicator (13) falls within the slot (15).
(e) Rotate the control arm (3.3) away from the adjusting hex (3.1)
towards the brake chamber (14), until the adjuster comes to a definite internal stop.
(f) Tighten nut (7.5) securely. Ensure that control arm does not move
its position when tightening nut (7.5).
(g) Tighten locknut (7.1) securely. Torque locknut (7.1) to 100-115

foot-pounds (136-156 N*m).
(h) Install clevis pin (2).
NOTE
A minimum of 13 foot-pounds (18 N*m) of torque is necessary to overcome the slack
adjuster’s internal clutch. A ratcheting sound will occur.
13-30
TM 08780B-20
(i) Rotate adjusting hex (3.1) clockwise until the brake lining contacts the
drum. Once contact is made, back-off the adjusting hex (3.1) by 1/2 turn.
d. Adjustment
(1) With full air pressure, release spring and service brake and check that the
automatic slack adjuster’s installation indicator (13) is within slotted area.
(2) Remove clevis pin (2) and check that the clevis hole and adjuster hole
remain in alignment. If the brake chamber clevis (3.4) pulls into the brake chamber (14), repeat
installation steps (c) (4) (a) through (c) (4) (c).
(3) After automatic slack adjuster (3.2) is adjusted properly, install new cotter
pin (1) into clevis pin (2).
END OF TASK
NOTE
TM 08780B-20 Install brake shoes (para 13-7).
Install axle shaft (para 12-4).
13-31
TM 08780B-20
1. Cotter Pin 7.3. Anchor Bracket*

2. Clevis Pin 7.4. Inner Washer*
3.1. Adjusting Hex* 7.5. Nut*
3.2. Automatic Slack 8. Seal
Adjuster* 9. Seal
3.3. Control Arm* 10. Bushing
3.4. Clevis* 11. Bushing
4. C-Clip 12. Bracket
5. Shim (A/R) 13. Installation Indicator*
6. Camshaft 14. Brake Chamber
7.1. Locknut* 15. Slot*
7.2. Washer*
13-32
TM 08780B-20
13-11. BRAKE SPIDER AND BRACKET REPLACEMENT (NO. 2, 3 AND 4 AXLES)

c. Installation

Condition Condition
Locknut (8) (MS51943-44) item 7 TM 08780B-20 Wheel and tire
Locknut (2) (MS51967-20) item 1 removed (para 14-5).
Locknut (MS <TBD>) item 1
(LVSA1 series vehicles only) Axle shaft removed
(para 12-4).
Hub and drum

Brake shoes removed

(para 13-7).
Camshaft and slack

adjuster removed
(para 13-10).
a. Removal
(1) Remove two locknuts (1) and washers (2) from brake chamber (3).
NOTE
(2) Remove locknut (1) and washer (2) from brake chamber (3). Discard
locknut (1).
(3) Remove brake chamber (3).
(4) Remove four capscrews (4) and washers (5) from bracket (6).
(6) Remove six locknuts (7) and washers (8) from brake shoe side of
spider (9). Mark spider (9) for location during assembly. Discard locknuts (7).
13-33
TM 08780B-20
(7) Remove two locknuts (7) and washers (8) from axle housing side of
spider (9). Discard locknuts (7).
(8) Remove eight capscrews (10) from spider (9).
(9) Remove spider (9).
(2) Inspect bracket (6) and spider (9) for damage and overheating.
(3) Check anchor pin (11) for flat spots.
(4) Inspect capscrews and nuts for damaged threads.
c. Installation
NOTE
If new spider will be installed, position it as shown in illustration.
1. Locknut 7. Locknut (8)

2. Washer 8. Washer (8)
3. Brake Chamber 9. Spider
5. Washer (4) 11. Anchor Pin
6. Bracket 12. Axle Housing
13-34
TM 08780B-20
(1) Position spider (9) as marked onto axle housing (12).
(2) Install eight capscrews (10) through spider (9) and axle housing (12).
Install the two capscrews (10) closest to bracket (6) from the opposite side.
(3) Install eight washers (8) and new locknuts (7). Torque locknuts to 180
(4) Install bracket (6) onto spider (9).
(5) Install four capscrews (4) and washers (5). Tighten capscrews (4)
securely.
(6) Install brake chamber (3).
(7) Install washer (2) and locknut (1). Tighten locknut (1) to 100-115 foot-
pounds (136-156 N*m).
END OF TASK
NOTE
TM 08780B-20 Install camshaft and slack
adjuster (para 13-10).
Install axle shaft (para 12-4).
13-35
TM 08780B-20
13-12. BRAKE CHAMBER REPLACEMENT (NO. 2, 3 AND 4 AXLES)

c. Installation

Condition Condition
Pipe sealant (item 48, Appendix D) TM 08780B-10 Air system
Cotter pin (MS24665-353) item 9 drained (para 3-5).
Locknut (2) (P/N X X) item 11
pressure from the air system. Block wheels
of truck to prevent personal injury.
a. Removal
WARNING
• BRAKE CHAMBER CONTAINS A SPRING UNDER GREAT PRESSURE. TO

PREVENT PERSONAL INJURY OR DEATH, NEVER WORK DIRECTLY BEHIND
CHAMBER. CAGE SPRING BEFORE REMOVING BRAKE CHAMBER. IF
CAGING BOLT WILL NOT ENGAGE PROPERLY, SPRING MAY BE BROKEN.
• AIR LINES UNDER PRESSURE WILL MOVE VIOLENTLY WHEN REMOVED.

TO PREVENT PERSONAL INJURY, DRAIN ALL AIR PRESSURE FROM
SYSTEM BEFORE REMOVING AIR LINE.
NOTE
Brake chambers have changed to a new style that has a crimped ring around the parking
brake section of the chamber instead of a bolt together ring. When repairing a non-A1
vehicle, use the new style chamber to replace the old style chamber. Refer to TM 08780B-24P
for correct part identification.
(1) Remove caging bolt (1), nut (2) and washer (3) from side of brake chamber (4).
Remove dust cap (5).
CAUTION
IF INSIDE OF CHAMBER IS CLOGGED WITH MUD, SAND OR DIRT, DO NOT

PROCEED WITH SPRING CAGING OPERATION UNLESS CHAMBER CAN BE
CLEARED.
13-36
TM 08780B-20
(2) Insert T-end of caging bolt (1) into hole in the back of chamber. T-end
must engage keyway inside chamber. Turn caging bolt (1) clockwise until it stops(about 1/4
turn).
NOTE
If caging bolt (1) cannot be pulled directly out, it is properly inserted.
(3) With caging bolt (1) properly inserted, install washer (3) and nut (2) onto
caging bolt (1).
NOTE
When spring is fully caged, caging bolt (1) will stick out 3 inches (7.62 cm).
(4) Tighten nut (2) until spring is fully caged. Watch clevis (6), it must retract
while nut (2) is being tightened. Do not torque beyond 50 foot-pounds (68 N*m).
NOTE
If unable to cage spring properly, tension on push rod may be released by backing off slack
adjuster.
(5) Tag and remove two air lines (7) from brake chamber (4). Remove two
air fittings (8).
(6) Remove cotter pin (9) and pin (10), from clevis (6). Discard cotter pin (9).
13-37
TM 08780B-20
1. Caging Bolt 8. Air Fitting (2)

2. Nut 9. Cotter Pin
3. Washer 10. Pin
4. Brake Chamber 10.1. Adjusting Hex*
5. Dust Cap 11. Locknut (2)
6. Clevis 12. Washer (2)
7. Air Line (2) 13. Bracket
13-38
TM 08780B-20
NOTE
(7) Turn slack adjuster adjusting hex (10.1) counter-clockwise until slack
adjuster arm is clear of clevis.
(8) Remove two locknuts (11) and washers(12) from bracket (13). Discard
locknuts (11).
(9) Remove brake chamber (4).
c. Installation
WARNING
BRAKE CHAMBER CONTAINS A SPRING UNDER GREAT PRESSURE. TO PREVENT

PERSONAL INJURY OR DEATH, NEVER WORK DIRECTLY BEHIND CHAMBER.
(1) Install brake chamber (4) onto bracket(13) so that air fittings will point
away from tire.
(2) Position stud (14) 1/8 inch (3.18 mm) from bottom of slot (15). Install
two washers (12) and locknuts (11). Tighten locknuts (11) to 100-115 foot-pounds (136-156
N*m).
(3) If brake chamber (4) is not caged, cage spring. Refer to REMOVAL
steps (1) thru (4).
(4) Adjust clevis (6) to allow pin (10) to be installed easily.
(5) Install pin (10) and new cotter pin (9).
(6) Coat threads of air fittings (8) with pipe sealant. Install two air fittings (8)
and air lines (7).
(7) Uncage spring by slowly unscrewing nut (2). Remove nut (2) and washer
(3).
13-39
TM 08780B-20
(8) Remove caging bolt (1) and install it in holder on side of brake chamber
(4). Nut side of caging bolt (1) must face away from tire.
(9) Install washer (3) and nut (2) onto caging bolt (1). Tighten nut (2)
securely.
(10) Install dust cap (5).
END OF TASK
NOTE
TM 08780B-20 Adjust brakes (para 13-5).
1. Caging Bolt
2. Nut
3. Washer
4. Brake Chamber
5. Dust Cap
6. Clevis
7. Air Line (2)
8. Air Fitting (2)
9. Cotter Pin
10. Pin
10.1. Adjusting Hex
11. Locknut (2)*
12. Washer (2)
13. Bracket
14. Stud
15. Slot
*LVSA1 SERIES
VEHICLES ONLY
13-40
TM 08780B-20
13-13. BRAKE CHAMBER REPLACEMENT (NO. 1 AXLE)

c. Installation

Condition Condition
MK48 TM 08780B-10 Air system
drained (para 3-5).
Materials/Parts
Pipe Sealant (item 48, Appendix D) TM 08780B-20 Hub and drum
Non-hardening sealer (item 49, Appendix D) removed (para 14-4).
Grease, Aircraft (item 20, Appendix D)
pressure from the air system. Block wheels
a. Removal
WARNING
AIR LINES UNDER PRESSURE WILL MOVE VIOLENTLY WHEN REMOVED. TO

PREVENT PERSONAL INJURY, DRAIN ALL AIR PRESSURE FROM SYSTEM BEFORE
REMOVING AIR LINE.
NOTE
• Air lines (1) and (1.1) are a compression type line. This air line has sleeves inserted
into the ends to help support line. It also uses eyelets to seal the line. When paragraph
removing air line the eyelet may stay with the line or may stay with the fitting. Refer to
paragraph 13-22 for air line repair procedures.
• Air line (1.1) and air fitting (3.1) are present on LVSA1 series vehicles only.
(1) Remove air lines (1) and (1.1) from brake chamber (2). Remove air
fittings (3) and (3.1) from brake chamber (2).
(2) Using a punch and hammer, loosen collet nut (4).
(3) Unscrew and remove brake chamber (2).
(4) Remove collet nut (4).
13-41
TM 08780B-20
(5) Note position of wedge assembly (5) and remove wedge assembly (5)
from brake chamber (2).
(2) Inspect all parts for damage. Refer to 2-12.
c. Installation
NOTE
Make sure wedge assembly (5) is properly seated in plunger housing (6).
(1) Coat actuating rollers and spring of wedge assembly (5) with aircraft
grease. Install wedge assembly (5) into plunger housing (6).
(2) Install collet nut (4) on brake chamber (2).
(3) Apply non-hardening sealer to first three threads on brake chamber (2).
(4) Thread brake chamber (2) into plunger housing (6) until it bottoms.
(5) Turn brake chamber (2) out no more than one turn, to place air port in top
position.
(6) Coat threads of air fittings (3) and (3.1) with pipe sealant. Install air
fittings (3) and (3.1) and air lines (1) and (1.1). Tighten securely.
(7) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Build air
pressure. Shut off engine. Refer to paragraph 2-13 (TM 08780B-10).
(8) Have assistant make and hold a full brake application. Tighten collet nut
(4) by hand until tight. Using a punch and hammer, continue to tighten collet nut (4) one and
one half teeth more. Assistant releases brake application.
END OF TASK
NOTE
TM 08780B-20 Install hub and drum (para 14-4).
13-42
TM 08780B-20
1. Air Line 3.1. Air Fitting*

1.1. Air Line* 4. Collet Nut
2. Brake Chamber 5. Wedge Assembly
3. Air Fitting 6. Plunger Housing
13-43
TM 08780B-20
13-14. BRAKE TREADLE VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Sealing compound (item 50, Appendix D) TM 08780B-20 90 degree gear
Lockwasher (2) (MS35338-45) items 28, 30 and 41 box removed
(para 15-11), steps
(1) and (2).

injury. To prevent personal injury, drain all
a. Removal
NOTE
Tag all air lines and wires for location during installation.
(1) Remove four screws (1) from cover plate (2).
(2) Remove flasher (3) from clip (4) and remove cover plate (2).
(3) Remove two nuts (5) and four wires (6, 7, 8 and 9) from bottom stop light
switch (10).
1. Screw (4)
2. Cover Plate
3. Flasher
4. Clip
13-44
TM 08780B-20
(4) Remove two nuts (11) and six wires (12, 13 and 14, 15, 16 and 17) from
top stop light switch (18).
(5) Remove two wires (19 and 20) from two sending units (21 and 22).
(6) Remove two air lines (23 and 24) from treadle valve (25).
(7) Remove two nuts (26), capscrews (27), lockwashers (28). Discard
lockwashers (28).
(8) Remove two capscrews (29), lockwashers(30) and washers (31). Discard
lockwashers (30).
(9) Remove four air lines (32, 33, 34 and 35) from back of treadle valve (25).
(10) Remove fittings (36, 37, 38 and 39).
13-45
TM 08780B-20
5. Nut (2) 17. Wire (No. 005) 29. Capscrew (2)

6. Wire (No. 009) 18. Stop Light Switch 30. Lockwasher (2)
7. Wire (No. 009) 19. Wire (No. 120) 31. Washer (2)
8. Wire (No. 005) 20. Wire (No. 120) 32. Air Line
9. Wire (No. 005) 21. Sending Unit 33. Air Line
10. Stop Light Switch 22. Sending Unit 34. Air Line
11. Nut (2) 23. Air Line 35. Air Line
12. Wire (No. 009) 24. Air Line 36. Fitting
13. Wire (No. 009) 25. Treadle Valve 37. Fitting
14. Wire (No. 009) 26. Nut (2) 38. Fitting
15. Wire (No. 005) 27. Capscrew (2) 39. Fitting
16. Wire (No 005) 28. Lockwasher (2)
13-46
TM 08780B-20
(41).
(12) Remove treadle valve (25) from mounting bracket (42).
(13) Remove two stop light switches (10 and 18).
(14) Remove two sending units (21 and 22).
(15) Remove two fittings (43) from treadle valve (25).
(16) Remove two plugs (44).
c. Installation
(1) Install treadle valve (25) to mounting bracket (42).
(2) Install three new lockwashers (41) and capscrews (40). Tighten securely.
NOTE
Apply sealing compound to threads of all plugs, air fittings, sending units and switches before
installing.
(3) Install two plugs (44) and tighten securely.
(4) Install two fittings (43) and tighten securely.
(5) Install two sending units (21 and 22) and tighten securely.
(6) Install two stop light switches (10 and 18) and tighten securely.
(7) Loosely install two washers (31), new lockwashers (30) and capscrews
(29). Do NOT tighten.
13-47
TM 08780B-20
10. Stop Light Switch 31. Washer (2)

18. Stop Light Switch 40. Capscrew (3)
21. Sending Unit 41. Lockwasher (3)
22. Sending Unit 42. Mounting Bracket
25. Treadle Valve 43. Fitting (2)
29. Capscrew (2) 44. Plug (2)
30. Lockwasher (2)
(8) Install fittings (36, 37, 38 and 39). Tighten securely.
(9) Install four airlines (32, 33, 34 and 35) onto back of treadle valve (25).
(10) Install treadle valve (25) into truck so that slots in mounting bracket (42)
engage capscrews (29).
(11) Install two new lockwashers (28), capscrews (27) and nuts (26).
(12) Tighten two capscrews (27) and two capscrews (29).
(13) Install two air lines (23 and 24).
(14) Connect two wires (19 and 20) to sending units (21 and 22).
(15) Connect six wires (12, 13, 14, 15, 16 and 17) to stop light switch (18).
Install and tighten two nuts (11).
13-48
TM 08780B-20
(16) Connect wires (6, 7, 8 and 9) to stop light switch (10). Install and tighten
two nuts (5).
25. Treadle Valve 36. Fitting

32. Air Line 37. Fitting
35. Air Line 42. Mounting Bracket
(17) Install cover plate (2) and four screws (1).
(18) Install flasher (3) into clip (4).
END OF TASK
NOTE
TM 08780B-20 90 degree gear box installed (para 15-11).

proper brake operation.
13-49
TM 08780B-20
1. Screw (4) 11. Nut (2) 21. Sending Unit

2. Cover Plate 12. Wire (No. 009) 22. Sending Unit
3. Flasher 13. Wire (No. 009) 23. Air Line
4. Clip 14. Wire (No. 005) 24. Air Line
5. Nut (2) 15. Wire (No. 005) 25. Treadle Valve
6. Wire (No. 009) 16. Wire (No. 005) 26. Nut (2)
7. Wire (No. 009) 17. Wire (No. 005) 27. Capscrew (2)
8. Wire (No. 009) 18. Stop Light Switch 28. Lockwasher (2)
9. Wire (No. 005) 19. Wire (No. 120) 29. Capscrew (2)
10. Stop Light Switch 20. Wire (No. 120)
13-50
TM 08780B-20
13-15. RELAY VALVE REPLACEMENT (MK48)

c. Installation
d. Leak Testing

Condition Condition
drained (para 3-5).
Materials/Parts
Sealing compound (item 50, Appendix D) General Safety Instructions
Soap and water solution (item 54, Appendix D) Block wheels of truck to prevent personal
Lockwasher (2) (MS35338-45) item 14 injury. To prevent personal injury drain all
Locknut (2) (1437220) item 5
Personnel Required
1 MOS 3521
1 Assistant
References
TM 08780B-10
NOTE
These procedures are for non-ABS modified vehicles only.
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
• Both relay valves (2) are replaced in the same manner. This procedure describes the
replacement of one relay valve only.
• Tag all air lines to insure proper installation.
• Air lines (1 and 4) are compression type lines. These air lines have sleeves inserted
into the ends to help support line. They also use eyelets to seal lines. When removing
air lines the eyelet may stay with the line or may stay with the fitting. Refer to
13-51
TM 08780B-20
(1) Remove air line (1) from side of relay valve (2).
(2) Remove two air lines (3) from bottom of relay valve (2).
(3) Remove two air lines (4) from top of relay valve (2).
NOTE
Mounting hardware for LVS relay valve has changed from capscrew, lockwasher and hex nut
to a flanged type capscrew and locknut. When repairing a non-A1 vehicle, use the new style
flanged mounting hardware to replace the old style hardware. Refer to TM 08780B-24P for
(5) Remove relay valve (2).
13-52
TM 08780B-20
1. Air Line 10.1. Double Check Valve* 10.9. Front Relay Valve
2. Relay Valve 10.2. Tee* 11. Air Fitting (2)
3. Air Line (2) 10.3. Elbow* 12. Plug (2)
4. Air Line (2) 10.4. Rear Relay Valve 13. Capscrew (2)
5. Locknut (2) 10.5. Street Tee* 14. Lockwasher (2)
8. Capscrew (2) 10.6. Tee* 15. Bracket (2)
9. Air Fitting 10.7. Elbow*
10. Air Fitting (2) 10.8. Connector (2)*
13-53
TM 08780B-20
NOTE
Air fittings on front and rear relay valves are different. Note shape and type during removal
for use during installation.
(6) Remove air fitting (9) from side of relay valve (2).
(7) Remove air fitting (10) from top of relay valve (2).
NOTE
(8) Remove double check valve (10.1), tee (10.2) and elbow (10.3) from top
of rear relay valve (10.4).
(9) Remove tee (10.2) and elbow (10.3) from double check valve (10.1).
(10) Remove street tee (10.5), tee (10.6), elbow (10.7) and two
connectors(10.8) from top of front relay valve (10.9).
(11) Remove tee (10.6), elbow (10.7) and two connectors (10.8) from street tee
(10.5).
(12) Remove two air fittings (11) from bottom of relay valve (2).
(13) Remove two plugs (12) from bottom of relay valve (2).
(14) If damaged, remove two capscrews (13), lockwashers (14) and bracket
(3) Replace all parts failing inspection,
c. Installation
(1) If removed, install bracket (15) using two capscrews (13) and new
lockwashers (14).
NOTE
Apply sealing compound to threads of fittings and plugs before installing.
13-54
TM 08780B-20
(2) Install two plugs (12) and air fittings (11) into bottom of relay valve (2).
(3) Install air fitting (10) into top of relay valve (2).
NOTE
(4) Install tee (10.6), elbow (10.7) and two connectors (10.8) on street tee
(10.5).
(5) Install tee (10.6), elbow (10.7), two connectors (10.8) and street tee (10.5)
on front relay valve (10.9).
(6) Install tee (10.2) and elbow (10.3) on double check valve (10.1).
(7) Install tee (10.2), elbow (10.3) and double check valve (10.1) on top of
rear relay valve (10.4).
(8) Install air fitting (9) into side of relay valve (2).
(9) Install relay valve (2) using capscrews (8) and new locknuts (5). Tighten
(10) Connect two air lines (4) to top of relay valve (2).
(11) Connect air line (1) to side of relay valve (2).
(12) Connect two air lines (3) to air fittings (11) in bottom of relay valve (2).
END OF TASK
13-55
TM 08780B-20
2. Relay Valve 10.1. Double Check Valve* 10.9. Front Relay Valve
3. Air Line (2) 10.2. Tee* 11. Air Fitting (2)
4. Air Line (2) 10.4. Rear Relay Valve 12. Plug (2)
5. Locknut (2) 10.5. Street Tee* 13. Capscrew (2)
8. Capscrew (2) 10.6. Tee* 14. Lockwasher (2)
9. Air Fitting 10.7. Elbow* 15. Bracket (2)
10. Air Fitting (2) 10.8. Connector (2)*
13-56
TM 08780B-20
13-16. RELAY VALVE REPLACEMENT (MK14, 15, 16, 17)

c. Installation
d. Leak Testing

Condition Condition
MK15 drained (para 3-5).
MK16
MK17 General Safety Instructions
Block wheel to prevent personal injury.
Materials/Parts To prevent personal injury, drain all
Sealing compound (item 50, Appendix D) from air system.
Soap solution (item 54, Appendix D)
Lockwashers (2) (MS35338-46) item 18
Locknut (2) (1437220) item 12
References
TM 08780B-10
NOTE
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
• This procedure will work for either the right or left mounted valves. Use the
illustration for the valve you are working on.
• Air lines are compression type lines. These air lines have sleeves inserted into the ends
to help support line. They also use eyelets to seal lines. When removing air lines the
eyelet may stay with the line or may stay with the fitting. Refer to paragraph 13-23 for
air line repair procedures.
13-57
TM 08780B-20
• Left relay valve (1) has one air line on top. Right relay valve (2) has three air lines on
top.
(1) For left relay valve (1) remove air line (3) and air fitting (4).
(2) For right relay valve (2) remove three air lines (5, 6 and 7), check valve
(8) and tee fitting (9).
(3) Remove air line (10) and two air lines (11) from relay valve (1 or 2).
NOTE
Mounting hardware for LVSA1 relay valve has changed from a capscrew, lockwasher and hex
nut to a flanged type capscrew and locknut. When repairing non-A1 vehicles, use the new
style flanged mounting hardware to replace the old style hardware. Refer to TM 08780B-24P
for correct mounting hardware.
(4) Remove two locknuts (12), capscrews (14) and relay valve (1 or 2).
(5) Remove air fitting (15) from side of relay valve (1 or 2).
(6) Remove two air fittings (16) from bottom of relay valve (1 or 2).
(7) If damaged, remove two capscrews (17), lockwashers (18) and bracket
(19) from relay valve (1 or 2). Discard lockwashers (18).
13-58
TM 08780B-20
1. Relay Valve 8. Check Valve 16. Air Fitting (2)

2. Relay Valve 9. Tee Fitting 17. Capscrew (2)
3. Air Line 10. Air Line 18. Lockwasher (2)
4. Air Fitting 11. Air Line (2) 19. Bracket
5. Air Line 12. Locknut (2)
7. Air Line 15. Air Fitting
NOTE
Apply sealing compound to threads of all air fittings before installing.
13-59
TM 08780B-20
c. Installation
(1) Make sure bracket (19) is properly positioned on relay valve (1 or 2).
Opening (20) should be opposite bracket (19) for right relay valve (2). It should be on the same
side for left relay valve (1).
(2) If removed, install bracket (19) onto relay valve (1 or 2) using two
capscrews (17) and new lockwashers (18).
(3) Install two air fittings (16) into bottom of relay valve (1 or 2).
(4) Install air fitting (15) into side of relay valve (1 or 2).
(5) Install relay valve (1 or 2) with capscrews (14) and new locknuts (12).
(6) Connect two air lines (11) to two air fittings (16). Connect air line (10) to
air fitting (15).
(7) For right relay valve (2), install tee fitting (9) into check valve (8). Install
check valve (8) and connect three air lines (5, 6 and 7).
(8) For left relay valve (1), install air fitting (4) and connect air fine (3).
1. Relay Valve 18. Lockwasher (2)

2. Relay Valve 19. Bracket
17. Capscrew (2) 20. Opening
13-60
TM 08780B-20
d. Leak Testing
(1) Start engine and bring air system to operating pressure. Refer to
paragraph 2-13, TM 08780B-10.
(2) Have assistant apply and release brakes several times. Check operation of
brakes at each wheel.
(3) Coat fittings and lines with soap solution and apply brakes. A one inch
bubble in three seconds is permitted.
(4) Release brakes and retest. A one inch bubble in three seconds is
permitted.
(5) Repeat steps (3) and (4). Coat exhaust valve on bottom and top cover with
soap solution. Exhaust valve is allowed a one inch bubble in three seconds. The cover is
allowed NO leakage.
1. Relay Valve 6. Air Line 11. Air Line (2)

2. Relay Valve 7. Air Line 12. Locknut (2)
3. Air Line 8. Check Valve 14. Capscrew (2)
4. Air Fitting 9. Tee Fitting 15. Air Fitting
5. Air Line 10. Air Line 16. Air Fitting (2)
END OF TASK
13-61
TM 08780B-20
13-17. QUICK RELEASE VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Locknut (2) 1333510 item 4 Block wheels of truck to prevent personal
pressure from air system.
NOTE
a. Removal
WARNING

REMOVING PRESSURIZED COMPONENTS.
NOTE
• Tag air lines (1 and 3) and wires (8) before removal to insure proper installation.
• Air lines (1 and 3) are compression type lines. These air lines have sleeves inserted
• Mounting hardware for LVSA1 quick release valves has changed from a capscrew,
lockwasher and hex nut to a flanged type capscrew and locknut. When repairing a
non-Al vehicle, use the new style flanged mounting hardware to replace the old style
hardware. Refer to TM 08780B-24P for correct parts identification.
(1) Remove air line (1) from top of quick release valve (2).
(2) Remove air line (3) from rear of quick release valve (2).
13-62
TM 08780B-20
(4) Remove two nuts (7) and wires (8).
(5) Remove quick release valve (2).
(6) Remove two 90 degree elbows (9).
(7) Remove stop light switch (10).
c. Installation
NOTE
Coat threads of 90 degree elbows (9), reducer (11) and stop light switch (10) with sealing
compound before installing. Tighten fittings and lines securely.
(1) Install reducer (11) and stop light switch (10) into quick release valve (2).
(2) Install two 90 degree elbows (9).
(3) Install two wires (8) and nuts (7) and tighten securely.
(4) Install quick release valve (2) using two capscrews (6) and nuts (4).
(5) Install air lines (1 and 3) into 90 degree elbows (9).
END OF TASK
NOTE
13-63
TM 08780B-20
1. Air Line 7. Nut (2)

2. Quick Release Valve 8. Wire (No. 009) (2)
3. Air Line 9. 90 Degree Elbow (2)
4. Locknut (2) 10. Stop Light Switch
6. Capscrew (2) 11. Reducer
13-64
TM 08780B-20
13-18. QUICK RELEASE VALVE REPLACEMENT (LVSA1 SERIES VEHICLES

ONLY)

c. Installation

Condition Condition
MK48A1 TM 08780B-10 Air system
drained (para 3-5).
Materials/Parts
Locknut (2) (1333510) item 7 Block wheels of truck to prevent personal
Locknut (2) (1437220) item 13 injury. To prevent personal injury, drain all
NOTE
a. Removal
WARNING

NOTE
• Tag air lines (1, 2, 5 and 6) before removal to insure proper installation.
• Air lines (1, 2, 5 and 6) are compression type lines. These air lines have sleeves
inserted into the ends to help support line. They also use eyelets to seal lines. When
removing air lines the eyelet may stay with the line or may stay with the fitting. Refer
to paragraph 13-23 for air line repair procedures.
(1) Remove air lines (1 and 2) from tops of left quick release valve (3) and
right quick release valve (4).
(2) Remove air lines (5 and 6) from sides of left and right quick release valves
(3 and 4).
(3) Remove two locknuts (7), capscrews (8) and left and right quick release
valves (3 and 4). Discard locknuts (7).
13-65
TM 08780B-20
(4) Remove 90 degree elbows (9) from tops of left and right quick release
valves (3 and 4).
(5) Remove 45 degree elbow (10) from end of left quick release valve (3).
(6) Remove connector (11) from end of right quick release valve (4).
(7) Remove plugs (12) from ends of left and right quick release valves (3 and
4).
NOTE
Relay valve is removed with quick release valve bracket (16). To remove relay valve, refer to
(8) Remove two locknuts (13), capscrews (14), clamp (15) and quick release
valve bracket (16). Discard locknuts (13).
(9) Secure relay valve as necessary to avoid damage to equipment.
c. Installation
NOTE
Coat threads of 90 degree elbows (9), 45 degree elbow (10), connector (11) and plugs (12) with
sealing compound before installing. Tighten fittings and lines securely.
(1) Install quick release valve bracket (16) and clamp (15) using two
capscrews (14) and new locknuts (13). Tighten locknuts (13) securely.
(2) Install plugs (12) into ends of left and right quick release valves (3 and 4).
Tighten plugs (12) securely.
(3) Install connector (11) into end of right quick release valve (4). Tighten
connector (11) securely.
(4) Install 45 degree elbow (10) into end of left quick release valve (3).
Tighten 45 degree elbow (10) securely.
13-66
TM 08780B-20
(5) Install 90 degree elbows (9) into tops of left and right quick release valves
(3 and 4).
(6) Install left and right quick release valves (3 and 4) onto quick release
valve bracket (16) using two capscrews (8) and new locknuts (7). Tighten locknuts (7) securely.
(7) Install air lines (5 and 6) into sides of left and right quick release valves (3
and 4).
(8) Install air lines (1 and 2) into tops of left and right quick release valves (3
and 4).
END OF TASK
NOTE

3. Left Quick Release Valve
4. Right Quick Release Valve
7. Locknut (2)
8. Capscrew (2)
9. 90 Degree Elbow (2)
10. 45 Degree Elbow
11. Connector
12. Plug (2)
13. Locknut (2)
14. Capscrew (2)
15. Clamp
16. Quick Release Valve Bracket
13-67
TM 08780B-20
13-19. PRESSURE PROTECTION VALVE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Center skid plate
grille removed
Sealing compound (item 50, Appendix D)
TM 08780B-10 Air system drained
(para 3-5).

a. Removal
WARNING

NOTE
Air line (1) is a compression type line. This air line has a sleeve inserted into the end to help
support line. It also has an eyelet to seal line. When removing air line the sleeve may stay
with the line or may stay with the fitting. Refer to paragraph 13-23 for air line repair
procedures.
(1) Remove air line (1) from fitting (2).
(2) Remove adapter (3) and pressure protection valve (4) from air tank (5).
(3) Remove adapter (3) and nipple (6) from pressure protection valve (4).
Remove nipple (6) from adapter (3).
(4) Remove fitting (2) from pressure protection valve (4).
13-68
TM 08780B-20
c. Installation
NOTE
Apply sealing compound to plate threads of air fitting (2), nipple (6) and adapter (3) before
installing.
(1) Install air fitting (2) into pressure protection valve (4).
(2) Install nipple (6) into adapter (3) and pressure protection valve (4).
(3) Install pressure protection valve (4) assembly into air tank (5).
(4) Install air line (1) onto air fitting (2).
END OF TASK
NOTE
TM 08780B-20 Install skid grille (para 18-17).

13-69
TM 08780B-20
1. Air Line 4. Pressure Protection Valve

2 Air Fitting 5. Air Tank
13-70
TM 08780B-20
13-20. SPRING BRAKE CONTROL VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Locknut (2) (1333510) item 7 Block wheels of truck to prevent personal
injury.
a. Removal
WARNING

NOTE
• Air lines (1 thru 5) are compression type lines. These air lines have sleeves inserted
into the ends to help support line. When removing air lines the eyelet may stay with the
line or may stay with the fitting. Refer to paragraph 13-23 for air line repair
procedures.
• Mounting hardware for LVSA1 spring brake control valves has changed from a
capscrew, lockwasher and hex nut to a flanged type capscrew and locknut. When
repairing a non-A1 vehicle, use the new style flanged mounting hardware to replace
the old style hardware. Refer to TM 08780B-24P for correct parts identification.
(1) Tag air lines (1, 2, 3, 4 and 5).
(2) Disconnect five air lines (1, 2, 3, 4 and 5) from valve (6).
(3) Remove two locknuts (7) and two capscrews (9). Discard locknuts (7).
(4) Remove valve (6).
(5) Remove fittings (10, 11 and 12) from valve (6).
(6) Remove nipple (13) and reducer coupling (14) from valve (6).
13-71
TM 08780B-20
(7) Remove plug (15) from valve (6).
(8) While holding nut (16) with a wrench, remove nipple (17) and tee (18)
from valve (6).
(9) Remove nipple (17), elbow (19) and reducer coupling (20) from tee (18).
c. Installation
NOTE
• Coat all fittings with sealing compound before installing.
• Tighten all fittings securely during installation.
(1) Install reducer coupling (20), elbow (19) and nipple (17) into fitting (18).
(2) While holding nut (16) with a wrench, install tee fitting (18) and nipple
(17) into valve (16).
(3) Install plug (15) in valve (6).
(4) Install fitting (10 and 11) in valve (6).
(5) Assemble nipple (13), reducer coupling (14) and fitting (12).
(6) Install nipple (13) in valve (6).
(7) Mount valve (6) on vehicle using two capscrews (9) and two new locknuts
(7).
(8) Connect five air lines (1, 2, 3, 4 and 5) and tighten securely.
END OF TASK
13-72
TM 08780B-20
NOTE
TM 08780B-10 Start engine, build air pressure and check for
air leaks (para 2-13).
Check operation of parking brake

(para 2-13).
1. Air Line (No. 623A) 9. Capscrew (2) 15. Plug

2. Air Line (No. 664) 10. Fitting 16. Nut
3. Air Line (No. 621) 11. Fitting 17. Nipple
4. Air Line (No. 622) 12. Fitting 18. Tee
5. Air Line (No. 621A) 13. Nipple 19. Elbow
6. Valve 14. Reducer Coupling 20. Reducer Coupling
7. Locknut (2)
13-73
TM 08780B-20
13-21. PARKING BRAKE VALVE MAINTENANCE
THIS TASK COVERS: a. Removal and Disassembly

c. Assembly and Installation

Condition Condition
drained (para 3-5).
Materials/Parts
O-ring (P/N 117072) item 21 disconnected (para
Locknut (NSN 5310-00-010-8415) item 22 7-45 or 7-46 on
O-ring (P/N 116345) item 27 LVSA1 Series
O-ring (P/N 116302) item 26.1 Vehicles).

TM 08780B-10 Block wheels of truck to prevent personal
working on electrical components. To
prevent personal injury, drain all pressure
from air system.
a. Removal and Disassembly
WARNING

REMOVING AIR LINE.
NOTE
Air lines (9 thru 12) are compression type lines. These air lines have sleeves inserted into the
ends to help support line. They also use eyelets to seal lines. When removing air lines the
eyelet may stay with the line or may stay with the fitting. Refer to paragraph 13-23 for air line
repair procedures.
Lean instrument panel (2) against steering wheel (4).
(2) Remove roll pin (5) and knob (6).
(3) Remove nut (7). Push valve (8) through dash (3).
13-74
TM 08780B-20
(4) Reach under dash (3) and pull valve (8), with air lines attached, down until
clear.
(5) Tag and remove four air lines (9 thru 12). Remove valve (8).
NOTE
Mark position of fittings for proper installation.
(6) Remove three 90 degree elbows (13, 14 and 15).
(7) Remove straight fitting (16) from tee (17).
NOTE
Air line fittings for the LVSA1 parking brake valve have changed from a nipple and tee to
street tee. When repairing a non-A1 vehicle, use the new style fittings to replace the old style
fittings. Refer to TM 08780B-24P for correct parts identification.
(8) Remove tee (17).
(9) Remove two screws (19), end cap (20) and O-ring (21). Discard O-ring
(21).
(10) Remove locknut (22), washer (23), poppet (24) and stem (25) from body
(26). Discard locknut (22).
NOTE
The old style parking brake valves will not have an O-ring (26.1). New style parking brake
valves will have an O-ring (26.1). Perform step (11) only if repairing a new style parking
brake valve.
(11) Remove and discard O-ring (26.1) from poppet (24) or body (26).
(12) Remove and discard O-ring (27) from stem (25).
13-75
TM 08780B-20
1. Screw 10. Air Line 612 20. End Cap

2. Instrument Panel 11. Air Line 54 21. O-Ring
3. Dash 12. Air Line 611 22. Locknut
4. Steering Wheel 13. 90 Degree Elbow 23. Washer
5. Roll Pin 14. 90 Degree Elbow 24. Poppet
6. Knob 15. 90 Degree Elbow 25. Stem
7. Nut 16. Straight Fitting 26. Body
8. Valve 17. Tee 26.1. O-Ring
9. Air Line 661 19. Screw (2) 27. O-Ring
NOTE
Apply sealant to threads of elbows, fittings and tee before installing.
(1) Install new O-ring (27) onto stem (25).
(2) Install new O-ring (26.1) on poppet (24).
(3) Install stem (25), poppet (24), washer (23) and new locknut (22) into body
(26). Tighten locknut (22) securely.
(4) Install new O-ring (21), end cap (20) and two screws (19). Tighten screws
(19) securely.
13-76
TM 08780B-20
(5) Install tee (17) into valve (8).
(6) Install straight fitting (16) into tee (17).
(7) Install three 90 degree elbows (13, 14 and 15).
(8) Install four air lines (9, 10, 11 and 12) onto valve (8).
(9) Install valve (8) into dash (3).
(10) Install nut (7). Tighten securely.
(11) Install knob (6) with roll pin (5).
(12) Install instrument panel (2) with six screws (1). Tighten screws (1)
securely.
END OF TASK
NOTE
TM 08780B-20 Connect batteries (para 7-45 or 7-46 on
TM 08780B-10 Check parking brakes for proper operation

(para 2-13).
13-77
TM 08780B-20
1. Screw 10. Air Line 612 20. End Cap

2. Instrument Panel 11. Air Line 54 21. O-Ring
3. Dash 12. Air Line 611 22. Locknut
4. Steering Wheel 13. 90 Degree Elbow 23. Washer
5. Roll Pin 14. 90 Degree Elbow 24. Poppet
6. Knob 15. 90 Degree Elbow 25. Stem
7. Nut 16. Straight Fitting 26. Body
8. Valve 17. Tee 26.1. O-Ring
9. Air Line 661 19. Screw (2) 27. O-Ring
13-78
TM 08780B-20
13-22. TRACTOR PROTECTION VALVE REPLACEMENT

c. Installation

Condition Condition
MK16
Materials/Parts injury. To prevent personal injury, drain all
Sealing Compound (item 50, Appendix D) pressure from air system.
Locknut (2) (369AX1) item 2
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
• Tractor protection valve is the same on all units (MK14, MK15, MK16 and MK17) and
upper fittings on MK16 differ as explained below.
• Air lines (1) are compression type lines. These air lines have sleeves inserted into the
ends to help support line. They also use eyelets to seal lines. When removing air lines
the eyelet may stay with the line or may stay with the fitting. Refer to paragraph 13-23
for air line repair procedures.
• Mounting hardware for the LVSA1 tractor protection valve has changed from a
capscrew, lockwasher and hex nut to a flanged-type capscrew and locknut. When
repairing a non-A1 vehicle, use the new style flanged hardware to replace the old style
(1) Tag four air lines (1).
(2) Disconnect four air lines (1).
13-79
TM 08780B-20
(4) Remove valve (5) from vehicle.
(5) On MK14, MK15 and MK17 only, tag four fittings (6).
(6) Remove fittings (6) from valve (5).
NOTE
Air fittings for the MK16A1 tractor protection valve have changed from a nipple and reducer
to a hex nipple. When repairing non-A1 vehicles, use the new style fitting to replace the old
style fittings. Refer to TM 08780B-24P for correct parts identification.
(7) On MK16 only, tag and remove two lower fittings (6). Remove two
elbows (7), two trailer hose lines (8), two adapters (9), two tees (10) and two hex nipples (12).
c. Installation
(1) Coat threads of fittings with sealing compound.
(2) Install four fittings (6) on new valve (5).
(3) On MK16 only, install two hex nipples (12), two tees (10), two adapters
(9), two elbows (7) and two trailer hose lines (8).
(4) Mount valve (5) on vehicle with two capscrews (4) and new locknuts (2).
(5) Connect four air lines (1). Tighten securely.
END OF TASK
NOTE
TM 08780B-10 Start engine, build system air pressure and
check connections for air leaks (para 2-13).
13-80
TM 08780B-20
1. Air Line (4) 7. Elbow (2)

2. Locknut (2) 8. Trailer Hose Line (2)
4. Capscrew (2) 9. Adapter (2)
5. Valve 10. Tee (2)
6. Fitting (4) 12. Hex Nipple (2)
13-81
TM 08780B-20
13-23. AIR LINE AND FITTING REPLACEMENT
THIS TASK COVERS: a. Air Line Replacement

b. Compression Type Fitting Replacement
c. Reusable Type Fitting Replacement

Condition Condition
Sealing Compound (item 50, Appendix D) TM 08780B-10 Air system
Soap and water solution (item 54, Appendix D) drained (para 3-5).

a. Removal
WARNING
• AIR LINES UNDER PRESSURE WILL MOVE VIOLENTLY WHEN REMOVED.

TO PREVENT PERSONAL INJURY, DRAIN ALL AIR PRESSURE FROM
SYSTEM BEFORE REMOVING AIR LINE.
• DO NOT MIX HOSE ASSEMBLY COMPONENTS FROM DIFFERENT

MANUFACTURERS. DURING ASSEMBLY REPAIR MAKE SURE ALL
COMPONENTS (HOSE AND FITTINGS) ARE FROM THE SAME
MANUFACTURER. NEVER REUSE EXISTING HOSE. ALWAYS REPLACE
WITH NEW HOSE. IF YOU CAN NOT POSITIVELY IDENTIFY THE
MANUFACTURER OF ALL COMPONENTS OR YOU CANNOT OBTAIN
REPLACEMENT PARTS FROM THE SAME MANUFACTURER, REPLACE THE
ENTIRE ASSEMBLY. HOSE ASSEMBLIES MADE UP OF DIFFERENT
MANUFACTURER’S PARTS CAN FAIL. FAILURE TO COMPLY COULD
RESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL.
NOTE
Tag all air lines to insure proper installation.
(1) Tag and remove air line (1).
(2) Remove fittings (2) from both ends of air line (1). Refer to section b or c.
(3) Measure length of air line (1). Cut new air line to proper length.
(4) Install fittings (2) on both ends of air line. Refer to section b or c.
13-82
TM 08780B-20
(5) Install air line (1) in tagged position. Tighten fittings (2) securely.
pressure to normal operating pressure. Use soap and water solution to check for leaks.
1. Air Line
2. Fitting (2)
b. Compression Type Fitting Replacement
NOTE
Air line (1) is a compression type line. This air line has eyelets inserted into the ends to help
support line. It also uses sleeves to seal lines. When removing air lines the eyelet may stay
with the line or may stay with the fitting.
(1) Remove nut (3) from fitting (4).
(2) Remove eyelet (5).
(3) Cut air line (1) just behind sleeve (6). Discard sleeve (6). Slide nut (3) off
air line (1).
(5) Inspect nut (3) and fitting (4) for damage. If damaged, replace.
(6) Apply sealing compound to threads (7) of fitting (4) only. Do not apply to
nut side of fitting. Install fitting (4). Tighten securely.
13-83
TM 08780B-20
1. Air Line 5. Eyelet

3. Nut 6. Sleeve
4. Fitting 7. Threads
(7) Slide nut (3) onto air line (1) with threads facing out.
(8) Slide new sleeve (6) onto air line (1). Install eyelet (5) into air line (1).
(9) Push air line (1) with eyelet (5) into fitting (4) as far as possible.
(10) Slide nut (3) onto fitting (4). Tighten nut (3) securely.
pressure to normal operating pressure. Use soap and water solution to check for leaks.
c. Reusable Type Fitting Replacement
(1) Loosen nut (8). Remove air line (9).
(3) Install fitting (10) into nut (8). Jam fitting (10) tightly against nut (8).
Remove nipple (11) from nut (12).
(4) Remove fitting (10) from nut (8).
NOTE
Nut (12) has a left hand thread.
(5) Remove nut (12) from air line (9).
(6) Inspect all fittings and nuts for damage. Replace all parts failing
inspection.
13-84
TM 08780B-20
1. Air Line 5. Eyelet

3. Nut 6. Sleeve
4. Fitting 7. Threads
7. Threads 10. Fitting

8. Nut 11. Nipple
9. Air Line 12. Nut
(7) Install nut (12) onto air line (9).
(8) Install nipple (11) through nut (8) as shown.
(9) Install fitting (10) into nut (8). Jam fitting(10) tightly against nut (8).
(10) Thread nipple (11) into nut (12). Tighten nipple (11) until there is 0.3125
inch (0.7935 mm) between nipple (11) and nut (12).
13-85
TM 08780B-20
WARNING

(12) Using compressed air, clean air line (9).
(13) Apply pipe sealant to threads (7) of fitting (10) only. Do not apply to nut
(8) side of fitting (10).
(14) Install fitting (10). Tighten securely.
(15) Install nut (8) onto fitting (10). Tighten nut (8) securely.
(16) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Build up air
pressure to operating pressure. Use soap and water solution to check for leaks.
END OF TASK
13-86
TM 08780B-20
13-24. FRONT AIR MANIFOLD REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Soap and water solution (item 54, Appendix D) To prevent personal injury, drain all
Locknut (2) (1600460) item 6 pressure from the air system. Block wheels
References
TM 08780B-10
a. Removal
WARNING

REMOVING AIR LINE. WEAR EYE PROTECTION WHEN DISCONNECTING AIR
LINES.
NOTE
air lines the eyelets may stay with the line or may stay with the fitting. Refer to
• Mounting hardware for LVSA1 air manifolds has changed from a capscrew,
lockwasher and hex nut to a flanged type capscrew and locknut. When repairing
anon-A1 vehicle, use the new style flanged mounting hardware to replace the old style
(1) Remove five air lines (1 thru 5).
13-87
TM 08780B-20
(2) Remove two locknuts (6), spacers (8) and capscrews (10) from air manifold
assembly (11). Remove air manifold assembly (11). Discard locknuts (6).
b. Disassembly
NOTE
• Air line fittings for the LVSA1 front air manifold have changed from a nipple and
check valve, to a check valve with a male fitting. When repairing a non-A1 vehicle, use
the new style fittings to replace the old style fittings. Refer to TM 08780B-24P for
• Tag and mark location of fittings to insure proper installation.
(1) Apply wrench to small hexagon nut (14) of check valve (13) and remove
check valve (13) as a unit from air manifold (15).
(2) If damaged, remove three 90 degree elbows (16, 17 and 18) from air
manifold (15).
(3) Remove 90 degree elbow (19) from check valve (20). Apply wrench to
lower hexagon nut of check valve (20) and remove check valve (20) as a unit from elbow (22).
(4) Remove elbow (22) from air manifold (15).
c. Cleaning/Installation
d. Assembly
NOTE
• Air line fittings for the LVSA1 front air manifold have changed from a nipple and
check valve to check valve with male fitting. When repairing a non-All vehicle, use the
new style fittings to replace the old style fittings. Refer to TM 08780B-24P for correct
• Apply sealing compound to threads of all fittings before installing.
(1) Install elbow (22) on manifold (15).
(2) Apply wrench to lower hexagon nut of check valve (20) and install check
valve (20) into elbow (22). Install 90 degree elbow (19) into check valve (20).
13-88
TM 08780B-20
(3) If removed, install three 90 degree elbows (16, 17 and 18) into air
manifold (15).
(4) Apply wrench to small hexagon nut (14) of check valve (13) and install
check valve (13) into air manifold (15).
e. Installation
(1) Install air manifold assembly (11) using two capscrews (10), spacers (8)
and new locknuts (6). Tighten locknuts (6) securely.
(2) Install five air lines (1 through 5).
(3) Start engine. Refer to paragraph 2-13 (TM 08780B-10).
(4) Build up air pressure to normal operating pressure 120 psi. Use soap and
water solution to check for air leaks.
END OF TASK
NOTE
TM 08780B-20 Install glad hand (para 13-36, LVSA1
13-89
TM 08780B-20
1. Air Line 10. Capscrew (2) 16. 90 Degree Elbow

2. Air Line 11. Air Manifold 17. 90 Degree Elbow
3. Air Line Assembly 18. 90 Degree Elbow
4. Air Line 13. Check Valve 19. 90 Degree Elbow
5. Air Line 14. Small Hexagon Nut 20. Check Valve
6. Locknut (2) 15. Air Manifold 22. Elbow
8. Spacer (2)
13-90
TM 08780B-20
13-25. REAR AIR MANIFOLD REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Soap and water solution (item 60, Appendix D) To prevent personal injury, drain all air
Locknut (2) (1600460) item 6 pressure from the air system. Block wheels
References
TM 08780B-10
a. Removal
WARNING

NOTE
paragraph 13-23 for air line procedures.
• Mounting hardware for LVSA1 air manifolds has changed from a capscrew,
non-A1 vehicle, use the new style flanged mounting hardware to replace the old style
(1) Remove four air lines (1 thru 4) from manifold (5).
13-91
TM 08780B-20
(3) Remove manifold (5) from valve mounting plate (10).
b. Disassembly
NOTE
Mark and tag all fittings to insure proper installation.
(1) Remove plug (11) from manifold (5).
(2) Remove four elbows (12) thru (15) from manifold (5).
(3) Remove three reducers (16).
(3) Inspect manifold (5) for cracks or damaged threads.
(4) Inspect fittings for cracks or damaged threads.
d. Assembly
NOTE
Apply sealing compound to all fittings and plugs before installation.
(1) Install plug (11) into manifold (5).
(2) Install three reducers (16) into manifold (5).
(3) Install four elbows (12 thru 15) into manifold.
e. Installation
(1) Install manifold (5) onto valve mounting plate (10) using two capscrews
(9) and new locknuts (6).
(2) Connect four air lines (1 thru 4).
13-92
TM 08780B-20
(4) Build air pressure to normal operating pressure. Use soap and water
solution to check for air leaks.
END OF TASK
1. Air Line (No. 069d) 6. Locknut (2) 13. Elbow

2. Airline (No. 069c) 9. Capscrew (2) 14. Elbow
3. Air Line (No. 069b) 10. Valve Mounting Plate 15. Elbow
4. Air Line (No. 069) 11. Plug 16. Reducer (3)
5. Manifold 12. Elbow
13-93
TM 08780B-20
13-26. MAIN AIR MANIFOLD REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Sealing compound (item 50, Appendix D) TM 08780B-20 Bracket removed
Lockwasher (4) (MS35338-44) item 13 (para 7-33, step5
Lockwasher (3) (MS35338-44) item 13 item 9).
(LVSA1 series vehicles only)
Lockwasher (4) (353AX) item 12.2 Washer reservoir
Soap and water solution (item 54, Appendix D) hoses replaced (para
21-8 and 21-9).
References
TM 08780B-10 General Safety Instructions
a. Removal
WARNING

NOTE
• Tag all air lines as they are removed to insure proper installation.
(1) Remove eight air lines (1 thru 8) from top edge of manifold (9).
13-94
TM 08780B-20
1. Air Line (No. 662) 7. Air Line (No. 706) 12.1. Nut (4)*
2. Air Line (No. 665) 8. Air Line (No. 069) 12.2. Lockwasher (4)*
3. Air Line (No. 663) 9. Manifold 12.3. Capscrew*
4. Air Line (No. 611) 10. Air Line (No. 415) 13. Lockwasher (4)
5. Air Line (No. 612) 11. Air Line (No. 416) 13.1. Washer*
6. Air Line (No. 623) 12. Capscrew (4) 13.2. Clamp*
13-95
TM 08780B-20
9. Manifold
(2) Remove two air lines (10 and 11) from bottom edge of manifold (9).
(3) Remove four capscrews (12) and lockwashers (13) from manifold (9).
NOTE
Perform steps 4 and 5 on LVSA1 series vehicles only.
(4) Remove three nuts (12.1), lockwashers (12.2) and capscrews (12) from
manifold (9). Discard lockwashers (12.2).
(5) Remove nut (12.1), lockwasher (12.2), capscrew (12.3), washer (13.1) and
clamp (13.2) from manifold (9). Discard lockwasher (12.2).
(6) Remove ten air lines (14 thru 23) from manifold (9).
(7) Remove manifold (9).
b. Disassembly
NOTE
Mark and tag all fittings to insure proper installation.
(1) Remove two 90° elbows (24 and 25) from bottom edge of manifold (9).
(2) Remove eight straight fittings (26 thru 33) from top edge of manifold (9).
(3) Remove ten 90° elbows (34 thru 43) from manifold (9).
(4) Remove two plugs (44) from manifold (9).
13-96
TM 08780B-20
9. Manifold 31. Straight Fitting 38. 90° Elbow

24. 90º Elbow 32. Straight Fitting 39. 90° Elbow
25. 90° Elbow 33. Straight Fitting 40. 90° Elbow
26. Straight Fitting 34. 90° Elbow 41. 90° Elbow
28. Straight Fitting 36. 90° Elbow 43. 90º Elbow
29. Straight Fitting 37. 90° Elbow 44. Plug (2)
30. Straight Fitting
(2) Inspect all parts. Refer to paragraphs 2-12.
(3) Inspect manifold (9) for cracks or damaged threads.
(4) Inspect all fittings for cracks or damaged threads.
d. Assembly
NOTE
Apply sealing compound to threads of all fittings and plugs before installing. Tighten securely
when installing.
(1) Install two plugs (44) into manifold (9).
(2) Install ten 90° fittings (34 thru 43) into manifold (9).
13-97
TM 08780B-20
(3) Install eight straight fittings (26 thru 33) into top edge of manifold (9).
(4) Install two 90° elbows (24 and 25) into bottom edge of manifold (9).
e. Installation
NOTE
Apply sealing compound to threads of fittings before installing and tighten securely when
installing.
(1) Working from the inside of the cab, install two air lines (20 and 21) to 90°
elbows (38 and 41) respectively.
(2) Install manifold (9) using four new lockwashers (13) and capscrews (12).
NOTE
(3) Install manifold (9) using three capscrews (12), new lockwashers (12.2)
and nuts (12.1).
9. Manifold 31. Straight Fitting 38. 90° Elbow

26. Straight Fitting 34. 90° Elbow 41. 90º Elbow
29. Straight Fitting 37. 90° Elbow 44. Plug (2)
13-98
TM 08780B-20
(4) Secure hoses using clamp (13.2), two washer (13.1), capscrew (12.3), new
lockwasher (12.2) and nut (12.1).
(5) Connect eight air lines in order as follows: air line (15) to 90° elbow (35),
air line (17) to 90° elbow (37), air line(14) to 90° elbow (34), air line (16) to 90° elbow (36), air
line (18) to 90° elbow (40), air line (19) to 90° elbow to (39), air line (23) to 90° elbow (42) and
air line (22) to 90° elbow (43).
(6) Connect eight air lines (1 thru 8) in order as follows: air line (10 to
straight fitting (26), air line (20) to straight fitting (27), air line (3) to straight fitting (28), air line
(4) to straight fitting (29), air line (5) to straight fitting (30), air line (6) to straight fitting (31), air
line (7) to straight fitting (32) and air line (8) to straight fitting (33).
(7) Connect two air lines (10 and 11) to 90° elbows (24 and 25) respectively.
solution check for air leaks.
END OF TASK
NOTE
TM 08780B-20 Install bracket (para 7-33, Step 2, item 9).
13-99
TM 08780B-20
1. Air Line (No. 662) 11. Air Line (No. 416) 15. Air Line (No. 069)
2. Air Line (No. 665) 12. Capscrew (4) 16. Air Line (No. 612)
3. Air Line (No. 663) 12.1. Nut (4) 17. Air Line (No. 623)
4. Air Line (No. 611) 12.2. Lockwasher (4)* 18. Air Line (No. 663)
5. Air Line (No. 612) 12.3. Capscrew* 19. Air Line (No. 611)
6. Air Line (No. 623) 13. Lockwasher (4) 20. Air Line (No. 416)
7. Air Line (No. 706) 13.1. Washer* 21. Air Line (No. 415)
8. Air Line (No. 069) 13.2. Clamp* 22. Air Line (No. 665)
9. Manifold 14. Air Line (No. 706) 23. Air Line (No. 662)
13-100
TM 08780B-20
13-27. LEFT INSTRUMENT PANEL AIR MANIFOLD REPLACEMENT

b. Disassembly
d. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Sealing compound (item 50, Appendix D) TM 08780B-20 Batteries
Soap and water solution (item 54, Appendix D) disconnected
Lockwasher (2) (MS35338-44) item 6 (para 7-45).
References Instrument panel

TM 08780B-10 removed (para 7-11).

injury.
a. Removal
WARNING

NOTE
(1) Remove four air lines (1, 2, 3 and 4).
(2) Remove two nuts (5), lockwashers (6) and capscrews (7). Discard
lockwashers (6).
13-101
TM 08780B-20
(3) Tag and remove air manifold (8).
b. Disassembly
NOTE
Mark position and tag all fittings and plugs to insure proper installation.
(1) Remove four plugs (9) from air manifold (8).
(2) Remove two 90 degree elbows (10 and 11) from air manifold (8).
(3) Remove two straight fittings (12 and 13) from air manifold (8).
(4) Remove protection valve (14) and nipple (15) from air manifold (8).
Remove nipple (15) from protection valve (14).

2. Air Line (No 006)
5. Nut (2)
6. Lockwasher (2)
7. Capscrew (2)
8. Air Manifold
9. Plug (4)
10. 90 Degree Elbow
11. 90 Degree Elbow
14. Protection Valve
15. Nipple
13-102
TM 08780B-20
(3) Inspect air manifold (8) for cracks or damaged threads.
d. Assembly
NOTE
(1) Install nipple (15) into protection valve (14). Install protection valve (14)
and nipple (15) into air manifold (8).
(2) Install two 90 degree elbows (10 and 11) into air manifold (8).
(3) Install two straight fittings (12 and 13) into air manifold (8).
(4) Install four plugs (9) into air manifold (8).
e. Installation
(1) Install air manifold (8) using two capscrews (7), new lockwashers (6) and
nuts (5).
(2) Install four air lines (1, 2, 3 and 4) onto air manifold (8).
(5) Build up air pressure to normal operating pressure. Use soap and water
solution to check for air leaks. A one inch bubble in three seconds is permitted.
END OF TASK
13-103
TM 08780B-20
NOTE
TM 08780B-20 Install instrument panel (para 7-11).

5. Nut (2)
6. Lockwasher (2)
7. Capscrew (2)
8. Air Manifold
9. Plug (4)
10. 90 Degree Elbow
11. 90 Degree Elbow
14. Protection Valve
15. Nipple
13-104
TM 08780B-20
13-28. ONE-WAY CHECK VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Soap and water solution (item 54, Appendix D) To prevent personal injury, block wheels
and drain all pressure from air system.
References
TM 08780B-10
a. Removal
WARNING

NOTE
• There are one-way check valves in the left and right air reservoirs and in front and
rear air manifold. Because removal is basically the same for all check valves, only the
air manifold check valves are covered here.
(2) Rotate elbow (3) to allow access for removal of 90 degree fitting (4).
(3) Remove 90 degree fitting (4) from check valve (5).
(4) Remove straight fitting (6) from check valve (7).
13-105
TM 08780B-20
NOTE
Mark direction of flow arrow on check valve.
(5) Apply wrench to small hexagon nut (8) and remove two check valves (5
and 7).
c. Installation
NOTE
Tighten all lines and fittings as they are installed.
(1) Apply sealing compound to male threads of check valves (5 and 7).
(2) Install check valves (5 and 7).
(3) Install 90 degree fitting (4) into check valve (5).
(4) Rotate elbow (3) so check valve (5) points up.
(5) Install straight fitting (6) into check valve (7).
(6) Connect two air lines (1 and 2).
13-106
TM 08780B-20
1. Air Line 5. Check Valve

2. Air Line 6. Straight Fitting
3. Elbow 7. Check Valve
4. 90 Degree Fitting 8. Small Hexagon Nut
13-107
TM 08780B-20
13-29. BALL VALVE REPLACEMENT

c. Installation

Condition Condition
Sealing compound (item 50, Appendix D) TM 08780B-10 Air system
References Block wheels of truck to prevent personal
TM 08780B-10 injury. To prevent personal injury, drain all
a. Removal
WARNING

NOTE
• All three ball valves are removed in the same manner.
(2) Remove 90 degree elbow (3) from ball valve (4).
(3) Remove ball valve (4) from anchor stud (5).
(4) Remove 90 degree elbow (6) from anchor stud (5).
(5) Remove nut (7), star washer (8) and anchor stud (5). Discard star washer
(8).
13-108
TM 08780B-20
c. Installation
NOTE
Apply sealing compound to fittings before installing.
(1) Install anchor stud (5) using new star washer (8) and nut (7). Tighten nut
(7) securely.
(2) Install 90 degree elbow (6) into anchor stud (5). Connect air line (1).
(3) Install ball valve (4) onto anchor stud (5) with handle (9) facing up.
(4) Install 90 degree elbow (3) onto ball valve (4).
(5) Connect air line (2).
13-109
TM 08780B-20
1. Air Line 6. 90 Degree Elbow

2. Air Line 7. Nut
3. 90 Degree Elbow 8. Star Washer
4. Ball Valve 9. Handle
5. Anchor Stud
END OF TASK
13-110
TM 08780B-20
13-30. RIGHT INSTRUMENT PANEL AIR MANIFOLD REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
(para 7-45).
References
TM 08780B-10 Access panel
removed (para
18-15, item 3).
Remove defroster
hose (para 22-20,
item 4).

electrical components. Block wheels of
truck to prevent personal injury.
a. Removal
WARNING

PREVENT PERSONAL INJURY, DRAIN ALL PRESSURE FROM SYSTEM BEFORE
REMOVING COMPONENTS.
NOTE
13-111
TM 08780B-20
• Tag all air lines and fittings to insure proper installation.
(1) Remove six air lines (1 thru 6) from air manifold (7).
(2) Remove two plugs (8) and straight fitting (9) from air manifold (7).
(4) Remove two capscrews (12) from air manifold (7). Remove manifold (7).
b. Disassembly
(1) Remove straight fitting (13) from air manifold (7).

7. Air Manifold
8. Plug (2)
9. Straight Fitting
10. 45 Degree Elbow
11. 45 Degree Elbow
12. Capscrew (2)
14. 90 Degree Elbow
15. 90 Degree Elbow
13-112
TM 08780B-20
(3) Inspect air manifold (7) for cracks or damaged threads.
d. Assembly
NOTE
(2) Install straight fitting (13) into air manifold (7).
e. Installation
(1) Install air manifold (7) using two capscrews (12).
(3) Install two plugs (8) and straight fitting (9) into air manifold (7)
(4) Install six air lines (1 thru 6) onto air manifold (7).
solution to check for air leaks. A one inch bubble in three seconds is permitted.
END OF TASK
13-113
TM 08780B-20
NOTE
TM 08780B-20 Install defroster hose (para 22-20), item 4.
Install access panel (para 18-15), item 3.
1. Air Line (No. 035) 6. Air Line (No. 074) 11. 45 Degree Elbow
2. Air Line (No. 071) 7. Air Manifold 12. Capscrew (2)
3. Air Line (No. 032) 8. Plug (2) 13. Straight Fitting
4. Air Line (No. 073) 9. Straight Fitting 14. 90 Degree Elbow
5. Air Line (No. 038) 10. 45 Degree Elbow 15. 90 Degree Elbow
13-114
TM 08780B-20
13-31. QUICK DISCONNECT FITTING REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials Parts
Soap and water solution (item 54, Appendix D) Block wheels of truck to prevent personal
References pressure from the air system.
TM 08780B-10
a. Removal
NOTE
Quick disconnect fittings for the LVSA1 left air reservoir have changed from a reducer, nipple
and quick disconnect fitting to hex nipple and quick disconnect fitting. When repairing a
non-A1 vehicle, use the new fittings to replace the old fittings. Refer to TM 08780B-24P for
(1) Hold hex nipple (1). Remove quick disconnect fitting (2) from hex nipple
(1).
(2) Remove hex nipple (1) from tee (3).
(3) Inspect hex nipple (1) for damaged threads.
c. Installation
(1) Apply sealing compound to hex nipple (1).
(2) Install hex nipple (1) into tee (3).
13-115
TM 08780B-20
(3) Install quick disconnect fitting (2) onto hex nipple (1). Tighten securely.
pressure to normal operating pressure. Use a soap and water solution to check for air leaks.
1. Hex Nipple
2. Quick Disconnect Fitting
3. Tee
END OF TASK
13-116
TM 08780B-20
13-32. QUICK BUILD-UP AIR RESERVOIR REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (2) (MS35338-46) item 4 TM 08780B-20 Skid plate grille
Sealing compound (item 50, Appendix D) removed (para 18-17).
Soap and water solution (item 54, Appendix D)
Locknut (4) (1437220) item B Pressure protection
valve removed
References (para 13-19).
TM 08780B-10
To prevent personal injury, block wheels
and drain all pressure from the air system.
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
air line procedures.
• Tag all air lines and fittings to insure proper installation.
• Mounting hardware for LVSA1 air reservoirs has changed from a capscrew,
13-117
TM 08780B-20
(1) Remove three air lines (1). Disconnect pull chain (2).
(2) Remove two nuts (3) and lockwashers (4) from reservoir mounting bracket
(3) Remove two capscrews (6) from reservoir mounting bracket (5).
(4) Spread reservoir mounting brackets (5) and remove reservoir (7).
(5) If needed, remove four locknuts (8) and reservoir mounting brackets (5).
Remove four capscrews (10). Discard four locknuts (8).
b. Disassembly
(1) Remove two elbows (11 and 12) from reservoir (7).
(2) Remove safety valve (13) from tee (14).
(3) Remove fitting (15) from tee (14).
NOTE
Air line fittings for the LVSA1 quick build-up air reservoir have changed from a nipple and
tee to a street tee. When repairing a non-A1 vehicle, use the new style tee to replace the old
style tee. Refer to TM 08780B-24P for correct parts identification.
(4) Remove tee (14) from reducer (17).
(5) Remove drain valve (18) from reducer (19).
(6) Remove two reducers (17 and 19) from reservoir (7).
13-118
TM 08780B-20
1. Air Line (3) 7. Reservoir 14. Tee

2. Pull Chain 8. Locknut (4) 15. Fitting
3. Nut (2) 10. Capscrew (4) 17. Reducer
4. Lockwasher (2) 11. Elbow 18. Drain Valve
5. Reservoir Mounting 12. Elbow 19. Reducer
Bracket (4) 13. Safety Valve
6. Capscrew (2)
(3) Inspect reservoir (7) for dents or cracks.
13-119
TM 08780B-20
d. Assembly
NOTE
Apply sealing compound to threads of fittings, tee, reducers, safety valve and drain valve.
(1) Install two 90 degree elbows (11 and 12) into reservoir (7).
(2) Install two reducers (17 and 19) into reservoir (7).
NOTE
Air line fittings for the LVSA1 quick build-up air reservoir have changed from a nipple and
tee to street tee. When repairing a non-A1 vehicle, use the new style hardware to replace the
old style hardware. Refer to TM 08780B-24P for correct parts identification.
(3) Install tee (14) into reducer (17).
(4) Install safety valve (13) into tee (14).
(5) Install fitting (15) into tee (14).
(6) Install drain valve (18) into reducer (19).
7. Reservoir
11. Elbow
12. Elbow
13. Safety Valve
14. Tee
15. Fitting
16. Deleted
17. Reducer
18. Drain Valve
19. Reducer
13-120
TM 08780B-20
e. Installation
(1) If removed, install reservoir mounting brackets (5) with four capscrews
(10) and new locknuts (8). Tighten locknuts (8) securely.
CAUTION
TO PREVENT PARTS DAMAGE, MAKE SURE HARDWARE ON TOP OF RESERVOIR

(7) CLEARS ALL FRAMEWORK.
(2) Spread reservoir mounting brackets (5) and install reservoir (7) with drain
valve (18) facing down.
(3) While supporting reservoir (7), install two capscrews (6) through reservoir
mounting brackets (5).
(4) Install two new lockwashers (4) and two nuts (3). Tighten nuts (3)
securely.
(5) Install three air lines (1) in their tagged position. Install pull chain (2).
(6) Install pressure protection valve. Refer to paragraph 13-19 of this manual.
END OF TASK
NOTE
13-121
TM 08780B-20
1. Air Line (3) 6. Capscrew (2)

2. Pull Chain 7. Reservoir
3. Nut (2) 8. Locknut (4)
4. Lockwasher (2) 10. Capscrew (4)
5. Reservoir Mounting 18. Drain Valve
Bracket (4)
13-122
TM 08780B-20
13-33. RIGHT AIR RESERVOIR REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK48 TM 08780B-10 Remove spare tire
and wheel (para 3-8).
Materials/Parts
Pipe sealant (item 48, Appendix D) Drain air system
Soap and water solution (item 54, Appendix D) (para 3-5).
Lockwasher (2) (MS 35338-48) item 10
Locknut (8) (1437220) items 13, 16 and 20 TM 08780B-20 Right yaw cylinder
hoses disconnected
References at motion control
TM 08780B-10 valve (para 23-7).
Special Environmental Conditions Two hoses

Work in a clean area free of blowing dust. disconnected from
bracket at transfer
General Safety Instructions case (para 23-13).
To prevent personal injury, drain all pressure Right fuel tank
from the air system. removed (para 4-11).
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
to help support line. They also use eyelets to seal lines. When removing air lines, the
• Tag all air lines to ensure proper installation.
13-123
TM 08780B-20
• Right air tank on ABS modified vehicles are removed in the same manner.
(1) Remove two air lines (1 and 2) from rear of right air reservoir (3).
(2) Remove three air lines (4, 5 and 6).
(3) Remove two air lines (7 and 8) from front of right air reservoir (3).
(4) Working from under truck, remove two nuts (9), lockwashers (10) and
capscrews (11) from reservoir mounting bracket (12). Discard lockwashers (10).
(5) Spread reservoir mounting brackets (12). Slide right air reservoir (3) to
rear and remove from vehicle.
(6) If damaged, remove four locknuts (13), capscrews (15) and four mounting
brackets (12). Discard locknuts (13).
(7) If damaged, remove two locknuts (16), capscrews (18) and rear bracket
(8) If damaged, remove two locknuts (20), capscrews (22) and front bracket
13-124
TM 08780B-20
1. Air Line
2. Air Line
3. Right Air Reservoir
4. Air Line
5. Air Line
6. Air Line
7. Air Line
8. Air Line
9. Nut (2)
10. Lockwasher (2)
11. Capscrew (2)
12. Reservoir Mounting
Bracket (4)
13. Locknut (4)
15. Capscrew (4)
16. Locknut (4)
18. Capscrew (2)
19. Rear Bracket
20. Locknut (2)
22. Capscrew (2)
23. Front Bracket
13-125
TM 08780B-20
b. Disassembly
NOTE
• Mark position of all fittings for proper installation.
• Air line fittings for the LVSA1 right air reservoir have changed from a nipple and tee
to a street tee. When repairing a non-A1 vehicle, use the new style fittings to replace
the old style fittings. Refer to TM 08780B-24P for correct parts identification.
(1) Remove drain cock (24) from rear of right air reservoir (3).
(2) Tag and remove straight fitting (25) and 45 degree elbow (26) from tee
(27).
(3) Remove tee (27) from check valve (29).
(4) Remove check valve (29) from right air reservoir (3).
(5) Remove two 90 degree elbows (31 and 32) from tee (33).
(6) Remove tee (33) from reservoir.
(7) Remove 90 degree elbow (35) from right air reservoir (3).
(8) Remove 90 degree elbow (36) from tee (37). Remove straight fitting (38)
from check valve (40). Remove check valve (40).
(9) Remove tee (37) and nipple (41) from reducer (42). Remove nipple (41)
from tee (37).
(10) Remove reducer (42) from right air reservoir (3).
(3) Inspect right air reservoir (3) for dents or cracks.
(4) Inspect all fittings for bends, cracks or damaged threads.
13-126
TM 08780B-20
d. Assembly
NOTE
Apply pipe sealant to threads of tees, nipple, fittings, check valves and reducers before
installing.
(1) Install reducer (42) into front of right air reservoir (3).
(2) Install nipple (41) into tee (37). Install tee (37) and nipple (41) into
reducer (42).
(3) Install check valve (40) into tee (37). Install straight fitting (38) into
check valve (40).
(4) Install 90 degree elbow (36) into tee (37).
(5) Install 90 degree elbow (35) into right air reservoir (3).
(6) Install tee (33) into right air reservoir (3).
(7) Install two 90 degree elbows (31 and 32) into tee (33).
(8) Install check valve (29) into right air reservoir (3).
(9) Install tee (27) into check valve (29).
(10) Install straight fitting (25) and 45 degree elbow (26) into tee (27).
(11) Install drain cock (24) into right air reservoir (3).
13-127
TM 08780B-20
3. Right Reservoir 31. 90 Degree Elbow 37. Tee

24. Drain Cock 32. 90 Degree Elbow 38. Straight Fitting
25. Straight Fitting 33. Tee 40. Check Valve
26. 45 Degree Elbow 35. 90 Degree Elbow 41. Nipple
27. Tee 36. 90 Degree Elbow 42. Reducer
29. Check Valve
e. Installation
(1) If removed, install front bracket (23) using two capscrews (22) and new
(2) If removed, install rear bracket (19) using two capscrews (18) and new
locknuts (16). Tighten locknut (16) securely.
(3) If removed, install four reservoir brackets (12) using four capscrews (15)
(4) Slide right air reservoir (3) into reservoir mounting brackets (12).
Working from underneath vehicle, install two capscrews (11), new lockwashers (10) and nuts
(9). Tighten nuts (9) securely.
(5) Install two air lines (7 and 8) at front of right air reservoir (3).
(6) Install three air lines (4, 5 and 6).
(7) Install two air lines (1 and 2) at rear of right air reservoir (3).
(8) Install right fuel tank. Refer to paragraph 4-11.
13-128
TM 08780B-20
(9) Connect two hoses at bracket on transfer case. Refer to paragraph 23-13.
(10) Connect right yaw cylinder hoses at motion control valve. Refer to
paragraph 23-7.
solution to check for leaks.
END OF TASK
NOTE
TM 08780B-10 Install spare tire and wheel (para 3-8).
13-129
TM 08780B-20
3. Right Air
Reservoir
4. Air Line
5. Air Line
7. Air Line
8. Air Line
1. Air Line 11. Capscrew (2) 18. Capscrew (2)

2. Air Line 12. Reservoir Mounting 19. Rear Bracket
3. Right Air Reservoir Bracket 20. Locknut (2)
6. Air Line 13. Locknut (4) 22. Capscrew (2)
9. Nut (2) 15. Capscrew (4) 23. Front Bracket
10. Lockwasher (2) 16. Locknut (2)
13-130
TM 08780B-20
13-34. LEFT AIR RESERVOIR REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Pipe sealant (item 48, Appendix D) TM 08780B-20 Left fuel tank
Soap and water solution (item 54, Appendix D) removed (para 4-10).
Lockwasher (2) (MS 35338-46) item 7
Locknut (6) (1437220) items 10 and 13 General Safety Instructions
References injury. Drain air system to prevent
TM 08780B-10 personal injury.
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
to help support the line. They also use eyelets to seal lines. When removing air lines,
the eyelet may stay with the line or may stay with the fitting. Refer to paragraph 13-23
for air line repair procedures.
• Procedures for removal of left air reservoir on ABS modified vehicles are the same.
13-131
TM 08780B-20
(1) Remove air line (1) from rear of left air reservoir (2).
(2) Remove air line (3) from left air reservoir (2).
(3) Remove two air lines (4 and 5) from front of left air reservoir (2).
(4) Remove two nuts (6), lockwashers (7) and capscrews (8) from air
reservoir mounting bracket (9). Discard lockwasher (7).
(5) Slide left air reservoir (2) to rear and remove from vehicle.
(6) If damaged, remove four locknuts (10), capscrews (12) and four air
reservoir mounting brackets (9). Discard locknuts (10).
1. Air Line 7. Lockwasher (2) 13. Locknut (2)

2. Left Air Reservoir 8. Capscrew (2) 15. Capscrew (2)
3. Air Line 9. Air Reservoir 16. Rear Bracket
4. Air Line Mounting Bracket (4) 17. Front Bracket
5. Air Line 10. Locknut (4)
6. Nut (2) 12. Capscrew (4)
(7) If damaged, remove two nuts (13), lockwashers (14), capscrews (15) and
rear bracket (16). Discard lockwashers (14).
(8) If damaged, repeat step (7) for front bracket (17).
b. Disassembly
NOTE
Mark position of all fittings for proper installation.
(1) Remove drain cock (18) from rear of left air reservoir (2).
13-132
TM 08780B-20
NOTE
Air line fittings for the LVSA1 left air reservoir have changed from a nipple and tee to street
tee. When repairing a non-A1 vehicle, use the new style street tee to replace the old style tee.
(2) Remove straight fitting (19) and hex nipple (22) from tee (20). Remove
quick disconnect fitting (21) from hex nipple (22).
(3) Remove bushing (23) from tee (20).
(4) Remove tee (20) from check valve (24).
(5) Remove check valve (24) and reducer (25) from left air reservoir (2).
Remove check valve (24) from reducer (25).
(6) Remove 90 degree elbow (26) and plug (27) from left air reservoir (2).
NOTE
Step (7) is for ABS modified vehicles only.
(7) Remove both 90 degree elbows (26 and 31) from left air reservoir (2).
(8) Remove 90 degree elbow (28) and straight fitting (29) from tee (30).
(9) Remove tee (30) from left air reservoir (2).
2. Left Air Reservoir 22. Hex Nipple 28. 90 Degree Elbow

18. Drain Cock 24. Check Valve 29. Straight Fitting
19. Straight Fitting 25. Reducer 30. Tee
20. Tee 26. 90 Degree Elbow 31. 90 Degree Elbow (ABS Only)
21. Quick Disconnect Fitting 27. Plug
13-133
TM 08780B-20
(2) Inspect all parts. Refer to paragraph 2-12
(3) Inspect left air reservoir (2) for dents or cracks.
(4) Inspect all fittings for bends, cracks or damaged threads.
d. Assembly
(1) Install tee (30) into front of left air reservoir (2).
(2) Install straight fitting (29) and 90 degree elbow (28) into tee (30).
(3) Install plug (27) and 90 degree elbow (26) into left air reservoir (2).
NOTE
(4) Install two 90 degree elbows (26 and 31) into left reservoir (2).
(5) Install check valve (24) into reducer (25). Install reducer (25) and check
valve (24) into left air reservoir (2).
(6) Install tee (20) into check valve (24).
(7) Install straight fitting (19) and hex nipple (22) into tee (20).
(8) Install quick disconnect fitting (21) onto hex nipple (22).
e. Installation
NOTE
Procedures for installation of left air reservoir on ABS modified vehicles are the same.
(1) If removed, install front bracket (17) using two capscrews (15), new
lockwashers (14) and nuts (13). Tighten securely.
(2) If removed, repeat step (1) to install rear bracket (16).
(3) If removed, install four air reservoir mounting brackets (9) using four
capscrews (12), new lockwashers (11) and nuts (10). Tighten nuts (10) securely.
13-134
TM 08780B-20
(4) Slide left air reservoir (2) into air reservoir mounting brackets (9). Install
two capscrews (8), new lockwashers (7) and nuts (6). Tighten nuts (6) securely.
NOTE
Step (5) is used on ABS modified vehicles only.
(5) Slide left air reservoir (2) into reservoir bracket ensuring that the rear end
of the reservoir (2) is 7 inches from the mounting bracket (9). Working from underneath vehicle,
install two capscrews (8), new lockwashers (7) and nuts (6). Tighten nuts securely.
(6) Install air lines (4 and 5) at front of left air reservoir (2).
(7) Install air line (3) to out board fitting (26).
(8) Install air line (1) at rear of left air reservoir (2).
2. Left Air Reservoir 22. Hex Nipple 28. 90 Degree Elbow

18. Drain Cock 24. Check Valve 29. Straight Fitting
19. Straight Fitting 25. Reducer 30. Tee
20. Tee 26. 90 Degree Elbow 31. 90 Degree Elbow (ABS Only)
21. Quick Disconnect Fitting 27. Plug
NOTE
(9) Install air line from governor to 90 degree elbow (31).
(10) Install left fuel tank. Refer to paragraph 4-10 in this manual.
13-135
TM 08780B-20
1. Air Line 7. Lockwasher (2) 12. Capscrew (4)

2. Left Air Reservoir 8. Capscrew (2) 13. Locknut (2)
3. Air Line 9. Air Reservoir 15. Capscrew (2)
4. Air Line Mounting Bracket (4) 16. Rear Bracket
5. Air Line 10. Locknut (4) 17. Front Bracket
6. Nut (2)
END OF TASK
13-136
TM 08780B-20
13-35. REAR UNIT AIR RESERVOIR REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK16
Materials/Parts pressure from the air system. Block wheels
Sealing compound (item 50, Appendix D) of truck to prevent personal injury.
Soap and water solution (item 54, Appendix D)
Locknut (8) (1437220) item 11
References
TM 08780B-10
a. Removal
WARNING

REMOVING AIR LINE OR COMPONENTS.
NOTE
• The following procedure will work for the right or left air tank and the two forward
and two rearward air tanks on ABS modified vehicles.
(1) Remove two lines (1 and 2) from front of left air reservoir (3).
13-137
TM 08780B-20
(2) Remove two air lines (4 and 5) from right air reservoir (6).
(3) Remove two nuts (7) and lockwashers(8). Remove the two capscrews (9)
that go through mounting bracket (10). Discard lockwashers (8).
(4) Spread mounting brackets (10). Remove left or right air reservoirs (3 or
6).
NOTE
Mounting hardware for LVSA1 air reservoirs has changed from a capscrew, lockwasher and
hex nut to a flanged type capscrew and locknut. When repairing a non-A1 vehicle, use the
new style flanged mounting hardware to replace the old style hardware. Refer to TM 08780B-
24P for correct parts identification.
1. Air Line 10. Mounting Bracket (4) 16. 90 Degree Elbow

2. Air Line 11. Locknut (4) 17. Tee Fitting
3. Left Air Reservoir 13. Spacer 19. Plug
7. Nut (2) 14. Capscrew (4) 20. Plug
8. Lockwasher (2) 15. 90 Degree Elbow 21. Drain Cock
9. Capscrew (2)
(5) If required, remove mounting bracket(10) by removing four locknuts (11),
spacers (13) and capscrews (14). Discard locknuts (11).
13-138
TM 08780B-20
b. Disassembly
NOTE
Tag and mark location of fittings for proper installation.
(1) Remove two 90 degree elbows (15 and 16) from tee (17) on left air
reservoir (3).
NOTE
Air fittings for LVSA1 air reservoir have changed from a tee and nipple to a street tee. When
repairing non-A1 vehicles, use new style fitting to replace old style fitting. Refer to TM
08780B-24P for correct parts identification.
(2) Remove tee fitting (17) from left air reservoir (3).
(3) Remove two plugs (19 and 20) and drain cock (21) from left air reservoir
(3).
(4) Remove two straight fittings (22 and 23) from right air reservoir (6).
(5) Remove plug (24) and drain cock (25) from right air reservoir (6).
4. Air Line 9. Capscrew (2) 22. Straight Fitting

5. Air Line 10. Mounting Bracket (4) 23. Straight Fitting
6. Right Air Reservoir 11. Locknut (4) 24. Plug
7. Nut (2) 13. Spacer (4) 25. Drain Cock
13-139
TM 08780B-20
(3) Inspect reservoirs for dents or cracks.
d. Assembly
NOTE
Apply sealing compound to threads of fittings, plugs and drain cocks before installing.
(1) Install plug (24) and drain cock (25) in right air reservoir (6).
(2) Install two straight fittings (22 and 23) into right air reservoir (6).
(3) Install two plugs (19 and 20) and drain cock (21) into left air reservoir (3).
(4) Install tee fitting (17) into left air reservoir (3).
13-140
TM 08780B-20
4. Air Line 9. Capscrew (2) 22. Straight Fitting

5. Air Line 10. Mounting Bracket (4) 23. Straight Fitting
6. Right Air Reservoir 11. Locknut (4) 24. Plug
7. Nut (2) 13. Spacer (4) 25. Drain Cock
1. Air Line 10. Mounting Bracket (4) 16. 90 Degree Elbow

2. Air Line 11. Locknut (4) 17. Tee Fitting
3. Left Air Reservoir 13. Spacer 19. Plug
7. Nut (2) 14. Capscrew (4) 20. Plug
8. Lockwasher (2) 15. 90 Degree Elbow 21. Drain Cock
9. Capscrew (2)
13-141
TM 08780B-20
e. Installation
NOTE
The two forward and two rearward air tanks on ABS modified vehicles are installed in the
same manner.
(1) If removed, install mounting brackets (10) using four capscrews (14),
spacers (13) and new locknuts (11). Tighten locknuts (11) securely.
(2) Install left or right air reservoirs (3 or 6) and brackets (10).
(3) Install two capscrews (9) into mounting brackets (10).
(4) Install two new lockwashers (8) and nuts (7) onto capscrews (9). Tighten
nuts (7) securely.
(5) Install two air lines (1 and 2) onto left reservoir (3).
(6) Install two air lines (4 and 5) onto right air reservoir (5).
END OF TASK
13-142
TM 08780B-20
13-143
TM 08780B-20
13-36. GLAD HAND REPLACEMENT

c. Installation

Condition Condition
Sealing compound (item 50, Appendix D) TM 08780B-10 Air system
Starwasher (MS35334-26) item 7
TM 08780B-20 Front air manifold
References removed (para 13-24)
TM 08780B-10 (LVSA1 series
vehicles only).
Ball valve removed

(para 13-29) (LVSA1

a. Removal
(1) For removal of MK16 trailer glad hands, go to step (9). For MK48A1 and
others, go to step (2).
(2) Remove dummy coupler (1) from glad hand (2).
(3) Tag and disconnect air line (3) from fitting (4).
(4) Remove fitting (4) from anchor stud (5).
(5) Remove nut (6) and star washer (7). Discard starwasher (7).
(6) Remove glad hand (2) and anchor stud (5) from bracket (8).
(7) Remove anchor stud (5) from glad hand (2).
13-144
TM 08780B-20
1. Dummy Coupler 6. Nut 8.1. Glad Hand

2. Glad Hand 7. Star Washer Mounting Bracket*
3. Air Line 7.1. Capscrew (2)* 8.2. Front Engine
4. Fitting 7.2. Nut (2)* Mounting Bracket
5. Anchor Stud 8. Bracket
NOTE
(8) Remove two capscrews (7.1), nuts (7.2) and glad hand mounting bracket
(8.1) from front engine mount (8.2).
(9) Remove trailer glad hands on MK16 as follows:
13-145
TM 08780B-20
9. Glad Hand
10. Holder
11. Fitting
12. Air Line
(a) Remove glad hands (9) from holder (10).
(b) Remove glad hand (9) from fitting (11) on air line (12).
(c) Remove fitting (11) from air line (12).
c. Installation
(1) For installation of MK16 trailer glad hands, go to step (10). For MK48A1
and others, go to step (2).
(2) Coat threads of anchor stud (5) with sealing compound.
(3) Install anchor stud (5) into glad hand (2) with short side of anchor stud (5)
facing glad hand (2). Tighten securely.
NOTE
Emergency glad hand (red) must be installed on the left side of bracket (8). Service glad hand
(blue) must be installed on right side.
13-146
TM 08780B-20
(4) Install glad hand (2) and anchor stud (5) into bracket (8).
(5) Install new starwasher (7) and nut (6) on rear-mounted glad hand (2).
Position with opening to right. On front-mounted glad hand (2), position with opening down.
Tighten nut (6) securely.
(6) Apply sealing compound to fitting (4).
(7) Install fitting (4) into anchor stud (5). Tighten securely.
NOTE
(8) Install glad hand mounting bracket (8.1) onto front engine mount (8.2)
using two capscrews (7.1) and nuts
(9) Install air line (3) on fitting (4). Tighten securely.
(10) Install trailer glad hands (2) on MK16 as follows:
(a) Apply sealing compound to fitting (11) and install on air line (12).
Tighten securely.
(b) Install glad hand (9) onto fitting (11). Tighten securely.
(c) Install glad hand (9) on holder (10).
pressure to operating pressure. Use soap and water solution to check for air leaks.
END OF TASK
13-147
TM 08780B-20
13-37. AIR GOVERNOR MAINTENANCE

c. Installation
d. Adjustment

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (2) (MS35338-44) item 4 Block wheels of truck to prevent personal
Lockwasher (2) (MS35338-47) item 10 injury. To prevent personal injury, drain all
pressure from the air system. Engine,
References muffler and connecting parts may be hot.
TM 08780B-10 Avoid contact to prevent possibility of
serious burns.
a. Removal
WARNING

PREVENT PERSONAL INJURY, DRAIN ALL AIR PRESSURE BEFORE REMOVING
COMPONENTS.
NOTE
• For ABS modified vehicles, go to step (2).
(1) Remove four air lines (1) from air governor (2).
(2) Remove five air lines (3 through 7) from air governor and synchronizing
valve.
NOTE
For ABS modified vehicles, go to step (6).
(3) Tag and remove elbow (3).
(4) Remove two socket head capscrews (4) and lockwashers (5). Discard
lockwashers (5).
13-148
TM 08780B-20
(5) Remove air governor (2).
(6) Remove air governor and synchronizing valve one as assembly.
NOTE
Steps (7) through (9) are for non-ABS modified vehicles only.
(7) Tag and remove fitting (6).
(8) Tag and remove tee fitting (7).
(9) Tag and remove three plugs (8).
(10) Remove two capscrews (9) and lockwashers (10). Discard lockwashers
(10).
(11) Remove mounting plate (11).
(3) Inspect mounting plate (11) for dents, bends, cracks or other signs of
damage.
13-149
TM 08780B-20
1. Air Line (4) 7. Tee Fitting

2. Air Governor 8. Plug (3)
3. Elbow 9. Capscrew (2)
4. Socket Head Capscrew (2) 10. Lockwasher (2)
5. Lockwasher (2) 11. Mounting Plate
6. Fitting
c. Installation
(1) Install mounting plate (11) with two capscrews (9) and two new
lockwashers (10). Tighten capscrews (9) securely.
13-150
TM 08780B-20
NOTE
Steps (2) through (4) are for non-ABS modified vehicles only.
(2) Apply pipe sealant to plugs (8). Install three plugs (8) into air governor
(2). Tighten plugs (8) securely.
(3) Apply pipe sealant to tee fitting (7). Install tee fitting (7) into air governor (2).
Tighten tee fitting (7) securely.
(4) Apply pipe sealant to fitting (6). Install fitting (6) into air governor (2) and
tighten securely.
1. Air Line (4) 7. Tee Fitting

2. Air Governor 8. Plug (3)
3. Elbow 9. Capscrew (2)
4. Socket Head Capscrew (2) 10. Lockwasher (2)
5. Lockwasher (2) 11. Mounting Plate
6. Fitting
13-151
TM 08780B-20
CAUTION
MAKE SURE MATING SURFACES OF GOVERNOR MOUNTING PLATE (11) AND AIR
GOVERNOR (2) ARE CLEAN.
(5) Install air governor (2) to mounting plate (11) using two socket head
capscrews (4) and two new lockwashers (5). Tighten capscrews (4) securely.
NOTE
For ABS modified vehicles, go to step (8).
(6) Apply pipe sealant to elbow (3). Install elbow (3) into air governor (2)
and tighten securely.
(7) Install four air lines (1).
(8) Install five air lines (3 through 7) to governor and synchronizing valve.
WARNING
EXHAUST MANIFOLD AND CONNECTING PARTS MAY BE HOT. AVOID CONTACT

TO PREVENT POSSIBILITY OF SERIOUS BURNS.
(9) Start engine. Refer to paragraph 2-13 (TM 08780B-10). As air pressure
builds, use soap and water solution to check for air leaks.
13-152
TM 08780B-20
d. Adjustment
(2) Watch air pressure gauge (12). Needle (13) will move up scale as system
builds pressure.
12. Air Pressure gauge

13. Needle
(3) When pressure is at 120 psi (827 kPa), as indicated by air pressure gauge
(12), air governor (2) should cut out. When air governor (2) cuts out, air dryer will discharge air.
(4) If air governor (2) does not cut out adjust as follows:
(a) Remove cover (14) from air governor (2).
(b) Loosen locknut (15) on adjusting screw (16).
(c) Shut off engine. Refer to paragraph 2-13 (TM 08780B-10).
14. Cover
15. Locknut
16. Adjusting Screw
13-153
TM 08780B-20
(d) Drain all pressure. Refer to paragraph 3-5 (TM 08780B-10).
(e) Start engine. Refer to paragraph 2-13 (TM 08780B-10).
(f) Buildup air pressure, noting pressure at which governor cuts out.
To increase pressure, turn adjusting screw (16) counterclockwise. To decrease pressure, turn
adjusting screw (16) clockwise.
(g) Once governor cut out is set at 120 psi tighten locknut (15). Install
cover (14) on air governor (2).
END OF TASK
13-154
TM 08780B-20
13-38. AIR DRYER MAINTENANCE

b. Disassembly
d. Assembly
e. Installation

Condition Condition
drained (para 3-5).
References
Materials/Parts pressure from the air system. Block wheels
Pipe sealant (item 48, Appendix D) of truck to prevent personal injury.
Check valve repair kit (NSN 4820-01-080-9603)
Lockwasher (3) (MS204682) item 32
Purge valve repair kit (NSN 4820-01-080-7437)
Locknut (4) 1437220 item 4
Thermostat repair kit (NSN 6620-01-246-4287)
Desiccant cartridge, remanufactured
(NSN 4410-01-241-7538)
End cover repair kit (NSN 2540-01-093-7352)
Lockwasher (3) (202985) (ABS only)
Lockwasher (2) (202983) (ABS only)
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
(1) Remove three air lines (1, 2 and 3).
13-155
TM 08780B-20
1. Air Line 10. Boot

2. Air Line 11. Terminal
3. Air Line 12. Nut
4. Locknut (4) 13. Lockwasher
7. Capscrew (4) 14. Wire
9. Air Dryer
13-156
TM 08780B-20
NOTE
Mounting hardware for air dryer has changed from a lockwasher, washer and nut to a
flanged style locknut and capscrew. When repairing a non-A1 vehicle, use the new style
mounting hardware to replace the old style hardware. Refer to TM 08780B-24P for correct
part identification.
(2) Remove four locknuts (4). Discard locknuts (4). Remove four capscrews
(7).
(3) Lift air dryer (9) slightly. Pull boot (10) away from terminal (11).
Remove nut (12) and lockwasher (13) from terminal (11). Tag and remove wire (14). Discard
lockwasher (13).
(4) Remove air dryer (9).
NOTE
Steps (5)through (8) are for ABS modified vehicles only.
(5) Remove three air lines (1, 2, and 3).
(6) Remove two electronic leads (4 and 5).
NOTE
Mounting hardware for air dryer has changed from a lockwasher, washer and nut to a
flanged style locknut and capscrew. When repairing a non-A1 vehicle, use the new style
mounting hardware to replace the old style hardware. Refer to TM 08780B-24P for correct
part identification.
(7) Remove three nuts (8), three lockwashers (7) and three 3/8 inch bolts (6)
holding air dryer (9) and bracket (10) to right hand transfer case mounting plate (10). Remove
air dryer. Discard lockwashers.
(8) Remove 90 degree elbow (11) and 45 degree elbow (12) from air dryer
(9).
13-157
TM 08780B-20
1. Air Line
2. Air Line
3. Air Line
4. Electrical Lead
5. Electrical Lead
6. Capscrew (3)
7. Lockwasher (3)
8. Nut (3)
9. Air Dryer
10. Mounting Plate
11. 90 Degree Elbow
12. 45 Degree Elbow
NOTE
Steps (1) through (19) are for non-ABS modified vehicles and step (20) is for ABS modified
vehicles only.
b. Disassembly
(1) Remove two nuts (15) and lockwashers (16) from two capscrews (17).
Remove two brackets (18). Discard lockwashers (16).
NOTE
Mark position of fittings to insure proper installation.
(2) Remove 90 degree elbow (19) and 45 degree elbow (20) from air dryer
(9).
(3) Remove safety valve (21) from air dryer (9).
(4) Remove check valve (22) from air dryer (9) and position check valve (22)
in a soft-jawed vise.
13-158
TM 08780B-20
(5) Remove valve body (23), O-ring (24), sealing washer (25), spring guide
(26), spring (27) and ball (28) from check valve (22). Discard O-ring (24).
(6) Matchmark air dryer end cover (29) to air dryer shell (30).
(7) Remove three capscrews (31), lockwashers (32) and locks (33) from air
dryer end cover (29). Discard lockwashers (32).
(8) While pushing air dryer end cover (29) into air dryer shell (30), remove
retaining ring (34). Remove air dryer end cover (29) and O-ring (35). Discard O-ring (35).
(9) Remove reducer (36) and elbow (37).
(10) Remove three screws (38) and exhaust cover (39) from purge valve (40).
(11) Remove exhaust plate (41).
(12) Remove screw (42), washer (43) and diaphragm (44).
9. Air Dryer 22. Check Valve 30. Air Dryer Shell

15. Nut (2) 23. Valve Body 31. Capscrew (3)
16. Lockwasher (2) 24. O-Ring 32. Lockwasher (3)
17. Capscrew (2) 25. Sealing Washer 33. Lock (3)
18. Bracket (2) 26. Spring Guide 34. Retaining Ring
19. 90 Degree Elbow 27. Spring 35. O-Ring
20. 45 Degree Elbow 28. Ball 36. Reducer
21. Safety Valve 29. Air Dryer End Cover 37. Elbow
13-159
TM 08780B-20
29. End Cover 49. Lockwasher

38. Screw (3) 50. Valve
39. Exhaust Cover 51. Spring
40. Purge Valve 52. O-Ring
41. Exhaust Plate 53. Nut
42. Screw 54. Washer
43. Washer 55. O-Ring
44. Diaphragm 56. Thermostat
45. O-Ring 57. Screw (4)
46. O-Ring 58. Cover
47. Purge Valve 59. Gasket
Piston
48. Screw
(13) Remove purge valve (40) and two O-rings (45 and 46) from end cover
(29). Discard 0-rings (45 and 46).
(14) Hold purge valve piston (47) and remove screw (48), lockwasher (49),
valve (50), spring (51) and O-ring (52). Discard O-ring (52). Discard lockwasher (49).
(15) Remove nut (53), washer (54) and O-ring (55) from thermostat (56).
Discard O-ring (55).
(16) Remove four screws (57), cover (58) and gasket (59). Discard gasket
(59).
(17) Remove thermostat (56) if damaged.
(18) Remove desiccant cartridge (60) from air dryer shell (30) by turning
capscrew (61) counterclockwise. Recycle cartridge.
13-160
TM 08780B-20
30. Air Dryer Shell

60. Desiccant Cartridge
61. Capscrew
(19) Remove plug (77).
NOTE
(20) Remove desiccant cartridge from air dryer shell (30) by turning desiccant
cartridge (60) counterclockwise. Discard cartridge.
60
30
30. Air Dryer Shell

13-161
TM 08780B-20
(3) Inspect for evidence of oil coming from dryer.
d. Assembly
30. Air Dryer Shell

61. Capscrew
77. Plug
(2) Install new desiccant cartridge (60) into air dryer shell (30). Tighten
(3) Install new O-ring (52) on purge valve piston (47).
(4) Install purge valve piston (47), spring (51) and valve (50), with
screw (48) and new lockwasher (49) in purge valve (40).
(5) Secure diaphragm (44) and washer (43) to exhaust plate (41) with
screw (42).
13-162
TM 08780B-20
(6) Install exhaust plate (41) and exhaust cover (39) on purge valve (40) using
three screws (38). Install two new O-rings (45 and 46) on purge valve (40). Install purge
valve (40) into end cover (29).
(7) Install thermostat (56) if removed.
(8) Install new gasket (59) and cover (58) with four screws (57). Tighten
securely.
(9) Install new O-ring (55), washer (54) and nut (53) on thermostat (56).
Tighten nut (53) securely.
(10) Apply pipe sealant to reducer (36) and elbow (37). Install elbow (37) and
reducer (36) into end cover (29).
29. End Cover 48. Screw

36. Reducer 49. Lockwasher
37. Elbow 50. Valve
38. Screw (3) 51. Spring
39. Exhaust Cover 52. O-Ring
40. Purge Valve 53. Nut
41. Exhaust Plate 54. Washer
42. Screw 55. O-Ring
43. Washer 56. Thermostat
44. Diaphragm 57. Screw (4)
45. O-Ring 58. Cover
46. O-Ring 59. Gasket
47. Purge Valve Piston
29. Air Dryer End Cover 33. Lock (3)

30. Air Dryer Shell 34. Retaining Ring
31. Capscrew (3) 35. O-Ring
32. Lockwasher (3)
13-163
TM 08780B-20
(11) Install new O-ring (35) on air dryer end cover (29). Install end cover (29)
into air dryer shell (30). Align matchmarks.
22. Check Valve

23. Valve Body
24. O-Ring
25. Sealing Washer
26. Spring Guide
27. Spring
28. Ball
(12) Install retaining ring (34). Install three locks (33), new lockwashers (32)
and capscrews (31).
(13) Position check valve (22) in soft-jawed vise.
(14) Coat spring guide (26), valve body (23), ball valve (28), spring (27) and
new sealing washer (25) with lubricating oil and install in check valve (22).
(15) Install new O-ring (24) on valve body (23). Install check valve (22) into
air dryer (9).
(16) Install safety valve (21) into air dryer (9).
(17) Apply pipe sealant to 90 degree elbow (19) and 45 degree elbow (20).
Install two elbows (19 and 20) into air dryer (9).
(18) Install two brackets (18), using two capscrews (17), new lockwashers (16)
and nuts (15). Position brackets (18) so that elbows (19 and 20) face engine.
13-164
TM 08780B-20
(19) Install bracket (10) to air dryer (9) using two 1/2 bolts , lockwashers and
nuts.
NOTE
(20) Install new desiccant cartridge (60) into top of air dryer (30) by turning
cartridge clockwise.
60
30
30. Air Dryer Shell

e. Installation
(1) Connect wire (14) to terminal (11) using new lockwasher (13) and nut
(12). Install boot (10) onto terminal (11).
(2) Install air dryer (9) using four capscrews (7) and new locknuts (4).
Tighten securely.
(3) Connect three air lines (1, 2 and 3).
(4) Connect two air lines (1 and 2) and three electrical leads (3, 4 and 5) to air
dryer assembly.
NOTE
Steps (5) and (6) are for ABS modified vehicles only.
(5) Attach air dryer (9) and bracket (10) as one assembly to the right hand
transfer case mounting bracket (10) using three bolts (6), lockwashers (7) and nuts (8).
(6) Install 90 degree elbow (11) and 45 degree elbow (12) onto air dryer (9).
(7) Connect three air lines (1, 2, and 3) and two electrical leads (4 and 5) to air
dryer assembly.
13-165
TM 08780B-20
(8) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Check for air
leaks.
1. Air Line 11. Terminal 18. Bracket (2)

2. Air Line 12. Nut 19. 90 Degree Elbow
3. Air Line 13. Lockwasher 20. 45 Degree Elbow
4. Locknut (4) 14. Wire 21. Safety Valve
7. Capscrew (4) 15. Nut (2) 22. Check Valve
9. Air Dryer 16. Lockwasher (2)
10. Boot 17. Capscrew (2)
13-166
TM 08780B-20
1. Air Line 7. Lockwasher (3)

2. Air Line 8. Nut (3)
3. Air Line 9. Air Dryer
4. Electrical Lead 10. Mounting Plate
5. Electrical Lead 11. 90 Degree Elbow
6. Capscrew (3) 12. 45 Degree Elbow
END OF TASK
13-167
TM 08780B-20
13-39. HAND CONTROL VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Soap and water solution disconnected
(item 54, Appendix D) (para7-45 or 7-46 on
Lockwasher (2) (MS35338-44) item 7 LVSA1 series
Locknut (4) (MS17829-4C) item 10 vehicles only).
References Access panel removed

TM 08780B-10 (para 18-15, item 3).

electrical components. To prevent personal
injury, drain all pressure from the air
system.
a. Removal
WARNING

REMOVING AIR LINE.
NOTE
(1) Remove two air lines (1 and 2) from hand control valve (3).
13-168
TM 08780B-20
(2) Remove two nuts (4), wires (5 and 6) and lockwashers (7) from stop light
switch (8). Discard lockwashers (7).
(3) Remove straight fitting (9).
(4) Remove four locknuts (10) from screws (11). Remove four screws (11).
(5) Remove hand control valve (3) from panel (12).
(6) Remove 90 degree elbow (13) from hand control valve (3).
(7) Remove stop light switch (8) from tee fitting (14).
(8) Remove 45 degree elbow (15) from tee fitting (14).
1. Air Line
2. Air Line
3. Hand Control Valve
4. Nut (2)
5. Wire (No. 009)
6. Wire (No. 005)
7. Lockwasher (2)
9. Straight Fitting
10. Locknut (4)
11. Screw (4)
12. Panel
13. 90 Degree Elbow
14. Tee Fitting
15. 45 Degree Elbow
17. 90 Degree Elbow
13-169
TM 08780B-20
NOTE
Air line fittings for the LVSA1 hand control valve have changed from a nipple and tee to street
tee. When repairing a non-A1 vehicle, use the new style fittings to replace the old style
(9) Remove tee fitting (14) from 90 degree elbow (17).
(10) Remove 90 degree elbow (17) from hand control valve (3).
(2) Clean all sealant from stop light switch (8) and all fittings.
(4) Inspect stop light switch (8) for loose terminals.
(5) Inspect wires (5 and 6) for loose connection.
c. Installation
NOTE
Apply pipe sealant to threads of fittings before installing.
(1) Install 90 degree elbow (17) into hand control valve (3).
(2) Install tee fitting (14) into 90 degree elbow (17).
(3) Install 45 degree elbow (15) into tee fitting (14).
(4) Install stop light switch (8) into tee fitting (14).
(5) Install 90 degree elbow (13) into hand control valve (3).
(6) Install hand control valve (3) into panel (12) using four screws (11) and
new locknuts (10).
(7) Install straight fitting (9) into 90 degree elbow (13).
(8) Install two wires (5 and 6) onto stop light switch (8) using two nuts (4)
and new lockwashers (7).
13-170
TM 08780B-20
(9) Install two air lines (1 and 2) onto hand control valve (3).
END OF TASK
NOTE
TM 08780B-20 Install access panels (para 18-15, item 3).
Connect batteries (para 7-45 or 7-46 on

TM 08780B-10 Start engine (para 2-13). Build air pressure

to normal operating pressure. Use soap and
water solution to check for air leaks.
1. Air Line 7. Lockwasher (2) 13. 90 Degree Elbow

2. Air Line 8. Stop Light Switch 14. Tee Fitting
3. Hand Control Valve 9. Straight Fitting 15. 45 Degree Elbow
4. Nut (2) 10. Locknut (4) 17. 90 Degree Elbow
5. Wire (No. 009) 11. Screw (4)
6. Wire (No. 005) 12. Panel
13-171
TM 08780B-20
13-40. TRAILER AIR SUPPLY VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Roll pin (NSN 5315-01-069-0602) item 6 disconnected
(para 7-45).
References
and drain all pressure from air system.
a. Removal
WARNING

(1) Remove four capscrews (1) and cover plate (2). Remove flasher (3) from
clip (4) and remove cover plate (2).
NOTE
(2) Tag and remove two electrical wires (5) from pressure switch (6).
(3) Remove three air lines (7).
(4) Remove roll pin (8) from knob (9). Remove knob (9). Discard roll pin
(8).
13-172
TM 08780B-20
(5) Remove nut (10). Remove trailer air supply valve (11) from dash (12).
NOTE
Note direction of elbows and fittings before removal to ensure proper installation.
(6) Tag and remove two elbows (13 and 14).
(7) Remove pressure switch (6) from tee fitting (15).
(8) Remove elbow (16) from tee fitting (15). Remove tee fitting (15) from
trailer air supply valve (11).
1. Capscrew (4) 10. Nut

2. Cover Plate 11. Trailer Air Supply Valve
3. Flasher 12. Dash
4. Clip 13. Elbow
5. Electrical Wire (2) 14. Elbow
6. Pressure Switch 15. Tee Fitting
7. Air Line (3) 16. Elbow
8. Roll Pin 17. Terminals
9. Knob
13-173
TM 08780B-20
(2) Clean all sealant from pressure switch (6) and all fittings.
(4) Inspect two electrical wires (5) for frays or loose connections.
(5) Inspect air lines (7) for kinks, chafing or damaged fittings.
(6) Inspect pressure switch (6) for loose terminals (17).
c. Installation
(1) Apply sealing compound to two elbows (13 and 14). Install elbows (13
and 14) into trailer air supply valve (11). Tighten securely.
(2) Apply sealing compound to tee fitting (15). Install tee fitting (15) into
trailer air supply valve (11). Tighten securely.
(3) Apply sealing compound to elbow (16). Install elbow (16) into tee fitting
(4) Apply sealing compound to pressure switch (6). Install pressure switch
(6) into tee fitting (15). Tighten securely.
(5) Install trailer air supply valve (11) into dash (12). Install nut (10).
Tighten securely.
(6) Install knob (9) onto trailer air supply valve (11) with new roll pin (8).
(7) Install three air lines (7).
(8) Connect two electrical wires (5) to pressure switch (6). Install flasher (3)
into clip (4). Install cover plate (2) using four capscrews (1).
pressure to normal operating pressure. Use soap and water solution to check for air leaks.
END OF TASK
13-174
TM 08780B-20
13-41. TRACTION CONTROL VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (4) (MS35333-72) items 6 and 13 (para 7-45 or 7-46 on
LVSA1 series
References vehicles only).
TM 08780B-10 Instrument panel
assembly open (para
7-11).

and drain all pressure from the air system.
a. Removal
WARNING

REMOVING AIR LINES OR COMPONENTS.
NOTE
(1) Remove two screws (1) from instruction plate (2).
(2) Turn traction control valve (3) and remove from dash (4).
(3) Remove two screws (5) and lockwashers (6). Tag and remove two wires
(7) from pressure switches (8). Discard lockwashers (6).
(4) Remove three air lines (9) from traction control valve (3).
13-175
TM 08780B-20
NOTE
• Mark location and tag all fittings to insure proper installation.
(5) Remove two elbows (10) from tee fittings (11).
(6) Remove two screws (12) and lockwashers (13). Remove jumper wire (14) from
pressure switches (8). Discard lockwashers (13).
(7) Remove two pressure switches (8) from tee fittings (11).
1. Screw
2. Instruction Plate
3. Traction Control Valve
4. Dash
5. Screw (2)
6. Lockwasher (2)
7. Wire (2)
8. Pressure Switch (2)
9. Air Line (3)
10. Elbow (2)
11. Tee Fitting (2)
12. Screw (2)
13. Lockwasher (2)
14. Jumper Wire .
16. Elbow (2)
17. Elbow
18. Terminal (4)
19. Screw (4)
NOTE
Air line fittings for the LVSA1 traction control valve have changed from a nipple and tee to
street tee. When repairing a non-A1 vehicle, use the new style fittings to replace the old style
13-176
TM 08780B-20
(8) Remove two tee fittings (11) from elbows (16).
(9) Remove three elbows (16 and 17) from traction control valve (3).
(10) If damaged, remove four screws (19) and instruction plate (2).
(2) Clean sealant from all fittings and pressure switches (8).
(4) Inspect wires (7 and 14) for chafing or loose connections.
(5) Inspect pressure switches (8) for loose terminals (18).
c. Installation
(1) If removed, install instruction plate (2) using four screws (19).
(2) Apply pipe sealant to three elbows (16 and 17). Install elbows (16 and 17)
into traction control valve (3). Tighten securely.
(3) Apply pipe sealant to tee fittings (11). Install into two elbows (16).
Tighten securely.
(4) Apply pipe sealant to two pressure switches (8). Install pressure switches
(8) into tee fittings (11).
(5) Install jumper wire (14) using two screws (12) and two new lockwashers
(13).
(6) Apply pipe sealant to two elbows (10). Install elbows (10) into tee fittings
(11).
(7) Install three air lines (9).
(8) Install two wires (7) using two screws (5) and two lockwashers (6).
(9) Install traction control valve (3) into dash (4).
13-177
TM 08780B-20
(10) Install two screws (1) into traction control valve (3). Tighten securely.
(11) Connect batteries. Refer to paragraph 7-45 or 7-46 on LVSA1 series

vehicles only.
(13) Build up air to normal operating pressure. Use soap and water solution to
check for leaks.
END OF TASK
NOTE
TM 08780B-20 Instrument panel assembly closed
(para 7-11).
Connect batteries (para 7-45 or 7-46).
1. Screw
2. Instruction Plate
3. Traction Control Valve
4. Dash
5. Screw (2)
6. Lockwasher (2)
7. Wire (2)
8. Pressure Switch (2)
9. Air Line (3)
10. Elbow (2)
11. Tee Fitting (2)
12. Screw (2)
13. Lockwasher (2)
14. Jumper Wire
16. Elbow (2)
17. Elbow
19. Screw (4)
13-178
TM 08780B-20
13-42. ELECTRONIC CONTROL UNIT/AIR CONTROL VALVE REPLACEMENT

b. Disassembly
d. Assembly
e. Installation
f. Testing

Condition Condition
drained (para 3-5).
Materials/Parts
Bracket Locknut (3) (244748) item Batteries
Air Lockwasher (2) (202983) item disconnected
(para 7-45 or 7-46 on
LVSA1 series
References vehicles only).
TM 08780B-10
Special Tools To prevent personal injury, block wheels
Teflon Tape and drain all pressure from the air system.
Dielectric Grease
a. Removal
WARNING

NOTE
• Removal of electronic control unit/air control valve are the same on the front power
unit and rear body unit.
(1) Tag and remove electrical cable (1) to electronic control unit (2).
(2) Tab and remove air lines from seven fittings (4, 5, 6, 7, 8, 9 and 10) from
air control valves (3).
13-179
TM 08780B-20
(3) Remove three nuts (11), lockwashers (12) and bolts (13) attaching
electronic control valve to bracket (14). Remove ECU from bracket. Discard lockwashers.
(4) Remove two nuts (15), lockwashers (16) and bolts (17) attaching air
control valves (3) to bracket (14). Remove air control valves. Discard lockwashers.
b. Disassembly
(1) Tag and remove seven fittings (4, 5, 6, 7, 8, 9 and 10) and tees from air
control valve.
(2) Remove crossover line (18) from two valves (3).
(3) Separate two valves (3) by unscrewing tee (20).
13-180
TM 08780B-20
NOTE
• Apply Teflon tape to threads of tees and fittings before installing.
• See illustrations for orientation of fittings.
d. Assembly
(1) Join two valves (3) together by screwing onto straight tee (20).
(2) Replace cross over line (18) between air control valves (3).
(3) Install six fittings (4, 5, 6, 7, 8 and 9) onto air control valves (3).
13-181
TM 08780B-20
e. Installation
(1) Install air control valve assembly (3) onto bracket (14) using two bolts
(17), lockwashers (16) and nuts (15). Tighten nuts securely.
(2) Install electronic control valve (2) to bracket (14) using three bolts (13),
lockwashers (12) and nuts (11). Tighten nuts securely.
NOTE
See illustrations for orientations of lines and fittings.
(3) Install six air lines to six fittings (4, 5, 6, 7, 8 and 9).
13-182
TM 08780B-20
(4) Attach electrical cable (1) to electrical control unit (2).
(5) Connect batteries (para 7-45 or 7-46 on LVSA1 series vehicles only).
13-183
TM 08780B-20
f. Testing
CAUTION
THE FOLLOWING TESTS SHOULD BE PERFORMED WITH VEHICLE ON A HARD,

DRY LEVEL SURFACE FREE OF SAND, GRAVEL AND OTHER LOOSE DEBRIS.
IDEALLY, TEST AREA WOULD BE 3/4 TO 1 MILE LONG, WITH TRAFFIC CONES
PLACED IN THE CENTER OF TEST AREA IN PARALLEL LINES, 12 FEET APART, 10
FEET INCREMENTS FOR A DISTANCE OF 120 FEET. THIS WILL ALLOW FOR A
START UP RUN OF 1/8TH MILE, TEST AREA, THEN AN EMERGENCY STOPPING
AREA OF BETTER THAN 1/2 MILE. PERFORM TEST FIRST WITH VEHICLE
UNLOADED, REPEAT WITH VEHICLE LOADED.
(1) Test Parameters and results can be less than, but not exceed limits
established below.
a. When traveling 20 miles per hour, from point at which service

brakes are initiated; vehicle should come to a complete stop within a distance not greater than 40
feet.
b. When traveling 20 miles per hour, from point at which emergency

brake system is applied, the vehicle must be capable of stopping in a distance not greater than 90
feet.
c. With vehicle on a 20 to 30 per cent grade, apply parking brake.

Brakes shall hold vehicle in place. This test shall be performed in the direction of accent as well
as decent.
(2) Test results should adhere to the above requirements. There should be a
discerning pulsation of the brake system, this means that the brakes are being applied and
released systematically; there should not be any noticeable wheel chatter or luck up.
13-184
TM 08780B-20
13-43. ANTILOCKING BRAKE SYSTEM SENSOR REMOVAL

c. Installation
d. Testing

Condition Condition
drained (para 3-5).
Materials/Parts
Tie Wraps (102679AA) TM 2320-10/12B Wheel and tire
Removed
(para 14-5).
Hub and drum

Removed (para
14-3).

Batteries disconnected (para 7-45 or 7-46 on
a. Removal
NOTE
Sensors are mounted on number 2, 3 and 4 axles.
(1) Cut and remove tie straps (1) securing ABS leads (2) to air lines and axles
(3).
(2) Disconnect ABS sensor lead (2) from ECU cable.
(3) Pull ABS sensor assembly (4) from clip (5) and sensor bracket (6).
(4) Pull clip (5) from sensor bracket (6).
13-185
TM 08780B-20
13-186
TM 08780B-20
(2) Check sensor clip for damage.
c. Installation
(1) Insert sensor clip (5) completely into sensor bracket (6).
(2) Insert sensor (4) completely into sensor bracket (6).
(3) Route ABS sensor lead (2) along air lines and axle (3). Secure with
double lock tie wrap (1) every 6-8 inches (15.24-20.32 cm).
(4) Connect ABS sensor lead (2) to correct ECU connector. Secure with
double lock tie wrap (1).
(5) Install hub and drum assembly (para 4-3).
(6) Install wheel and tire (para 4-5).
(7) Connect batteries (para 7-45 or 7-46 on LVSA1 series vehicles only).
(9) Build air pressure to normal operating pressure.
13-187
TM 08780B-20
d. Testing
CAUTION

START UP RUN OF 1/8TH MILE, TEST AREA, THEN AN EMERGENCY STOPPING
established below.

feet.

feet.

as decent.
released systematically; there should not be any noticeable wheel chatter or lock up.
13-188
TM 08780B-20
13-44. QUICK RELEASE VALVE REPLACEMENT

c. Installation
d. Testing

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (2) (202982) item 6 General Safety Instructions
Batteries disconnected (para 7-45 or 7-46 on
References LVSA1 series vehicles only).
TM 08780B-10
a. Removal
WARNING

NOTE
• Left and right quick release valves are removed in the same manner.
(1) Tag and remove two air lines (2 and 3) from quick release valve (1).
(2) Remove two nuts (4), washers (5), lockwashers (6) and bolts (7)holding
quick release valve (1) to transmission external oil filter mounting bracket (8). Remove valve.
Discard lockwashers.
(3) Remove fittings (9) from quick release valve (1).
13-189
TM 08780B-20
c. Installation
(1) Install fittings (9) onto quick release valve (1).
(2) Install quick release valve (1) to transmission external oil filter mounting
bracket (8) using two bolts (7), lockwashers (6), washer (5) and nuts (4). Tighten nuts securely.
13-190
TM 08780B-20
(3) Attach air lines to quick release valve (1).
13-191
TM 08780B-20
(5) Build air pressure to normal operating pressure. Use a soap and water
d. Testing
CAUTION

START UP RUN OF 1/8 TH MILE, TEST AREA, THEN AN EMERGENCY STOPPING
established below.

feet.

feet.

as decent.
released systematically; there should not be any noticeable wheel chatter or luck up.
END OF TASK
13-192
TM 08780B-20
13-45. R14 VALVE REPLACEMENT

c. Installation
d. Testing

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (2) (210047) item 3 General Safety Instructions
References and drain all pressure from the air system.
TM 08780B-10
a. Removal
WARNING

NOTE
(1) Tag and disconnect three air lines from R14 valve (1).
(2) Remove two nuts (2), lockwashers (3) and bolts (4) holding R14 valve (1)
to front trailer support cross beam (5). Remove R14 valve. Discard lockwashers.
(3) Remove fittings (6, 7, 8, 9, 10 and 11) from R14 valve (1).
13-193
TM 08780B-20
(2) Check sensor clip for damage.
c. Installation
(1) Install fittings (6, 7, 8, 9, 10 and 11) onto R14 valve (1).
(2) Attach R14 valve (1) to front trailer support cross beam (5) using two
bolts (4), lockwashers (3) and nuts (2). Tighten nuts securely.
(3) Attach three air lines to R14 valve (1).
13-194
TM 08780B-20
(5) Build air pressure to normal operating pressure. Use a soap and water
d. Testing
CAUTION

START UP RUN OF 1/8 TH MILE, TEST AREA, THEN AN EMERGENCY STOPPING
established below.
13-195
TM 08780B-20

feet.

feet.

as decent.
released systematically; there should not be any noticeable wheel chatter or lock up.
END OF TASK
13-196
TM 08780B-20
CHAPTER 14
WHEELS AND TIRES
procedures for the vehicle's wheels and tires.
a. General. The LVS can be equipped with standard tires, sand tires or run flat tires.
All tires are mounted on three-piece, split-style wheels.
b. Standard Tire. The standard tire is a tubeless, five ply, steel belted radial. It is
made for both on and off road use.
c. Sand Tire. The sand tire is a radial, tubeless tire. The tire and wheel are wider
than the standard tire. The tread design and width allow the vehicle to operate on loose sand.
d. Run Flat. The run flat is a steel wheel mounted between the tire and the regular
wheel. It allows the vehicle to operate in emergency situations after the tire has been deflated.
Tires that are equipped with the run flat device are marked R.F. on the flange clamps. These
tires should be handled in the same way as other tires, using the same inflation pressure. Tire
mounting and demounting procedures are different. These differences are covered in paragraphs
14-1
TM 08780B-20
14-3. HUB, DRUM, TONER RING AND WHEEL BEARING REPLACEMENT (NO. 2,
3 AND 4 AXLES)

c. Installation

Condition Condition
Handle (RD296) TM 08780B-20 Wheel and tire
Adapter (RD291) removed (para 14-5).
Pilot (RD414)
No. 2, 3 and 4 axle
Materials/Parts shaft removed
Nut lock (NSN 5310-01-145-9118) item 1 (para 12-4).
Oil seal (NSN 5330-01-162-0414) item 6
(No. 2 axle only) Brake air chamber
Oil seal (NSN 5330-01-048-6240) item 6 caged (para 13-12).
Personnel Required General Safety Instructions

1 MOS 3521 Block wheels of truck to prevent personal
1 Assistant injury. Support axle with a jack stand rated
at 10 tons or more.
a. Removal
(1) Straighten tabs on nut lock (1).
(2) Remove outer locknut (2) and nut lock (1), using axle bearing locknut
wrench. Discard nut lock (1).
(3) Remove inner locknut (3).
(4) Remove outer bearing cone (4).
WARNING
HUB AND DRUM ASSEMBLY IS EXTREMELY HEAVY. TO PREVENT SERIOUS

INJURY, HUB AND DRUM ASSEMBLY MUST NOT FALL ON PERSONNEL. BE SURE
HUB AND DRUM ASSEMBLY IS SAFELY SECURE ON FLOOR JACK.
(5) Position a floor jack under hub and drum assembly (5). Raise jack to
support hub and drum assembly (5). Remove hub and drum assembly (5).
(6) Remove seal (6) and inner bearing cone (7) from hub (8).
14-2
TM 08780B-20
(7) Install 10 lug nuts (9) onto studs (10) until outside edge of lug nut is even
(1) with the end of stud (10).
(8) Drive 10 studs (10) out of hub (8).
NOTE
Step (9) is for No. 2 and 4 axles on ABS modified vehicles only.
(9) Remove toner ring (17) from inside of drum (11.
(10) Separate hub (8) and drum (11).
(11) If needed, remove bearing cups (12 and 13).
(12) If hub (8) will be replaced, remove eight studs (14).
NOTE
• Wear sleeves (15) are not used on axles number three and four.
• Seals on LVSA1 number two axles have changed from a wear sleeve and oil seal to an
oil seal only. When repairing non-A1 vehicles, use the new hardware to replace the old
CAUTION
BE CAREFUL WHEN REMOVING WEAR SLEEVE (15). DO NOT NICK OR DAMAGE

SKEIN (16).
(13) If present, split wear sleeve (15) and remove from skein (16).
WARNING
WHEN CLEANING BEARINGS, DO NOT USE COMPRESSED AIR. A SPINNING

BEARING CAN FLY APART AND CAUSE PERSONAL INJURY.
(2) Rotate bearing cones (4 and 7) slowly and inspect for damage, roughness,
pits or binding.
(3) Inspect bearing cups (12 and 13) for damage or signs of overheating.
(4) Inspect studs (10 and 14) for thread damage.
14-3
TM 08780B-20
(5) Inspect skein (16) for burrs. Remove any nicks or burrs.
(6) Inspect drum (11) for signs of overheating, out-of-roundness or wear.

Maximum inside diameter is 16.614 inches 42.199 cm).
(7) Clean inside of drum where toner ring makes contact with mounting
surface using compressed air and wire brush.
c. Installation
NOTE
When installing wheel studs, be sure to use right hand threaded studs on right hub and drum
and left hand threaded studs on left hub and drum.
(1) Install drum (11) onto hub (8).
NOTE
Step (2) is for No. 2 and 4 axles on ABS modified vehicles only.
(2) Place toner ring (17) inside of drum (11) insuring 10 holes in ring align
with holes in drum.
(3) Install 10 studs (10) through hub (8), toner ring (17) (ABS modified
vehicles only) and drum (11). Drive studs (10) down until heads are flush with surface of drum
(11).
1. Nut Lock 7. Inner Bearing Cone 12. Bearing Cup

2. Outer Locknut 8. Hub 13. Bearing Cup
3. Inner Locknut 9. Lug Nut (10) 14. Stud (8)
4. Outer Bearing Cone 10. Stud (10) 15. Wear Sleeve
5. Hub And Drum Assembly 11. Drum 16. Skein
6. Seal
14-4
TM 08780B-20
(4) If removed, install bearing cups (12 and 13).
(5) Apply gear oil to inner wheel bearing cone (7) and install inner wheel
bearing cone.
(6) Using seal installation tools, install new seal (6) into hub (8).
CAUTION
DO NOT DAMAGE OIL SEAL WHEN INSTALLING HUB ON SKEIN.
(7) Install hub (8) and drum (11) over skein (16).
(8) Apply gear oil to outer bearing cone (4) and install outer bearing cone.
(9) Install inner locknut (3) with machined surface against bearing cone (4).
Do not tighten.
NOTE
• On No. 2 axle, 1.41 inches to 1.53 inches of stud threads should be showing/visible out
of the hub nut.
• On No. 3 and No. 4 axles, 1.56 inches to 1.68 inches of stud threads should be
showing/visible out of the hub nut.
(10) If removed, install eight studs (14).
14-5
TM 08780B-20
(11) Slowly torque inner locknut (3) to 250 foot-pounds (340 N*m) while
rotating drum (11) in forward and reverse directions.
(12) Loosen inner locknut (3) until it turns by hand.
(13) Torque inner locknut (3) to 50 foot-pounds (68 N*m) while rotating drum
(11) in forward and reverse directions.
(14) Back off inner locknut (3) 1/8 turn.
(15) Install new nut lock (1).
(16) Install outer locknut (2). Torque to 250 foot-pounds (340 N*m).
(17) Bend one tab of nut lock (1) over each locknut (2 and 3) to secure in place.
Wheel should move freely in both directions.
END OF TASK
NOTE
TM 08780B-20 Release brake air chamber (para 13-12).
Install No. 2, 3 or 4 axle shaft (para 12-4).
14-6
TM 08780B-20
1. Nut Lock 7. Inner Bearing Cone 12. Bearing Cup

2. Outer Locknut 8. Hub 13. Bearing Cup
3. Inner Locknut 9. Lug Nut (10) 14. Stud (8)
4. Outer Bearing Cone 10. Stud (10) 16. Skein
5. Hub & Drum Assembly 11. Drum
6. Seal
14-7
TM 08780B-20
14-4. HUB, DRUM AND WHEEL BEARING REPLACEMENT (NO. 1 AXLE)

b. Disassembly
d. Assembly

Condition Condition
MK48 TM 08780B-20 Wheel and tire
assembly removed
Special Tools (para 14-5).
Front wheel bearing wrench (409 GX)
Materials/Parts Block wheels of truck to prevent personal
Grease (item 21, Appendix D) injury. Support axle with a jack stand rated
Sealing compound (item 50, Appendix D) at 10 tons or more
Capscrew (2) (MS16208-108) item 5
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Loosen brake adjustment so that hub and drum assembly (1) will slide off
easily. Refer to paragraph 13-4.
(2) Remove 10 nuts (2) and lockwashers (3) from hub cap (4). Discard
lockwashers (3).
NOTE
Capscrews (5) should be tightened evenly, alternating from one side to the other.
(3) Screw two capscrews (5) into hub cap (4). This will release hub cap (4)
from hub (6).
(4) Remove hub cap (4) and capscrews (5).
(5) Position a floor jack under hub and drum assembly (1). Raise jack to
support hub and drum assembly (1).
14-8
TM 08780B-20
NOTE
Align notch in hub to allow access to capscrew (7).
(6) Remove capscrew (7) and lockwasher (8) from wheel bearing locknut (9).
(7) Remove lockplate (10).
(8) Remove wheel bearing locknut (9) using front wheel bearing wrench.
(9) Remove outer wheel bearing cone (11) and tag for later use.
WARNING
HUB AND DRUM ASSEMBLY IS EXTREMELY HEAVY. TO PREVENT SERIOUS

INJURY, HUB AND DRUM ASSEMBLY MUST NOT FALL ON PERSONNEL. BE SURE
HUB AND DRUM ASSEMBLY IS SAFELY SECURE ON FLOOR JACK.
(10) Using floor jack, remove hub and drum assembly (1).
b. Disassembly
(1) Remove oil seal (12) and seal spacer (13).
(2) Remove inner wheel bearing cone (14) and tag for later use.
(3) Wheel bearing cups (15 and 16) should not be removed unless hub (6) or
cups (15 and 16) are being replaced.
(4) Remove bearing cups (15 and 16) by inserting a driver into the grooves in
hub (6).
(5) Position hub and drum assembly (1) with wheel lug studs (17) facing
upward.
(6) Separate hub (6) from drum (19) by installing a lug nut (18) on each wheel
lug stud (17) until lug nut (18) is flush with top of wheel lug stud (17).
(7) Drive ten wheel lug studs (17) downward until loose. Remove lug nuts
(18) and wheel lug studs (17) from hub and drum assembly (1).
(8) Remove drum (19) from hub (6).
(9) Remove studs (20) from hub (6).
14-9
TM 08780B-20
1. Hub & Drum Assembly 9. Locknut 15. Inner Wheel

2. Nut (10) 10. Lockplate Bearing Cup
3. Lockwasher (10) 11. Outer Wheel 16. Outer Wheel
4. Hub Cap Bearing Cone Bearing Cup
5. Capscrew (2) 12. Oil Seal 17. Wheel Lug Stud (10)
6. Hub 13. Seal Spacer 18. Lug Nut (10)
7 Capscrew 14. Inner Wheel 19. Drum
8. Lockwasher Bearing Cone 20. Stud (10)
14-10
TM 08780B-20
WARNING
WHEN CLEANING BEARINGS, DO NOT USE COMPRESSED AIR. A SPINNING

BEARING CAN FLY APART AND CAUSE PERSONAL INJURY.
(2) Clean bearing cones (11 and 14).
(3) Rotate bearing cones (11 and 14) slowly and inspect for damage,
roughness, pits or binding.
(4) Inspect hub (6) and drum (19) for cracks or wear grooves.
(5) Inspect all studs, bolts and nuts for thread damage.
(6) Inspect center of hub cap (4) for damage or looseness.
d. Assembly
(1) Install ten wheel lug studs (17) into holes in hub (6). Drive wheel lug studs
(17) down until flush.
(2) Install bearing cups (15 and 16) into hub (6) if removed. Drive in until
fully seated.
(3) Pack the inner wall of hub (6) with grease.
(4) Pack both inner (14) and outer (11) wheel bearing cones with grease.
(5) Install inner wheel bearing cone (14) into hub (6).
(6) Install seal spacer (13) into hub (6) with inner chamfer facing out.
(7) Install oil seal (12) into hub (6) with lip of oil seal (12) facing in and flush
with face of hub (6).
(8) Coat lip of oil seal (12) with grease.
CAUTION
DO NOT DAMAGE OIL SEAL WHEN INSTALLING HUB ON SKEIN.
(9) Slide hub (6) over axle skein (21).
14-11
TM 08780B-20
(10) Install outer wheel bearing cone (11) into hub (6).
(11) Remove excess grease from threads of axle skein (21).
(12) Using front wheel bearing wrench, install wheel bearing locknut (9) onto
skein (21).
CAUTION
ADJUSTMENT OF LOCKNUT IS VERY IMPORTANT. IT MUST BE TIGHT ENOUGH

TO ELIMINATE END PLAY IN HUB, BUT NOT TIGHT ENOUGH TO CAUSE
EXCESSIVE DRAG.
(13) Rotate hub (6) while tightening wheel bearing locknut (9). Tighten wheel
bearing locknut (9) until hub (6) is tight. Loosen locknut (9) one quarter turn.
(14) Align slot (22) in locknut (9) with slot (23) in skein (21).
(15) Install lockplate (10) into slots (22 and 23). Install capscrew (7) and new
lockwasher (8). Torque capscrew (7) to 25 foot-pounds (33.9 N*m).
(16) Pack inside of hub cap (4) with 1/2 inch of grease.
(17) Coat hub cap (4) with silicone sealant.
(18) Install hub cap (4) onto hub (6) by tapping it onto studs (20) with a brass
drift and a hammer.
(19) Install ten new lockwashers (3) and nuts (2) onto studs (20). Torque to
130 foot-pounds (180 N*m).
(20) With help from an assistant, install drum (19) onto hub (6).
END OF TASK
NOTE
TM 08780B-20 Install wheel and tire assembly (para 14-5).
14-12
TM 08780B-20
1. Hub & Drum Assembly 10. Lockplate 16. Outer Wheel

2. Nut (10) 11. Outer Wheel Bearing Cup
3. Lockwasher (10) Bearing Cone 17. Wheel Lug Stud (10)
4. Hub Cap 12. Oil Seal 18. Lug Nut (10)
5. Capscrew (2) 13. Seal Spacer 19. Drum
6. Hub 14. Inner Wheel 20. Stud (10)
7. Capscrew Bearing Cone 21. Skein
8. Lockwasher 15. Inner Wheel 22. Slot
9. Locknut Bearing Cup 23. Slot
14-13
TM 08780B-20
14.-5 WHEEL AND TIRE REPLACEMENT

c. Installation

References injury.
TM 08780B-10
a. Removal
WARNING
• IF THE TIRE HAS BEEN DRIVEN UNDER INFLATED OR OVER INFLATED OR

THERE IS OBVIOUS OR SUSPECTED DAMAGE ON THE TIRE OR WHEEL
COMPONENTS, THE TIRE MUST BE COMPLETELY DEFLATED. TO
DEFLATE THE TIRE, REMOVE THE VALVE CORE FROM THE VALVE STEM.
STAND OUT OF THE TRAJECTORY AREA OR PERSONAL INJURY OR DEATH
MAY RESULT.
• TIRE AIR PRESSURE MUST BE CHECKED PROPERLY OR SERIOUS INJURY

OR DEATH MAY RESULT.
• IF TIRE HAS BEEN RUN FLAT OR IS OVER OR UNDER INFLATED WHEN

TIRE PRESSURE MEASURED AND OPERATING TERRAIN IS COMPARED TO
TABLE 14-1 OR IF WHEEL/TIRE ASSEMBLY HAS OBVIOUS OR SUSPECTED
DAMAGE, IT IS NOT SAFE TO ADJUST TIRE PRESSURE. COMPLETELY
DEFLATE TIRE BY REMOVING VALVE CORE FROM THE VALVE STEM AND
REMOVE THE TIRE FROM THE AXLE. FAILURE TO FOLLOW THESE
PROCEDURES MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
NOTE
Trajectory area as shown applies to all wheel/tire assemblies.
14-14
TM 08780B-20
Table 14-1. Unsafe Inflation Pressures
MK48 Tires Are: MK14, 15, 16 and MK48 Tires Are: MK14, 15, 16 and
17 Tires Are: 17 Tires Are:
Over inflated. Tire Over inflated. Tire Under inflated. Under inflated.
pressure measured pressure measured Tire pressure Tire pressure
is 25% or more is 25% or more measured is 80% measured is 80%
above standard above standard or less than the or less than the
pressure. pressure. standard tire standard tire
pressure. pressure.
Do not adjust Do not adjust Do not adjust Do not adjust

pressure if above pressure if above pressure if below pressure if below
pressure shown pressure shown pressure shown pressure shown
below. below. below. below.
ON ROAD 75 psi 138 psi 48 psi 88 psi
(517 kPa) (948 kPa) (331 kPa) (607 kPa)
OFF ROAD 56 psi 56 psi 36 psi 36 psi
(386 kPa) (386 kPa) (248 kPa) (248 kPa)
EMERGENCY 38 psi 38 psi 24 psi 24 psi
(Sand, Mud and (262 kPa) (262 kPa) (165 kPa) (165 kPa)
Snow)
(1) Take tire pressure reading on tire/wheel to be changed and compare

reading to Table 14-1. If tire is over inflated or under inflated or there is obvious or suspected
damage to wheel or tire, completely deflate tire before removing from truck.
(2) Place suitable jack (1) under axle being lifted.
WARNING
AN MK48 IS EXTREMELY FRONT HEAVY WHEN DETACHED FROM REAR TRAILER.

DO NOT ATTEMPT TO RAISE NO. 2 AXLE WITHOUT PLACING TWO JACK STANDS
AT FRONT LIFTING BRACKETS. SERIOUS INJURY OR DEATH COULD RESULT.
NOTE
• Lug nuts on left side of vehicle are left hand thread. Lug nuts on right side of vehicle
are right hand thread. Do not attempt to switch sides.
• Loosen lug nuts (2) before raising tire off ground.
(3) On separated MK48 only, position two jack stands (3) under front lifting
brackets before raising No. 2 axle.
(4) Raise axle until tire (4) clears ground.
14-15
TM 08780B-20
NOTE
Position jack stand on flat surface of axle nearest end being worked on.
(5) Position jack stand (3) directly under axle as shown.
(6) Slowly lower axle, until axle is resting on jack stand (3) with tire (4) clear
of ground.
(7) Remove 10 lug nuts (2).
(8) Remove tire (4) from hub (5).
3) Replace all parts failing inspection.
c. Installation
(1) Install tire (4) onto hub (5).
(2) Install 10 lug nuts (2). Hand tighten lug nuts (2) following pattern shown.
(3) Raise axle to clear jack stand (3). Remove jack stand (3).
(4) Slowly lower axle until tire (4) contacts ground.
(5) Torque lug nuts (2) to 650-750 foot-pounds (881.4-1,017 N*m) following
pattern shown.
14-16
TM 08780B-20
1. Jack
2. Lug Nuts
3. Jack Stand
4. Tire
5. Hub
END OF TASK
14-17
TM 08780B-20
14-6. TIRE MAINTENANCE (NON RUN FLAT)

b. Cleaning
c. Inspection
d. Assembly

Condition Condition
All non run flat tires TM 08780B-20 Wheel and tire
removed from
Materials/Parts vehicle (para 14-5).
Tire bead lubricant (item 61, Appendix D)
O-ring (P/N OR21TA) item 9 Rim and tire service can be dangerous if
Valve stem (NSN 2640-01-103-3631) item 11 proper procedures are not followed. To
prevent serious injury or death, follow task
procedure carefully.
Do not take tire pressure readings or

perform wheel/tire repairs without first
reading warnings or personal injury or death
may result.
Failure to comply with these procedures

may result in faulty positioning of the tire
and/or rim parts and cause the assembly to
burst with explosive force, sufficient to
cause serious physical injury or death.
Never mount or use damaged tires or rims.
a. Disassembly
WARNING
• WHEEL/TIRE ASSEMBLY MUST BE DEFLATED IN A SAFETY CAGE OR

PERSONAL INJURY OR DEATH MAY RESULT.
• ALWAYS COMPLETELY DEFLATE TIRE BY REMOVING VALVE CORE FROM

VALVE STEM BEFORE ATTEMPTING DEMOUNTING OPERATION. AFTER
AIR HAS FINISHED EXHAUSTING FROM VALVE STEM, CAREFULLY RUN A
PIECE OF WIRE THROUGH VALVE STEM TO ENSURE IT IS NOT PLUGGED
AND TIRE IS COMPLETELY DEFLATED. FAILURE TO COMPLY MAY RESULT
IN INJURY TO PERSONNEL.
14-18
TM 08780B-20
• STAND CLEAR OF TRAJECTORY AREA DURING DEFLATION OR PERSONAL

INJURY OR DEATH MAY RESULT.
1. Valve Core 8. Lock Ring

2. Capscrew (6) 9. O-Ring
3. Lockwasher (6) 10. Rim Base
4. Plate Flange Clamp (3) 11. Valve Stem Assembly
5. Tire Tool 12. Lock Ring Groove
6. Tire 13. O-Ring Groove
7. Flange
14-19
TM 08780B-20
WARNING
HIGH AIR PRESSURE MAY BE RELEASED FROM VALVE STEM WHEN VALVE CORE
IS REMOVED. STAY CLEAR OF VALVE STEM AFTER CORE IS REMOVED. ENSURE
ALL PERSONNEL WEAR SUITABLE EYE PROTECTION. FAILURE TO COMPLY MAY
RESULT IN SERIOUS INJURY TO PERSONNEL.
CAUTION
NEVER HAMMER ON RIM WITH STEEL HAMMERS. DAMAGE MAY RESULT.
NOTE
Some valve caps can be turned over and used to remove valve core (1).
(1) Place wheel assembly in a safety cage and remove valve core (1). Allow
all air to escape.
(2) Remove six capscrews (2), six lockwashers (3) and three plate flange
clamps (4). Discard lockwashers (3).
(3) Place wheel and tire assembly on wooden blocks, flange side up.
(4) Place curved end of two tire tools (5) between tire (6) and flange (7) about
five inches apart.
(5) Pry down with both tire tools (5).
(6) Leave one tire tool (5) in place and slide second tire tool (5) five inches
around rim. Pry down. Repeat until bead is free.
WARNING
KEEP FINGERS OUT OF THE WAY WHEN REMOVING LOCK RING. IT MAY SLIP
AND CAUSE INJURY.
(7) Using a soft-faced hammer, drive flange (7) down about one inch (2.54
cm).
(8) Tap one tire tool (5) in between flange (7) and lock ring (8) at separation
in lock ring (8). Pry lock ring (8) up from flange (7) and remove.
(9) Using tire tool (5) to hold flange (7) down, remove, cut in two and discard
O-ring (9).
14-20
TM 08780B-20
WARNING
FLANGE IS HEAVY. TO AVOID PERSONAL INJURY, USE CARE WHEN REMOVING.
(10) Using two tire tools (5), pry flange (7) from rim base (10).
WARNING
• RIM BASE IS HEAVY. TO AVOID PERSONAL INJURY, USE CARE WHEN

REMOVING.
• RIM BASE MAY DROP AS TIRE IS TURNED OVER. USE CARE TO PREVENT
PERSONAL INJURY.
(11) Turn assembly over. Repeat steps (4), (5) and (6).
(12) Remove rim base (10) from tire (6).
(13) Remove and discard valve stem assembly (11).
b. Cleaning
(1) Use wire brush to clean all dirt, rust and corrosion from wheel.
(2) Clean lock ring groove (12) and O-ring groove (13) thoroughly.
c. Inspection
WARNING
DO NOT WELD, HEAT OR BRAZE WHEEL PARTS THAT ARE CRACKED, BENT,
BROKEN OR DAMAGED. REPAIRED PARTS MAY NOT HOLD UP IN SERVICE.
ALWAYS REPLACE WITH NEW PARTS OF SAME SIZE AND TYPE.
(1) Inspect tire tread for nails, glass and other foreign particles and for
irregular wear, cuts and blisters.
(2) Inspect bead of tire for damaged rim seal ridges.
(3) Inspect complete inside surface of inner liner for imperfections,

discoloration or irregular surface that may indicate excessive heat or other fabric damage.
(4) Check rim for cracks, dents, dirt and rust, especially in the lock ring
groove.
14-21
TM 08780B-20
(5) Paint wheel assembly parts as needed to protect against rust.
NOTE
Ensure all parts that are replaced are placed in scrap metal to be destroyed.
(6) Do not use a lock ring or side ring if they are bent, distorted, cracked or
heavily corroded. Replace all damaged parts.
(7) Remove rust, gummy rubber deposits, nicks and gouges in the rim bead
seat surfaces.
d. Assembly
WARNING
THREE PIECE RIMS HAVE PART NUMBERS STAMPED ON THEM. USE ONLY
EXACT REPLACEMENT PARTS. PART NUMBERS MUST MATCH PARTS BEING
REPLACED. SERIOUS INJURY OR DEATH COULD RESULT IF WHEEL SHOULD
BURST DUE TO MISMATCHED PARTS.
(1) Install new valve stem assembly (11) in rim base (10). Valve stem
assembly (11) must be installed facing flange (7).
(2) Place rim base (10) on wooden blocks, grooved side up.
(3) Place tire (6) over rim base (10).
(4) Align flange nuts (15) with stops (14) in rim base (10). Place flange (7)
over rim base (10). Tap down to expose grooves (12 and 13).
CAUTION
BE SURE BEVELED EDGE OF LOCK RING (8) FACES FLANGE (7).
(5) Install lock ring (8) into lock ring groove (12) of rim base (10).
(6) Lubricate new O-ring (9) and O-ring groove (13) in rim base (10) with tire
bead lubricant.
(7) Stretch new O-ring (9) around O-ring groove (13) and snap into place.
DO NOT roll O-ring (9). It may be necessary to hold flange (7) down with tire tool (5).
(8) Using tire bead lubricant, lubricate tire bead.
(9) Use tire tool (5) to pry up flange (7) while tapping rim base (10) with a
soft-faced hammer to seat flange (7) against lock ring (8).
14-22
TM 08780B-20
(10) Install plate flange clamps (4) with new lockwashers (3) and capscrews
(2). Torque capscrews (2) to 70 foot-pounds (95 N*m).
1. Valve Core 6. Tire 11. Valve Stem Assembly

2. Capscrew (6) 7. Flange 12. Lock Ring Groove
3. Lockwasher (6) 8. Lock Ring 13. O-Ring Groove
4. Plate Flange Clamp (3) 9. O-Ring 14. Stop (2)
5. Tire Tool (2) 10. Rim Base 15. Flange Nut (6)
14-23
TM 08780B-20
WARNING
• TO PREVENT PERSONAL INJURY OR DEATH:
• FAILURE TO PLACE WHEEL/TIRE ASSEMBLY IN SAFETY CAGE PRIOR TO

INITIAL INFLATION COULD RESULT IN SERIOUS INJURY OR DEATH TO
PERSONNEL.
• WHEN A WHEEL/TIRE ASSEMBLY IS IN A RESTRAINING DEVICE, DO NOT

REST OR LEAN ANY PART OF BODY OR EQUIPMENT ON OR AGAINST THE
RESTRAINING DEVICE OR INJURY OR DEATH MAY RESULT.
(11) Place assembly in safety cage. Install valve core (1).
WARNING
• WHILE CHANGING TIRES OR WHILE PERFORMING TIRE MAINTENANCE,

STAY OUT OF THE TRAJECTORY AREA AS SHOWN BY THE AREA
INDICATED. FAILURE TO FOLLOW PROPER PROCEDURES MAY RESULT IN
INJURY OR DEATH TO PERSONNEL.
• IMPROPERLY SEATED LOCK RINGS AND FLANGE MAY BLOW OFF DURING
INFLATION. NEVER ATTEMPT TO SEAT A LOCK RING OR FLANGE DURING
OR AFTER INFLATION. SERIOUS INJURY OR DEATH MAY RESULT.
• WHEN INFLATING TIRES, ALWAYS USE AN INFLATION HOSE WITH AN IN-

LINE GAUGE AND A CLIP-ON CHUCK. THE GAUGE AND VALVE MUST BE
MOUNTED A MINIMUM OF TEN FEET (3 M) AWAY FROM AIR CHUCK.
• ALL PERSONNEL MUST REMAIN A MINIMUM OF TEN FEET (3 M) AWAY

FROM TIRE AND NOT IN POSSIBLE PATH OF LOCK RING OR FLANGE.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH.
• DO NOT INFLATE ABOVE 3 PSI (20 KPA) OR PERSONAL INJURY OR DEATH

MAY RESULT.
• NO ATTEMPT SHALL BE MADE TO CORRECT THE SEATING OF FLANGES

AND LOCK RINGS BY HAMMERING, STRIKING OR FORCING THE
COMPONENTS WHILE THE TIRE IS PRESSURIZED OR DAMAGE OR INJURY
• WHENEVER MULTI-PIECE RIM WHEELS ARE BEING HANDLED,

PERSONNEL SHALL STAY OUT OF THE TRAJECTORY AREA UNLESS THE
SUPERVISOR CAN DEMONSTRATE THE PERFORMANCE OF THE
SERVICING MAKES THE PERSONNEL'S PRESENCE IN THE TRAJECTORY
AREA NECESSARY OR DAMAGE OR INJURY OR DEATH MAY RESULT.
14-24
TM 08780B-20
(12) Using an inflation hose with an in-line gauge and clip-on chuck, inflate
tire to 3 psi (20 kPa). Check for correct assembly.
WARNING
IMPROPERLY SEATED LOCK RINGS OR FLANGES MAY BLOW OFF AT ANY TIME.
NEVER ATTEMPT TO SEAT A LOCK RING OR FLANGE DURING OR AFTER
INFLATION. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH.
(13) If assembly is not correct, deflate, disassemble and correct.
WARNING
NEVER INFLATE TIRES OVER 40 PSI (276 KPA) TO SEAT TIRE BEADS. IF BEADS
DO NOT SEAT, DEFLATE, DEMOUNT AND CHECK TIRE/RIM PARTS.
RELUBRICATE AND REMOUNT TIRE. SERIOUS INJURY OR DEATH COULD
RESULT IF THESE PROCEDURES ARE NOT FOLLOWED.
(14) If assembly is correct, continue inflation to 20 psi (138 kPa).
WARNING
ENSURE THAT TIRE AND RIM PARTS ARE IN PROPER POSITION AND THAT TIRE
LOWER SIDEWALL CIRCUMFERENTIAL GROOVE TO THE SIDEWALL TOP OF THE
RIM FLANGE DOES NOT VARY MORE THAN 1/8 IN. (3.2 MM) AND THAT EACH
BEAD DOES NOT VARY MORE THAN 1/8 IN (3 2 MM) AROUND THE
CIRCUMFERENCE OR FROM ONE BEAD TO THE OTHER. MEASUREMENTS
EXCEEDING 1/8 IN. (3.2 MM) REQUIRE UNSEATING TIRE BEADS, RELUBRICATING
TIRE BEADS AND REMOUNTING TIRE OR SERIOUS INJURY OR DEATH MAY
RESULT WHEN TIRE IS REMOVED FROM SAFETY CAGE.
(15) Inflate wheel/tire assembly to 110 psi (758 kPa) and check tire/rim parts
for proper assembly.
(16) If assembly is not correct, deflate, disassemble and reposition parts.

Relubricate parts and repeat steps (12 thru 15).
(17) Install valve cap.
(18) Remove wheel/tire assembly from safety cage.
END OF TASK
14-25
TM 08780B-20
NOTE
TM 08780B-20 Install wheel and tire (para 14-5).
1. Valve Core 6. Tire 11. Valve Stem Assembly

2. Capscrew (6) 7. Flange 12. Lock Ring Groove
3. Lockwasher (6) 8. Lock Ring 13. O-Ring Groove
4. Plate Flange Clamp (3) 9. O-Ring 14. Stop (2)
5. Tire Tool (2) 10. Rim Base 15. Flange Nut (6)
14-26
TM 08780B-20
14-7. TIRE MAINTENANCE (RUN FLAT)

b. Cleaning
c. Inspection
d. Assembly

Condition Condition
Tires equipped with run flat. TM 08780B-20 Wheel and tire
removed from vehicle
Special Tools (para 14-5).
Mounting Tool (1818)
Materials/Parts Rim and tire service can be dangerous if
Tire bead lubricant (item 61, Appendix D) proper procedures are not followed. To
Lockwasher (MS35338-50) item 3 prevent serious injury or death, follow task
O-ring (OR21TA) item 11 procedure carefully.
Valve stem (NSN 2640-01-103-3631) item 16
Filament tape (898) item 20 Do not take tire pressure readings or
Lube packets (823141) item 21 perform wheel/tire repairs without first
reading warnings or personal injury or death
may result.
Failure to comply with these procedures

may result in faulty positioning of the tire
and/or rim parts and cause the assembly to
burst with explosive force, sufficient to
cause serious physical injury or death.
Never mount or use damaged tires or rims.
a. Disassembly
WARNING
• WHEEL/TIRE ASSEMBLY MUST BE DEFLATED IN A SAFETY CAGE OR

PERSONAL INJURY OR DEATH MAY RESULT.
• ALWAYS COMPLETELY DEFLATE TIRE BY REMOVING VALVE CORE FROM

VALVE STEM BEFORE ATTEMPTING DEMOUNTING OPERATION. AFTER
AIR HAS FINISHED EXHAUSTING FROM VALVE STEM, CAREFULLY RUN A
PIECE OF WIRE THROUGH VALVE STEM TO ENSURE IT IS NOT PLUGGED
AND TIRE IS COMPLETELY DEFLATED. FAILURE TO COMPLY MAY
RESULT IN INJURY TO PERSONNEL.
14-27
TM 08780B-20
• STAND CLEAR OF TRAJECTORY AREA DURING DEFLATION OR PERSONAL

1. Valve Core 6. Mounting Tool Capscrews 11. O-Ring

2. Capscrew (6) 7. Rim Base 13. Lock Ring Groove
3. Lockwasher (6) 8. Mounting Feet 14. O-Ring Groove
4. Plate Flange Clamp (3) 9. Flange 15. Tire
5. Mounting Tool 10. Lock Ring 16. Valve Stem
Assembly
14-28
TM 08780B-20
WARNING
HIGH AIR PRESSURE MAY BE RELEASED FROM VALVE STEM WHEN VALVE CORE
IS REMOVED. STAY CLEAR OF VALVE STEM AFTER CORE IS REMOVED. ENSURE
ALL PERSONNEL WEAR SUITABLE EYE PROTECTION. FAILURE TO COMPLY MAY
RESULT IN SERIOUS INJURY TO PERSONNEL.
CAUTION
(1) Place wheel assembly in a safety cage and remove valve core (1). Allow
all air to escape.
(2) Remove six capscrews (2), six lockwashers (3) and three plate flange
clamps (4). Discard lockwashers (3).
(3) Place wheel and tire assembly on wooden blocks, flange side up.
(4) Install mounting tool (5) by placing mounting tool capscrews (6) through
holes in rim base (7) and into mounting feet (8).
(5) Tighten mounting tool capscrews (6) to compress flange (9) far enough to
expose lock ring (10) and O-ring (11).
(6) Tap one tire tool (12) in between flange (9) and lock ring (10) at
separation in lock ring (10). Pry lock ring (10) up from flange (9). Remove lock ring (10) from
lock ring groove (13).
(7) Remove, cut in two and discard O-ring (11) from O-ring groove (14).
(8) Remove mounting tool (5).
WARNING
FLANGE IS HEAVY. TO AVOID PERSONAL INJURY, USE CARE WHEN REMOVING

IT.
(9) Using two tire tools (12) pry flange (9) from rim base (7).
WARNING
• RIM BASE IS HEAVY. TO AVOID PERSONAL INJURY, USE CARE WHEN

REMOVING IT.
14-29
TM 08780B-20
• RIM BASE MAY DROP AS TIRE IS TURNED OVER. USE CARE TO PREVENT
PERSONAL INJURY.
(10) Turn wheel and tire assembly over.
(11) Place curved end of two tire tools (12) between tire (15) and rim base (7)
about five inches apart.
(12) Pry down with both tire tools (12).
(13) Leave one tire tool (12) in place and slide the second tire tool (12) five
inches around rim base (7). Pry down. Repeat until bead is free.
(14) Lift rim base (7) straight up and remove it from tire (15).
(15) Remove and discard valve stem assembly (16).
(16) Lay tire (15) on its side and remove four capscrews (17) and nuts (18)
from two halves of the run flat (19) inside tire (15).
(17) Remove two halves of run flat (19).
(18) Remove filament tape (20) and lube packets (21).
b. Cleaning
(1) Use wire brush to clean all dirt, rust and corrosion from wheel.
(2) Clean lock ring groove (13) and O-ring groove (14) thoroughly.
c. Inspection
WARNING
DO NOT WELD, HEAT OR BRAZE WHEEL PARTS THAT ARE CRACKED, BENT,
BROKEN OR DAMAGED. REPAIRED PARTS MAY NOT HOLD UP IN SERVICE.
ALWAYS REPLACE WITH NEW PARTS OF SAME SIZE AND TYPE.
(1) Inspect tire tread for nails, glass and other foreign particles and for
irregular wear, cuts and blisters.
(2) Inspect bead of tire for damaged rim seal ridges.
14-30
TM 08780B-20
(3) Inspect complete inside surface of inner liner for imperfections,

discoloration or irregular surface that may indicate excessive heat or other fabric damage.
(4) Check rim for cracks, dents, dirt and rust, especially in the lock ring
groove.
(5) Paint wheel assembly parts as needed to protect against rust.
(6) Do not use a lock ring or side ring if they are bent, distorted, cracked or
heavily corroded. Destroy all damaged parts.
(7) Remove rust, gummy rubber deposits, nicks and gouges in the rim bead
seat surfaces.
(8) Inspect lube packets (21). Replace if not intact.
15. Tire 20. Filament Tape

17. Capscrew (4) 21. Lube Packet
18 Nut (4) 22. Extended Ribs
19. Run Flat 23. Tire Bead
d. Assembly
WARNING
THREE PIECE RIMS HAVE PART NUMBERS STAMPED ON THEM. USE ONLY
EXACT REPLACEMENT PARTS. PART NUMBERS MUST MATCH PARTS BEING
REPLACED. SERIOUS INJURY OR DEATH COULD RESULT IF WHEEL SHOULD
BURST DUE TO MISMATCHED PARTS.
14-31
TM 08780B-20
CAUTION
(1) Stand half of run flat (19) on end.
(2) Use one lube packet (21) on each side of run flat (19) on outside surface,
five inches (12.70 cm) from ends of run flat (19). Make sure jell in lube packet (21) is spread
evenly.
CAUTION
USE CARE WHEN TAPING LUBE PACKETS (21) OR THEY MAY RUPTURE. IF A
LUBE PACKET (21) RUPTURES, IT MUST BE REPLACED.
(3) Using filament tape (20), double wrap both ends of lube packets (21) to
the run flat (19). Do not wrap filament tape (20) on extended ribs (22).
(4) Double wrap lube packets (21) about four and a half inches (11.43 cm)
from each end. Do not wrap filament tape (20) on extended ribs (22).
(5) Repeat steps (1) thru (4) with other half of run flat (19 ).
CAUTION
BE CAREFUL WHEN INSTALLING RUN FLAT (19). IF LUBE PACKET (21)

RUPTURES, IT MUST BE REPLACED.
(6) Carefully install half of run flat (19) completely inside tire (15) with lube
packets (21) facing tire tread. If necessary, use pry bars to spread tire beads (23) for clearance.
(7) Carefully install other half of run flat (19). Align capscrew holes. Install
four capscrews (17) and nuts (18). Torque capscrews (17) to 150-175 foot-pounds (203-237
N*m).
(8) Position run flat (19) evenly around the tire (15).
(9) Install new valve stem assembly (16) in rim base (7). Valve stem
assembly (16) must be installed facing down.
(10) Align an extended rib (22) between notches of inboard driver (24) at a 90
degree angle from capscrews (17). Install rim base (7). Make sure an extended rib (22) is
aligned between notches of inboard driver (24).
14-32
TM 08780B-20
7. Rim Base
13. Lock Ring Groove
14. O-Ring Groove
15. Tire
16. Valve Stem Assembly
17. Capscrew (4)
19. Run Flat
22. Extended Rib
24. Inboard Drivers
WARNING
RIM BASE (7) MAY DROP AS TIRE IS TURNED OVER. USE CARE TO PREVENT
PERSONAL INJURY.
(11) Turn assembly over onto wooden blocks with grooved side of rim base (7)
facing up.
(12) Align flange nuts (25) with stops (26) in rim base (7). Using a soft-faced
hammer, tap flange (9) onto rim base (7).
(13) Lubricate O-ring (11) with tire bead lubricant.
(14) Place O-ring (11) and lock ring (10) on flange (9). Do not attempt to
install at this time.
14-33
TM 08780B-20
7. Rim Base
9. Flange
25. Flange Nuts
26. Stops
5. Mounting Tool 10. Lock Ring

6 Mounting Tool Capscrew (4) 11. O-Ring
7. Rim Base 13. Lock Ring Groove
8. Mounting Feet 14. O-Ring Groove
9. Flange
CAUTION
TO AVOID DAMAGING O-RING, USE CARE WHEN INSTALLING MOUNTING TOOL

(5).
NOTE
Make sure that O-ring (11) and lock ring (10) are positioned so that the mounting tool
capscrews (6) go though the center of O-ring (11) and lock ring (10).
(15) Install mounting tool (5) by placing mounting tool capscrews (6) through
holes in rim base (7) and into mounting feet (8).
14-34
TM 08780B-20
(16) Tighten mounting tool capscrews (6) of mounting tool (5) until O-ring and
lock ring grooves (13 and 14) of rim base (7) are exposed.
(17) Install lock ring (10) into top lock ring groove (13).
NOTE
Be sure beveled edge of lock ring faces flange (9).
(18) Stretch O-ring (11) around O-ring groove (14) and snap into place. Do not
roll O-ring (11).
(19) Loosen mounting tool capscrews (6) of mounting tool (5).
(20) Check lock ring (10), flange (9) and rim base (7) for proper assembly. If
not correct, disassemble and fix problem.
(21) Remove mounting tool (5).
(22) Pry up flange (9) while tapping rim base (7) with a soft-faced hammer to
seat flange (9) against lock ring (10).
NOTE
Plate flange clamps (4) are stamped RF to indicate run flat. Install plate flange clamps (4) so
that the RF stamp will show. If new plate flange clamps (4) are used, they must be stamped
RF.
(23) Install plate flange clamps (4) with new lockwashers (3) and capscrews
(2).
(24) Torque capscrews (2) to 70 foot-pounds (95 N*m).
WARNING
• TO PREVENT PERSONAL INJURY OR 10 DEATH:
• FAILURE TO PLACE WHEEL/TIRE ASSEMBLY IN SAFETY CAGE PRIOR TO

INITIAL INFLATION COULD RESULT IN SERIOUS INJURY OR DEATH TO
PERSONNEL.
• WHEN A WHEEL/TIRE ASSEMBLY IS IN A RESTRAINING DEVICE, DO NOT

REST OR LEAN ANY PART OF BODY OR EQUIPMENT ON OR AGAINST THE
RESTRAINING DEVICE OR INJURY OR DEATH MAY RESULT.
(25) Place assembly in safety cage. Install valve core (1).
14-35
TM 08780B-20
1. Valve Core
2. Capscrew (6)
3. Lockwasher (6)
4. Plate Flange Clamp (3)
7. Rim Base
9. Flange
10. Lock Ring
11. O-Ring
13. Lock Ring Groove
14. O-Ring Groove
WARNING
• WHILE CHANGING TIRES OR WHILE PERFORMING TIRE MAINTENANCE,

STAY OUT OF THE TRAJECTORY AREA AS SHOWN BY THE AREA
INDICATED. FAILURE TO FOLLOW PROPER PROCEDURES MAY RESULT IN
INJURY OR DEATH TO PERSONNEL. IMPROPERLY SEATED LOCK RINGS
AND FLANGE MAY BLOW OFF DURING INFLATION. NEVER ATTEMPT TO
SEAT A LOCK RING OR FLANGE DURING OR AFTER INFLATION. SERIOUS
• WHEN INFLATING TIRES, ALWAYS USE AN INFLATION HOSE WITH AN IN-

LINE GAUGE AND A CLIP-ON CHUCK. THE GAUGE AND VALVE MUST BE
MOUNTED A MINIMUM OF TEN FEET (3 M) AWAY FROM AIR CHUCK.
• ALL PERSONNEL MUST REMAIN A MINIMUM OF TEN FEET (3 M) AWAY

FROM TIRE AND NOT IN POSSIBLE PATH OF LOCK RING OR FLANGE.
FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH.
• DO NOT INFLATE ABOVE 3 PSI (20 KPA) OR PERSONAL INJURY OR DEATH

MAY RESULT.
• NO ATTEMPT SHALL BE MADE TO CORRECT THE SEATING OF FLANGES

AND LOCK RINGS BY HAMMERING, STRIKING OR FORCING THE
COMPONENTS WHILE THE TIRE IS PRESSURIZED OR DAMAGE OR INJURY
14-36
TM 08780B-20
• WHENEVER MULTI-PIECE RIM WHEELS ARE BEING HANDLED,

PERSONNEL SHALL STAY OUT OF THE TRAJECTORY AREA UNLESS THE
SUPERVISOR CAN DEMONSTRATE THE PERFORMANCE OF THE
SERVICING MAKES THE PERSONNEL'S PRESENCE IN THE TRAJECTORY
AREA NECESSARY OR DAMAGE OR INJURY OR DEATH MAY RESULT.
(26) Using an inflation hose with an in-line gauge and clip-on chuck, inflate
tire to three psi (20 kPa). Check for correct assembly.
WARNING
IMPROPERLY SEATED LOCK RINGS OR FLANGES MAY BLOW OFF AT ANY TIME.
NEVER ATTEMPT TO SEAT A LOCK RING OR FLANGE DURING OR AFTER
INFLATION. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH.
(27) If assembly is not correct, deflate, disassemble and correct.
WARNING
NEVER INFLATE TIRE OVER 40 PSI (276 KPA) TO SEAT TIRE BEADS. IF BEADS DO
NOT SEAT, DEFLATE, DEMOUNT AND CHECK TIRE/RIM PARTS. RELUBRICATE
AND REMOUNT TIRE. SERIOUS INJURY OR DEATH COULD RESULT IF THESE
PROCEDURES ARE NOT FOLLOWED.
(28) If assembly is correct, continue inflation to 20 psi (138 kPa).
WARNING
ENSURE THAT TIRE AND RIM PARTS ARE IN PROPER POSITION AND THAT TIRE
LOWER SIDEWALL CIRCUMFERENTIAL GROOVE TO THE TOP OF THE RIM
FLANGE DOES NOT VARY MORE THAN 1/8 IN. (3.2 MM) AND THAT EACH BEAD
DOES NOT VARY MORE THAN 1/8 IN. (3.2 MM) AROUND THE CIRCUMFERENCE OR
FROM ONE BEAD TO THE OTHER. MEASUREMENTS EXCEEDING 1/8 IN. (3.2 MM)
REQUIRE UNSEATING TIRE BEADS, RELUBRICATING TIRE BEADS AND
REMOUNTING TIRE OR SERIOUS INJURY OR DEATH MAY RESULT WHEN TIRE IS
REMOVED FROM SAFETY CAGE.
(29) Inflate wheel/tire assembly to 110 psi (758 kPa) and check tire/rim parts
for proper assembly.
(30) If assembly is not correct, deflate, disassemble and reposition parts.

Relubricate parts and repeat steps (26 thru 29).
(31) Install valve cap.
14-37
TM 08780B-20
(32) Remove wheel/tire assembly from safety cage.
END OF TASK
NOTE
TM 08780B-20 Install wheel and tire (para 14-5).
14-38
TM 08780B-20
CHAPTER 15
STEERING SYSTEM
maintenance and replacement procedures for the vehicle's steering system.
a. General Description. The steering gear is a conventional power-assist type. It is

connected to a bell crank by a pitman arm and a drag link. The bell crank coordinates the
steering action of the front axle with two double acting yaw cylinders, using a yaw control valve
and a mechanical feedback linkage. Hydraulic pressure for the steering system is provided by an
engine driven tandem pump through flow control valves.
b. Steering Wheel. Rotates the steering shafts to actuate the steering system.
c. 90 Degree Gear Boxes (2). Changes direction of rotating steering shafts.
d. Steering Shafts (2). Connect steering wheel to 90 degree gear boxes and 90
degree gear boxes to steering gear.
e. Steering Gear. Hydraulically multiplies torque of steering wheel and transfers it

to the pitman arm.
f. Pitman Arm. Transfers steering torque to the upper drag link.
g. Upper Drag Link. Connects pitman arm to bell crank.
h. Bell Crank. Transfers motion of steering gear to front axle and to yaw control
valve and mechanical feedback linkage.
i. Yaw Control Valve. Directs hydraulic pressure through the motion control valve,
to the yaw cylinders.
j. Feedback Linkage. Maintains alignment between front and rear bodies.
k. Yaw Cylinders. Double acting hydraulic cylinders.
l. Motion Control Valve. Meters hydraulic pressure to the yaw cylinders.
15-1
TM 08780B-20
15-2
TM 08780B-20
15-3. STEERING WHEEL REPLACEMENT

c. Installation

Condition Condition
disconnected
(para 7-43).
Wheels straight ahead

(para 15-17), task c,
step (1).

a. Removal
(1) Depress horn button (1) and turn 1/4 turn counterclockwise.
(2) Remove horn button (1), cup (2) and spring (3).
(3) Remove two short screws (4) and long screw (5). Note location of long
screw (5).
(4) Remove base plate (6).
(5) Remove nut (7).
(6) Using puller, remove steering wheel (8) from steering column (9).
(7) Turn steering wheel (8) over and remove two screws (10).
(8) Remove contact plate (11) from steering wheel (8). Note position of
screws (10).
15-3
TM 08780B-20
c. Installation
NOTE
Position two screw holes on bottom of steering wheel (8) and line up plate (11) accordingly.
(1) Position contact plate (11) on bottom side of steering wheel (8) and secure
with two screws (10).
(2) Center steering wheel (8) over steering column (9) aligned for straight
ahead and install.
(3) Install nut (7) and tighten securely.
(4) Secure base plate (6) with two short screws (4) and long screw (5).
(5) Install spring (3), cup (2) and horn button (1) by depressing and turning
clockwise until horn button (1) seats.
END OF TASK
NOTE
TM 08780B-20 Connect batteries (para 7-43).
TM 08780B-10 Test horn operation (para 2-1).
15-4
TM 08780B-20
1. Horn Button
2. Cup
3. Spring
4. Short Screw (2)
5. Long Screw
6. Base Plate
7. Nut
8. Steering Wheel
9. Steering Column
10. Screw (2)
11. Contact Plate
15-5
TM 08780B-20
15-4. STEERING COLUMN REPLACEMENT

c. Installation

Condition Condition
disconnected
Lockwasher (2) (MS35338-46) item 7 Wheel straight ahead
General Safety Instructions step (1).
To prevent personal injury, make sure batteries Turn signal switch
are disconnected before working on electrical removed (para 7-16).
components.
Steering wheel and
horn kit removed
(para 15-3).
Instrument panel
opened to expose
wiring harness (para
7-11).
a. Removal
(1) Disconnect horn wire (1) at quick disconnect under dash panel, behind
steering column (2).
(2) Remove clamping-capscrew (3) and locknut (4) from end yoke (5).
(3) Spread end yoke (5) slightly with drift pin.
(4) Remove two capscrews (6), lockwashers (7) and nuts (8) that hold steering
column (2) and front and rear caps (9) to steering column brace (10). Discard lockwashers (7).
(5) Lower steering column (2). Remove two caps (9) and two pads (11).
(6) Slide steering column (2) out of end yoke (5) and remove.
15-6
TM 08780B-20
c. Installation
(1) Insert steering column spline (12) into end yoke (5).
(2) Secure steering column (2) to steering column brace (10) with caps (9),
two pads (11), two capscrews (6), new lockwashers (7) and nuts (8).
(3) Tighten capscrews (6) and nuts (8) securely.
(4) Install clamping capscrew (3) and new locknut (4) into end yoke (5).
Tighten securely.
(5) Connect horn wire (1) to quick disconnect (13).
END OF TASK
NOTE
TM 08780B-20 Replace instrument panel (para 7-11).
Install turn signal switch (para 7-16).
Install steering wheel with horn button kit

(para 15-3).
15-7
TM 08780B-20
1. Horn Wire 8. Nut (2)

2. Steering Column 9. Cap (2)
3. Clam Ping-Capscrew 10. Steering Column Brace
4. Locknut 11. Pad (2)
5. End Yoke 12. Steering Column Spline
6. Capscrew (2) 13. Quick Disconnect
7. Lockwasher (2)
15-8
TM 08780B-20
15-5. STEERING COLUMN REPAIR

c. Assembly

Condition Condition
MK48 TM 08780B-20 Steering column
Materials/Parts
References
TM 08780B-10
a. Disassembly
(1) Remove spacer (1) and upper spring seat (2) from housing (3).
(2) Remove dust cap (4), spring (5) and lower spring seat (6) from tube (7).
Remove shaft (8) from tube (7).
(3) Remove bearing (9) from tube (7).
(4) Remove contact (10) from housing (3). Carefully pull wire (11) from tube
(7).
(5) Remove tube (7) from housing (3).
CAUTION
TO PREVENT DAMAGE TO BEARING (12), REMOVE BY PRESSING AGAINST OUTER

BEARING SHELL ONLY.
(6) Using a press, remove bearing (12) from housing (3).
15-9
TM 08780B-20
c. Assembly
CAUTION
TO PREVENT DAMAGE TO BEARING (12), PRESS AGAINST OUTER BEARING

SHELL ONLY.
(1) Using a press, install bearing (12) into housing (3).
(2) Install housing (3) onto tube (7) and bend retainer clips.
(3) Install contact (10) by feeding wire (11) through housing (3) and tube (7).
Push contact (10) firmly into housing (3).
(4) Pressing on outer bearing shell only, install bearing (9) into tube (7).
(5) Using grease, lightly coat shaft (8). Install shaft (8) through tube (7) and
housing (3).
(6) Install lower spring seat (6) into tube (7).
(7) Install spring (5) and dust cap (4) into tube (7).
(8) Install upper spring seat (2) and spacer (1) over shaft (8).
END OF TASK
NOTE
TM 08780B-20 Install steering column (para 15-4).
15-10
TM 08780B-20
1. Spacer 7. Tube
2. Upper Spring Seat 8. Shaft
3. Housing 9. Bearing
4. Dust Cap 10. Contact
5. Spring 11. Wire
6. Lower Spring Seat 12. Bearing
15-11
TM 08780B-20
15-6. STEERING LINKAGE AND UNIVERSAL JOINT MAINTENANCE


Condition Condition
MK48 TM 08780B-20 Frame 90 degree gear
box removed (para
Cab 90 degree gear
Personnel Required box removed (para
1 MOS 3521 15-11).
1 Assistant
injury.
NOTE
All three end yoke assemblies are removed and disassembled in the same way. They differ
only in location. To remove or disassemble any one of the three, follow steps (1) thru (4)
below.
(1) Remove clamping capscrew (1) and nut (2) from yoke (3).
(2) Spread end yoke (3) slightly and remove end yoke assembly (4). Remove
two keys (5).
(3) Remove four snap rings (6) from bearing caps (7).
(4) Remove four bearing caps (7) and universal-joint (8).
(5) With assistant holding nuts (9), remove three capscrews (10), nuts (9) and
lockwashers (11) from two bearing supports (12). Discard lockwashers (11).
(6) Remove carrier bearing (13) and linkage (14).
(7) Remove carrier bearing (13) from linkage (14).
15-12
TM 08780B-20
(2) Inspect end yokes and linkage for trueness, cracks, peening or burrs.
(3) Inspect carrier bearing for binding.
(1) Insert linkage (14) into carrier bearing (13).
CAUTION
BE SURE TO INSTALL BOTH CARRIER BEARING SUPPORTS (12) INSIDE CAB.
(2) With help from assistant, secure carrier bearing (13) with two carrier
bearing supports (12) into place using three capscrews (10), new lockwashers (11) and nuts (9).
(3) Install two keys (5) onto linkage (14).
(4) Install universal-joint (8) into end yokes (3) with four bearing caps (7).
(5) Install four snaprings (6) on bearing caps (7).
(6) Slide end yoke assembly (4) onto linkage (14).
(7) Secure end yoke assembly (4) with clamping capscrew (1) and nut (2).
END OF TASK
NOTE
TM 08780B-20 Install frame 90 degree gear box
(para 15-12).
Install cab 90 degree gear box (para 15-11).
15-13
TM 08780B-20
1. Clamping Capscrew (2) 8. Universal-Joint

2. Nut (2) 9. Nut (3)
3. End Yoke (2) 10 Capscrew (3)
4. End Yoke Assembly 11. Lockwasher (3)
5. Key (2) 12. Carrier Bearing Support (2)
6. Snapring (4) 13. Carrier Bearing
7. Bearing Cap (4) 14. Linkage
15-14
TM 08780B-20
15-7. DRAG LINK MAINTENANCE

c. Disassembly
d. Adjustment
e. Installation

Condition Condition
MK48 TM 08780B-20 Left front tire
Special Tools
Torque adapter (SRES28) General Safety Instructions
Materials/Parts injury.
Anti-seize compound (item 10, Appendix D)
Cotter pin (4) (MS24665-360) item 1
a. Removal
NOTE
Upper and lower drag links are removed in same manner.
(1) Remove and discard two cotter pins (1).
(2) Remove castle nuts (2 and 3).
(3) Using a drag link removal tool and hammer, remove socket assemblies (4
and 5). Remove upper drag link assembly (6).
(4) Repeat steps (1) thru (3) for lower drag link assembly (7).
c. Disassembly
(1) Remove clamping capscrew (8) and nut (9) from clamp (10).
15-15
TM 08780B-20
(2) Unscrew adjustable socket assembly (5) from drag link assemblies
(6 and 7).
(3) Remove grease fittings (11) if damaged.
(3.1) Remove dust covers (11.1) and (11.2), if damaged.
d. Adjustment
(1) Coat threads of adjustable socket assembly (5) with anti-seize compound
and install on ends of drag links (6 and 7).
NOTE
Adjustment for drag links (upper and lower) are the same except as noted.
(2) Turn adjustable end socket assembly (5) in or out of drag link (6 and 7), as
required. To set proper length, measure from center of socket assembly (5) to center of socket
assembly (4).
(a) Length for upper drag link (6) must be 30 inches (76.2 cm).
(b) Length for lower drag link (7) must be 28 inches (71.1 cm).
NOTE
Socket assemblies on upper drag link face opposite each other. Socket assemblies on lower
drag link are at 90 degree angles to each other as shown.
(3) Snug locking clamp (10) with clamping capscrew (8) and nut (9). Do not
tighten.
e. Installation
(1) If removed, install grease fittings (11).
(2) If removed, install dust covers (11.1) and (11.2).
(3) Coat threads of socket assemblies (4 and 5), with anti-seize compound.
(4) Install upper drag link assembly (6) as follows:
(a) Insert socket assembly (5) into pitman arm (12).
(b) Insert socket assembly (4) into top hole of bell crank (13).
(c) Secure socket assembly (4) with castle nut (3). Torque castle nut
(3) to 110-125 foot-pounds (149-170 N*m).
15-16
TM 08780B-20
(d) Secure socket assembly (5) with castle nut (2). Torque castle nut
(2) to 90-100 foot-pounds (122-135.6 N*m).
(5) Install lower drag link assembly (7) as follows:
(a) Insert socket assembly (5) into steering arm (14).
(b) Insert socket assembly (5) into lower hole of bell crank (13).
(c) Secure socket assemblies (4 and 5) with castle nuts (2 and 3).
Torque castle nuts (2 and 3) to 110-125 foot-pounds (149-170 N*m).
(6) Turn clamp (10) for maximum clearance of truck chassis. Torque
clamping capscrew (8) to 50-60 foot-pounds (67.8-81.4 N*m).
(7) If necessary, tighten castle nuts (2 or 3) further to align holes for cotter
pins (1). Do not back castle nuts (2 or 3) off to align holes. Install new cotter pins (1).
END OF TASK
NOTE
TM 08780B-20 Install left front tire (para 14-5).
Check steering alignment (para 15-17).
LI 2320-12/9 Grease socket assemblies.

LO 9-2320-297-12
15-17
TM 08780B-20
1. Cotter Pin (4) 9. Nut (2)

2. Castle Nut (2) 10. Clamp (2)
3. Castle Nut (2) 11. Grease Fitting (4)
4. Socket Assembly (2) 11.1. Dust Cover (2)
5. Socket Assembly (2) 11.2. Dust Cover (2)
6. Upper Drag Link Assembly 12. Pitman Arm
7. Lower Drag Link Assembly 13. Bell Crank
8. Clamping Capscrew (2) 14. Steering Arm
15-18
TM 08780B-20
15-8. TIE ROD MAINTENANCE

b. Disassembly
d. Assembly
e. Installation
INITIAL SETUP

injury.
Materials/Parts
Anti-seize compound (item 10, Appendix D)
a. Removal
(1) Remove and discard cotter pin (1).
(2) Remove castle nut (2).
(3) Using removal tool and hammer, remove tie rod end (3) from tie rod arm
(4).
(4) Repeat steps (1), (2) and (3) for other end of tie rod (5).
(5) Remove tie rod (5) assembly from under truck and place on bench.
b. Disassembly
(1) Remove capscrew (6) and locknut (7). Discard locknut (7).
NOTE
Left tie rod end has left hand threads and right tie rod end has right hand threads.
(2) Remove two tie rod ends (3) and record number of turns needed for
removal.
15-19
TM 08780B-20
d. Assembly
CAUTION
THREADS OF TIE ROD END (3) MUST EXTEND BEYOND SLOT IN TIE ROD (5).
(1) Coat threads of tie rod ends (3) with anti-seize compound and thread into
tie rod (5), using same number of turns as recorded during removal.
(2) Install capscrew (6) and new locknut (7). Do not tighten at this time.
e. Installation
(1) Place tie rod (5) assembly under front of truck, behind front wheels. Make
sure that right hand threaded tie rod end (3) is on the right side of truck.
NOTE
Make sure tie rod end (3) is installed beyond end of slot in tie rod arm (4).
(2) Install tie rod end (3) into tie rod arm (4).
(3) Install castle nut (2).
(4) Torque castle nut (2) to 125 foot-pounds (169.5 N*m) then continue to
tighten until new cotter pin (1) can be inserted.
(5) Repeat steps (2), (3) and (4) for other end of tie rod (5).
END OF TASK
NOTE
TM 08780B-20 Adjust toe-in (para 15-17).
15-20
TM 08780B-20
1. Cotter Pin
2. Castle Nut
3. Tie Rod End
4. Tie Rod Arm
5. Tie Rod
6. Capscrew
7. Locknut
15-21
TM 08780B-20
15-9. PITMAN ARM MAINTENANCE

c. Installation

Condition Condition
MK48 TM 08780B-20 Left front tire
Materials/Parts
Anti-seize compound (item 10, Appendix D) Upper drag link
Lockwasher (MS35338-48) item 2 removed (para 15-7).
Flat washer (MS27183-18) item 8
Capscrew (MS90727-128) item 9 Wheels straight
ahead (para 15-17),
task c, step (1).

injury.
a. Removal
CAUTION
DO NOT HEAT, POUND ON OR WELD THE PITMAN ARM. ANY OF THESE COULD
CAUSE THE PITMAN ARM TO FAIL IN SERVICE.
(1) Remove capscrew (1), lockwasher (2) and flat washer (3).
(2) Remove two locking set screws (4).
(3) Using puller, remove pitman arm (5) from steering gear output shaft (6).
15-22
TM 08780B-20
c. Installation
(1) Align timing marks on steering gear output shaft (6) and pitman arm (5).
Move pitman arm (5) one notch clockwise as shown.
(2) Start pitman arm (5) onto steering gear output shaft (6).
(3) Using a 1-7/8 inch socket (7), a flat washer (8) and installing capscrew (9)
long enough (4 1/4 to 4 1/2 inches, 108 to 114 mm) to draw pitman arm (5) onto steering gear
output shaft (6).
NOTE
The output shaft must not extend beyond pitman arm more than 3/64 inch (1.19 mm). After
torquing, it may recess slightly.
(4) Torque installing capscrew (9) to 85 foot-pounds (115.26 N*m).
(5) Remove flat washer (8), installing capscrew (9) and socket (7).
(6) Coat threads of locking set screws (4) and capscrew (1) with anti-seize
compound.
(7) Install capscrew (1), new lockwasher (2) and flat washer (3). Torque
capscrew (1) to 65 foot-pounds (88 N*m).
(8) Install two locking set screws (4). Torque to 10-12 foot-pounds (13.6-
16.27 N*m).
END OF TASK
NOTE
TM 08780B-20 Replace upper drag link (para 15-7).
Install left front tire (para 14-5).
15-23
TM 08780B-20
1. Capscrew
2. Lockwasher
3. Flat Washer
4. Locking Set Screw (2)
5. Pitman Arm
6. Steering Gear Output Shaft
7. Socket (Tool)
8. Flat Washer
9. Installing Capscrew
15-24
TM 08780B-20
15-10. BELL CRANK MAINTENANCE

c. Installation

Condition Condition
MK48 TM 08780B-20 Remove yaw control
valve (para 22-5), task
a, steps (5), (6) and
Materials/Parts (7).
Grease (item 21, Appendix D) Disconnect rear of
Lockwasher (4) (MS35338-45) item 2 upper and lower drag
Seal (P/N 23703) item 11 links (para 15-7),
Locknut (6) (5310-00-186-0567) item 16 items 6 and 7.
References Remove vehicle

TM 08780B-20 step (para 18-7).
LI 2320-12/9
LO 9-2320-297-12 General Safety Instructions
injury.
a. Removal
(1) Remove four capscrews (1), lockwashers(2) and cover (3). Discard
lockwashers (2).
(2) Bend tabs of lockwasher (4) and remove locknut (5), lockwasher (4),
locknut (6) and torque washer (7).
NOTE
Do not mix bearing cones. They are mated with bearing cups.
(3) Tag and remove outer bearing cone (8) from bell crank (9).
(4) Remove bell crank (9) from bell crank bracket (10).
(5) Remove and discard seal (11).
(6) Tag and remove inner bearing cone (12) from bell crank (9).
15-25
TM 08780B-20
(7) Tag and remove outer bearing cup (13) from bell crank (9). Tag and
remove inner bearing cup (14) from bell crank (9).
NOTE
Grease fitting may be located on either side of bell crank.
(8) If damaged, remove grease fitting (15).
(9) If damaged, remove bell crank bracket (10) by removing six locknuts (16)
and capscrews (17). Discard locknuts (16).
1. Capscrew 10. Bell Crank Bracket

2. Lockwasher (4) 11. Seal
3. Cover 12. Inner Bearing Cone
4. Lockwasher 13. Outer Bearing Cup
5. Locknut 14. Inner Bearing Cup
6. Locknut 15. Grease Fitting
7. Torque Washer 16. Locknut (6)
8. Outer Bearing Cone 17. Capscrew (6)
9. Bell Crank
15-26
TM 08780B-20
(2) Inspect bearing cones (8 and 10) and bearing cups (12 and 13) for pits,
cracks or scoring.
c. Installation
(1) If removed, install bell crank bracket (10) using six capscrews(17) and
new locknuts (16).
(2) If removed, install grease fitting (15) into bell crank (9).
NOTE
Be sure inner and outer bearing cups (13 and 14) are seated in bell crank (9).
(3) Install inner bearing cup (14) into bell crank (9). Install outer bearing cup
(13) into bell crank (9).
(4) Pack inner and outer bearing cones (8 and 12) with grease.
(5) Install inner bearing cone (12) into bell crank (9).
(6) Install new seal (11) into bell crank (9). Lip of seal (11) must face inner
bearing cone (12).
(7) Slide inner bearing cone (12) and bell crank (9) onto bell crank bracket
(10).
(8) Slide outer bearing cone (8) onto bell crank bracket (10).
(9) Align tang (18) of torque washer (7) with slot (19) on bell crank bracket
(10). Install torque washer (7) onto bell crank bracket (10).
CAUTION
ADJUSTMENT OF LOCKNUT (6) IS VERY IMPORTANT. IT MUST BE TIGHT

ENOUGH TO ELIMINATE END PLAY BUT NOT TIGHT ENOUGH TO CAUSE
BINDING.
15-27
TM 08780B-20
(10) Install locknut (6) onto bell crank bracket (10). Tighten locknut (6) until
bell crank (9) movement becomes stiff. Loosen locknut (6) 1/3 turn.
(11) Install lockwasher (4) and locknut (5). Bend one or two tabs of
lockwasher (4) over locknuts (5 and 6).
(12) Apply silicone sealant to cover (3). Install cover (3) using four capscrews
(1) and new lockwashers (2). Tighten capscrews (1) securely.
END OF TASK
NOTE
TM 08780B-20 Install yaw control valve (para 22-5), task c,
steps (3), (4) and (5).
Connect rear of upper and lower drag links

(para 15-7), items 6 and 7.
Install vehicle step (para 18-7).
LI 2320-12/9 Lubricate bell crank and socket assembly.

LO 9-2320-297-12
15-28
TM 08780B-20
1. Capscrew 11. Seal

2. Lockwasher (4) 12. Inner Bearing Cone
3. Cover 13. Outer Bearing Cup
4. Lockwasher 14. Inner Bearing Cup
5. Locknut 15. Grease Fitting
6. Locknut 16. Locknut (6)
7. Torque Washer 17. Capscrew (6)
8. Outer Bearing Cone 18. Tang
9. Bell Crank 19. Slot
10. Bell Crank Bracket
15-29
TM 08780B-20
15-11. CAB 90 DEGREE GEAR BOX REPLACEMENT

b. Disassembly
d. Assembly
e. Installation

Condition Condition
disconnected
Star washer (4) (MS35335-63) items 17 and 20 Wheels straight
ahead (para 15-17),
task c, step (1).

a. Removal
Lean instrument panel (2) against steering wheel (4).
(2) Remove four capscrews (5) and lockwashers (6). This will permit
lowering of 90 degree gear box (7). Discard lockwashers (6).
(3) Remove three locking capscrews (8) and nuts (9) from end yokes (10 and
11).
(4) Spread end yokes (10 and 11).
(5) Remove 90 degree gear box (7).
b. Disassembly
(1) Slide padlock bracket (12) off shaft (13).
(2) Remove two keys (14) from keyways (15).
15-30
TM 08780B-20
(3) Remove two hex socket screws (16) and star washers (17). Discard star
washers (17).
(4) Remove lock bracket retainer (18).
(5) Remove two hex socket screws (19) and star washers (20). Discard star
washers (20).
(6) Remove steering lock assembly (21).
(2) Inspect all parts for breaks, chips, crossed threads, burrs or other damage.
d. Assembly
(1) Secure steering lock assembly (21) with two hex socket screws (19) and
new starwashers (20). Tighten securely.
(2) Secure lock bracket retainer (18) with two hex socket screws (16) and new
starwashers (17). Tighten securely.
(3) Install two keys (14) in keyways (15).
(4) Align padlock bracket (12) and slide on shaft (13).
e. Installation
(1) Align two shafts (13) and two keys (14) with end yokes (10 and 11).
(2) Insert two shafts (13) into end yokes (10 and 11).
15-31
TM 08780B-20
7. 90 Degree Gear Box

12. Padlock Bracket
13. Shaft (2)
14. Key (2)
15. Keyway (2)
16. Hex Socket Screw (2)
17. Star Washer (2)
18. Lock Bracket Retainer
19. Hex Socket Screw (2)
20. Star Washer (2)
21. Steering Lock Assembly
1. Screw (6)
2. Instrument Panel
3. Dash
4. Steering Wheel
5. Capscrew (4)
6. Lockwasher (4)
8. Locking Capscrew (3)
9. Nut (3)
10. End Yoke
11. End Yoke
15-32
TM 08780B-20
(3) Raise 90 degree gear box (7) into position. Secure with four capscrews (5)
and new lockwashers (6). Tighten capscrews (5) securely.
(4) Install three locking capscrews (8) and nuts (9) into end yokes (10 and 11).
Torque nuts (9) to 35-40 foot-pounds (47-54 N*m).
(5) Install instrument panel (2) with six screws (1). Tighten securely.
END OF TASK
NOTE
TM 08780B-20 Check steering alignment (para 15-17).
15-33
TM 08780B-20
15-12. FRAME 90 DEGREE GEAR BOX REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Wheels straight
ahead (para 15-17),
Materials/Parts task c, step (1).
Locknut (2) (MS51922-17) item 5 Skid plate grille

injury.
a. Removal
(1) Remove four capscrews (1), lockwashers (2) and flat washers (3). Discard
lockwashers (2).
(2) Loosen and remove two clamping screws (4) and locknuts (5) from end
yokes (6 and 7).
(3) Spread end yokes (6 and 7) slightly and remove 90 degree gear box (8).
(4) Remove two keys (9) from keyways (10).
(2) Inspect all parts for breaks, chips, crossed threads, burrs or other damage.
c. Installation
(1) Install two keys (9) into keyways (10).
(2) Align keys of shafts (11 and 12) with end yokes (6 and 7). Insert shafts
(11 and 12) into end yokes (6 and 7).
15-34
TM 08780B-20
(3) Install two clamping screws (4) and new locknuts (5) into end yokes (6
and 7). Torque locknuts (5) to 35-40 foot-pounds (47-54 N*m).
(4) Align mounting holes and secure 90 degree gear box (8) to mounting plate
(13) with four capscrews (1) new lockwashers (2) and flat washers (3). Tighten capscrews (1)
securely.
END OF TASK
NOTE
TM 08780B-20 Replace skid plate grille (para 18-16).
Check steering for proper operation

(para 15-17).
1. Capscrew (4)
2. Lockwasher (4)
3. Flatwasher (4)
4. Clamping Screw (27
5. Locknut (2)
6. End Yoke
7. End Yoke
9. Key (2)
10. Keyway (2)
11. Long Shaft
12. Shaft
13. Mounting Plate
15-35
TM 08780B-20
15-13. YAW FEEDBACK LINKAGE MAINTENANCE.

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK48 TM 08780B-20 Fuse link assembly
partially removed
Materials/Parts (para 15-15), task
Grease, GAA (item 21, Appendix D) a, steps (1), (2)
Cotter pin (2) (MS24665-285) item 1 and (3).
Cotter pin (MS24665-355) item 15 Wheels straight
ahead (para 15-17),
task c, step (1).

injury.
a. Removal
(1) Remove two cotter pins (1) and castle nuts (2). Discard cotter pins (1).
(2) Remove drag link (3) with socket assemblies (4 and 5) from yaw bell
crank assembly (6) and lever assembly (7).
(3) Remove four capscrews (8), lockwashers(9) and lever assembly (7).
CAUTION
NOTE LOCATION OF FLAT WASHER (12) BETWEEN CAPSCREW (10) AND YAW
BELL CRANK ASSEMBLY (6). IT MUST BE REPLACED TO INSURE PROPER
ATTACHMENT OF BELL CRANK TO CASTING.
(4) Remove four capscrews (10), nuts (11), one flat washer (12) and yaw bell
crank assembly (6).
15-36
TM 08780B-20
1. Cotter Pin (2) 7. Lever Assembly

2. Castle Nut (2) 8. Capscrew (4)
3. Drag Link 9. Lockwasher (4)
4. Socket Assembly (Left Hand) 10. Capscrew (4)
5. Socket Assembly (Right Hand) 11. Nut (4)
6. Yaw Bell Crank Assembly 12. Flat Washer
15-37
TM 08780B-20
b. Disassembly
(1) Secure pivot bracket (13) of yaw bell crank assembly (6) in vise with
mounting plate down.
(2) Carefully pry hub cap (14) off yaw bell crank assembly (6).
(3) Remove cotter pin (15), castle nut (16) and flat washer (17). Discard
cotter pin (15).
(4) Lift bell crank arm (18) off pivot bracket (13).
(5) Remove upper bearing cone (19) from bell crank arm (18).
(6) Push lower bearing cone (20) and seal (21) out of bottom of bell crank arm
(18).
(7) If replacing bearing cones (19 and 20), carefully tap bearing cups (22 and
23) from bell crank arm (18) using a drift pin.
CAUTION
NOTE LOCATION OF LOCKING CAPSCREWS (24), NUTS (25) AND CLAMPS (26)
WHEN DISASSEMBLING. IMPROPER ASSEMBLY OF CLAMPS, CAPSCREWS AND
NUTS COULD CAUSE INTERFERENCE CAUSING EQUIPMENT DAMAGE OR
IMPAIRED STEERING.
(8) Remove two locking capscrews (24), nuts (25) and clamps (26).
(9) Turn socket assemblies (4 and 5) out of drag link (3). Socket assembly (4)
has left hand thread, socket assembly (5) has right hand thread.
(2) Inspect bearing cones (19 and 20) for pits, corrosion, damaged or missing
rollers.
(3) Inspect socket assemblies (4 and 5) for play, cracks or corrosion.
(4) Inspect bell crank arm (18) and pivot bracket (13) for cracks, chips, breaks
or corrosion.
(5) Inspect drag link (3) and lever assembly (7) for cracks, chips, breaks or
corrosion.
15-38
TM 08780B-20
(6) Check for proper alignment between drag link (3) and lever assembly (7).
d. Assembly
(1) Thread socket assemblies (4 and 5) into drag link (3) until distance
between centers of socket assemblies is 20 inches (50.8 cm).
(2) Install clamps as removed (26) onto drag link (3) and secure with two
locking capscrews (24) and nuts (25).
3. Drag Link
4. Socket Assembly (Left Hand)
5. Socket Assembly (Right Hand)
13. Pivot Bracket
14. Hubcap
15. Cotter Pin
16. Castle Nut
17. Flat Washer
18. Bell Crank Arm
19. Bearing Cone (Upper)
20. Bearing Cone (Lower)
21. Seal
22. Bearing Cup (Upper)
23. Bearing Cup (Lower)
24. Capscrew (Locking) (2)
25. Nut (2)
26. Clamp (2)
(3) Hand tighten capscrews (24) and nuts (25). Final adjustment will be made
after installation.
(4) Pack new bearing cones (19 and 20) with grease.
(5) If removed, install new bearing cups (22 and 23) in bell crank arm (18).
(6) Install lower bearing cone (20) into bottom of bell crank arm (18).
(7) Install new seal (21), spring side down, over lower bearing cone (20).
15-39
TM 08780B-20
(8) Turn bell crank arm (18) over and install upper bearing cone (19).
(9) Slide bell crank arm (18) with bearing cones (19 and 20) onto pivot
bracket (13).
(10) Install flat washer (17) and castle nut (16) onto pivot bracket (13). Torque
castle nut (16) to 100 inch-pounds (11.3 N*m). Continue tightening to align slots for cotter pin
(15). Do not back castle nut (16) off to align slots.
(11) Tap bell crank arm (18) with soft-faced hammer to seat bearing cones (19
and 20). Make sure bell crank arm (18) turns freely without binding.
(12) Install new cotter pin (15) to secure castle nut (16).
(13) Tap hub cap (14) onto bell crank arm (18) with a soft-faced hammer until
seated.
e. Installation
(1) Secure yaw bell crank assembly (6) with four capscrews (10), one flat
washer (12), in location shown and four nuts (11).
(2) Secure lever assembly (7) with four capscrews (8) and new lockwashers
(3) Install drag link (3) with left hand threaded socket assembly (4) at lever
assembly (7). Install right hand threaded socket assembly (5) at yaw bell crank assembly(6).
(4) Install two castle nuts (2) on socket assemblies (3 and 4). Torque castle
nuts (2) to 17-25 foot-pounds (23-34 N*m). Continue tightening to align slots for cotter pins (1).
Do not back castle nuts (2) off to align slots.
(5) Install two new cotter pins (1) to secure castle nuts (2).
END OF TASK
NOTE
TM 08780B-20 Install fuse link assembly (para 15-15).
15-40
TM 08780B-20
1. Cotter Pin (2)

2. Castle Nut (2)
3. Drag Link
4. Socket Assembly (Left Hand)
5. Socket Assembly (Right Hand)
6. Yaw Bell Crank Assembly
7. Lever Assembly
8. Capscrew (4)
9. Lockwasher (4)
10. Capscrew (4)
11. Nut (4)
12. Flat Washer
15-41
TM 08780B-20
15-14. STEERING SHAFT ASSEMBLY MAINTENANCE

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK48 TM 08780B-20 Frame 90 degree
gear box removed
injury.
a. Removal
(1) Remove clamping capscrew (1) and locknut (2), from splined yoke (3).
(2) Spread splined yoke (3) slightly as needed. Slide splined yoke (3) off
from steering gear (4) and input shaft (5).
(3) Remove steering shaft assembly (6) from vehicle.
1. Clamping Capscrew
2. Locknut
3. Splined Yoke
4. Steering Gear
5. Input Shaft
6. Steering Shaft Assembly
15-42
TM 08780B-20
b. Disassembly
(1) Slide splined shaft (7) out of yoke sleeve assembly (8).
(2) Remove dust cover (9) and gasket (10) from yoke sleeve assembly (8).
NOTE
Disassemble U-joint only if it fails inspection. Procedure for U-joints (11 and 12) is the same.
Repeat steps (3) and (4) for either U-joint.
(3) Remove four snaprings (13) from bearing caps (14).
(4) Remove four bearing caps (14) and U-joint (11 or 12).
(5) Remove three grease fittings (15, 16 and 17).
7. Splined Shaft
8. Yoke Sleeve Assembly
9. Dust Cover
10. Gasket
11. U-Joint
12. U-Joint
13. Snapring (8)
14. Bearing Cap (8)
15. Grease Fitting
16. Grease Fitting
17. Grease Fitting
(2) Inspect shafts for trueness, dents, cracks or peened yoke ends.
(3) Inspect U-joints for play at bearing caps, binding or cracks.
15-43
TM 08780B-20
d. Assembly
NOTE
All three grease fittings (15, 16 and 17) must face the same side of the shaft assembly to ease
lubrication.
(1) Install three grease fittings (15,16 and 17).
NOTE
Steps (2) and (3) apply for either U-joint (11 or 12).
(2) With new U-joint (11 or 12) in yokes (3 and 18) or (19 and 20) install four
bearing caps (14).
(3) Install four snaprings (13) onto bearing caps (14).
(4) Slide dust cover (9) with gasket (10) onto splined shaft (7).
(5) Insert splined shaft (7) into yoke sleeve assembly (8).
(6) Secure dust cover (9) to yoke sleeve assembly (8) by bending in tabs.
3. Splined Yoke 11. U-Joint 16. Grease Fitting

7. Splined Shaft 12. U-Joint 17. Grease Fitting
8. Yoke Sleeve 13. Snapring (8) 18. Yoke
Assembly 14. Bearing Cap (8) 19. Yoke
9. Dust Cover 15. Grease Fitting 20. Yoke
10. Gasket
15-44
TM 08780B-20
e. Installation
(1) Slide splined yoke (3) onto input shaft (5) of steering gear (4).
(2) Secure splined yoke (3) to steering gear (4) with clamping capscrew (1)
and new locknut (2). Torque locknut (2) to 35-40 foot-pounds (47-54 N*m).
END OF TASK
NOTE
TM 08780B-20 Install frame 90 degree gear box
(para 15-12).
1. Clamping Capscrew
2. Locknut
3. Splined Yoke
4. Steering Gear
5. Input Shaft
15-45
TM 08780B-20
15-15. FUSE LINK MAINTENANCE

b. Disassembly
d. Assembly
e. Replacement

Condition Condition
MK48 TM 08780B-20 Wheels straight ahead
Materials/Parts step (1).
Grease (item 21, Appendix D) General Safety Instructions
Cotter pin (MS24665-285) item 1 Block wheels of truck to prevent personal
Self-locking nut (3X-282787) item 6 injury.
References
LI 2320-12/9
LO 9-2320-297-12
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Remove cotter pin (1) from socket assembly (2). Discard cotter pin (1).
(2) Remove castle nut (3) from socket assembly (2).
(3) Remove socket assembly (2) from yaw bell crank (4).
(4) Remove locking capscrew (5) and locknut (6) from yaw control valve (7).
(5) Turn fuse link assembly (8) with fuse link cover (9) counterclockwise out
of yaw control valve (7). Remove fuse link assembly (8) from vehicle.
15-46
TM 08780B-20
7 5
3
6 1
4
9
8
1. Cotter Pin 6. Locknut

2. Socket Assembly 7. Yaw Control Valve
3. Castle Nut 8. Fuse Link Assembly
4. Yaw Bell Crank 9. Fuse Link Cover
5. Locking Capscrew
15-47
TM 08780B-20
b. Disassembly
(1) Remove capscrew (10) and nut (11) from clamp (12).
(2) Turn socket assembly (2) out of fuse link rod (13).
(3) Remove clamp (12) from fuse link rod (13).
(4) Loosen and remove hose clamp (14) and hose clamp (15) from fuse link
assembly (8).
(5) Slide boot (16) off fuse link rod (13).
(6) Secure fuse link housing (17) in vise.
(7) Remove four socket head capscrews (18) and locknuts (19) from fuse link
housing(17). Discard locknuts (19).
(8) Remove fuse link cover (9) from fuse link housing (17).
(9) Slide fuse link spacer (20) out from fuse link housing (17).
(10) Remove set screw (21) and pellet (22) from adjusting collar (23).
(11) While assistant pulls fuse link rod (13) to compress spring (24), turn
adjusting collar (23) off fuse link rod (13).
(12) Release fuse link rod (13) slowly to ease tension on spring (24).
(13) Slide adjusting collar (23) off fuse link rod (13).
(14) Slide fuse link rod (13) with spring cap (25) and spring (24), out from fuse
link housing (17). Remove spring (24) and spring cap (25) from fuse link rod (13).
(15) Insert fuse link rod (13) into fuse link housing (17) and cap (26). Install
adjusting collar (20).
(16) Slide fuse link rod (13), cap (26) and adjusting collar (23) out of fuse link
housing (17).
(17) Remove adjusting collar (23) and cap (26) from fuse link rod (13).
(18) Remove lubrication fitting (27) from fuse link housing (17).
15-48
TM 08780B-20
(2) Inspect for visible damage.
d. Assembly
(1) Insert fuse link rod (13), in sequence, through spring cap (25), spring (24)
and cap (25).
(2) Coat inside of fuse link housing (17) with a thin film of grease. Insert fuse
link rod (13) with spring (24), cap (26) and spring cap (25) into fuse link housing (17).
(3) Slide adjusting collar (23) onto fuse link rod (13).
(4) While assistant pulls on fuse link rod (13) to compress spring (24), start
threads of adjusting collar (23) onto fuse link rod (13). Ease off pressure on fuse link rod (13).
(5) Insert fuse link spacer (20) into fuse link housing (17).
(6) Apply sealant to mating surfaces of fuse link housing (17) and fuse link
cover (9).
(7) Install fuse link cover (9) making sure flat of threads face same side as
lubrications fittings (27). Secure with four sockethead capscrews (18) and new locknuts (19).
Tighten securely.
(8) Turn adjusting collar (23) against cap (26) until all end play is removed
from fuse link rod (13).
(9) Insert pellet (22) and secure adjusting collar (23) with set screw (21).
(10) Slide boot (16) over fuse link rod (13) and fuse link housing (17). Secure
boot (16) with hose clamps (14 and 15).
(11) Install clamp (12) on fuse link rod (13).
(12) Fill slotted end of fuse link rod (13) with silicone sealant. Start threads of
socket assembly (2) into fuse link rod (13).
(13) Install capscrew (10) and nut (11) on clamp (12). Do not tighten. Final
adjustment of socket assembly is done on vehicle.
15-49
TM 08780B-20
(14) Install lubrication fitting (27) on fuse link housing (17).
2. Socket Assembly 15. Hose Clamp 21. Set Screw

8. Fuse Link Assembly 16. Boot 22. Pellet
9. Fuse Link Cover 17. Fuse Link Housing 23. Adjusting Collar
10. Capscrew 18. Socket Head 24 Spring
11. Nut Capscrew (4) 25. Spring Cap
12. Clamp 19. Locknut (4) 26. Cap
13. Fuse Link Rod 20. Fuse Link Spacer 27. Lubrication Fitting
14. Hose Clamp
e. Replacement
NOTE
This is a temporary adjustment. Steering must be properly adjusted as soon as possible.
(1) Turn threads of fuse link cover (9) into yaw control valve (7) until tight.
Make sure flat on threads of fuse link cover align with locking capscrew (5).
(2) Install locking capscrew (5) and new locknut (6) in yaw control valve.
Tighten securely.
15-50
TM 08780B-20
(3) Turn socket assembly (2) in or out of fuse link rod (13) so that socket
assembly will go into yaw bell crank (4). Do not disturb yaw bell crank (4). Torque nut (11) to
55 foot-pounds (75 N*m).
(4) Install castle nut (3) on socket assembly (2). Torque castle nut (3) to
17-25 foot-pounds (23-34 N*m). Continue tightening to align slots for cotter pin (1). Do not
back castle nut (3) off to align slots.
(5) Install new cotter pin (1) in socket assembly (2).
END OF TASK
NOTE
LI 2320-12/9 Grease fuse link assembly.
LO 9-2320-297-12
TM 08780B-20 Check steering alignment (para 15-17).
15-51
TM 08780B-20
5
7
3
1
6 4
2
13
9 11
1. Cotter Pin
2. Socket Assembly
3. Castle Nut
4. Yaw Bell Crank
5. Locking Capscrew
6. Locknut
7. Yaw Control Valve
9. Fuse Link Cover
11. Nut
13. Fuse Link Rod
15-52
TM 08780B-20
15-16. STEERING SYSTEM HOSE AND FITTING REPLACEMENT

c. Installation
INITIAL SETUP

injury.
Materials/Parts
References
TM 08780B-10
a. Removal
NOTE
The following procedure works for all steering system hoses and fittings.
(1) Loosen two nuts (1). Remove hose (2).
(3) Install fitting (3) into nut (1). Jam fitting (3) tightly against nuts (1).
(4) Remove nipple (4) and nut (1) from nut (5).
NOTE
Nut (5) has a left hand thread.
(5) Remove nut (5) from hydraulic hose (2).
(6) Remove fitting (3) from nut (1). Remove nipple (4) from nut (1).
15-53
TM 08780B-20
c. Installation
(1) Install nut (5) onto hose (2).
(2) Install nipple (4) through nut (1) as shown.
(3) Install fitting (3) into nut (1). Jam fitting (3) tightly against nut (1).
(4) Thread nipple (4) into nut (5). Tighten nipple (4) until there is 0.3125 inch
(0.7935 mm) between nuts (1) and nut (5).
WARNING

(6) Using compressed air, clean hose (2).
(7) Apply sealing compound to threads (6) of fitting (3) only. Do not apply to
nut side (7) of fitting (3).
(8) Install fitting (3).
(9) Install nut (1) onto fitting (3). Tighten nut (1) securely.
(11) Check for oil leaks.
1. Nut (2)
2. Hose
3. Fitting
4. Nipple
5. Nut
6. Threads
7. Nut Side of Fitting
END OF TASK
15-54
TM 08780B-20
15-17. STEERING ADJUSTMENT
THIS TASK COVERS: a. Toe-in Adjustment

b. Cramp Adjustment
c. No. 1 Axle Alignment
d. No. 2 Axle Alignment
e. Articulation joint Alignment
f. Pitman Arm Adjustment
g. Steering Gear Relief Adjustment
h. No. 3 and No. 4 Axle Alignment
(uncoupled units)
i. Alignment of Axles (coupled units)

Condition Condition
Chalk line (5210-00-273-9793) TM 08780B-10 Tires inflated to
Plumb bob (5120-00-234-8949) proper pressure
Square (5210-00-810-3490) (para 2-12).
Cramp angle tool (1532210)
1/8 inch (3 mm) shim Trailer separated
(para 2-15).
Personnel Required
1 MOS 3521 Special Environmental Conditions
1 Assistant Work on a hard, flat, level surface.

LI 2320-12/9 injury. Use caution when working at
LO 9-2320-297-12 articulation joint area.
a. Toe-In Adjustment
(1) Raise No. 1 axle so that tires are just off ground.
(2) Scribe a straight, vertical line all the way around each tire.
(3) Lower No. 1 axle so that tires are completely on the ground.
(4) At a point 12 inches (304.8 mm) from ground, measure distance between
vertical lines at front of tires.
(5) At a point 12 inches (304.8 mm) from ground, measure distance between
vertical lines at rear of tires.
15-55
TM 08780B-20
(6) Front measurement should be 1/8 inch (3.175 mm) less than rear
measurement.
(7) Adjust toe-in as follows:
(a) Raise No. 1 axle until tires clear ground.
(b) Loosen two nuts (1) and capscrews (2) on two tie-rod clamps (3).
(c) Turn tie-rod tube (4) as shown to increase or decrease toe-in.
(d) Repeat steps (3) thru (6) until toe-in is correct.
(e) Torque nuts (1) and capscrews (2) to 50-60 foot-pounds once toe-
in is set.
1. Nut (2)
2. Capscrew (2)
3. Tie Rod Clamp (2)
4. Tie Rod Tube
15-56
TM 08780B-20
5. Front Wheel (2)

6. Axle Ball Flange
7. Trunnion Housing
b. Cramp Adjustment
(1) Make sure front wheels (5) are straight by measuring between axle ball
flange (6) and trunnion housing (7) on both sides. Both measurements should be the same.
NOTE
• Cramp angle is properly set when cramp angle adjusting tool (8) has an interference fit
between axle stop capscrew and ball socket.
• If cramp adjusting tool (8) fits too loosely or cannot be inserted, axle stop capscrew
must be adjusted.
(2) Insert cramp angle adjusting tool (8) between right axle stop capscrew (9)
and ball socket (10) as shown. Notch (11) must be squarely on the edge of ball socket (10) with
the back (12) toward stop screw (9) and bevel (13) on ball socket (10).
(3) Loosen jam nut (14).
(4) Adjust right axle stop capscrew (9) in or out as needed.
(5) When cramp angle adjusting tool (8) has an interference fit right axle stop
capscrew is properly adjusted. Tighten jam nut (14) securely.
(6) Repeat steps (1) thru (5) for left axle stop capscrew (15) and jam nut (16).
15-57
TM 08780B-20
8. Cramp Angle Adjusting Tool 13. Bevel

9. Right Axle Stop Capscrew 14. Jam Nut
10. Ball Socket 15. Left Axle Stop Capscrew
11. Notch 16. Jam Nut
12. Back
15-58
TM 08780B-20
5. Front Wheel (2)

6. Axle Ball Flange
7. Trunnion Housing
17. Front Crossmember
18. Plumb Bob (2)
c. No. 1 Axle Alignment
NOTE
• All measurements must be accurate.
• Move vehicle forward and backward in a straight line approximately 30 feet (9.14 m) to
remove any twist or flex in frame or wheels.
(1) Make sure front wheels (5) are straight. Measure between axle ball flange
(6) and trunnion housing (7) on both sides of axle. Both measurements must be the same.
(2) Using front crossmember (17) as an anchor point, drop two plumb bobs
(18) to the floor.
15-59
TM 08780B-20
(3) Be sure plumb bobs (18) have stopped moving. Mark floor at two points
under plumb bobs (18) with chalk.
19. Chalk Line

25. Chalk Mark
(4) Stretch a chalk line (19) across two chalk marks on floor. Chalk line (19)
must extend beyond both wheels.
(5) Pull chalk line (19) tight. Snap chalk line (19) against floor.
(6) Locate center of No. 1 axle end cap (20) by drawing a line across the
center of two opposite axle studs (21). Draw a minimum of three lines. The point where lines
cross (22) is the center of No. 1 axle end cap (20).
20. No 1 Axle End Cap

21. Opposite Axle Studs
22. Crossing Lines
23. Square
15-60
TM 08780B-20
(7) Position a square (23) against wheel (24). Make sure edge of square (23)
crosses center of No. 1 axle end cap (20). Mark floor with chalk mark (25).
20. No. 1 Axle End Cap

23. Square
24. Wheel
25. Chalk Mark
(8) Repeat steps (6) and (7) for opposite side of axle No. 1.
(9) Using square (23) as a guide, measure from chalk mark (25) to front chalk
line (19). Measure at both right and left side of axle No. 1. Measurement should be the same ±
1/16 (1.587 mm).
(10) If needed, reposition No. 1 axle as follows:
(a) Remove two nuts (26), four washers (27) and two capscrews (28)
from torque rod (29) at No. 1 axle.
(b) To move axle either to the front or rear, add or remove hardened
washers (30) between No. 1 axle housing and torque rod (29) as shown.
(c) Install torque rod (29) using two capscrews (28), four washers
(27), hardened washers (30) and two nuts (26). Torque nuts (26) to 170 foot-pounds (231 N*m).
d. No. 2 Axle Alignment
NOTE
15-61
TM 08780B-20
(18) to the floor.
5. Front Wheel (2) 26. Nut (2)

6. Axle Ball Flange 27. Washer (4)
7. Trunnion Housing 28. Capscrew (2)
17. Crossmember 29. Torque Rod
18. Plumb Bob (2) 30. Hardened Washers
19. Chalk Line
15-62
TM 08780B-20
(6) Place a piece of tape (31) over No. 2 axle shaft (32).
31. Tape On No 2 Axle

32. No 2 Axle Shaft
33. Opposite Studs
34. Crossing Lines
(7) Locate the center of No. 2 axle shaft (32) by drawing a line across the
center of two opposite axle studs (33). Draw a minimum of three lines. The point where lines
cross (34) is the center of No. 2 axle shaft (32).
23. Square
32. 24. Wheel
32. No 2 Axle Shaft
35. Chalk Mark
crosses center of No. 2 axle shaft (32). Mark floor with chalk mark (35).
(9) Repeat steps (6) thru (8) for opposite side.
15-63
TM 08780B-20
(10) Using square (23) as a guide, measure from chalk mark (35) to front chalk
line (19). Measure on both left and right side of vehicle. Measurement should be the same ±
1/16 inch (1.587 mm).
(a) Remove two nuts (36), four washers (37) and two capscrews (38)
from torque rod (39).
(b) To move axle either to the front or rear, add or remove hardened
washers (40) between No. 2 axle housing and torque rod (39) as shown.
(37), hardened washers (40) and two nuts (36). Torque nuts (36) to 170 foot-pounds (231 N*m).
19. Chalk Line 37. Washer (4)

23. Square 38. Capscrew (2)
32. Axle Shaft 39. Torque Rod
35. Chalk Mark 40. Hardened Washers
36. Nut (2)
15-64
TM 08780B-20
e. Articulation Joint Alignment
WARNING
SEPARATED MK48 IS EXTREMELY FRONT HEAVY. USE CAUTION WHEN

WORKING ON OR MOVING A SEPARATED MK48 TO PREVENT PERSONAL INJURY
OR EQUIPMENT DAMAGE.
NOTE
(18) to the floor.
5. Front Wheel (2)

6. Axle Ball Flange
7. Trunnion Housing
17. Front Crossmember
18. Plumb Bob (2)
19. Chalk Line
15-65
TM 08780B-20
(6) Disconnect yaw cylinders (41). Refer to paragraph 22-7.
(7) Disconnect yaw feedback linkage (42) at bracket (43) by removing cotter
pin (44) and nut (45).
(8) Using articulation joint mating surface (46) as an anchor, drop two plum
bobs (18) to the floor.
(9) Be sure plum bobs (18) have stopped moving. Mark floor at two points
under plum bobs (18) with chalk.
(10) Stretch a chalk line (47) across the two chalk marks. Chalk line (47) must
extend beyond both wheels.
(12) Measure from line at front of vehicle to line at articulation joint. Measure
on both sides of vehicle. Manually move articulation joint left or right, as required to obtain the
same measurement on both sides.
(13) Repeat steps (8) thru (12) until measurements on both sides are the same.
18. Plumb Bob (2) 46. Articulation Joint

41. Yaw Cylinder (2) Mating Surface
42. Yaw Feedback 47. Chalk Line
Linkage 48. Nut
43. Bracket 49. Capscrew
44. Cotter Pin 50. Clamp
45. Nut
15-66
TM 08780B-20
(14) Loosen nut (48) and capscrew (49) on clamp (50).
(15) Adjust yaw feedback linkage (42) so that it will drop into bracket (43).
CAUTION
MAKE SURE CLAMPS (50) ARE INSTALLED AS SHOWN. FAILURE TO INSTALL

CLAMPS PROPERLY COULD RESULT IN EQUIPMENT DAMAGE.
(16) Install and tighten nut (45) securely. Install new cotter pin (44 ). Tighten
nut (48) and capscrew (49).
(17) Connect yaw cylinders (41). Refer to paragraph 22-7.
f. Pitman Arm Adjustment
(1) Raise No. 1 axle until tires are off ground.
(2) Turn steering wheel slowly all the way to right until axle stop (51)
contacts ball socket (52).
(3) Adjust length of front pitman arm stop capscrew (53) so that pitman arm
(54) contacts front pitman arm stop capscrew (53) at same time as axle stop (51)contacts ball
socket (52).
(4) Turn steering wheel slowly all the way to left until axle stop (55) contacts
ball socket (56).
(5) Adjust length of rear pitman arm stop capscrew (57) so that pitman arm
(54) contacts rear pitman arm stop capscrew (57) at the same time as axle stop (55) contacts ball
socket (56).
15-67
TM 08780B-20
51. Axle Stop 55. Axle Stop

52. Ball Socket 56. Ball Socket
53. Pitman Arm Stop Capscrew 57. Pitman Arm Stop Capscrew
54. Pitman Arm
15-68
TM 08780B-20
9. Right Angle Stop Capscrew 15. Left Axle Stop Capscrew

10. Ball Socket 16. Jam Nut
14. Jam Nut 61 1/8 Inch (3 mm) Shim
g. Steering Gear Relief Adjustment
(1) Raise No. 1 axle until tires just clear ground.
15-69
TM 08780B-20
CAUTION
WHILE SETTING STEERING GEAR RELIEFS, DO NOT HOLD STEERING WHEEL

AGAINST STOP FOR MORE THAN 15 SECONDS AT A TIME. PROLONGED
OPERATION AT SYSTEM RELIEF WILL CAUSE DAMAGE TO HYDRAULIC SYSTEM.
(2) Install pressure gauge (58)into steering circuit as shown.
(3) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Place

transmission in neutral and engage parking brake.
WARNING
DO NOT TURN FRONT OR REAR STEERING GEAR RELIEFS OUT PAST END OF END
CAPS. RELIEF NEEDLES COULD POP OUT, CAUSING DAMAGE TO STEERING
SYSTEM AND THE RELEASE OF HOT OIL UNDER PRESSURE, CAUSING PERSONAL
INJURY.
(4) Turn front and rear steering gear reliefs (59) and (60) out until even with
steering gear end caps.
WARNING
WHEN INSTALLING SHIM (61), KEEP HANDS CLEAR OF AXLE STOP CAPSCREW
(15, 9) AND BALL SOCKET (10). AXLE STOP CAPSCREW CAN CRUSH HANDS IF
PLACED BETWEEN CAPSCREW AND BALL SOCKET.
NOTE
Pressure will go to 1750 psi (12,066.25 kPa).
(5) Insert a 1/8 inch (3.1 mm) shim (61) between left axle stop capscrew (15)
and ball socket (10) while assistant turns steering wheel slowly to right until left axle stop
capscrew (15) contacts ball socket (10). Pressure will go to 1750 psi (12,066.25 kPa).
(6) While assistant holds steering wheel fully right, adjust rear relief (60) until
pressure reads 700 psi (4826.5 kPa). Remove shim (61).
(7) Insert a 1/8 inch (3.1 mm) shim (61) between right axle stop capscrew (9)
and ball socket (10) while assistant turns steering wheel slowly to left until right axle stop
capscrew (9) contacts ball socket (10). Pressure will go to 1750 psi (12,066.25 kPa).
(8) While assistant holds steering wheel fully left, adjust front relief (59) until
pressure reads 700 psi (4826.5 kPa). Remove shim (61).
15-70
TM 08780B-20
(9) Shut down engine. Refer to paragraph 2-13 (TM 08780B-10). Remove
pressure gauge (58) from steering unit.
58. Pressure Gauge

59. Front Relief
60. Rear Relief
h. No. 3 and No. 4 Axle Alignments (uncoupled units)
NOTE
• Rear unit must be level before measuring or adjusting axles.
• Raise and lower No. 3 and No. 4 axles to eliminate suspension twist.
(1) Using rear body mating surface (62) as an anchor, drop two plumb bobs
(18) to the floor.
(5) Place a piece of tape over No. 3 and No. 4 axle shafts (63 and 64).
15-71
TM 08780B-20
(6) Locate the center of No. 3 axle shaft (63) by drawing a line across the
center of two opposite axle studs (65). Draw a minimum of three lines. The points where lines
cross (66) is the center of No. 3 axle shaft (63).
crosses center of No. 3 axle shaft (63). Place chalk mark (67) on floor at this point.
(8) Repeat steps (6) and (7) for other side of No. 3 axle.
(9) Using square (23) as a guide, measure from chalk line (19) to chalk mark
(67). Measure at both right and left side of No. 3 axle. Measurement should be the same ± 1/16
inch (1.587 mm).
18. Plumb Bob (2) 63. No 3 Axle Shaft

19. Chalk Line 64. No. 4 Axle Shaft
23. Square 65. Opposite Axle Studs
24. Positioning of Square 66. Crossing Lines
61. No. 3 Axle Shaft 67. Chalk Mark
62. Mating Surface
(a) Remove two nuts (68), four washers (68), four washers (69) and
two capscrews (70) from lower torque rod (71).
(b) To move No. 3 axle either to the front or the rear, add or remove
hardened washers (72) between No. 3 axle housing and torque rod (71).
15-72
TM 08780B-20
(69), hardened washers (72) and two nuts (68). Torque nuts (68) to 460 foot-pounds
(623.76 N*m).
(11) Repeat steps (6) thru (10), if necessary, for No. 4 axle shaft (64).
64. No. 4 Axle Shaft 70. Capscrew (2)

68. Nut (2) 71. Torque Rod
69. Washer (4) 72. Installation of
Hardened Washers
i. Alignment of Axles (coupled units)
(1) Disconnect both yaw cylinders at articulation joint. Refer to paragraph

22-7.
(2) Remove cotter pin (44) and nut (45) from yaw feedback linkage (42) at
bracket (43).
(3) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Drive vehicle
straight ahead 40-50 feet (12.2-15.25 cm) on hard, flat surface.
(4) Measure distance between center of No. 1 axle end cap (20) and center of
No. 2 axle shaft (31) on both the right and the left side. Measurements should be the same ±
1/16 inch (1.587 mm). If measurement is not within limits, refer to sections c and d.
15-73
TM 08780B-20
(5) Measure distance between center of No. 2 axle shaft (31) to center of No.
3 axle shaft (63) on the right and the left side. Measurements should be the same ± 1/16 inch
(1.587 mm).
(6) Measure distance between center of No. 3 axle shaft (63) to center of No.
4 axle shaft (64) on both the right and the left side. Measurements should be the same ± inch
(1.587 mm). If measurement is not within limits, refer to section (g).
(7) Drive vehicle forward 40-50 feet (12.2-15.25 m). Adjust yaw feedback
linkage (42) so that it drops into bracket (43). Install nut (45). Install new cotter pin (44).
(8) Road test vehicle. After a few miles, stop vehicle on flat section of the
road. Disconnect yaw feedback linkage (42) at bracket (43).
(9) Drive vehicle straight ahead for 100 feet (30.5 m). Drop yaw feedback
linkage (42) into bracket (43). If linkage (42) will not drop into bracket (43), repeat step (7).
(10) Connect both yaw cylinders. Refer to paragraph 22-7.
20. No. 1 Axle End Cap 44. Cotter Pin

31. No. 2 Axle Shaft 45. Nut
42. Feedback Linkage 63. No. 3 Axle Shaft
43. Bracket 64. No. 4 Axle Shaft
END OF TASK
15-74
TM 08780B-20
CHAPTER 16
FRAME
procedures for the vehicle’s frame.
a. General. The frame consists of two heat treated side rails joined together by
crossmembers and braces. Attached to the frame rails on all trailers are two landing legs and a
pintle. Attached to the frame rails on the MK16 is an adjustable fifth wheel and two fifth wheel
ramps. Also attached to the frame are the vehicle tie downs.
b. Landing Legs. Support trailer when separated from MK48.
c. Fifth Wheel. Attaches semitrailer to the MK16.
d. Fifth Wheel Ramps. Aids in alignment of semitrailer onto fifth wheel.
e. Vehicle Tie Downs. Used to secure vehicle during shipment.
16-1
TM 08780B-20
16-3. FIFTH WHEEL RAMP REPLACEMENT

c. Installation
INITIAL SETUP

injury.
Materials/Parts
Locknut (10) (NSN 5310-01-081-8244) items 4 and 7
Locknut (10) (NSN 5310-01-111-0645) items 10, 13 and 17
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Place two wooden blocks (1) between fifth wheel (2) and frame (3).
(2) Remove six locknuts (4), six capscrews (5), two block assemblies (5.1) and
two block storage brackets (5.2) from front crossbrace (6). Remove front crossbrace (6).
(3) Remove four locknuts (7) and capscrews (8) from rear crossbrace (9).
Remove crossbrace (9). Discard locknuts (7).
(4) Remove six locknuts (10) and capscrews (11) from left fifth wheel ramp
(12). Using an assistant, remove left fifth wheel ramp (12) from vehicle. Discard locknuts (10).
16-2
TM 08780B-20
1. Wooden Block (2) 6. Front Crossbrace 14. Capscrew (2)

2. Fifth Wheel 7. Locknut (4) 15. Bracket
3. Frame 8. Capscrew (4) 16. Right Fifth Wheel Ramp
4. Locknut (6) 9. Rear Crossbrace 17. Locknut (4)
5. Capscrew (6) 10. Locknut (6) 18. Capscrew (4)
5.1. Block Assembly (2)* 11. Capscrew (6) 19. Capscrew Hole
5.2. Block Storage 12. Left Fifth Wheel Ramp 20. Capscrew Hole
Bracket (2)* 13. Locknut (2)

(5) Remove two locknuts (13), capscrews (14) and bracket (15) from right
fifth wheel ram (16). Discard locknuts (13).
(6) Remove four locknuts (17) and capscrews (18) from right fifth wheel
ramp (16). Discard locknuts (17).
c. Installation
(1) With help from assistant, place left fifth wheel ramp (12) on frame (3).
Align capscrew holes (19).
16-3
TM 08780B-20
(2) Install six capscrews (11) and six new locknuts (10). Tighten locknuts
(10) securely.
(3) With help from assistant, set right fifth wheel ramp (16) on frame (3).
Align capscrew holes (20).
(4) Install four capscrews (18) and new locknuts (17).
(5) Install bracket (15) using two capscrews (14) and new locknuts (13).
(6) Tighten locknuts (13 and 17) securely.
(7) Install rear crossbrace (9) using four capscrews (8) and new locknuts (7).
(8) Install front crossbrace (6), two block storage brackets (5.2) and block
assemblies (5.1) using six capscrews (5) and new locknuts (4). Tighten locknuts (4) securely.
(9) Remove wooden blocks (1) from fifth wheel (2).
1. Wooden Block (2) 6. Front Crossbrace 14. Capscrew (2)

2. Fifth Wheel 7. Locknut (4) 15. Bracket
3. Frame 8. Capscrew (4) 16. Right Fifth Wheel Ramp
4. Locknut (6) 9. Rear Crossbrace 17. Locknut (4)
5. Capscrew (6) 10. Locknut (6) 18. Capscrew (4)
5.1. Block Assembly (2)* 11. Capscrew (6) 19. Capscrew Hole
5.2. Block Storage 12. Left Fifth Wheel Ramp 20. Capscrew Hole
Bracket (2)* 13. Locknut (2)

END OF TASK
16-4
TM 08780B-20
16-4. LANDING LEG ASSEMBLY REPLACEMENT

c. Installation
INITIAL SETUP

MK15 injury.
MK16
MK17
Materials/Parts
Locknut (2) (NSN 5310-01-159-8178) item 6
References
TM 08780B-10
a. Removal
NOTE
• This procedure will work for either the left or the right landing leg.
• For MK17 rear landing leg, go to step (9).
(1) Lower landing leg (1). Refer to paragraph 2-15 (TM 08780B-10).
(2) Remove locknut (2), capscrew (3) and washer (4). Remove handle (5).
(3) Remove two locknuts (6) and two capscrews (7). Discard two locknuts
(6). Remove bracket (8).
(4) Remove landing leg (1).
(5) Remove eight capscrews (9) from bracket (10).
(7) Remove tie down ring (11) from bracket (10).
16-5
TM 08780B-20
(8) Repeat steps (1) thru (7) for landing leg on other side.
1. Landing Leg 7. Capscrew (2)

2. Locknut 8. Bracket
3. Capscrew 9. Capscrew (8)
4. Washer 10. Bracket
5. Handle 11. Tie Down Ring
6. Locknut (2)
(9) Remove MK17 rear landing leg (12) as follows:
(a) Place rear landing leg (12) in the deployed position. Refer to
paragraph 2-15 (TM 08780B-10).
16-6
TM 08780B-20
WARNING
TO PREVENT PERSONAL INJURY, SUPPORT REAR OF MK17 TO PREVENT TIPPING
WHILE LANDING LEG IS REMOVED.
(b) Remove two cotter pins (13) and washers (14) from pin (15).
Remove pin (15). Discard cotter pins (13).
(c) Remove quick release pin (16) and pin (17).
(d) Slide rear landing leg (12) away from bracket (18).
(e) Remove quick release pin (19), pin (20) and lower landing leg
(21).
12. Rear Landing Leg

13. Cotter Pin (2)
14. Washer (2)
15. Pin
16. Quick Release Pin
17. Pin
18. Bracket
20. Pin
21. Lower Landing Leg
16-7
TM 08780B-20
c. Installation
(1) Install tie down ring (11) into bracket (10).
(2) Apply adhesive to threads of eight capscrews (9). Install bracket (10) with
eight capscrews (9). Tighten capscrews (9) to 375 foot-pounds (508.5 N*m).
(3) Install landing leg (1) into bracket (10).
(4) Install bracket (8) using two capscrews (7) and new locknuts (6). Tighten
(5) Install handle (5) using capscrew (3), washer (4) and new locknut (2).
Make sure handle (5) slides freely into the stowed position.
(6) Repeat steps (1) thru (5) for landing leg on other side.
1. Landing Leg 7. Capscrew (2)

2. Locknut 8. Bracket
3. Capscrew 9. Capscrew (8)
4. Washer 10. Bracket
5. Handle 11. Tie Down Ring
6. Locknut (2)
16-8
TM 08780B-20
(7) Install MK17 rear landing leg (12) as follows:
(a) Install rear landing leg (12) into bracket (18) using pin (15), two
washers (14) and new cotter pins (13).
(b) Install lower landing leg (21) into its uppermost position. Insert
pin (20) and secure with quick release pin (19).
(c) Swing rear landing leg (12) into the stowed position. Install pin
(17) and quick release pin (16).
END OF TASK
NOTE
TM 08780B-10 Check for proper operation of landing legs
(para 2-15).
12. Rear Landing Leg

13. Cotter Pin (2)
14. Washer (2)
15. Pin
17. Pin
18. Bracket
20. Pin
16-9
TM 08780B-20
16-5. LANDING LEG ASSEMBLY REPAIR

c. Assembly

Condition Condition
MK14 TM 08780B-20 Landing leg removed
MK15 (para 16-4).
MK16
MK17
Materials/Parts
Retaining compound (item 13, Appendix D)
Gasket (NSN 5330-00-323-1627) item 3
References
LI 2320-12/9
LO 9-2320-297-12
a. Disassembly
(1) Remove two screws (1). Remove cover (2) and gasket (3). Discard
gasket (3).
(2) Remove spiral pin (4) from bevel pinion gear (5).
(3) Remove gear shaft (6) from bevel pinion gear (5). Remove bevel pinion
gear (5) from upper landing leg (7).
NOTE
Landing leg must be fully extended.
(4) Remove jam nut (8) from elevating screw (9).
(5) Using a soft faced hammer, tap elevating screw (9) down. Remove bevel
gear (10) and woodruff key (11) from elevating screw (9).
(6) Pull lower landing leg (12) with elevating screw (9) from upper landing
leg (7).
(7) Remove thrust bearing (13) and thrust washer (14) from elevating screw
(9).
16-10
TM 08780B-20
(8) Remove bushing (15) from elevating screw (9).
(9) Remove two pins (16) from skid foot axle (17).
(10) Remove skid foot axle (17) and skid foot (18). If necessary, remove two
grease fittings (19).
(3) Inspect bevel pinion gear (5) and bevel gear (10) for worn or cracked
teeth.
1. Screw (2)
2. Cover
3. Gasket
4. Spiral Pin
5. Bevel Pinion Gear
6. Gear Shaft
7. Upper Landing Leg
8. Jam Nut
9. Elevating Screw
10. Bevel Gear
11. Woodruff Key
13. Thrust Bearing
14. Thrust Washer
15. Bushing
16. Pin (2)
17. Skid Foot Axle
18. Skid Foot
16-11
TM 08780B-20
(4) Inspect elevating screw (9) for freedom of movement. There should be no
binding.
(5) Inspect upper and lower landing legs (7 and 12) for dents, cracks or bends.
(6) Inspect skid foot (18) for cracks or broken welds.
c. Assembly
(1) Install thrust washer (14) onto elevating screw (9).
(2) Install thrust bearing (13), with cup facing up, onto elevating screw (9).
(3) Insert lower landing leg (12) into upper landing leg (7) until threads (20)
of elevating screw (9) are visible in upper landing leg (7).
(4) Install bushing (15) onto elevating screw (9). Push bushing (15) down
until it stops.
(5) Install woodruff key (11) onto elevating screw (9).
(6) Install bevel gear (10) onto elevating screw (9) and woodruff key (11).
NOTE
Landing leg must be fully extended.
(7) Apply retaining compound on threads (20) of elevating screw (9). Install
jam nut (8). Tighten jam nut (8) securely. Make sure bevel gear (10) turns freely.
(8) Install bevel pinion gear (5) into upper landing leg (7).
(9) Install gear shaft (6) into upper landing leg (7) and bevel pinion gear (5).
Install spiral pin (4). Make sure bevel pinion gear (5) and bevel gear (10) turn freely.
(10) Pack upper landing leg (7) with grease.
(11) Install new gasket (3) and cover (2).
(12) Install two screws (1).
(13) Install skid foot (18) with skid foot axle (17).
(14) Install two pins (16) to secure skid foot axle (17). If removed, install two
grease fittings (19).
16-12
TM 08780B-20
END OF TASK
NOTE
TM 08780B-20 Install landing leg (para 16-4).
LI 2320-12/9 Lubricate landing leg.

LO 9-2320-297-12
1. Screw (2)
2. Cover
3. Gasket
4. Spiral Pin
5. Bevel Pinion Gear
6. Gear Shaft
7. Upper Landing Leg
8. Jam Nut
9. Elevating Screw
10. Bevel Gear
11. Woodruff Key
13. Thrust Bearing
14. Thrust Washer
15. Bushing
16. Pin (2)
17. Skid Foot Axle
18. Skid Foot
20. Threads
16-13
TM 08780B-20
16-6. PINTLE REPLACEMENT

c. Installation
INITIAL SETUP

MK15 personal injury.
MK16
MK17
Materials/Parts
Cotter pin (NSN 5315-01-169-3162) item 11
References
TM 08780B-10
a. Removal
NOTE
This procedure will work for extended pintle kits.
(1) Remove four nuts (1), lockwashers (2), eight washers (3) and four
capscrews (4). Discard lockwashers (2).
(2) Remove pintle assembly (5).
(3) Remove cotter pin (6) from nut (7). Discard cotter pin (6).
(4) Remove nut (7) and washer (8).
(5) Remove pintle (9) from mounting bracket (10).
(6) Remove cotter pin (11) from nut (12). Remove nut (12). Discard cotter
pin (11).
(7) Remove capscrew (13) and latch assembly (14).
(8) Remove drive screw (15), chain (16) and cotter pin (17).
(9) Remove three grease fittings (18) if damaged.
16-14
TM 08780B-20
c. Installation
(1) Install latch assembly (14) using one capscrew (13).
(2) Install nut (12) on capscrew (13). Install new cotter pin (11).
(3) Install cotter pin (17) and chain (16) using drive screw (15).
(4) Insert pintle (9) into mounting bracket (10).
(5) Install washer (8) and nut (7) onto pintle (9).
(6) Tighten nut (7) so that play between pintle assembly (5) and mounting
plate (10) is eliminated, but pintle (9) can still rotate freely. Install new cotter pin (6).
(7) Install pintle assembly (5) using four capscrews (4), eight washers (3),
four new lockwashers (2) and four nuts (1). Tighten nuts (1) securely.
(8) Install three grease fittings (18) if removed.
END OF TASK
NOTE
TM 08780B-10 Check pintle for proper operation (para 2-1).
16-15
TM 08780B-20
1. Nut (4) 7. Nut 13. Capscrew

2. Lockwasher (4) 8. Washer 14. Latch Assembly
3. Washer (8) 9. Pintle 15. Drive Screw
4. Capscrew (4) 10. Mounting Bracket 16. Chain
5. Pintle Assembly 11. Cotter Pin 17. Cotter Pin
6. Cotter Pin 12. Nut 18. Grease Fitting (3)
16-16
TM 08780B-20
CHAPTER 17
SUSPENSION
procedures for the vehicle’s shock absorbers and torque rods.
a Torque Rods. Three torque rods are mounted between each axle and the frame.
U U
These torque rods maintain alignment between the axle and the frame. They also absorb torque
reaction from the axles. The arrangement of two lower torque rods and one upper torque rod
provides for maximum positive wheel contact with the ground.
a. UShock Absorbers. The MK48 has four non-adjustable, double-acting shock

U
absorbers. The upper end of each shock absorber is secured to a mounting bracket that is
attached to the frame side rail. The lower end of each shock absorber is secured to a bracket on
either the No. 1 or the No. 2 axle. Two rubber bushings are installed in both the upper and the
lower mounting eyes.
17-1
TM 08780B-20
17-3. SHOCK ABSORBER AND BUSHING REPLACEMENT

c. Installation
INITIAL SETUP
U U General Safety Instructions
U U

injury.
Materials/Parts
U
Locknut (2) (NSN 5310-01-080-5747) item 1

Rubber bushing (4) (NSN 5365-00-999-7024) item 7
a. Removal
U U
NOTE
Replace shock absorbers in sets of four. This procedure describes the removal and installation
of only one shock absorber.
(1) Remove two locknuts (1) and hardened washer (2). Discard locknuts (1).
(2) Remove two retainers (3).
(3) Remove shock absorber (4) from two mounting brackets (5).
(4) Remove two inner retainers (6).
(5) Remove four rubber bushings (7) from shock absorber (4). Discard rubber
bushings (7).
U U
(2) Check shock absorber (4) for proper action, leaks, dents or straightness.
(3) Replace all four shock absorbers if any fail inspection.
c. Installation
U U
(1) Install two inner retainers (6) on mounting brackets (5) with small end
toward rubber bushing (7).
17-2
TM 08780B-20
(2) Install four new rubber bushings (7) into shock absorber (4).
(3) Install shock absorber (4) onto mounting brackets (5).
(4) Place two retainers (3) over rubber bushing (7) with small end toward
rubber bushing (7).
(5) Install two hardened washers (2) and new locknuts (1).
1. Locknut (2)
2. Hardened Washer (2)
3. Retainer (2)
4. Shock Absorber
5. Mounting Bracket (2)
6. Inner Retainer (2)
7. Rubber Bushing (4)
END OF TASK
17-3
TM 08780B-20
17-4. TORQUE ROD REPLACEMENT (MK48)
THIS TASK COVERS: a. Upper Torque Rod Removal

b. Lower Torque Rod Removal
d. Lower Torque Rod Installation
e. Upper Torque Rod Installation
INITIAL SETUP
U U General Safety Instructions
U U
MK48 Block wheels to prevent movement.
Materials/Parts
Locknuts (10) (NSN 5310-01-107-3586)
items 6, 11, 21, 27, 32 and 40
a. Upper Torque Rod Removal
(1) Remove nut (1), two washers (2) and capscrew (3) from two brackets (4).
Remove brackets (4) from upper front torque rod (5).
(2) Remove two locknuts (6), washers (7), capscrews (8) and washers (9)
from upper front torque rod (5) at No. 1 axle housing (10). Discard locknuts (6).
(3) Remove two locknuts (11) and washers (12) from upper front torque rod
(4) Remove upper front torque rod (5), two capscrews (13) and washers (14)
from suspension bracket (31).
(5) Remove nut (16), two washers (17) and capscrew (18) from two brackets
(19). Remove brackets (19) from upper rear torque rod (20).
(6) Remove two locknuts (21), washers (22), capscrews (23), washers (24)
and two hardened washers (25) from upper rear torque rod (20) at No. 2 axle housing (26).
(7) Remove two locknuts (27) and washers (28) from upper rear torque rod
(8) Remove two capscrews (29), washers (30) and upper rear torque rod (20)
from suspension bracket (15).
17-4
TM 08780B-20
1. Nut
2. Washer (2)
3. Capscrew
4. Bracket (2)
5. Upper Front
Torque Rod
6. Locknut (2)
7. Washer (2)
8. Capscrew (2)
9. Washer (2)
10. No. 1 Axle Housing
11. Locknut (2)
12. Washer (2)
13. Capscrew (2)
14. Washer (2)
15. Suspension Bracket
16. Nut
17. Washer (2)
18. Capscrew
19. Bracket (2)
20. Upper Rear
Torque Rod
21. Locknut (2)
22. Washer (2)
23. Capscrew (2)
24. Washer (2)
27. Locknut (2)
28. Washer (2)
29. Capscrew (2)
30. Washer (2)
17-5
TM 08780B-20
NOTE
• Tag hardened washers to maintain proper axle alignment. In some cases, hardened
washers may not be used or the number may vary.
• Left and right lower torque rods are removed in the same manner.
from lower front torque rod (36) at No. 1 axle and housing (10). Discard locknuts (32).
(2) Remove two capscrews (37), washers (38), lower front torque rod (36) and
hardened washers (39) from suspension bracket (31).
(3) Repeat steps (1) and (2) for opposite lower front torque rod.
and hardened washers (44) from lower rear torque rod (45) at No. 2 axle housing (26). Discard
locknuts (40).
(5) Remove two capscrews (46), washers (47), lower rear torque rod (45) and
(6) Repeat steps (4) and (5) for opposite lower rear torque rod.
(2) Inspect all parts. Refer to paragraph 2-12
NOTE
Left and right lower torque rods are installed in the same manner.
(1) Install lower rear torque rod (45) onto suspension bracket (31) using two
capscrews (46), washers (47), and hardened washers (48). Hand tighten capscrews (46).
(2) Install lower rear torque rod (45) onto No. 2 axle housing (26) using two
capscrews (42), four washers (41 and 43), hardened washers (44) and two new locknuts (40).
17-6
TM 08780B-20
(3) Torque locknuts (40) to 170 foot-pounds (230.5 N*m). Torque capscrews
(46) to 212 foot-pounds (287.47 N*m).
(4) Repeat steps (1) thru (3) for opposite lower torque rod.
(5) Install lower front torque rod (36) onto suspension bracket (31) using two
capscrews (37), washers (38) and hardened washers (39). Hand tighten capscrew (37).
(6) Install lower front torque rod (36) onto No. 1 axle housing (10) using two
capscrews (34), four washers (33 and 35) and two new locknuts (32).
(7) Torque locknuts (32) to 170 foot-pounds (230.5 N*m). Torque capscrews
(37) to 212 foot-pounds (287.47 N*m).
(8) Repeat steps (5) thru (7) for opposite lower front torque rod.

26. No 2 Axle Housing
32. Locknut (2)
33. Washer (2)
34. Capscrew (2)
35. Washer (2)
36. Lower Front Torque Rod
37. Capscrew (2)
38. Washer (2)
39. Hardened Washer (Air)
40. Locknut (2)
41. Washer (2)
42. Capscrew (2)
43. Washer (2)
45. Lower Rear Torque Rod
46. Capscrew (2)
47. Washer (2)
17-7
TM 08780B-20
(1) Install upper rear torque rod (20) onto suspension bracket (31) using two
capscrews (29), four washers (30 and 28) and two new locknuts (27). Hand tighten locknuts
(27).
(2) Install upper rear torque rod (20) onto No. 2 axle housing (26) using two
capscrews(23), four washers (24 and 22), two hardened washers (25) and two new locknuts (21).
(3) Torque locknuts (21 and 27) to 170 foot-pounds (230.5 N*m).
(4) Install two brackets (19) onto upper rear torque rod (20) using capscrew
(18), two washers (17) and nut (16). Tighten nut (16) securely.
(5) Install upper front torque rod (5) onto suspension bracket (15) using two
(11).
(6) Install upper front torque rod (5) onto No. 1 axle housing (10) using two
capscrews (8), four washers (7 and 9) and two new locknuts (6).
(7) Torque locknuts (6 and 11) to 170 foot-pounds (230.5 N*m).
(8) Install two brackets (4) onto upper front torque rod (5) using capscrew (3),
two washers (2) and nut (1).
END OF TASK
NOTE
TM 08780B-20 Check No. 1 and No. 2 axle alignment
(para 15-17).
17-8
TM 08780B-20
1. Nut 12. Washer (2) 22. Washer (2)

2. Washer (2) 13. Capscrew (2) 23. Capscrew (2)
3. Capscrew 14. Washer (2) 24. Washer (2)
4. Bracket (2) 15. Suspension Bracket 25. Hardened Washer(2)
5. Upper Front Torque Rod 16. Nut 26. No 2 Axle Housing
6. Locknut (2) 17. Washer (2) 27. Locknut (2)
7. Washer (2) 18. Capscrew 28. Washer (2)
8. Capscrew (2) 19. Bracket (2) 29. Capscrew (2)
9. Washer (2) 20. Upper Rear Torque Rod 30. Washer (2)
10. No 1 Axle Housing 21. Locknut (2) 31. Suspension Bracket
17-9
TM 08780B-20
17-5. TORQUE ROD REPLACEMENT (MK14, 15, 16 AND 17)
THIS TASK COVERS: a. Upper Torque Rod Removal

INITIAL SETUP

MK14 Block wheels to prevent movement.
M K15
MK16
MK17
Materials/Parts
Locknuts (12) (NSN 5310-01-107-3586) items 1, 8, 12, 21, 28 and 32
a. Upper Torque Rod Removal
(1) Remove two locknuts (1), washers (2), capscrews (3), washers (4) and
spacers (5) from upper rear torque rod (6) at No. 4 axle housing (7). Discard locknuts (1).
(2) Remove two locknuts (8) and washers (9). Remove upper rear torque rod
(6) and mounting bracket (10) from crossmember (11). Discard locknuts (8).
from upper front torque rod (16) from No. 3 axle housing (17). Discard locknuts (12).
(4) Remove capscrews (18), washers (19), upper front torque rod (16) and
mounting bracket (20) from crossmember (11).
17-10
TM 08780B-20
1. Locknut (2) 8. Locknut (2) 15. Washer (2)

2. Washer (2) 9. Washer (2) 16. Upper Front Torque Rod
3. Capscrew (2) 10. Mounting Bracket 17. No 3 Axle Housing
4. Washer (2) 11. Crossmember 18. Capscrew (2)
5. Spacer (2) 12. Locknut (2) 19. Washer (2)
6. Upper Rear Torque Rod 13. Washer (2) 20. Mounting Bracket
7. No 4 Axle Housing 14. Capscrew (2)
17-11
TM 08780B-20
NOTE
• Tag hardened washers to maintain proper axle alignment. In some cases, hardened
washers may not be used or the number may vary.
• Left and right lower torque rods are removed in the same manner.
and spacers (25) from lower rear torque rod (26) at No. 4 axle housing (27). Discard locknuts
(21).
(2) Remove two locknuts (28) and washers (29) from lower rear torque rod
(26) at suspension bracket (30). Discard locknuts (28).
(3) Remove lower rear torque rod (26) and hardened washers (31) from
vehicle.
(4) Repeat steps (1) thru (3) for opposite lower rear torque rod.
from lower front torque rod (36) at No. 3 axle housing (37). Discard locknuts (32).
(6) Remove two capscrews (38), washers (39), lower front torque rod (36) and
(3) Replace all parts failing inspection
NOTE
Left and right lower torque rods are installed in the same manner.
(1) Install lower front torque rod (36) onto No. 3 axle housing (37) using two
(32).
17-12
TM 08780B-20
(2) Install lower front torque rod (36) onto suspension bracket (30) using two
capscrews (38), washers (39) and hardened washers (40).
(4) Install hardened washers (31) onto capscrews (38) at suspension bracket
(30). Install lower rear torque rod (26) onto capscrews (38) using two washers (29) and new
locknuts (28). Hand tighten locknuts (28).
(5) Install lower rear torque rod (26) onto No. 4 axle housing (27) using two
capscrews (23), four washers (22 and 24), two spacers (25) and two new locknuts (21).
(6) Torque three locknuts (21, 28 and 32) to 460 foot-pounds (623.76 N*m).
(7) Repeat steps (4) thru (6) for opposite lower rear torque rod.
17-13
TM 08780B-20

22. Washer (2) 29. Washers (2) 36. Lower Front Torque Rod
23. Capscrew (2) 30. Suspension Bracket 37. No 3 Axle Housing
24. Washer (2) 31. Hardened Washer (Air) 38. Capscrew (2)
26. Lower Rear Torque Rod 33. Washer (2) 40. Hardened Washer (Air)
17-14
TM 08780B-20
(1) Install two capscrews (18) and washers (19) into upper front torque rod
(16).
(2) Install mounting bracket (20) onto capscrews (18). Install upper front
torque rod (16) and mounting bracket (20) onto crossmember (11).
(3) Install upper front torque rod (16) onto No. 3 axle housing (17) using two
(12).
(4) Install mounting bracket (10) onto two capscrews (18). Install upper rear
torque rod (6) onto two capscrews (18) and mounting bracket (10) using two washers (9) and
new locknuts (8). Hand tighten locknuts (8).
(5) Install upper rear torque rod (6) onto No. 4 axle housing (7) using two
capscrews (3), four washers (2 and 4), two spacers (5) and new locknuts (1).
(6) Torque locknuts (1, 8 and 12) to 460 foot-pounds (623.76 N*m).
END OF TASK
NOTE
TM 08780B-20 Check alignment of No. 3 and No. 4 axles
(para 15-17).
17-15
TM 08780B-20

2. Washer (2) 9. Washer (2) 16. Upper Front Torque Rod
3. Capscrew (2) 10. Mounting Bracket 17. No 3 Axle Housing
4. Washer (2) 11. Crossmember 18. Capscrew (2)
6. Upper Rear Torque Rod 13. Washer (2) 20. Mounting Bracket
17-16
TM 08780B-20
CHAPTER 18
CAB AND BODY
Maintenance level mechanics. The following chapter covers repair and replacement procedures
for the vehicle's cab and body.
18-2. CAB AND BODY. The LVS cab (1) is a welded steel shell mounted to the frame rails
(2). Rubber biscuits (3) are used between the frame rails (2) and cab mounts (4) to dampen
vibration. A panel (5) located on the right side of the cab roof provides access to the roof-
mounted machine gun. Access panels (6) are located throughout the interior of the cab (1).
These provide access to parts for maintenance and repairs. A skid plate (7) is mounted on the
front of the cab for protection. There is also a tool box (8) mounted on the right rear fender (9).
1. Cab 6. Access Panels

2. Frame Rails 7. Skid Plate
3 Rubber Biscuits 8. Tool Box
4. Cab Mounts 9. Fender
5. Panel
18-1
TM 08780B-20
18-3. DOOR REPLACEMENT

c. Installation
d. Adjustment
INITIAL SETUP
Applicable Configurations Personnel Required

MK48 1 MOS 3521
1 Assistant
Materials/Parts
a. Removal
(1) Remove two capscrews (1) and lockwashers (2) from door strap (3).
(2) Remove ten capscrews (4) from door (5) while assistant holds door (5) up.
(3) Remove door (5) from hinge (6) carefully.
(4) Remove six capscrews (7) and mirror bracket (8) if door (5) will be
replaced.
c. Installation
(1) Install mirror bracket (8) with six capscrews (7) if removed.
(2) Install door (5) with ten capscrews (4) while assistant holds door (5) in
place.
d. Adjustment
(1) Loosen nine capscrews (9) that fasten door hinge (6) to vehicle.
18-2
TM 08780B-20
(2) Adjust door (5) up or down, to insure proper closing and locking.
(3) Loosen ten capscrews (4) that fasten door (5) to door hinge (6).
(4) Adjust door (5) in or out to insure proper closing and locking.
(5) Tighten ten capscrews (4) and nine capscrews (9) after adjustment is
made.
(6) Install door strap (3) with two new lockwashers (2) and capscrews (1).
1. Capscrew (2)
2. Lockwasher (2)
3. Door Strap
4. Capscrew (10)
5. Door
6. Door Hinge
7. Capscrew (6)
8. Mirror Bracket
9. Capscrew (9)
END OF TASK
18-3
TM 08780B-20
18-4. DOOR REPAIR

c. Assembly and Adjustment
INITIAL SETUP
MK48
Materials/Parts
(LVSA1 Series Vehicles Only)
Lockwasher (8) (353AX) items 10.2,10.8 and 10.14
(LVSA1 Series Vehicles Only)
Locknut (2) (MS21083-N3) items 26 and 33
Adhesive (AR) (item 9, Appendix D)
a. Disassembly
(1) Open door (1). Be sure window is in the up position.
(2) Remove four screws (2) and door handle (3).
(3) Remove screw (4), window crank (5), cover (6) and spring (7).
(4) Remove two capscrews (8) and lockwashers (9) from door strap (10).
NOTE
• Perform steps (5) through (11) for LVSA1 series vehicles only.
• Removal, cleaning/inspection and installation/adjustment procedures may be used for

either RH or LH rifle mountings.
(5) Remove two capscrews (10.1), lockwashers (10.2), washers (10.3) and
upper rifle mounting bracket (10.4). Discard lockwashers (10.2).
(6) Remove clip (10.5) from rifle catch (10.6) and upper mounting rifle
mounting bracket (10.4).
18-4
TM 08780B-20
(7) Remove two capscrews (10.7), lockwashers (10.8), nuts (10.9), rifle boot
(10.11) and catch bracket (10.10) from upper rifle mounting bracket (10.4). Discard lockwashers
(10.8).
(8) Remove two capscrews (10.1), lockwashers (10.2), washers (10.3) and
lower rifle mounting bracket (10. 12). Discard lockwashers (10.2).
(9) Remove two capscrews (10.13), lockwashers (10.14), nut (10.15) and rifle
support (10.16) from lower rifle mounting bracket (10.12).
NOTE
If quickedge is damaged, perform step (10).
(10) Remove quickedge (10.17) from rifle support (10.16).
(11) Remove 19 screws (11), lockwashers (12) and door panel (13). Discard
lockwashers (12).
(12) Remove 23 screws (11), lockwashers (12) and door panel (13). Discard
lockwashers (12).
(13) Remove spring (14) from outer actuating rod link (15).
(14) Separate cable (16) and actuating rod link (15) from door lock lever (17).
(15) Remove capscrews (18 and 19).
(16) Loosen capscrew (20).
(17) Hold lock spacer plate (21) and remove capscrew (20).
(18) Remove lock mechanism (22) with spacer plate (21).
(19) Remove four screws (23) and remove door guide (24).
18-5
TM 08780B-20
1. Door 10.5. Clip* 11. Screw (19)

2. Screw (4) 10.6. Rifle Catch* 12. Lockwasher (19)*
3. Door Handle 10.7. Capscrew (2)* 13. Door Panel
4. Screw 10.8. Lockwasher (2)* 14. Spring
5. Window Crank 10.9. Nuts (2)* 15. Actuating Rod Link
6. Cover 10.10. Catch Bracket* 16. Cable
7. Spring 10.11. Rifle Boot* 17. Lever
8. Capscrew (2) 10.12. Lower Rifle 18. Capscrew
9. Lockwasher (2) Mounting Bracket* 19. Capscrew
10. Door Strap 10.13. Capscrew (2)* 20. Capscrew
10.1. Capscrew (4) 10.14. Lockwasher (2)* 21. Spacer Plate
10.2. Lockwasher (4) 10.15. Nut (2)* 22. Lock Mechanism
10.3. Washer (4)* 10.16. Rifle Support* 23. Screw (4)
10.4. Upper Rifle 10.17. Quickedge* 24. Door Guide
Mounting Bracket*
18-6
TM 08780B-20
(20) Remove locknut (25) from stud (26) on outside door latch (27). Discard
locknut (25).
(21) Remove latch retainer (28).
(22) Remove outside door latch (27).
(23) Remove cotter pin (29) from clevis pin (30) to disconnect actuating rod
(31) from outside door latch (27). Discard cotter pin (29).
(24) Remove locknut (32) from stud (33) on inside latch assembly (34).
(25) Remove latch retainer (35).
(26) Remove inside door handle (36) from door.
(27) Remove cotter pin (37) from clevis pin (38) to disconnect cable. Discard
cotter pin (37).
(28 Remove inside latch assembly (34).
(29) Remove two nuts (39) from rollers (40). Remove rollers (40) and cable
(41).
(30) Remove cable (41) from rollers (40).
c. Assembly and Adjustment
(1) Install two rollers (40) with two nuts (39).
(2) Install cable (41) through rollers (40).
(3) Install inside door latch assembly (34).
(4) Install new cotter pin (37) on clevis pin (38) to connect cable.
(5) Install inside door handle (36) in door.
18-7
TM 08780B-20
(6) Install latch retainer (35).
(7) Install new locknut (32) on stud (33) of inside latch assembly (34).
(8) Install new cotter pin (29) to clevis pin (30) connecting actuating rod (31)
to outside door latch (27).
(9) Install outside door latch (27).
(10) Install latch retainer (28).
(11) Install new locknut (25) on stud (26) of outside door latch (27).
25. Locknut
26. Stud
27. Door Latch (Outside)
28. Latch Retainer
29. Cotter Pin
30. Clevis Pin
31. Actuating Rod
32. Locknut
33. Stud
34. Latch Assembly (Inside)
35. Latch Retainer
36. Door Handle (Inside)
37. Cotter Pin
38. Clevis Pin
39. Nut (2)
40. Roller (2)
41. Cable
(12) Install door guide (24) with four screws (23). Torque screws to 36 inch-
pounds (4 N*m).
18-8
TM 08780B-20
(13) With spacer plate (21) and lock mechanism (22) held in place, start
capscrew (20).
(14) Install capscrews (18, 19 and 20). Torque capscrews to 130 inch-pounds
(15 N*m).
(15) Position cable (16) and actuating rod link (15) on door lock lever (17).
(16) Manually close door lock lever (17).
(17) Install actuating rod link (15) through door lock lever (17).
(18) If needed, adjust length of actuating rod link (15) by loosening jam nut
(42).
(19) Remove actuating rod link (15) from door lock lever (17).
(20) Turn actuating rod link (15) clockwise to shorten and counterclockwise to
lengthen.
(21) Install actuating rod link (15) through door lock lever (17).
(22) Tighten jam nut (42).
(23) Install spring (14) to actuating rod link (15).
(24) Install door panel (13) with 23 new lockwashers (12) and screws (11).
NOTE
Perform steps (25) thru (31) for LVSA1 series vehicles only.
(25) Install door panel (13) with 19 new lockwashers (12) and screws (11).
NOTE
If quickedge is damaged, perform step (26).
(26) Install quickedge (10.17) on rifle support (10.16).
(27) Install rifle support (10.16) on lower rifle mounting bracket (10.12) using
two nuts (10.15), new lockwashers (10.14) and capscrews (10.13).
(28) Install lower rifle mounting bracket (10.12) onto door using two washers
(10.3), new lockwashers (10.2) and capscrews (10.1). Torque capscrews (10.1) to 100 inch-
pounds (11 N*m).
18-9
TM 08780B-20
(29) Install catch bracket (10.10) and rifle catch (10.6) on upper rifle mounting
bracket (10.4) using two nuts (10.9), new lockwashers (10.8) and capscrews (10.7). Tighten nuts
(10.9) securely.
(30) Install clip (10.5) on rifle catch (10.6).
(31) Install upper rifle mounting bracket (10.4) onto door using two washers
(10.3), new lockwashers (10.2) capscrews (10.1). Torque capscrews(10.1) to 100 inch-pounds
(11 N*m).
(32) Install door strap (10) with two new lockwashers (9) and capscrews (8).
(33) Install spring (7), cover (6), window crank (5) and screw (4).
(34) Install door handle (3) with four screws (2).
18-10
TM 08780B-20
2. Screw (4) 10.5. Clip* 12. Lockwasher (19)

3. Door Handle 10.6. Rifle Catch* 13. Door Panel
4. Screw 10.7. Capscrew (2)* 14. Spring
5. Window Crank 10.8. Lockwasher (2)* 15. Actuating Rod Link
6. Cover 10.9. Nuts (2)* 16. Cable
7. Spring 10.10. Catch Bracket* 17. Lever
8. Capscrew (2) 10.11. Rifle Boot* 18. Capscrew
9. Lockwasher (2) 10.12. Lower Rifle 19. Capscrew
10. Door Strap Mounting Bracket* 20. Capscrew
10.1. Capscrew (4) 10.13. Capscrew (2)* 21. Spacer Plate
10.2. Lockwasher (4) 10.14. Lockwasher (2)* 22. Lock Mechanism
10.3. Washer (4)* 10.15. Nut (2)* 23. Screw (4)
10.4. Upper Rifle 10.16. Rifle Support* 24. Door Guide
Mounting Bracket* 10.17. Ouickedge* 42. Jam Nut
11. Screw (19)
END OF TASK
18-11
TM 08780B-20
18-5. MUD FLAP REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
a. Removal
(1) Remove three capscrews (1) and locknuts (2). Discard locknuts (2).
(2) Remove retainer strip (3) from splash guard (4).
(3) Remove splash guard (4) from fender (5).
c. Installation
(1) Install splash guard (4), retainer strip (3) and one capscrew (1) with new
locknut (2).
(2) Install and tighten remaining capscrews (1) and new locknuts (2).
18-12
TM 08780B-20
1. Capscrew (3)
2. Locknut (3)
3. Retainer Strip
4. Splash Guard
5. Fender
END OF TASK
18-13
TM 08780B-20
18-6. CAB STEP REPLACEMENT

b. Cleaning/inspection
c. Installation

Condition Condition
M K48 TM 08780B-20 Clearance light
removed from the
Materials/Parts step being replaced
Adhesive (Item 3, Appendix D) (para 7-31).
Locknut (6) (T893R) items 1, 8, 13, 18
a. Removal
NOTE
(1) Remove locknut (1), capscrew (2), five washers (3) and chain (4) from cab
step (5). Discard locknut (1).
(2) Remove rapid link (6) and chain (4) from lower step (7).
(3) Remove locknut (8), capscrew (9), washer (10), spacer (11) and lower step
(7) from step link (12). Discard locknut (8).
(4) Remove locknut (13), capscrew (14), washer (15), spacer (16) and step
link (12) from step support (17). Discard locknut (13).
(5) Remove three locknuts (18), capscrews (19) and step support (17) from
cab step (5). Discard locknuts (18).
(6) Remove four capscrews (20), lockwashers (21) and washers (22). Discard
lockwashers (21).
(7) Remove cab step (5).
18-14
TM 08780B-20
c. Installation
(1) Hold cab step (5) in place and install four washers (22), new lockwashers
(21) and capscrews (20).
NOTE
(3) Install step support (17) onto cab step (5) with three capscrews (19) and
new locknuts (18). Tighten locknuts (18) securely.
(4) Install step link (12) onto step support (17) with capscrew (14), washer
(15), spacer (16) and new locknut (13). Tighten locknut (13) securely.
(5) Install lower step (7) onto step link (12) with capscrew (9), washer (10),
spacer (11) and new locknut (8). Tighten locknut (8) securely.
(6) Install chain (4) to lower step (7) with rapid link (6).
(7) Apply adhesive to capscrew (2) threads.
(8) Install chain (4) onto cab step (5) with capscrew (2), five washers (3) and
new locknut (1). Tighten locknut (1) securely.
NOTE
TM 08780B-20 Install clearance light (para 7-31).
18-15
TM 08780B-20
1. Locknut* 9. Capscrew* 16. Spacer*

2. Capscrew* 10. Washer* 17. Step Support*
3. Washer (5)* 11. Spacer* 18. Locknut (3)*
4. Chain* 12. Step Link* 19. Capscrew (3)*
5. Cab Step 13. Locknut* 20. Capscrew (4)
6. Rapid Link* 14. Capscrew* 21. Lockwasher (4)
7. Lower Step* 15. Washer* 22. Washer (4)
8. Locknut*
END OF TASK
18-16
TM 08780B-20
18-7. VEHICLE STEP REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Locknut (8) (T893R) items 1, 3, 6 and 9
a. Removal
NOTE
Mounting hardware for LVSA1 vehicle steps has changed from a capscrew, lockwasher and
hex nut to a flanged style capscrew and locknut. When repairing a non-LVSA1 vehicle, use
the new flanged style mounting hardware to replace the old style hardware. Refer to TM
08780B-24P for correct mounting hardware.
(2) Remove two locknuts (3), capscrews (4) and vehicle step (5). Discard
locknuts (3).
(3) Remove two locknuts (6), capscrews (7) and supports (8). Discard
locknuts (6).
NOTE
(4) Remove two locknuts (9), capscrews (10) and step (11). Discard locknuts
(9).
18-17
TM 08780B-20
c. Installation
(1) Install two supports (8) onto vehicle step (5) with two capscrews (7) and
(2) Hold vehicle step (5) in position and install two capscrews (4) with new
locknuts (3).
(3) Install two capscrews (2) with new locknuts (1) to secure supports (8).
(4) Tighten locknuts (1 and 3) securely.
NOTE
(5) Install step (11) with two capscrews(10) and new locknuts (9). Tighten
locknuts (9) as necessary to allow free movement of step (11).
1. Locknut (2)
2. Capscrew (2)
3. Locknut (2)
4. Capscrew (2)
5. Vehicle Step
6. Locknut (2)
7. Capscrew (2)
8. Support (2)
9. Locknut (2)*
10. Capscrew (2)*
11. Step*

END OF TASK
18-18
TM 08780B-20
18-8. WINDSHIELD GLASS REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Cab clearance light
mounting bracket
Adhesive, Sikaflex (item 4.1, Appendix D)
Primer, Sikaflex (item 43.1, Appendix D Windshield wiper
Soap solution (item 54, Appendix D) arms removed (para
21-5, steps 1, 2
Personnel Required and 3).
1 MOS 3521
1 Assistant
a. Removal
CAUTION
USE CARE NOT TO DAMAGE WEATHER STRIPPING WITH FLAT EDGED TOOL
WHEN PULLING SEAM OUTWARD.
NOTE
It may be necessary to apply a soapy solution to weather stripping while prying.
(1) Windshield weather stripping (1) must be pried at the seam (2) with a flat-
edged tool to separate halves (3 and 4).
(2) Outside half (3) of weather stripping must be pried from under inside half
(4).
(3) Fold inside half (4) of weather stripping (1) outward to show windshield
(5).
(4) From inside cab, apply even pressure to one corner of windshield (5) until
it comes loose.
(5) From outside vehicle, work with assistant to carefully work windshield (5)
out from weather stripping (1).
(6) Remove weather stripping (1).
18-19
TM 08780B-20
(1) Clean all dirt and sealant out of weather stripping channel.
(3) Inspect weather stripping for cuts or rips. Make sure sealing lips within
seam are in good condition.
c. Installation
(1) Coat weather stripping (1) with soapy solution.
(2) Install weather stripping (1) so end is at bottom center of windshield frame
(6).
(3) Install weather stripping (1) starting at bottom and pushing downward
until fully seated.
(4) Apply soapy solution to weather stripping glass channel.
(5) With an assistant, guide bottom of windshield into weather stripping

channel and seat it.
(6) From bottom of windshield, insert flat edged tool along inner molding lip.
(7) Work weather stripping all around glass until fully seated.
(8) Slide outside half (3) of weather stripping (1) under inside half (4).
(9) Clean ends of weather stripping (7) with primer and apply adhesive to
ends of weather stripping (7).
(10) Test weather stripping for leaks by using a water hose.
END OF TASK
18-20
TM 08780B-20
NOTE
TM 08780B-20 Install front cab clearance light mounting
bracket (para 7-32).
Install windshield wiper arms (para 21-5),

steps (3), (4) and (5).
1. Weather Stripping 5. Windshield

2. Seam 6. Bottom Center Of Windshield Frame
3. Outside Half 7. Weather Stripping Ends
4. Inside Half
18-21
TM 08780B-20
18-9. REAR WINDOW GLASS, DOOR VENT WINDOW GLASS, AND PEEP GLASS
REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Adhesive, Sikaflex (item 4.1, Appendix D)
Primer, Sikaflex (item 43.1, Appendix D)
Soap solution (item 54, Appendix D)
a. Removal
NOTE
Rear window glass, door vent to window glass and peep window glass replacement are done in
the same manner.
(1) Remove capscrew (1), washer (2) and nut (3) to drop window guard (4)
covering peep window.
(2) Remove locking strip (5).
(3) Fold inside edge (6) of locking channel out around entire window (7).
(4) Remove window (7).
(5) Remove locking channel (8).
(1) Clean edge of window frame.
(2) Clean locking strip (5) and locking channel (8).
(3) Clean all other parts. Refer to paragraph 2-11.
(4) Inspect locking strip (5) and locking channel (8) for tears or rips.
(5) Inspect all other parts. Refer paragraph 2-12.
18-22
TM 08780B-20
c. Installation
(1) Coat locking strip (5) and locking channel (8) with soapy solution.
(2) Install locking channel (8) on window frame with channel facing out.
(3) Fold inside edge (6) of locking channel (8) out.
(4) Fit new window (7) in locking channel (8).
(5) Place inside edge (6) over window (7).
NOTE
When installing locking strip on peep window, start at top center of locking channel.
(6) Install locking strip (5) in locking channel (8).
(7) Clean ends of locking channel (9) with primer and apply adhesive to ends
of locking channel (9).
(8) Check for leaks with water hose.
(9) Install capscrew (1), washer (2) and nut (3) to secure window guard (4)
covering peep window.
18-23
TM 08780B-20
1. Capscrew 6. Inside Edge

2. Washer 7. Window
3. Nut 8. Locking Channel
4. Window Guard 9. Ends Of Locking Channel
5. Locking Strip
END OF TASK
18-24
TM 08780B-20
18-10. DOOR GLASS AND REGULATOR REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Inner panel removed
(para 18-4).
Materials/Parts
Cement, general purpose (item 9, Appendix D)
a. Removal
(1) Remove six screws (1) and remove regulator (2).
(2) Remove cotter pin (3) from clevis pin (4). Discard cotter pin (3).
(3) Remove clevis pin (4) and clevis (5) from door latch (6).
(4) Pull felt strip (7) away from glass channel (8).
(5) Remove two nuts (9) from glass channel (8).
(6) Push glass (10) up and hold while removing glass channel (8).
(7) Carefully remove glass (10) from the side.
c. Installation
(1) Carefully install glass (10) from the side.
(2) Push glass (10) up and hold while installing glass channel (8).
(3) Install two nuts (9) on glass channel (8).
18-25
TM 08780B-20
(4) Apply cement to glass channel (8).
(5) Install felt strip (7) into glass channel (8).
(6) Install clevis pin (4) through door latch (6) and clevis (5).
(7) Install new cotter pin (3).
(8) Install six screws (1) to secure regulator (2).
END OF TASK
NOTE
TM 08780B-20 Install inner panel (para 18-4).
1. Screw (6)
2. Regulator
3. Cotter Pin
4. Clevis Pin
5. Clevis
6. Door Latch
7. Felt Strip
8. Glass Channel
9. Nut (2)
10. Glass
18-26
TM 08780B-20
18-11. SEAT CUSHION REPLACEMENT

c. Installation
INITIAL SETUP
MK48
a. Removal
(1) Remove capscrew (1) and clamp (2) on side nearest door.
(2) Lift seat cushion (3) and remove capscrew(4) and clamp (5).
(3) Remove bottom seat cushion (3).
(4) Remove five hooks (6) from bottom of seat back cover (7).
(5) Pull seat back cushion (8) off seat frame assembly (9).
c. Installation
(1) Install seat back cushion (8) on seat frame assembly (9).
(2) Install five hooks (6) through bottom of seat back cover (7).
(3) Position seat cushion (3) on seat frame (10) with front down and rear
slightly raised.
(4) Install clamp (5) and capscrew (4).
(5) Lower seat cushion (3) until flat on seat frame (10).
(6) Install clamp (2) and capscrew (1).
18-27
TM 08780B-20
1. Capscrew
2. Clamp
3. Seat Cushion
4. Capscrew
5. Clamp
6. Hook (5)
7. Seat Back Cover
8. Seat Back Cushion
9. Seat Frame Assembly
10. Seat Frame
END OF TASK
18-28
TM 08780B-20
18-12. SEAT FRAME ASSEMBLY REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Locknut (2) (MS17529-7C) items 4.1 and 4.7
a. Removal
NOTE
• Operator and passenger seat frames are not alike; however, they are removed and
installed identically.
• The LVSA1 series vehicles have 3-point seat belts. Perform steps (3), (4) and (7) when
repairing LVSA1 series vehicles.
(1) Slide seat (1) to full forward position.
(2) Disconnect seat belts (2) by removing two capscrews (3) and nuts (4) from
each side of seat (1).
(3) Remove locknut (4.1), capscrew (4.2), washer (4.3), seat belt bracket (4.4)
and tether bracket (4.5) from seat assembly (4.6). Discard locknut (4.1).
NOTE
Bushing may fall from seat assembly during removal.
(4) Remove locknut (4.7), capscrew (4.8), washers (4.9), seat belt (4.10) and
tether bracket (4.11) from seat assembly (4.6). Discard locknut (4.7).
(5) Remove two nuts (5) from each side of seat frame (6).
(6) Remove seat frame (6) from seat mount (7).
(7) Remove stop bracket (7.1) on driver’s side seat frame (6).
(8) Remove four nuts (8), capscrews (9), washers (10) and seat mount (7).
18-29
TM 08780B-20
c. Installation
NOTE
Perform steps (2), (6) and (7) when repairing LVSA1 series vehicles.
(1) Install seat mount (7) with four capscrews (9), washers (10) and nuts(8).
(2) Install stop bracket (7.1) on driver’s side seat frame (6).
(3) Install seat frame (6) on seat mount (7).
(4) Install two nuts (5) on each side of seat frame (6). Tighten securely.
(5) Install seat belt (2) to seat frame (6) with two capscrews (3) and nuts (4).
Tighten securely.
1. Seat
2. Seat Belt
3. Capscrew (2)
4. Nut (2)
5. Nut (4)
6. Seat Frame
7. Seat Mount
7.1. Stop Bracket*
8. Nut (4)
9. Capscrew (4)
10. Washer (4)
18-30
TM 08780B-20
NOTE
• Tighten locknut (4.1) until tether bracket (4.5) can slowly rotate.
• Ensure bushing is positioned in seat assembly before installation.
(6) Install seat belt (4.10) and tether bracket (4.5) on seat assembly (4.6) with
washer (4.3), capscrew (4.2) and new locknut (4.1).
NOTE
Tighten locknut (4.1) until seat belt bracket (4.4) can slowly rotate.
(7) Install tether bracket (4.5) and seat belt bracket (4.4) on seat assembly
(4.6) with washer (4.3), capscrew (4.2) and new locknut (4.1).
(8) Adjust seat (1) on tracks as needed.
4.1. Locknut* 4.7. Locknut*

4.2. Capscrew* 4.8. Capscrew*
4.3. Washer* 4.9. Washer (2)*
4.4. Seat Belt Bracket* 4.10. Seat Belt*
4.5. Tether Bracket* 4.11. Tether Bracket*
4.6. Seat Assembly*
18-31
TM 08780B-20
1. Seat
2. Seat Belt
3. Capscrew (2)
4. Nut (2)
5. Nut (4)
6. Seat Frame
7. Seat Mount
8. Nut (4)
9. Capscrew (4)
10. Washer (4)
END OF TASK
18-32
TM 08780B-20
18-13. SEAT BELT REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
a. Removal
NOTE
• The following procedure will work for the driver's or the passenger's seat belt.
• Passenger seat belt installs opposite of driver's seat belt.
(1) Remove nut (1), capscrew (2) and seat belts (3 and 4).
(2) Reinstall capscrew (2) and nut (1) finger-tight to hold seat back (5) in
place.
(3) Remove capscrew (6), lockwasher (7) and seat belt (4). Discard
lockwasher (7).
(4) Remove nut (8), capscrew (9) and seat belts (10 and 11).
(5) Reinstall capscrew (9) and nut (8) finger-tight to hold seat back (5) in
place.
(6) Remove capscrew (12), lockwasher (13) and seat belt (11). Discard
lockwasher (13).
(7) Remove nut (14), seat belt (10), nut (15) and washer (16) from stud (17).
18-33
TM 08780B-20
c. Installation
(1) Install washer (16), nut (15), seat belt (10) and nut (14) onto stud (17).
Tighten nuts (14 and 15) securely.
(2) Install seat belt (11) with new lockwasher (13) and capscrew (12).
(3) Remove nut (8) and capscrew (9).
(4) Install seat belts (10 and 11) with capscrew (9) and nut (8). Tighten nut
(8) securely.
(5) Install seat belt (4) with capscrew (6) and new lockwasher (7). Tighten
(6) Remove nut (1) and capscrew (2).
(7) Install seat belts (3 and 4) with capscrew (2) and nut (1). Tighten nut (1)
securely.
1. Nut
2. Capscrew
3. Seat Belt
4. Seat Belt
5. Seat Back
6. Capscrew
7. Lockwasher
8. Nut
9. Capscrew
10. Seat Belt
11. Seat Belt
12. Capscrew
13. Lockwasher
14. Nut
15. Nut
16. Washer
17. Stud
END OF TASK
18-34
TM 08780B-20
18-14. SEAT BELT REPLACEMENT (LVSA1 SERIES VEHICLES ONLY)

c. Installation
INITIAL SETUP
MK48A1
Materials/Parts
Locknut (4) (MS17829-7C) items 5, 13, 20 and 27
Lockwasher (2) (352AX) items 2 and 11
a. Removal
NOTE
Both seat belts are removed the same way. Left seat is shown.
(1) Remove capscrew (1), lockwasher (2) and angled bracket (3) from cab
assembly (4). Discard lockwasher (2).
(2) Remove locknut (5), capscrew (6), two straps (7) and washer (8) from seat
assembly (9). Discard locknut (5).
(3) Remove capscrew (10), lockwasher (11) and angled bracket (12) from cab
(4) Remove locknut (13), capscrew (14), hardened washer (15), seat belt
bracket (16), hardened washer (17), tether bracket (18) and washer (19) from seat assembly (9).
(5) Remove locknut (20), washer (21), D-ring (22), spacer (23), comfort latch
(24), two hardened washers (25) and capscrew (26) from cab assembly (4). Discard locknut
(20).
(6) Remove locknut (27), capscrew (28), washer (29), L-bracket (30) and
retractor unit (31) from cab assembly (4). Discard locknut (27).
18-35
TM 08780B-20
c. Installation
NOTE
Procedure is identical for both seats. Left seat is shown.
(1) Position D-ring (22) in cab assembly (4) with two hardened washers (25),
comfort latch (24), spacer (23), washer (21), new locknut (20) and capscrew (26).
(2) Tighten locknut (20) to 70 to 75 inch-pounds (8 N*m).
(3) Install retractor unit (31) to cab assembly (4) with washer (29), capscrew
(28), L-bracket (30) and new locknut (27).
(4) Tighten locknut (27) to 70 to 75 inch-pounds (8 N*m).
(5) Install tether bracket (18), hardened washer (17), seat belt bracket (16) and
hardened washer (19) on seat assembly (9) with hardened washer (15), capscrew (14) and new
locknut (13). Tighten locknut until seat belt bracket can slowly rotate.
(6) Install angled bracket (12) on cab assembly (4) with lockwasher (11) and
capscrew (10).
(7) Install hardened washer (8) and two straps (7) on seat assembly (9) with
hardened washer (8), capscrew (6) and new locknut (5). Tighten locknut until buckle can slowly
rotate.
(8) Install angled bracket (3) on cab assembly (4) with new lockwasher (2)
and capscrew (1).
END OF TASK
18-36
TM 08780B-20
1. Capscrew
3. Angled Bracket
4. Cab Assembly
5. Locknut
6. Capscrew
7. Strap (2)
8. Washer
9. Seat Assembly
10. Capscrew
11. Lockwasher
12. Angled Bracket
13. Locknut
14. Capscrew
15. Hardened Washer
16. Seat Belt Bracket
17. Hardened Washer
18. Tether Bracket
19. Washer
20. Locknut
21. Washer
22. D-Ring
23. Spacer
24. Comfort Latch
26. Capscrew
27. Locknut
28. Capscrew
29. Washer
30. L-Bracket
31. Retractor Unit
18-37
TM 08780B-20
18-15. ACCESS COVER AND PANEL REPLACEMENT
THIS TASK COVERS: a. Cab Access Cover Replacement

b. Roof Access Cover Replacement
c. Top Engine Access Cover Replacement
d. Circuit Breaker Access Cover Replacement
e. Front Engine Access Cover Replacement
f. Diagnostic Connector Access Cover Replacement
g. Exterior Access Panel Replacement

Condition Condition
disconnected
Locknut (8) (MS51922-1) item 9 To prevent personal injury, make sure
Lockwasher (4) (MS35338-43) item 18 batteries are disconnected before working
Lockwasher (11) (MS35338-45) item 26 on electrical components.
a. Cab Access Cover Replacement
(1) Remove screws (1).
(2) Remove access cover (2, 3 or 4).
(3) Clean and inspect all parts. Refer to paragraphs 2-11 and 2-12.
(4) Install access cover (2, 3 or 4).
(5) Install and tighten screws (1).
b. Roof Access Cover Replacement
(1) Remove 36 capscrews (5).
(2) Remove access cover (6).
NOTE
New production vehicles may have adhesive sealing on mating surface of roof access cover
(6). If so, cover must be pried off and adhesive sealing removed from mating surface.
18-38
TM 08780B-20
(4) Apply silicone sealant around the outer edges of access cover (6). Install
access cover (6).
(5) Install and tighten 36 capscrews (5).
c. Top Engine Access Cover Replacement
(1) Remove screws (7) and lockwashers (8). Discard lockwashers (8).
(4) Install access cover (9) with screws (7) and new lockwashers (8). Tighten
securely.
d. Circuit Breaker Access Cover Replacement
(1) Remove six screws (10).
(2) Remove indicator lights (11). Refer to paragraph 7-29.
(3) Remove eight screws (12) and placards (13).
(6) Install placards (13) with eight screws (12). Tighten screws (12) securely.
(7) Install indicator lights (11). Refer to paragraph 7-29.
(8) Install access cover (14) with screws (10). Tighten screws (10) securely.
18-39
TM 08780B-20
1. Screws
2. Access Cover
3. Access Cover
4. Access Cover
5. Capscrew (36)
6. Access Cover
7. Screw
8. Lockwasher
9. Access Cover
10. Screw (6)
11. Indicator Lights
12. Screw (8)
13. Placard (2)
14. Access Cover
e. Front Engine Access Cover Replacement
(1) Remove circuit breaker access cover (14). Refer to task d of this
paragraph.
(4) Remove four nuts (17), lockwashers (18), screws (19) and fire
extinguisher bracket (20).
(6) Install fire extinguisher bracket (20) with four screws (20), new
18-40
TM 08780B-20
(8) Install circuit breaker access cover (14). Refer to task d of this paragraph.
14. Access Cover 19. Screw (4)

15. Screw 20. Fire Extinguisher Bracket
16. Access Cover 21. Screw
17. Nut (4) 22. Diagnostic Connector
18. Lockwasher (4) 23. Access Cover
f. Diagnostic Connector Access Cover Replacement
(2) Remove diagnostic connector (22) from access cover (23). Refer to
paragraph 7-48.
(5) Install diagnostic connector (22) on access cover (23). Refer to paragraph
7-48.
18-41
TM 08780B-20
g. Exterior Access Panel Replacement
(1) Remove capscrews (24), lockwashers (25) and washers (26) from exterior
access panel (27, 28, 29, 30 or 31). Discard lockwashers (26).
(2) Remove exterior access panel (27, 28, 29, 30 or 31). If needed, remove
molding (32) from exterior access panel (28).
(4) Install exterior access panels (27, 28, 29, 30 or 31) with capscrews (24),
washers (26) and new lockwashers (25). If removed, install molding (32) on exterior access
panel (28).
END OF TASK
NOTE
24. Capscrew (11) 29. Access Panel

25 Lockwasher (11) 30. Access Panel
26. Washer (11) 31. Access Panel
27. Access Panel 32. Molding
28. Access Panel
18-42
TM 08780B-20
18-16. ROOF VENT REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Have assistant hold locknuts (1) while removing screws (2) and
lockwashers (3). Discard locknuts (1) and lockwashers (3).
NOTE
Vent (4) will stick to roof (5). Use a prying tool to break vent (4) loose.
(2) Pry vent (4) up and remove it.
c. Installation
(1) Coat sealing surface of roof (5) with a bead of silicone sealant.
(2) Place new gasket (6) and vent (4) in position. Make sure all holes are
lined up.
18-43
TM 08780B-20
(3) Install screws (2) with new lockwashers (3).
(4) Have assistant install new locknuts (1) and tighten securely.
1. Locknuts (12)
2. Screws (12)
3. Lockwashers (12)
END OF TASK
18-44
TM 08780B-20
18-17. SKID PLATE GRILLE REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
a. Removal
(1) Remove eight capscrews (1), nuts (2) and lockwashers (3). Discard
lockwashers (3).
(2) Remove skid plate grille (4) from skid plate (5).
c. Installation
(1) Install skid plate grille (4) on skid plate (5) with eight capscrews (1), new
lockwashers(3) and nuts (2).
(2) Tighten capscrews (1) and nuts (2) securely.
18-45
TM 08780B-20
1. Cap Screw (8)

2. Nut (8)
3. Lockwasher (8)
4. Skid Plate Grille
5. Skid Plate
18-46
TM 08780B-20
18-18. SKID PLATE AND SKID PLATE FRAME REPLACEMENT

c. Installation

Condition Condition
Materials/Parts
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Remove eight capscrews (1), nuts (2) and washers (3) from headlight
guards (4).
(2) Remove headlight guards (4).
(3) Remove five capscrews (5), nuts (6) and washers (7) from peep window
guard (8).
(4) Remove peep window guard (8).
(5) Remove 11 capscrews (9), washers (10) and nuts (11) from skid plate (12).
(6) Remove ten capscrews (13), lockwashers (14) and washers (15) from skid
plate (12). Discard Lockwashers (14).
(7) Remove nine capscrews (16) and nuts (17) from skid plate (12).
WARNING
TO AVOID POSSIBLE INJURY OR DEATH, HAVE ASSISTANT HOLD SKID PLATE UP.
AFTER FOUR REMAINING CAPSCREWS ARE REMOVED, ASSISTANT MUST
PREVENT SKID PLATE FROM FALLING.
(8) Remove four capscrews (18), washers (19) and nuts (20) from skid plate
(12).
18-47
TM 08780B-20
(9) With assistant helping, carefully remove skid plate (12).
(10) Remove two nuts (21) and capscrews (22) from skid plate frame (23).
WARNING
TO AVOID POSSIBLE INJURY OR DEATH, HAVE ASSISTANT HOLD SKID PLATE

FRAME UP. AFTER EIGHT REMAINING CAPSCREWS ARE REMOVED, ASSISTANT
MUST PREVENT SKID PLATE FRAME FROM FALLING.
(11) Remove eight nuts (24) and capscrews (25) from skid plate frame (23).
(12) With assistant helping, carefully remove skid plate frame (23).
18-48
TM 08780B-20
1. Capscrew (8) 10. Washer (11) 18. Capscrew (4)

2. Nut (8) 11. Nut (11) 19. Washer (4)
3. Washer (8) 12. Skid Plate 20. Nut (4)
4. Headlight Guard (2) 13. Capscrew (10) 21. Nut (2)
5. Capscrew (5) 14. Lockwasher (10) 22. Capscrew (2)
6. Nut (5) 15. Washer (10) 23. Skid Plate Frame
7. Washer (5) 16. Capscrew (9) 24. Nut (8)
8. Peep Window Guard 17. Nut (9) 25. Capscrew (8)
9. Capscrew (11)
c. Installation
(1) With assistant helping, install skid plate frame (23) with eight capscrews
(25) and nuts (24). Tighten securely.
(2) Install two capscrews (22) and nuts (21) on skid plate frame (23). Tighten
securely.
18-49
TM 08780B-20
NOTE
Do not tighten any capscrews on skid plate until all capscrews are started.
(3) Install skid plate (12) with four capscrews (18), washers (19) and nuts
(20).
(4) Install nine capscrews (16) and nuts (17) on skid plate (12).
(5) Install ten capscrews (13), new lockwashers (14) and washers (15) on skid
plate (12).
(6) Install 11 capscrews (9), washers (10) and nuts (11) on skid plate (12).
(7) Tighten all capscrews on skid plate (12).
(8) Install peep window guard (8) with five capscrews (5), washers (7) and
(9) Install headlight guards (4) with eight capscrews (1), washers (3) and nuts
END OF TASK
NOTE
18-50
TM 08780B-20
1. Capscrew (8) 10. Washer (11) 18. Capscrew (4)

2. Nut (8) 11. Nut (11) 19. Washer (4)
3. Washer (8) 12. Skid Plate 20. Nut (4)
4. Headlight Guard (2) 13. Capscrew (10) 21. Nut (2)
5. Capscrew (5) 14. Lockwasher (10) 22. Capscrew (2)
6. Nut (5) 15. Washer (10) 23. Skid Plate Frame
7. Washer (5) 16. Capscrew (9) 24. Nut (8)
8. Peep Window Guard 17. Nut (9) 25. Capscrew (8)
9. Capscrew (11)
18-51
TM 08780B-20
18-19. ENGINE ACCESS DOOR REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Locknuts (11) (MS35338-43) item 2
a. Removal
(1) Remove 11 screws (1) and locknuts (2) from engine access door (3).
(2) Remove engine access door (3) from radiator grille assembly (4).
c. Installation
(1) Install engine access door (3) on radiator grille assembly (4).
(2) Install 11 screws (1) and new locknuts (2) on engine access door (3).
18-52
TM 08780B-20
1. Screw (11)
2. Locknut (11)
3. Engine Access Door
4. Radiator Grille Assembly
END OF TASK
18-53
TM 08780B-20
18-20. TOOL BOX AND STOWAGE COMPARTMENT REPLACEMENT

(MK14, 15, 17)

c. Installation
INITIAL SETUP
MK14
MK15
MK17
Materials/Parts
Locknut (AR) (MS51922-9) item 6
Cotter Pin (5) (356AX) item 9
Locknut (2) (6450AX) item 11
Sealant, Silicone (item 5, Appendix D)
a. Removal
NOTE
Rear tool box assemblies have mud flaps attached.
(1) Remove mud flaps from rear tool box assemblies. Refer to
paragraph 18-5.
(2) Remove eight locknuts (1) and capscrews (2) while supporting tool box
assembly (3).
(3) Remove tool box assembly (3) from cargo body (4).
NOTE
Number of straps (5) may vary.
(4) Remove locknut (6), two washers (7), capscrew (8) and strap (5). Discard
locknut (6).
NOTE
Remove cotter pins (9) through bottom of tool stowage box.
(5) Remove and discard five cotter pins (9).
(6) Remove three hole plugs (10). Discard hole plugs (10), if damaged.
18-54
TM 08780B-20
NOTE
Perform step (7) on MK14A1 series vehicles only.
(7) Remove two locknuts (11), washers (12), screws (13) and latch (14).
c. Installation
(1) Install strap (5), capscrew (8) with washers (7) and new locknut (6).
(2) Install three hole plugs (10) using silicone sealant. Use new hole plugs
(10) as necessary.
NOTE
Install cotter pins (9) through bottom of tool assembly (3).
(3) Install five new cotter pins (9).
NOTE
Perform step (4) on MK14A1 series vehicles only.
(4) Install latch (14) with two screws (13), washers (12) and new locknuts
(5) Support tool box assembly (3) on cargo body (4).
(6) Install eight capscrews (2) and locknuts (1) to secure tool box (7)
assembly (3).
(7) Install mud flaps on rear tool box assemblies. Refer to paragraph 18-5.
18-55
TM 08780B-20
1. Locknut (8) 8. Capscrew

2. Capscrew (8) 9. Cotter Pin (5)
3. Tool Box Assembly 10. Hole Plug (3)
4. Cargo Body 11. Locknut (2)*
5. Strap 12. Washer (2)*
6. Locknut 13. Screw (2)*
7. Washer (2) 14. Latch*
END OF TASK
18-56
TM 08780B-20
18-21. TOOL BOX AND STOWAGE COMPARTMENT REPLACEMENT (LVSA1

SERIES VEHICLES ONLY)
THIS TASK COVERS: a. Front Stowage Compartment Removal

b. Rear Stowage Compartment Removal
d. Rear Stowage Compartment Installation
e. Front Stowage Compartment Installation
INITIAL SETUP
MK15A1
MK17A1
Materials/Parts
Cotter Pin (10) (356AX) items 1 and 26
Locknut (4) (6450AX)Q items 2 and 30
Locknut (48) (110310A) items 6, 11, 14, 22, 34, 38, 41 and 44
Locknut (AR) (1333510) item 27
a. Front Stowage Compartment Removal
NOTE
Remove cotter pins (1) through bottom of tool box assembly.
(2) Remove two locknuts (2), washers (3), screws (4) and latch (5). Discard
locknuts (2).
(3) Remove six locknuts (6), four capscrews (7), two capscrews (8) and tool
box assembly (9) from support (10). Discard locknuts (6).
(4) Remove six locknuts (11), four capscrews (12), two capscrews (13) and
support (10). Discard locknuts (11).
NOTE
Perform step (5) on MK15A1 vehicles only.
(5) Remove six locknuts (14), capscrews (15), hanger bracket (16) and
support bracket (17) from frame (18). Discard locknuts (14).
18-57
TM 08780B-20
NOTE
(6) Remove six locknuts (19), washers (20), capscrews (21), hanger bracket
(16) and support bracket (17) from frame (18). Discard locknuts (19).
b. Rear Stowage Compartment Removal
(1) Remove mudflaps from rear tool box assemblies. Refer to

paragraph 18-5.
(2) Remove four locknuts (22), capscrews (23) and outrigger pad stowage
bracket (24). Discard locknuts (22).
(3) Remove three hole plugs (25). Discard damaged hole plugs (25) as
necessary.
NOTE
Remove cotter pins (26) through bottom of tool box assembly.
NOTE
(5) Remove locknut (27), capscrew (28) and strap(s) (29). Discard locknut
(27).
(6) Remove two locknuts (30), washers (31), screws (32) and latch (33).
(7) Remove eight locknuts (34), capscrews (35) and rear tool box assembly
(36) from support assembly (37). Discard locknuts (34).
(8) Remove six locknuts (38), four capscrews (39), two capscrews (40) and
support assembly (37). Discard locknuts (38).
(9) Remove four locknuts (41), capscrews (42) and two supports (43).
NOTE
(10) Remove eight locknuts (44), capscrews (45), hanger bracket (46) and
support bracket (47) from frame (18). Discard locknuts (44).
18-58
TM 08780B-20
NOTE
(11) Remove eight locknuts (48), washers (49), capscrews (50), hanger bracket
(46) and support bracket (47) from frame (18). Discard locknuts (48).
1. Cotter Pin (5) 18. Frame 35. Capscrew (8)

2. Locknut (2) 19. Locknut (6) 36. Rear Tool Box
3. Washer (2) 20. Washer (6) Assembly
4. Screw (2) 21. Capscrew (6) 37. Support Assembly
5. Latch 22. Locknut (4) 38. Locknut (6)
6. Locknut (6) 23. Capscrew (4) 39. Capscrew (4)
7. Capscrew (6) 24. Outrigger Pad 40. Capscrew (2)
8. Capscrew (2) Stowage Bracket 41. Locknut (4)
9. Front Tool 25. Hole Plug (3) 42. Capscrew (4)
Box Assembly 26. Cotter Pin (5) 43. Support (2)
10. Support 27. Locknut 44. Locknut (8)
11. Locknut (6) 28. Capscrew 45. Capscrew (8)
12. Capscrew (4) 29. Strap 46. Hanger Bracket
13. Capscrew (2) 30. Locknut (2) 47. Support Bracket
15. Capscrew (6) 32. Screw (2) 49. Washer (8)
16. Hanger Bracket 33. Latch 50. Capscrew (8)
17. Support Bracket 34. Locknut (8)
18-59
TM 08780B-20
d. Rear Stowage Compartment Installation
NOTE
(1) Install support bracket (47) and hanger bracket (46) onto frame (18) using
four capscrews (50), washers (49) and new locknuts (48). Torque locknuts (48) to 35 ft-lbs (47.5
N*m).
NOTE
eight capscrews (45) and new locknuts (44). Torque locknuts (44) to 35 ft-lbs (47.5 N*m).
(3) Assemble support assembly (37) using two supports (43), four capscrews
(41) and new locknuts (42). Tighten locknuts (42) securely.
(4) Install support assembly (37) using two capscrews (40), four capscrews
(39) and six new locknuts (38). Tighten locknuts (38) securely.
(5) Install tool box assembly (36) onto support assembly (37) using eight
capscrews (35) and new locknuts (34). Tighten locknuts (34) securely.
NOTE
(6) Install strap(s) (29) using capscrews (28) and new locknut (27). Tighten
locknut (27) securely.
NOTE
Install cotter pins (26) through bottom of tool box assembly.
(8) Install three hole plugs (25) using silicone sealant.
18-60
TM 08780B-20
(9) Install latch (33) with two screws (32), washers (31) and locknuts (30).
(10) Install outrigger pad stowage bracket (24) using four capscrews (23) and
(11) Install mud flaps on rear tool box assemblies. Refer to paragraph 18-5.
e. Front Stowage Compartment Installation
NOTE
six capscrews (21), washers (20) and new locknuts (19). Torque locknuts (19) to 35 foot-pounds
(47.5 N*m).
NOTE
six capscrews (15) and new locknuts (14). Torque locknuts (14) to 35 foot-pounds (47.5 N*m).
(3) Install support (10) using two capscrews (13), four capscrews (12) and six
(4) Install tool box assembly (9) onto support (10) using four capscrews (7),
two capscrews (8) and new locknuts (6). Tighten locknuts (6) securely.
(5) Install latch (5) with two screws (4), washers (3) and locknuts (2).
NOTE
Install cotter pins (1) through bottom of tool box assembly.
END OF TASK
18-61
TM 08780B-20
1. Cotter Pin (5) 18. Frame 35. Capscrew (8)

2. Locknut (2) 19. Locknut (6) 36. Rear Tool Box
3. Washer (2) 20. Washer (6) Assembly
4. Screw (2) 21. Capscrew (6) 37. Support Assembly
5. Latch 22. Locknut (4) 38. Locknut (6)
7. Capscrew (6) 24. Outrigger Pad 40. Capscrew (2)
8. Capscrew (2) Stowage Bracket 41. Locknut (4)
9. Front Tool 25. Hole Plug (3) 42. Capscrew (4)
Box Assembly 26. Cotter Pin (5) 43. Support (2)
10. Support 27. Locknut 44. Locknut (8)
11. Locknut (6) 28. Capscrew 45. Capscrew (8)
12. Capscrew (4) 29. Strap 46. Hanger Bracket
13. Capscrew (2) 30. Locknut (2) 47. Support Bracket
15. Capscrew (6) 32. Screw (2) 49. Washer (8)
16. Hanger Bracket 33. Latch 50. Capscrew (8)
17. Support Bracket 34. Locknut (8)
18-62
TM 08780B-20
18-22. STOWAGE COMPARTMENT REPLACEMENT (MK16)
THIS TASK COVERS: a. Right Stowage Compartment Removal

b. Left Stowage Compartment Removal
d. Left Stowage Compartment Installation
e. Right Stowage Compartment Installation
INITIAL SETUP
MK16
Materials/Parts
Locknut (31) (MS51922-1) items 1, 4, 7, 12, 16, 19, 26, 32 and 41
Locknut (4) (MS51922-17) item 29 Locknut (2) (MS51922-9) item 37
Locknut (4) (64050AX) items 18.1 and 44
Cotter Pin (10) (356AX) items 18.5 and 48
Personnel Required
1 MOS 3521
1 Assistant
a. Right Stowage Compartment Removal
(1) Remove four locknuts (1) and capscrews (2) from tool stowage bracket
(3). Remove tool stowage bracket (3) and discard locknuts (1).
(2) Remove four locknuts (4) and capscrews (5) from inside right stowage
compartment (6). Discard locknuts (4).
(3) Remove seven locknuts (7), two clamps (8), seven washers (9),
lockwashers (10) and capscrews (11) from bottom of right stowage compartment (6). Discard
locknuts (7) and lockwashers (10).
(4) With help from assistant, lift right stowage compartment (6) from vehicle.
(5) Remove two locknuts (12), capscrews (13) and handle (14) from right
stowage compartment (6). Discard locknuts (12).
NOTE
(6) Remove locknut (16), two washers (17), capscrew (18) and straps (15).
18-63
TM 08780B-20
NOTE
(7) Remove two locknuts (18.1), washers (18.2), screws (18.3) and latch
NOTE
Remove cotter pins (18.5) through bottom of right stowage compartment (6).
(8) Remove and discard five cotter pins (18.5).
1. Locknut (4)
2. Capscrew (4)
3. Tool Stowage
Bracket
4. Locknut (4)
5. Capscrew (4)
6. Right Stowage
Compartment
7. Locknut (7)
8. Clamp (2)
9. Washer (7)
10. Lockwasher (7)
11. Capscrew (7)
12. Locknut (2)
13. Capscrew (2)
14. Handle
15. Strap
16. Locknut
17. Washer (2)
18. Capscrew
18.1 Locknut (4)*
18.2 Washer (4)*
18.3 Screw (4)*
18.4 Latch (2)*
18.5 Cotter Pin (5)
18-64
TM 08780B-20
b. Left Stowage Compartment Removal
(1) Remove four locknuts (19) and capscrews (20) from tool stowage bracket
(21). Remove tool stowage bracket (21). Discard locknuts (19).
(2) Remove four nuts (22) and capscrews (23) from remote control stowage
compartment (24). Remove remote control stowage compartment (24).
(3) If damaged, remove cover (25) by removing two locknuts (26), washers
(27) and capscrews (28). Discard locknuts (26).
(4) Remove four locknuts (29) and capscrews (30) from inside left stowage
compartment (31). Discard locknuts (29).
(5) Remove six locknuts (32), lockwashers (33), washers (34), two clamps
(35) and six capscrews (36). Discard locknuts (32) and lockwashers (33).
(6) With help from an assistant, lift left stowage compartment (31) from
vehicle.
(7) Remove two locknuts (37), capscrews (38) and handle (39) from left
stowage compartment (31). Discard locknuts (37).
NOTE
(8) Remove locknut (41), two washers (42), capscrew (43) and strap (40).
NOTE
(9) Remove two locknuts (44), washers(45), screws (46) and latch (47).
NOTE
Remove cotter pins (48) through bottom of left stowage compartment (31).
18-65
TM 08780B-20
d. Left Stowage Compartment Installation
(1) Install handle (39) using two capscrews (38) and new locknuts (37).
(2) With help from an assistant, position left stowage compartment (31) onto
vehicle. Install six capscrews (36), two clamps (35), washers (34), new lockwashers (33) and
new locknuts (32).
(3) Install four capscrews (30) and new locknuts (29) inside left stowage
compartment (31).
(4) Install remote control stowage compartment cover (25) using two
capscrews (28), washers (27) and new locknuts (26). Tighten locknuts (26) so that cover (25)
moves freely.
(5) Install remote control stowage compartment (24) onto left stowage
compartment (31) using four capscrews (23) and nuts (22).
(6) Install tool stowage bracket (21) using four capscrews (20) and new
locknuts (19).
(7) Install strap (40) with capscrew (43), washers (42) and new locknut (41).
NOTE
Install cotter pins (48) through bottom of left stowage compartment (31).
NOTE
(9) Install latch (47) using two screws (46), washers (45) and new locknuts
18-66
TM 08780B-20
19. Locknut (4) 29. Locknut (4) 39. Handle

20. Capscrew (4) 30. Capscrew (4) 40. Strap
21. Tool Stowage Bracket 31. Left Stowage 41. Locknut
22. Nut (4) Compartment 42. Washer (2)
23. Capscrew (4) 32. Locknut (6) 43. Capscrew
24. Remote Control 33. Lockwasher (6) 44. Locknut (4)*
Stowage Compartment 34. Washer (6) 45. Washer (4)*
25. Cover 35. Clamp (2) 46. Screw (4)*
26. Washer (2) 36. Capscrew (6) 47. Latch (2)*
27. Washer (2) 37. Locknut (2) 48. Cotter Pin (5)
18-67
TM 08780B-20
e. Right Stowage Compartment Installation
(1) Install handle (14) using two capscrews (13) and new locknuts (12).
(2) With help from an assistant, position stowage compartment (6) onto
vehicle. Install seven capscrews (11), two clamps (8), seven washers (9), new lockwashers (10)
and new locknuts (7).
(3) Install four capscrews (5) and new locknuts (4) inside right stowage
compartment (6).
(4) Install tool stowage bracket (3) using four capscrews (2) and new locknuts
(1).
(5) Install strap (15) using capscrew (18), washer (17) and new locknut (16).
NOTE
Install cotter pins (18.5) through bottom of right stowage compartment.
(6) Install five new cotter pins (18.5).
NOTE
(7) Install latch (18.4) using two screws (18.3), washers (18.2) and new
locknuts (18.1). Tighten locknuts (18.1) securely.
18-68
TM 08780B-20
1. Locknut (4) 8. Clamp (2) 16. Locknut

2. Capscrew (4) 9. Washer (7) 17. Washer (2)
3. Tool Stowage 10. Lockwasher (7) 18. Capscrew
Bracket 11. Capscrew (7) 18.1. Locknut (4)*
4. Locknut (4) 12. Locknut (2) 18.2. Washer 141*
5. Capscrew (4) 13. Capscrew (2) 18.3. Screw (4)*
6. Right Stowage 14. Handle 18.4. Latch (2)*
Compartment 15. Strap 18.5. Cotter Pin (5)
7. Locknut (7)
*LVSAl Series Vehicles Only
18-69
TM 08780B-20
18-23. GRAB HANDLE REPLACEMENT (LVSA1 SERIES VEHICLES ONLY)

c. Installation
INITIAL SETUP
MK48A1
Materials/Parts
Lockwasher (2) (2463H)Q items 5 and 10
a. Removal
(2) Remove capscrew (4), lockwasher (5) and grab handle (3) from vehicle.
(4) Remove capscrew (9), lockwasher (10) and grab handle (8) from vehicle.
c. Installation
(1) Install grab handle (8), new lockwasher (10) and capscrew (9) on vehicle.
securely.
18-70
TM 08780B-20
(3) Install grab handle (3), new lockwasher (5) and capscrew (4) on vehicle.
securely.
1. Locknut (2) 6. Locknut (2)

3. Grab Handle 8. Grab Handle
4. Capscrew 9. Capscrew
5. Lockwasher 10. Lockwasher
END OF TASK
18-71/(18-72 blank)
TM 08780B-20
CHAPTER 19
WINCHES
maintenance and replacement procedures for the vehicle's winches.
a. General. The recovery winch is powered by a hydraulic motor that drives the
winch drum by way of a planetary gear box. The winch on the MK15 is controlled by either
manual levers or a hand held remote control. On the MK16, the recovery winch can only be
operated by a hand held remote control.
b. Hydraulic Motor. Uses hydraulic oil under pressure to drive a planetary gear.
c. Planetary Gear Box. Houses gears needed to rotate winch drum with 60,000
pounds (27.24 kg) of pulling strength.
19-1
TM 08780B-20
19-3. WINCH CABLE MAINTENANCE

c. Installation

Condition Condition
MK15 TM 08780B-10 Winch cable extended
MK16 (para 2-18 or 2-22).

TM 08780B-10 Wear heavy gloves when handling winch
cable. Do not let cable run through bare
hands. Frayed cable can cut hands.
a. Removal
NOTE
Even though cables are wrapped differently on the MK15 and MK16, the replacement is the
same.
(1) Remove two nuts (1) from cable clamp (2).
(2) Remove cable (3) from winch drum (4).
c. Installation
(1) Wrap cable (3) around winch drum (4).
(2) Install cable clamp (2) around cable (3) using two nuts (1).
(3) Torque nuts (1) to 243 foot-pounds (329.5 N*m).
END OF TASK
19-2
TM 08780B-20
NOTE
TM 08780B-10 Start engine (para 2-13).
Rewind winch cable (para 2-18 or 2-22).
1. Nut (2)
2. Cable Clamp
3. Cable
4. Winch Drum
19-3
TM 08780B-20
19-4. WINCH CONTROL HANDLE REPAIR (MK16)

c. Installation
INITIAL SETUP
MK16
Materials/Parts
Solder (item 52, Appendix D)
a. Removal
(1) Remove six screws (1) from station cover (2).
(2) Remove station cover (2) and rubber protector cover (3) from switch
station (4).
(3) Remove screw (5) from switch (6).
(4) Remove screw (7) from switch (8).
(5) Remove two switches (6 and 8) from switch station (4).
NOTE
Tag all wires for proper installation.
(6) Remove screw (9) from terminal (10). Tag and remove jumper wire (11)
from switch (6).
(7) Remove screw (12) from terminal (13). Tag and remove wire (14) and
jumper wire (11) from switch (6).
from switch (6).
from switch (6).
(10) Remove screw (21) from terminal (22) and remove jumper wire (20) from
switch (8).
19-4
TM 08780B-20
(11) Remove screw (23) from terminal (24) and remove jumper wire (17) from
switch (8).
jumper diodes (28) from switch (8).
jumper diode (28) from switch (8).
(14) Tag and cut wire (32) from diodes (28).
(15) Remove retainer cap (33) from switch station (4).
(16) Remove umbilical cord (34) from switch station (4).
(17) Remove rubber grommet (35), plastic spacer (36) and retainer cap (33)
from umbilical cord (34).
19-5
TM 08780B-20
1. Screw (6) 13. Terminal 25. Screw

2. Station Cover 14. Wire 26. Terminal
3. Rubber Protector Cover 15. Screw 27. Wire
4. Switch Station 16. Terminal 28. Jumper Diode (2)
5. Screw 17. Jumper Wire 29. Screw
6. Switch 18. Screw 30. Terminal
7. Screw 19. Terminal 31. Wire
8. Switch 20. Jumper Wire 32. Wire
9. Screw 21. Screw 33. Retainer Cap
10. Terminal 22. Terminal 34. Umbilical Cord
11. Jumper Wire 23. Screw 35. Rubber Grommet
12. Screw 24. Terminal 36. Plastic Spacer
19-6
TM 08780B-20
c. Installation
(1) Install retainer cap (33), plastic spacer (36) and rubber grommet (35) on
umbilical cord (34).
(2) Install umbilical cord (34) into switch station (4).
(3) Solder wire (32) to jumper diodes (28).
(4) Install jumper diode (28) wire (31) and screw (29) to terminal (30) on
switch (8). Tighten securely.
(5) Install jumper diode (28) wire (27) and screw (25) to terminal (26) on
(6) Install jumper wire (17) and screw (23) to terminal (24) on switch (8).
Tighten securely.
Tighten securely.
Tighten securely.
Tighten securely.
(10) Install jumper wire (11), wire (14) and screw (12) to terminal (13) on
Tighten securely.
CAUTION
IT MAY BE NECESSARY TO REROUTE WIRES DURING SWITCH INSTALLATION TO

AVOID WIRE DAMAGE.
(12) Install switch (8) and screw (7) into switch station (4). Tighten securely.
(13) Install switch (6) and screw (5) into switch station (4). Tighten securely.
(14) Install rubber protector cover (3), station cover (2) and six screws (1) on
switch station (4). Tighten securely.
19-7
TM 08780B-20
(15) Install rubber grommet (35), plastic spacer (36) and retainer cap (33) on
switch station (4). Tighten securely.
1. Screw (6) 13. Terminal 25. Screw

2. Station Cover 14. Wire 26. Terminal
3. Rubber Protector Cover 15. Screw 27. Wire
4. Switch Station 16. Terminal 28. Jumper Diode (2)
5. Screw 17. Jumper Wire 29. Screw
6. Switch 18. Screw 30. Terminal
7. Screw 19. Terminal 31. Wire
8. Switch 20. Jumper Wire 32. Wire
9. Screw 21. Screw 33. Retainer Cap
10. Terminal 22. Terminal 34. Umbilical Cord
11. Jumper Wire 23. Screw 35. Rubber Grommet
12. Screw 24. Terminal 36. Plastic Spacer
19-8
TM 08780B-20
CHAPTER 20
CRANE
Maintenance level mechanics. The following sections cover maintenance and replacement
procedures for the vehicle’s crane.
a. General. The MK15 and MK17 cranes are the same, except for mounting
location and control functions. Both are folding knuckle boom, hydraulic/electric cranes. They
are 19 ton meter rated. This means that at one meter from the center of rotation, the crane is
capable of lifting 19 tons. Beyond one meter, the crane is limited to lighter loads by a capacity
alert system. Both cranes rotate 350 degrees, with a 10 degree safety limit that protects the
control stations. Both cranes have remote control functions. Neither crane is dependent upon
electricity for operation. Only the remote control function requires electricity to operate. In the
event of electrical failure, both cranes can be manually operated by moving the electrical failure
valve to the closed position.
b. Electrical System. The crane’s electrical system operates on 24 volts DC,

supplied from the MK48. Electricity provides power for the remote control system. Electricity
also controls one function of the capacity alert system, that is the folding boom’s up restriction.
In the event of an electrical failure, all other functions of the crane will work hydraulically.
MK17
20-1
TM 08780B-20
(1) Junction Box. The junction box, located on the right slewing cylinder,
receives its power (24 volts DC) from the MK48. The junction box is the center for all of the
crane’s electrical connections.
(2) Proximity Switch. The proximity switch is a pendulum switch that signals
the capacity alert system if the folding boom is above or below horizontal.
(3) Solenoid Dump Valve. The solenoid dump valve works with the capacity
alert system to protect the crane from overload. Signals received from the proximity switch
change the position of the solenoid dump valve.
(4) Neutral Switch. The neutral switch is located on the electrical failure
valve. The neutral switch disconnects all electricity to the remote system when the electrical
failure valve is in use. A second neutral switch, found only on the MK15, activates the high idle
on the engine when the winch is in use.
(5) Relay. The relay located in the junction box is part of the capacity alert
system. It relays the signal from the proximity switch to the solenoid dump valve.
(6) Circuit Breakers. There are two circuit breakers, located in the junction
box, that provide electrical overload protection for the crane.
20-2
TM 08780B-20
c. Hydraulic System. The MK48 pumps hydraulic oil to the crane at a flow rate of
11 gallons per minute. This flow of hydraulic oil is directed and controlled by several valves on
the crane. Opening these valves permits oil to flow to the crane’s hydraulic cylinder. Here
hydraulic oil pressure builds until great enough to move the hydraulic cylinders. Relief valves
prevent this pressure from becoming too great. The relief valves release extra pressure and send
it back to the hydraulic reservoir on the MK48. Unwanted movement of the crane is prevented
by holding valves mounted on the crane’s booms.
The capacity alert system prevents overloading of the crane. Any load that is greater than the
crane can safely handle creates extra pressure in the system. This extra pressure is sensed by the
capacity alert system’s own relief valve. This relief valve then directs all oil pressure back to the
hydraulic reservoir on the MK48. All hydraulic oil eventually flows back to the MK48 through a
return line. There, the hydraulic oil is filtered and cooled. The hydraulic oil is then drawn into
the hydraulic pump where it begins the cycle again.
(1) Extension Cylinders. The two extension cylinders hydraulically extend or

retract the extension beams.
(2) Outrigger Cylinders. The two outrigger cylinders hydraulically extend or

retract the outrigger beams.
(3) Stabilizer Cylinders. The two hydraulic stabilizer cylinders are used
together with the outrigger beams to give the crane greater stability for handling loads.
20-3
TM 08780B-20
(4) A-Frame (MK15 Only). The A-frame provides hydraulic lifting capability
for towing.
(5) Hose Breakage Valves. The hose breakage valves sense loss of back
pressure combined with excessive flow due to a broken hydraulic line or hose. It immediately
shuts off all oil flow in the direction of the broken line or hose.
20-4
TM 08780B-20
(6) Manifold. The manifold is a junction block for hydraulic oil. From the
manifold, all hydraulic oil is returned to the reservoir.
(7) Basic Solenoid Valve. The basic solenoid valve is electrically operated. It
provides the crane with hydraulic power by stopping oil flow back to the reservoir. This causes
the oil to go through the control valves.
(8) Electrical Failure Valve. The electrical failure valve provides manual
backup for the basic solenoid valve. It should only be used in the event of an electrical failure.
(9) Double Holding Valve. The double holding valve prevents movement of
the extension cylinders until its preset safety pressure is overcome by hydraulic pressure from
operation of the crane’s controls.
(10) Main Relief Valve. The main relief valve protects the crane’s components
from pressures that might exceed 3,000 psi.
20-5
TM 08780B-20
(11) Stabilizer Selector/Locking Valves And Outrigger Selector/Locking

Valves. The stabilizer and outrigger selector/locking valves are gate valves used to shut off
hydraulic oil flow. This prevents unwanted movement of the stabilizer or outrigger cylinders.
(12) Folding Boom Holding Valve. The folding boom holding valve prevents
downward movement of the folding boom until its preset safety pressure is overcome by
hydraulic pressure from operation of the crane’s controls.
20-6
TM 08780B-20
(13) Main Boom Holding Valve. The main boom holding valve prevents
downward movement of the main boom until its preset safety pressure is overcome by hydraulic
pressure from operation of the crane’s controls.
20-7
TM 08780B-20
d. Accessories. The following items are needed for safe, convenient operation of the
crane.
(1) Stowage Box. The stowage box on both cranes (MK15 or MK17) houses
the remote control unit and umbilical cord.
20-8
TM 08780B-20
(2) Placards. The placards, which are located at prominent positions on the
crane, provide instructions and/or warnings.
(3) Stabilizer Pads. The stabilizer pads provide the base support for the crane
while working.
(4) Stowing Cables. The stowing cables ease stowing or deployment of the
stabilizer cylinders.
(5) Actuator Rods. The actuator rods provide the mechanical link between the
remote control and the control levers.
(6) Main And Auxiliary Control Levers. The main and auxiliary levers
provide the mechanical linkage for operation of the control valves.
(7) Stabilizer Stowing Pin. The stabilizer stowing pin locks the stabilizer
cylinder in either the stowed or working position.
(8) Travel Lock Pin. The travel lock pin holds the crane in the stowed
position.
20-9
TM 08780B-20
20-10
TM 08780B-20
20-3. JUNCTION BOX MAINTENANCE (MK15)

c. Installation

Condition Condition
disconnected
Locknut (15) (MS51858-5) items 2, 49, General Safety Instructions
51, 53, 55 and 60 Block wheels of truck to prevent personal
Star Washer (11) (MS46641-10) items 6, injury. To prevent personal injury, make
14 and 25 sure batteries are disconnected before
(1) Remove four Allen head screws (1) and locknuts (2). Discard locknuts
(2).
(2) Remove cover (3) from junction box (4).
1. Allen Head Screw (4)

2. Locknut (4)
3. Cover
4. Junction Box
20-11
TM 08780B-20
(3) Remove two nuts (5) and star washers (6) from terminal block (7).
Discard star washers (6).
NOTE
• Before removing wires, tag and mark with corresponding numbers from illustration
and legend.
• Some cranes can be equipped with an old style or new style proximity switch. The new
style switch can be identified by the red LED on the back side of the switch. This new
style switch is wired differently than the old style switch and should be noted upon
removal.
(4) Remove white wires (8, 9, 10 and 11) and jumper wire (12) from terminal
block (7).
(5) Remove three nuts (13) and star washers (14) from terminal block (15).
Discard star washers (14).
(6) Remove the following wires: black (16, 17, 18 and 19), green (20, 21 and
22) and white (23) from terminal block (15).
(7) Remove four nuts (24) and star washers (25) from circuit breakers (26 and
27). Discard star washers (25).
(8) Remove three black wires (28, 29 and 19) and one jumper wire (30) from
circuit breakers (26 and 27).
(9) Unplug four black wires (17, 18, 31 and 32) from relay (33).
20-12
TM 08780B-20
5. Nut (2) 15. Terminal Block 25. Star Washer (4)

6. Star Washer (2) 16. Black Wire 26. Circuit Breaker
7. Terminal Block 17. Black Wire 27. Circuit Breaker
8. White Wire 18. Black Wire 28. Black Wire
10. White Wire 20. Green Wire 30. Jumper Wire
11. White Wire 21. Green Wire 31. Black Wire
12. Jumper Wire 22. Green Wire 32. Black Wire
13. Nut (3) 23. White Wire 33. Relay
14. Star Washer (3) 24. Nut (4)
(10) Unscrew cap (34) from adapter (35).
(11) Slide cap (34), washer (36) and rubber grommet (37) back on cable (38).
(12) Tag and carefully remove cable (38) from adapter (35).
(13) Repeat steps (10) thru (12) for cables (39, 40, 41 and 42).
20-13
TM 08780B-20
(14) Remove five threaded lockwashers (43) and adapters (35) from junction
box (4).
(15) Remove two clamps (44).
(16) Remove junction box (4) from slewing cylinder (45).
(18) Remove two screws (48), locknuts (49) and terminal block (15) from
junction box (4). Discard locknuts (49).
4. Junction Box 39. Cable

34. Cap 40. Cable
35. Adapter 41. Cable
36. Washer 42. Cable
37. Rubber Grommet 43. Lockwasher (5)
38. Cable
20-14
TM 08780B-20
4. Junction Box 45. Slewing Cylinder 52. Mounting Bracket

7. Terminal Block 46. Screw (4) 53. Screw (2)
15. Terminal Block 47. Locknut (4) 54. Locknut (2)
26. Circuit Breaker 48. Screw (2) 55. Flat Washer (2)
27. Circuit Breaker 49. Locknut (2) 56. Circuit Breaker Bracket
33. Relay 50. Screw 57. Screw (2)
44. Clamp (2) 51. Locknut 58. Locknut (2)
(19) Remove screw (50), locknut (51) and relay (33) from junction box (4).
(20) Separate mounting bracket (52) from junction box (4).
(21) Remove two screws (53), locknuts (54), flat washers (55) and circuit
breaker bracket (56) with circuit breakers (26 and 27) from junction box (4). Discard locknuts
(54).
20-15
TM 08780B-20
(2) Inspect all parts for corrosion or other damage. Refer to paragraph 2-12.
c. Installation
(1) Fasten terminal block (7) in junction box (4) with two screws (57) and
new locknuts (58). Tighten securely.
(2) Fasten circuit breaker bracket (56) with circuit breakers (26 and 27) in
junction box (4) with two screws (53), flatwashers (55) and new locknuts (54). Tighten
locknuts(54) securely.
(3) Position mounting bracket (52) to junction box (4) and secure with four
screws (46) and new locknuts (47). Tighten locknuts (47) securely.
(4) Fasten relay (33) in junction box (4) with screw (50) and new locknut
(5) Fasten terminal block (15) in junction box (4) with two screws (48) and
(6) Secure junction box (4) to slewing cylinder (45) with two clamps (44).
Tighten securely.
20-16
TM 08780B-20
4. Junction Box 46. Screw (4) 53. Screw (2)

15. Terminal Block 48. Screw (2) 55. Flat Washer (2)
26. Circuit Breaker 49. Locknut (2) 56. Circuit Breaker
27. Circuit Breaker 50. Screw Bracket
33. Relay 51. Locknut 57. Screw (2)
44. Clamp (2) 52. Mounting 58. Locknut (2)
45. Slewing Cylinder Bracket
(7) Install five adapters (35) and secure with threaded lockwashers (43).
Tighten securely.
NOTE
Letters have been assigned to terminals of terminal blocks (7 and 15), circuit breakers (26 and
27) and relay (33) for ease of installation. See illustration below. Some terminals will not be
used.
20-17
TM 08780B-20
7. Terminal Block
15. Terminal Block
26. Circuit Breaker
27. Circuit Breaker
33. Relay
35. Adapter (5)
43. Lockwasher (5)
(8) Slide cap (34), washer (36) and rubber grommet (37) over cable (38)
approximately 12 inches (30.48 cm) from ends of white wire (8), black wire (28) and green wire
(20).
(9) Insert cable (38) through adapter (35).
(10) Connect white wire (8) to terminal (C) of terminal block (7).
(11) Connect black wire (28) to terminal (P) on circuit breaker (26).
(12) Connect jumper wire (30) on terminal (P) of circuit breaker (26) to
terminal (Q) of circuit breaker (27). Secure terminal (P) and terminal (Q) with two nuts (24) and
new star washers (25).
20-18
TM 08780B-20
(13) Connect green wire (20) to terminal (L) on terminal block (15).
(14) Slide rubber grommet (37) into adapter (35).
(15) Apply sealant to inside of cap (34) and slide washer (36) and cap (34) onto
adapter (35). Tighten cap (34) securely.
(16) Using one short jumper wire (12), connect terminals (C) to (F) on terminal
block (7).
7. Terminal Block 25. Star Washer (2) 34. Cap

8. White Wire 26. Circuit Breaker 35. Adapter
12. Jumper Wire (3) 27. Circuit Breaker 36. Washer
15. Terminal Block 28. Black Wire 37. Rubber Grommet
20. Green Wire 30. Jumper Wire 38. Cable
24. Nut (2)
(17) Connect one end of black wire (19) to terminal (R) of circuit breaker (27).
Secure terminal (R) with nut (24) and new star washer (25). Connect other end of black wire
(19) to terminal (N) of terminal block (15).
(18) Plug ends of black wires (17 and 18) to terminals (T and V) of relay (33).
Connect black wires (17 and 18) to terminal (N) of terminal block (15).
20-19
TM 08780B-20
(19) Slide cap (34), washer (36) and rubber grommet (37) over cable (39) leaving
approximately 12 inches to ends of wires (9 and 32).
(22) Secure wires (8, 9 and 12) on terminal (C) with nut (5) and new star
washers (6).
(23) Connect black wire (32) to terminal (U) on relay (33).
(25) Apply sealant to inside of cap (34). Slide washer (36) and cap (34) onto
5. Nut
6. Star Washer
7. Terminal Block
8. White Wire
9. White Wire
12. Jumper Wire
15. Terminal Block
17. Black Wire
18. Black Wire
19. Black Wire
24. Nut
25. Star Washer
27. Circuit Breaker
32. Black Wire
33. Relay
34. Cap
35. Adapter
36. Washer
37. Rubber Grommet
39. Cable
(26) Slide cap (34), washer (36) and rubber grommet (37) over cable (40),
leaving approximately 12 inches to end of cable (40).
20-20
TM 08780B-20
NOTE
New style proximity switch wire will be black.
(28) Connect black or white wire (10) to terminal (F) of terminal block (7).
NOTE
New style proximity switch wire will be white.
(29) Connect white or black wire (31) to terminal (S) on relay (33).
(30) Connect green wire (22) to terminal (N) of terminal block (15).
(31) Secure green wire (22) and black wires (17, 18 and 19) to terminal (N)
with nut (13) and new star washer (14).
7. Terminal Block
10. White Wire
13. Nut
14. Star Washer
15. Terminal Block
17. Black Wire
18. Black Wire
19. Black Wire
22. Green Wire
31. Black Wire
33. Relay
34. Cap
35. Adapter
36. Washer
37. Rubber Grommet
40. Cable
20-21
TM 08780B-20
leaving approximately 12 inches to end of cable.
(36) Connect white wire (11) to terminal (F) on terminal block (7).
(37) Secure white wires (10, 11 and 12) to terminal (F) with nut (5) and new
star washer (6).
(38) Connect black wire (29) to terminal (O) on circuit breaker (26).
(39) Secure black wire (29) to terminal (O) on circuit breaker (26) with nut
(24) and new star washer (25).
(40) Connect green wire (21) to terminal (M) on terminal block (15).
5. Nut
6. Star Washer
7. Terminal Block
10. White Wire
11. White Wire
12. White Wire
15. Terminal Block
21. Green Wire
24. Nut
25. Star Washer
26. Circuit Breaker
29. Black Wire
34. Cap
35. Adapter
36. Washer
37. Rubber Grommet
41. Cable
20-22
TM 08780B-20
leaving approximately 12 inches to end of cable.
(45) Connect white wire (23) to terminal (L) on terminal block (15).
(46) Secure white wire (23) and green wire (20) on terminal (L) with nut (13)
and new star washer (14).
(47) Connect black wire (16) on terminal (M) on terminal block (15).
(48) Secure black wire (16) and green wire (21) to terminal (M) with nut (13)
13. Nut
14. Star Washer
15. Terminal Block
16. Black Wire
20. Green Wire
21. Green Wire
23. White Wire
34. Cap
35. Adapter
36. Washer
37. Rubber Grommet
42. Cable
(51) Position cover (3) to junction box (4).
(52) Secure cover (3) to junction box (4) with four Allen head screws (1) and
END OF TASK
20-23
TM 08780B-20
NOTE
TM 08780B-10 Check crane for proper operation

(para 2-16).

2. Locknut (4)
3. Cover
4. Junction Box
20-24
TM 08780B-20
20-4. JUNCTION BOX MAINTENANCE (MK17)

c. Installation

Condition Condition
disconnected
Locknut (15) (MS51858-5) items 2, 46, General Safety Instructions
49, 51, 53 and 56 Block wheels of truck to prevent personal
Star Washer (7) (MS35333-73) items 6, injury. To prevent personal injury, make
15 and 23 sure batteries are disconnected before
(2).

2. Locknut (4)
3. Cover
4. Junction Box
20-25
TM 08780B-20
(3) Remove two nuts (5), star washers (6) and flat washer (7) from terminal
block (8). Discard star washers (6).
NOTE
and legend.
• Some cranes can be equipped with an old style or new style proximity switch. The new
style switch can be identified by the red LED on the back side of the switch. This new
style switch is wired differently than the old style switch and should be noted upon
removal.
(4) Remove white wires (9, 10, 11 and 12) and jumper wire (13) from
terminal block (8).
(5) Remove nut (14), star washer (15) and flat washer (16) from terminal
block (17). Discard star washer (15).
(6) Remove three black wires (18, 19 and 20) and one green wire (21) from
(7) Remove four nuts (22) and star washers (23) from circuit breakers (24 and
25). Discard star washers (23).
(8) Remove three black wires (20, 26 and 27) and jumper wire (28) from
circuit breakers (24 and 25).
(9) Unplug four black wires (18, 19, 29 and 30) from relay (31).
20-26
TM 08780B-20
5. Nut (2) 14. Nut 23 Star Washer (4)

6. Star Washer (2) 15. Star Washer 24. Circuit Breaker
7. Flat Washer (2) 16. Flat Washer 25. Circuit Breaker
8. Terminal Block 17. Terminal Block 26. Black Wire
10. White Wire 19. Black Wire 28. Jumper Wire
12. White Wire 21. Green Wire 30. Black Wire
13. Jumper Wire 22. Nut (4) 31 Relay
(10) Unscrew cap (32) and slide washer (33) and rubber grommet (34) back on
cable (35). Carefully remove cable (35) from adapter (36).
(11) Repeat step (10) for cables (37, 38 and 39).
(12) Remove four threaded lockwashers (40) and four adapters (36) from
junction box (4).
(13) Remove two screws (41) and clamps (42).
20-27
TM 08780B-20
(14) Remove two clamps (43).
(15) Remove junction box (4) from slewing cylinder (44).
4. Junction Box 36. Adapter (4)

32. Cap (4) 37. Cable
33. Washer (4) 38. Cable
34 Rubber Grommet (4) 39. Cable 32
35. Cable 40. Lockwasher (4)
20-28
TM 08780B-20

8. Terminal Block 46. Locknut(4) 53. Locknut(2)
24. Circuit Breaker 48. Locknut(2) 55. Flat Washer (2)
25. Circuit Breaker 49. Screw 56. Locknut (2)
31. Relay 50. Locknut 57. Circuit Breaker
43. Clamp (2) 51. Mounting Bracket Bracket
44. Slewing Cylinder
(18) Remove screw (49), locknut (50) and relay(31). Discard locknut (50).
(19) Separate mounting bracket (51) from junction box (4).
20-29
TM 08780B-20
(21) Remove two screws (54), flat washers (55), locknuts (56) and circuit
breaker bracket (57) from junction box (4). Discard locknuts (56).
c. Installation
(1) Position terminal block (8) in junction box (4). Secure terminal block (8)
to junction box (4) with two screws (52) and new locknuts (53). Tighten securely.
(2) Position circuit breaker bracket (57) with circuit breakers (24 and 25) in
junction box (4). Secure circuit breaker bracket (57) to junction box (4) with two screws (54),
flat washers (55) and new locknuts (56). Tighten securely.
(3) Position mounting bracket (51) to junction box (4). Secure mounting
bracket (51) to junction box (4) with four screws (45) and new locknuts (46). Tighten locknuts
securely.
(4) Position terminal block (17) in junction box (4). Secure terminal block
(17) to junction box (4) with two screws (47) and new locknuts (48). Tighten securely.
(5) Position relay (31) in junction box (4). Secure relay (31) to junction box
(4) with screw (49) and new locknut (50). Tighten securely.
(6) Secure junction box (4) to slewing cylinder (44) with two clamps (43).
Tighten securely.
20-30
TM 08780B-20

31. Relay 48. Locknut (2) 55. Flat Washer (2)
41. Screw (2) 49. Screw 56. Locknut (2)
42. Clamp (2) 50. Locknut 57. Circuit Breaker
43. Clamp (2) 51. Mounting Bracket Bracket
44. Slewing Cylinder
(7) Install four adapters (36) in junction box (4) and secure with four threaded
lockwashers (40). Tighten securely.
NOTE
To insure proper installation, letters have been assigned to terminals of terminal blocks (8 and
17), circuit breakers (24 and 25) and relay (31) for ease of installation. See illustration below.
Some terminals will not be used.
20-31
TM 08780B-20
4. Junction Box 25. Circuit Breaker

8. Terminal Block 31. Relay
17. Terminal Block 36. Adapter (4)
24. Circuit Breaker 40. Lockwasher (4)
(8) Install jumper wire (13) on terminal (F) and terminal (C) of terminal block
(8).
(9) Install jumper wire (28) on terminal (Q) of circuit breaker (24) and
terminal (R) of circuit breaker (25).
(10) Secure jumper wire (28) on terminal (R) of circuit breaker (25) with nut
(22) and new star washer (23).
20-32
TM 08780B-20
(11) Install black wire (20), on terminal (P) of circuit breaker (25). Install
other end of black wire (20) on terminal (N) of terminal block (17). Secure black wire (20) on
terminal (P) of circuit breaker (25) with nut(22) and new star washer (23).
(12) Plug black wire (19) into terminal (S) of relay (31). Install other end of
black wire (19) on terminal (N), of terminal block (17).
(13) Plug black wire (18) into terminal (V) of relay (31). Install other end of
black wire (18) on terminal (N), of terminal block (17).
(16) Connect black wire (26) to terminal (Q) of circuit breaker (24). Secure
wires (26 and 28) with nut (22) and new star washer (23).
(18) Apply sealant to the inside of cap (32). Slide washer (33) and cap (32)
onto adapter (36). Tighten cap (32) securely.
10. White Wire 33. Washer

26. Black Wire 34. Rubber Grommet
31. Relay 35. Cable
32. Cap 36. Adapter
20-33
TM 08780B-20
8. Terminal Block 22. Nut

10. White Wire 23. Star Washer
13. Jumper Wire 24. Circuit Breaker
17. Terminal Block 25. Circuit Breaker
18. Black Wire 26. Black Wire
19. Black Wire 28. Jumper Wire
20. Black Wire 31. Relay
leaving approximately 12 inches to the ends of cable (39).
(20) Connect white wire (11) to terminal (F) of terminal block (8).
(21) Connect black wire (27) to terminal (O) of circuit breaker (24). Secure
black wire (27) with nut (22) and new star washer (23).
20-34
TM 08780B-20
(23) Apply sealant to the inside of cap (32). Slide washer (33) and cap (32)
onto adapter (36). Tighten cap (32) securely.
8. Terminal Block 32. Cap

11. White Wire 33. Washer
22. Nut 34. Rubber Grommet
23. Star Washer 36. Adapter
24. Circuit Breaker 39. Cable
27. Black Wire
NOTE
New style proximity switch wire will be white.
(25) Plug black or white wire (30) onto terminal (T) of relay (31).
20-35
TM 08780B-20
(26) Connect green wire (21) onto terminal (N) of terminal block (17). Secure
wires (18, 19, 20 and 21) to terminal (N) with nut (14), flat washer (16) and new star washer
(15).
NOTE
New style proximity switch wire will be black.
(27) Connect black or white wire (12) onto terminal (F) of terminal block (8).
Secure wires (11, 12 and 13) to terminal (F) of terminal block (8) with nut (5), flat washer (7)
5. Nut 15. Star Washer 30. Black Wire

6. Star Washer 16. Flat Washer 31. Relay
7. Flat Washer 17. Terminal Block 32. Cap
8. Terminal Block 18. Black Wire 33. Washer
11 White Wire 19. Black Wire 34. Rubber Grommet
12. White Wire 20. Black Wire 36. Adapter
13. Jumper Wire 21. Green Wire 38. Cable
14 Nut
20-36
TM 08780B-20
(31) Plug black wire (29) onto terminal (U) of relay (31).
(32) Connect white wire (9) onto terminal (C) of terminal block (8). Secure
wires (9 and 10) and jumper wire (13) to terminal (C) with nut (5), flat washer (7) and new star
washer (6).
5. Nut 31. Relay

6. Star Washer 32. Cap
7. Flat Washer 33. Washer
8. Terminal Block 34. Rubber Grommet
9. White Wire 38. Adapter
13. Jumper Wire (4) 37. Cable
29. Black Wire
20-37
TM 08780B-20
(35) Install two clamps (42) over cable (37). Install two screws (41). Tighten
securely.
END OF TASK
NOTE

(para 2-25).
1. Allen Head Screw (4) 37. Cable

2. Locknut (4) 41. Screw (2)
3. Cover 42. Clamp (2)
4. Junction Box
20-38
TM 08780B-20
20-5. PROXIMITY SWITCH REPLACEMENT

c. Installation

Condition Condition
MK15 TM 08780B-20 Disconnect
MK17 batteries (para 7-45).
Materials/Parts MK15 proximity

Grease (item 21, Appendix D) switch leads
Lockwasher (MS35338-44) item 2 disconnected/
Nylon ties (AR) (MS3367-5-9) item 5 removed from
Lockwasher (2) (MS35338-46) item 10 junction box (para
Locknut (MS51922-17) item 16 20-3, leads10, 22
and 31).
References
TM 08780B-10 MK17 proximity
switch leads
disconnected/
removed from
junction box (para
20-4, leads 12, 21 and
30).

a. Removal
(1) On MK15 only, remove capscrew (1), lockwasher (2), washer (3) and
clamp (4). Discard lockwasher (2).
(2) Cut nylon ties (5) as needed along cable (6) to cordura sleeve (7).
(3) Secure length of mechanic’s wire to cable (6).
(4) Pull cable (6) through cordura sleeve (7). Disconnect cable (6) from
mechanic’s wire. Leave mechanic’s wire in cordura sleeve (7) to pull new cable (6) back
through.
20-39
TM 08780B-20
1. Capscrew 5. Nylon Tie (Air)

2. Lockwasher 6. Cable
3. Washer 7. Cordura Sleeve
4. Clamp
5. Nylon Tie
6. Cable
8. Hydraulic Hose
(5) Cut nylon ties (5) as needed to free cable (6) from hydraulic hose (8).
(6) Remove two capscrews (9), lockwashers (10) and proximity switch cover
(11) from folding boom (12). Discard lockwashers (10).
20-40
TM 08780B-20
(7) Remove nut (13) and proximity switch (14) from proximity switch cover
(11).
(8) Remove capscrew (15), two locknuts (16) and pendulum (17) from
proximity switch cover (11). Discard locknut (16).
9. Capscrew (2) 14. Proximity Switch

10. Lockwasher (2) 15. Capscrew
11. Proximity Switch Cover 16. Locknut (2)
12. Folding Boom 17. Pendulum
13. Nut
(2) Use wire brush to remove any rust on pendulum (17).
c. Installation
(1) Apply light coat of grease to capscrew (15). Secure pendulum (17) to
proximity switch cover (11) using capscrew (15) and two new locknuts (16). Make sure
pendulum (17) swings freely.
20-41
TM 08780B-20
(2) Install proximity switch (14) into proximity switch cover (11). Install nuts
(13) onto proximity switch (14).
(3) Position proximity switch (14) so there is 1/8 inch clearance between
pendulum (17) and proximity switch (14). Tighten nut (13) once clearance is obtained.
(4) Secure proximity switch cover (11) to folding boom (12) using two
capscrews (9) and new lockwashers (10). Tighten capscrews (9) securely.
(5) Secure cable (6) to mechanic’s wire in cordura sleeve (7). Pull wire and
cable (6) through cordura sleeve (7). Remove mechanic’s wire from cable (6).
(6) Secure cable (6) to hydraulic line (8) with nylon ties (5) as needed.
(7) On MK15 only, install clamp (4), capscrew (1), washer (3) and new
lockwasher (2). Tighten capscrew (1) securely.
(8) Secure cable (6) with nylon ties (5) as needed.
END OF TASK
NOTE
TM 08780B-20 MK15 proximity switch leads
installed/connected to junction box (para
20-3, leads 10, 22 and 31).
MK17 proximity switch leads

installed/connected to junction box (para
20-4, leads 12, 21 and 30).

(para 2-16 and 2-25).
20-42
TM 08780B-20
9. Capscrew (2)
10. Lockwasher (2)
11. Proximity Switch Cover
12. Folding Boom
13. Nut
14. Proximity Switch
15. Capscrew
16. Locknut (2)
17. Pendulum
20-43
TM 08780B-20
1. Capscrew 5. Nylon Tie

2. Lockwasher 6. Cable
3. Washer 7. Cordura Sleeve
4. Clamp 8. Hydraulic Hose
20-44
TM 08780B-20
20-6. SOLENOID DUMP VALVE WIRING REPLACEMENT

c. Installation

Condition Condition
MK17 disconnected
(para 7-45).
Materials/Parts
Silicone sealant (item 5, Appendix D) General Safety Instructions
Locknut (4) (MS51858-5) item 7 Block wheels of truck to prevent personal
Star washer (MS35333-73) item 17 injury. To prevent personal injury, make
a. Removal
(1) Unscrew plug (1) from solenoid dump valve (2).
(2) Unplug plug (1) with cable (3) from solenoid dump valve (2).
1. Plug
2. Solenoid Dump Valve
3. Cable
(3) Remove two screws (4) and clamps (5).
(7).
20-45
TM 08780B-20
(6) Unscrew cap (10). Slide cap (10), washer (11) and rubber grommet (12)
back on cable (3).
(7) Note position and unplug black wire (13) from terminal (14) of relay (15).
(8) Remove nut (16), star washer (17) and white wire (18) from terminal (19)
of terminal block (20). Tag terminal (19). Replace all wires disconnected with nut (16) and star
washer (17) on terminal (19).
(9) Pull cable (3) out of adapter (21) with wires (13 and 18).
(10) Remove rubber grommet (12), washer (11) and cap (10) from cable (3).
20-46
TM 08780B-20
3. Cable
4. Screw (2)
5. Clamp (2)
7. Locknut (4)
8. Cover
9. Junction Box
10. Cap
11. Washer
12. Rubber Grommet
13. Black Wire
14. Terminal
15. Relay
16. Nut
17. Star Washer
18. White Wire
19. Terminal
20. Terminal Block
21. Adapter
c. Installation
(1) Feed cable (3) through cap (10), washer (11), rubber grommet (12) and
adapter (20) into junction box (9).
(2) Route white wire (17) to terminal (18).
(3) Remove nut (16), star washer (17) and tag from terminal (18). Discard
star washer (17). Connect white wire (18) to terminal (19) and secure with nut (16) and new star
washer (17). Tighten nut (16) securely.
(4) Route black wire (13) to relay (15).
20-47
TM 08780B-20
3. Cable
4. Screw (2)
5. Clamp (2)
7. Locknut (4)
8. Cover
9. Junction Box
10. Cap
11. Washer
12. Rubber Grommet
13. Black Wire
14. Terminal
15. Relay
16. Nut
17. Star Washer
18. White Wire
19. Terminal
21 Adapter
(5) Connect black wire (13) to terminal (14) of relay (15).
(6) Apply silicone sealant to inside of cap (10).
(7) Position rubber grommet (12) and washer (11) to adapter (21). Screw cap
(10) to adapter (21).
new locknuts (7).
20-48
TM 08780B-20
(10) Secure cable (3) to junction box (9) with two screws (4) and clamps (5).
(11) Route cable (3) to solenoid dump valve (2).
(12) Connect plug (1) to solenoid dump valve (2).
END OF TASK
NOTE

(para 2-16 or 2-25).
1. Plug
2. Solenoid Dump Valve
3. Cable
20-49
TM 08780B-20
20-7. MAIN POWER WIRING REPLACEMENT

c. Installation

Condition Condition
MK17 disconnected
(para 7-45).
Materials/Parts
Sealant (item 5, Appendix D) General Safety Instructions
Nylon ties (AR) (MS3367-5-9) item 22 injury. To prevent personal injury, make
Star washer (2) (MS35333-73) items 6 and 10 sure batteries are disconnected before
Lockwasher (MS35338-43) item 14 working on electrical components.
a. Removal
(1) Remove four Allen head screws (1) and locknuts (2) from junction box
NOTE
Letters have been assigned to terminals for ease of installation. Some terminals will not be
used.
(3) On MK15 remove nut (5), star washer (6) and white wire (7) from
terminal (B) of terminal block (8). Tag terminal (B) and replace nut (5). Discard star washer
(6).
(4) On MK17 remove nut (5), star washer (6) and white wire (7) from
terminal (D) of terminal block (8). Tag terminal (D) and replace nut (5). Discard star washer
(6).
(5) On MK15 only, remove nut (9), star washer (10) and green wire (11) from
terminal (L) on terminal block (12). Discard star washer (10).
(6) Remove nut (13), lockwasher (14) and black wire (15) from terminal (P)
of circuit breaker (16). Tag terminal (P) and replace nut (13). Discard lockwasher (14).
(7) Unscrew cap (17) from adapter (18).
20-50
TM 08780B-20
(8) Slide cap (17), washer (19) and rubber grommet (20) back on cable (21).
(9) Pull cable (21) with wires (7, 11 and 15) out of adapter (18).

2. Locknut (4)
3. Junction Box
4. Cover
5. Nut
6. Star Washer
7. White Wire
8. Terminal Block
9. Nut
10. Star Washer
11. Green Wire
12. Terminal Block
13. Nut
14. Lock Washer
15. Black Wire
16. Circuit Breaker
17. Cap
18. Adapter
19. Washer
20. Rubber Grommet
21. Cable
20-51
TM 08780B-20
21. Cable
22. Nylon Tie (Air)
23. Coupler
24. Coupler
25. Main Wiring Harness
(10) Cut nylon ties (22) as needed along cable (21).
(11) Unplug coupler (23) of cable (21) from coupler (24) of main wiring
harness (25).
(12) Remove cable (21).
c. Installation
(1) Connect coupler (23) of cable (21) to coupler (24) of main wiring harness
(25).
(2) Route cable (21) to junction box (3).
(3) Secure cable (21) with nylon ties (22) as needed.
(4) Feed wires (7, 11 and 15) with cable (21) through cap (17), washer (19),
rubber grommet (20), adapter (18) and into junction box (3).
20-52
TM 08780B-20
(5) On MK15 route white wire (7) to terminal (B). On MK17 route white
wire (7) to terminal (D).
(6) Remove nut (5) and tag for location. Connect white wire (7) to terminal
(B or D) and secure with nut (5) and new star washer (6).
(7) On MK15 route green wire (11) to terminal (L) on terminal block (12).
(8) Remove nut (9) and tag from terminal (L). Connect green wire (11) to
terminal (L) and secure with nut (9) and new star washer (10).
(9) Route black wire (15) to terminal (P) on circuit breaker (16).
(10) Remove nut (13) and tag from terminal (P). Connect black wire (15) and
secure with nut (13) and new lockwasher (14).
(11) Apply sealant to inside of cap (17).
(12) Position rubber grommet (20) and washer (19) into adapter (18) and screw
cap (17) onto adapter (18).
new locknuts (2).
END OF TASK
NOTE

(para 2-16 or 2-25).
20-53
TM 08780B-20
1. Allen Head Screw (4) 8. Terminal Block 15. Black Wire

2. Locknut (4) 9. Nut 16. Circuit Breaker
3. Junction Box 10. Star Washer 17. Cap
4. Cover 11. Green Wire 18. Adapter
5. Nut 12. Terminal Block 19. Washer
6. Star Washer 13. Nut 20. Rubber Grommet
7. White Wire 14. Lock Washer 21. Cable
20-54
TM 08780B-20
20-8. NEUTRAL SWITCH REPLACEMENT

c. Installation

Condition Condition
MK17 disconnected
(para 7-45).
Materials/Parts
Sealant, thread (item 50, Appendix D) Block wheels of truck to prevent personal
a. Removal
(1) Cut nylon tie (1).
(2) Remove boot (2) from neutral switch (3).
(3) Unplug two bayonet connectors (4).
(4) Remove neutral switch (3) by turning counterclockwise.
(2) Inspect bayonet connectors (4) and wires (5) for damage.
(3) Inspect all other parts for damage. Refer to paragraph 2-12.
c. Installation
(1) Apply thread sealant to threads of neutral switch (3).
(2) Install neutral switch (3) and tighten securely.
(3) Plug two bayonet connectors (4) into neutral switch (3).
20-55
TM 08780B-20
(4) Install boot (2) onto neutral switch (3).
(5) Secure boot (2) with nylon tie (1).
END OF TASK
NOTE

(para 2-16 or 2-25).
1. Nylon Tie
2. Boot
3. Neutral Switch
4. Bayonet Connectors
20-56
TM 08780B-20
20-9. RELAY REPLACEMENT

c. Installation

Condition Condition
MK17 disconnected
(para 7-45).
Materials/Parts
Locknut (5) (MS51858-5) items 2 and 10 General Safety Instructions
sure batteries disconnected before working
a. Removal
(2).
(3) Remove black wires (5, 6, 7 and 8) one at a time and tag by position.
Black wire (5) is three o’clock, black wire (6) is six o’clock, black wire (7) is nine o’clock and
black wire (8) is twelve o’clock.
(4) Loosen two clamps (9) to gain access to locknut (10).
(5) Remove screw (11) and locknut (10). Discard locknut (10). Remove
relay (12).
20-57
TM 08780B-20
c. Installation
(1) Position new relay (12) in junction box (4) and secure with screw (11) and
new locknut (10).
(2) Tighten two clamps (9).
(3) Connect black wire (5) to terminal at three o’clock position on relay (12).
(4) Connect black wire (6) to terminal at six o’clock position on relay (12).
(5) Connect black wire (7) to terminal at nine o’clock position on relay (12).
(6) Connect black wire (8) to terminal at twelve o’clock position on relay
(12).
(7) Position cover (3) to junction box (4) and secure with four Allen head
screws (11) and new locknuts (2).
END OF TASK
NOTE

(para 2-16 or 2-25).
20-58
TM 08780B-20
1. Allen Head Screw (4) 7. Wire

2. Locknut (4) 8. Wire
3. Cover 9. Clamp (2)
4. Junction Box 10. Locknut
5. Wire 11. Screw
6. Wire 12. Relay
20-59
TM 08780B-20
20-10. CIRCUIT BREAKER REPLACEMENT (JUNCTION BOX)

c. Installation

Condition Condition
MK17 disconnected
(para 7-45).
Materials/Parts
Locknut (4) (MS51858-5) item 2 General Safety Instructions
Lockwasher (2) (MS 51441-16) item 6 Block wheels of truck to prevent personal
working an electrical equipment.
a. Removal
(2).
(3) Remove two nuts (5) and lockwashers (6) from circuit breaker (7 or 8)
being replaced. Discard lockwashers (6).
NOTE
• Letters have been assigned to terminals of relays (7 and 8) for ease of installation.
(4) Tag and remove wires (9, 10 and 11) and jumper wire (12) from circuit
breaker terminals (A, B, C and D).
(5) Pry up on circuit breaker (7 or 8) until it releases from mounting strip (13).
(6) Remove circuit breaker (7 or 8).
(2) Inspect wires for corrosion, breaks or missing insulation.
20-60
TM 08780B-20
(4) Replace any wire failing inspection.
c. Installation
NOTE
Make sure new circuit breaker (7 or 8) is the same amperage as the circuit breaker (7 or 8)
being replaced.
(1) Position new circuit breaker (7 or 8) to mounting strip (13). Press down
on circuit breaker (7 or 8) until it snaps into mounting strip (13).
(2) Install jumper wire (12) on terminal (C and D) of circuit breakers (7 and
8).
(3) Install wire (9) on terminal (C) of circuit breaker (8).
(4) Secure wires (9 and 12) with nuts (5) and new lockwashers (6) on
terminals (C and D).
(5) Install wire (10) on terminal (A) of circuit breaker (8).
(6) Secure wire (10) onto terminal (A) with new lockwasher (6) and nut (5).
(7) Install wire (11) onto terminal (B) of circuit breaker (7).
(8) Secure wire (11) onto terminal (B) with new lockwasher (6) and nut (5).
Secure cover (3) to junction box (4) with four Allen head screws (1) and
new locknuts (2).
END OF TASK
NOTE

(para 2-16 or 2-25).
20-61
TM 08780B-20
1. Allen Head Screw (4) 8. Circuit Breaker (6 Amp)

2. Locknut (4) 9. Wire
3. Cover 10. Wire
4. Junction Box 11. Wire
5. Nut (2) 12. Jumper Wire
6. Lockwasher (2) 13. Mounting Strip
7. Circuit Breaker (6 Amp)
20-62
TM 08780B-20
20-11. EXTENSION CYLINDER NO. 1 REPLACEMENT

c. Installation
INITIAL SETUP
MK15
MK17
Materials/Parts Special Environmental Conditions

O-ring (2) (NSN 5330-00-193-0692) Cleanliness is extremely important when
items 21 and 29 working on hydraulic equipment. Clean
all parts before disassembly and work
References in a clean area.
TM 08780B-10
Personnel Required Block wheels of truck to prevent personal
1 MOS 3521 injury. Wear safety glasses when working
1 Assistant on hydraulic system.
a. Removal
NOTE
To perform the following task, the crane must be operated under its own power. Hook up an
MK48 or slave lines from another vehicle, as explained in the operator’s manual
(TM 08780B-10).
(1) Position crane (1) over bed as shown.
(2) Remove one of two roll pins (2) from retaining pin (3).
(3) Remove retaining pin (3) from rod end (4) of cylinder (5) and boom
bracket (6).
(4) Using power of crane (1), retract rod end (4) from boom bracket (6) into
cylinder barrel (7).
WARNING
HYDRAULIC SYSTEM MAY BE UNDER PRESSURE. HYDRAULIC FLUID MAY SPURT

OUT WHEN LINES (8 AND 9) ARE DISCONNECTED. CRACK ALL LINES SLOWLY
AND KEEP YOUR FACE CLEAR OF THE LINES WHEN PERFORMING STEP (5).
20-63
TM 08780B-20
NOTE
Place a container to catch hydraulic oil before disconnecting hydraulic lines.
(5) Tag and disconnect hydraulic lines (8 and 9).
(6) Remove four Allen head capscrews (10) and retainer plate (11).
NOTE
Extension booms one and two must be fully extended to gain access to Allen head screws (12).
(7) Remove two Allen head screws (12) and retainer washers (13).
(8) Using a pry bar, spread cylinder bracket (14) and with help of an assistant,
remove cylinder (5).
20-64
TM 08780B-20
2. Roll Pin (2)

3. Retaining Pin
4. Rod End
5. Cylinder
6. Boom Bracket
7. Cylinder Barrel
8. Hydraulic Line
9. Hydraulic Line
10. Allen Head Capscrew (4)
11. Retainer Plate
13. Retainer Washer (2)
14. Cylinder Bracket
(9) Remove clamp (15) and two spacers (16).
(10) Disconnect tubing (17) from breakage valve (18).
(11) Remove breakage valve (18), reducer (19) and adapter (20) from cylinder
(5). Remove adapter (20) from reducer (19).
(12) Remove O-ring (21) from adapter (20). Discard O-ring (21).
(13) Slowly remove reducer (19) from breakage valve (18).
(14) Remove small spring (22), ball (23) and long spring (24) from breakage
valve (18).
20-65
TM 08780B-20
(15) Disconnect tubing (25) from breakage valve (26).
(5). Remove adapter (28) from reducer (27).
(17) Remove O-ring (29) from adapter (28). Discard O-ring (29).
valve (26).
(2) Inspect cylinder (5) for hydraulic leaks, dents, cracks or corrosion.
5. Cylinder 21. O-Ring 27. Reducer

15. Clamp 22. Small Spring 28. Adapter
16. Spacer (2) 23. Ball 29. O-Ring
17. Tubing 24. Long Spring 30. Small Spring
18. Breakage Valve 25. Tubing 31. Ball
19. Reducer 26. Breakage Valve 32. Long Spring
20. Adapter
20-66
TM 08780B-20
c. Installation
(1) Install long spring (32), ball (31) and small spring (30) into breakage valve
(26). Make sure large end of small spring (30) faces reducer (27). Install reducer (27).
(2) Install new O-ring (29) onto adapter (28). Install adapter (28) onto
reducer (27).
(3) Install breakage valve (26) into cylinder (5). Connect tubing (25) to
breakage valve (26).
(18). Make sure large end of small spring (22) faces reducer (19). Install reducer (19).
(5) Install new O-ring (21) onto adapter (20). Install adapter (20) onto
reducer (19).
(6) Install breakage valve (18) into cylinder (5). Connect tubing (17) to
(7) Install two spacers (16) and clamp (15). Tighten securely.
(8) With help from assistant, position cylinder (5) into cylinder bracket (14).
(9) Spread cylinder bracket (14) as needed to install cylinder (5).
(10) Secure cylinder bracket (14) and cylinder (5) with two Allen head screws
(12) and retainer washers (13).
(11) Secure retainer plate (11) to cylinder bracket (14) with four Allen head
capscrews (10).
(12) Connect hydraulic lines (8 and 9) as tagged.
20-67
TM 08780B-20
5. Cylinder 11. Retainer Plate

8. Hydraulic Line 12. Allen Head Screw (2)
9. Hydraulic Line 13. Retainer Washer (2)
10. Allen Head Capscrew (4) 14. Cylinder Bracket
(13) Using power of crane (1), extend rod end (4) into boom bracket (6).
(14) Secure rod end (4) to boom bracket (6) with retaining pin (3).
(15) Install roll pin (2) into retaining pin (3).
END OF TASK
NOTE
(paras 2-16 and 2-25).
LI 2320-12/9 Check hydraulic oil level.

LO 9-2320-297-12
20-68
TM 08780B-20
1. Crane
2. Roll Pin (2)

3. Retaining Pin
4. Rod End
6. Boom Bracket
20-69
TM 08780B-20
20-12. EXTENSION CYLINDER NO. 2 REPLACEMENT

c. Installation
INITIAL SETUP
Applicable Configurations Special Environmental Conditions

MK15 Cleanliness is extremely important when
MK17 working on hydraulic equipment. Clean
all parts before disassembly and work
Materials/Parts in a clean area.
O-rings (2) (NSN 5330-00-193-0692)
items 28 and 35 General Safety Instructions
injury.
Personnel Required
1 MOS 3521
2 Assistants
References
TM 08780B-10
a. Removal
NOTE
MK48 or end slave lines from another vehicle, as explained in the operator’s manual
(TM 08780B-10).
(1) Position crane (1) over bed as shown.
NOTE
Crane must remain fully extended.
(2) Remove inner roll pin (2) from retaining pin (3).
(3) Remove retaining pin (3) from rod end (4) of cylinder (5) and boom
bracket (6).
(4) Using power of crane (1), retract rod (4) into cylinder barrel (7).
20-70
TM 08780B-20
WARNING
HYDRAULICS MAY BE UNDER PRESSURE AND CAN SPURT OUT WHEN LINES (8
AND 9) ARE DISCONNECTED. KEEP YOUR FACE CLEAR OF THE LINES WHEN
PERFORMING STEP (5).
2. Inner Roll Pin 7. Cylinder Barrel 12. Tubing

3. Retaining Pin 8. Hydraulic Line 13. Tubing
4. Rod End (Cylinder) 9. Hydraulic Line 14. Holding Valve
5. Cylinder 10. Roll Pin (2) 15. Base End (Cylinder)
6. Boom Bracket 11. Retaining Pin 16. Mounting Bracket
20-71
TM 08780B-20
NOTE
(5) Tag and disconnect hydraulic line (8) and hydraulic line (9).
(6) Remove one of two roll pins (10) from base retaining pin (11).
(7) Tag and disconnect tubing (12) and tubing (13) at holding valve (14).
(8) With assistants helping support cylinder (5), remove retaining pin (11)
from base end (15) of cylinder (5) and base mounting bracket (16). Remove cylinder (5).
(10) Remove two capscrews (19) and locknuts (20). Discard locknuts (20).
(11) Remove four tube clamps (21).
(12) Tag and remove tubing (22).
(13) Remove tubing (12) and tubing (13).
5. Cylinder 19. Capscrew (2)

12. Tubing 20. Locknut (2)
13. Tubing 21. Tube Clamp
17. Clamp 22. Tubing
18. Spacer (2)
(14) Remove elbow (23).
(15) Remove two tees (24).
20-72
TM 08780B-20
(16) Remove breakage valve (25), reducer (26) and adapter(27) from cylinder
(5). Remove O-ring (28) from adapter (27). Discard O-ring (28).
(17) Remove adapter (27) from reducer (26).
valve (25).
(5). Remove O-ring (28) from adapter (27). Discard O-ring (28).
(21) Remove adapter (33) from reducer (34).
valve (32).
4. Rod End 21. Tube Clamp (4) 30. Ball

5. Cylinder 22. Tubing 31. Long Spring
12. Tubing 23. Elbow 32. Breakage Valve
13. Tubing 24. Tee (2) 33. Adapter
15. Base End 25. Breakage Valve 34. Reducer
17. Clamp 26. Reducer 35. O-Ring
18. Spacer (2) 27. Adapter 36. Small Spring
19 Capscrew (2) 28. O-Ring 37. Ball
20. Locknut (2) 29. Small Spring 38. Long Spring
20-73
TM 08780B-20
(2) Inspect cylinder (5) for hydraulic leaks, dents, cracks or corrosion.
c. Installation
(32). Make sure large end of small spring (36) faces reducer (34). Install reducer (34) into
(2) Install adapter (33) onto reducer (34). Install new O-ring (35) onto
adapter (33).
(3) Install breakage valve (32) into cylinder (5). Install tee (24) into breakage
valve (32).
(25). Make sure large end of small spring (29) faces reducer (26). Install reducer (26) into
adapter (27).
(6) Install breakage valve (25) into cylinder (5).
(7) Install tee (24) onto breakage valve (25).
(8) Connect elbow (23) to tee (24) at rod end (4). Tighten securely.
(9) Connect tubing (13) to tee (24) at base end (15). Tighten securely.
(10) Connect tubing (12) to tee (24) at rod end (4). Tighten securely.
(11) Connect tubing (22) to tee (24) at base end (15). Tighten securely.
20-74
TM 08780B-20
4. Rod End 21. Tube Clamp (4) 30. Ball

5. Cylinder 22. Tubing 31. Long Spring
12. Tubing 23. Elbow 32. Breakage Valve
13. Tubing 24. Tee (2) 33. Adapter
15. Base End 25. Breakage Valve 34. Reducer
17. Clamp 26. Reducer 35. O-Ring
18. Spacer (2) 27. Adapter 36. Small Spring
19 Capscrew (2) 28. O-Ring 37. Ball
20. Locknut (2) 29. Small Spring 38. Long Spring
2. Inner Roll Pin 9. Hydraulic Line 13. Tubing

3. Retaining Pin 10. Roll Pin (2) 14. Holding Valve
4. Rod End (Cylinder) 11. Retaining Pin 15. Base End (Cylinder)
6. Boom Bracket 12. Tubing 16. Mounting Bracket
8. Hydraulic Line
20-75
TM 08780B-20
(12) Install four tube clamps (21) with capscrews (19) and new locknuts (20).
(13) Install two spacers (18) and clamp (17). Tighten clamp (17) securely.
(14) Position base end (15) of cylinder (5) on mounting bracket (16).
(15) While assistants supports cylinder (5) in place, install base retaining pin
(11).
(16) Install roll pin (10) into base retaining pin (11).
(17) Align tubing (12 and 13) to holding valve (14) and connect. Tighten
securely.
(18) Align all fittings (23 and 24) and tubing (12, 13 and 22) and tighten
securely.
(19) Connect hydraulic line (8) and hydraulic line (9). Tighten securely.
(20) Using power of crane (1), extend cylinder rod end (4) into boom bracket
(6).
(21) Install retaining pin (3).
(22) Secure retaining pin (3) with inner roll pin (2).
END OF TASK
NOTE
(para 2-16 or 2-25).

LO 9-2320-297-12
20-76
TM 08780B-20
20-13. LEFT OUTRIGGER CYLINDER REPLACEMENT

c. Installation
INITIAL SETUP

MK17 working on hydraulic equipment. Clean all
parts before disassembly and work in a clean
Materials/Parts area.
Nylon tie (AR) (MS3367-1-9) item 12
O-ring (2) (NSN 5330-00-477-2380) General Safety Instructions
items 20 and 23 Block wheels of truck to prevent personal
injury.
Personnel Required
1 MOS 3521
1 Assistant
References
TM 08780B-10
a. Removal
(1) Position crane (1) as shown.
NOTE
To perform the following task, the crane must be operated under its own power. Hook-up an
(TM 08780B-10).
(2) Remove one of two roll pins (2) from pin (3).
(3) Remove pin (3) from rod end (4) of cylinder (5) and outrigger beam
bracket (6).
(4) Using crane’s (1) own power, retract rod end (4) of cylinder (5) into
20-77
TM 08780B-20
1. Crane (MK15 & MK17) 5. Cylinder

2. Roll Pin (2) 6. Outrigger Beam Bracket
3. Pin 7. Cylinder Barrel
4. Rod End
20-78
TM 08780B-20
(6) Remove pin (9) from base end (10) of cylinder (5) and bracket (11).
(7) Cut and remove nylon ties (12) as needed to move hydraulic hoses out of
way.
(8) Tag and remove hydraulic line (13) and hydraulic line (14).
(9) With help from assistant lift and remove cylinder (5).
5. Cylinder 11. Bracket

8. Roll Pin (2) 12. Nylon Tie (AR)
9. Pin 13. Hydraulic Line
10. Base End 14. Hydraulic Line
20-79
TM 08780B-20
(10) Remove two clamps (15) and spacers (16).
(11) Disconnect and remove tubing (17) from elbow (18).
(12) Note position and remove elbow (18) and boss nut (19). Discard O-ring
(20).
(13) Note position and remove elbow (21) and boss nut (22). Discard O-ring
(23).
c. Installation
(1) Install elbow (21) with new O-ring (23) and position. Secure elbow (21)
by tightening boss nut (22).
(2) Install elbow (18) with new O-ring (20) and position. Secure elbow (18)
by tightening boss nut (19).
(3) Connect tubing (17) to elbow (18).
(4) Install two clamps (15) and spacers (16) to hold tubing (17).
15. Clamp 20. O-Ring

16. Spacer (2) 21. Elbow
17. Tubing (2) 22. Boss Nut
18. Elbow 23. O-Ring
19. Boss Nut
20-80
TM 08780B-20

(5) With help from assistant position cylinder (5) in place.
(6) Connect hydraulic line (14) and hydraulic line (13) as tagged.
(7) Install pin (9) to secure base end (10) of cylinder (5) to bracket (11).
(8) Install roll pin (8) in pin (9).
(9) Using crane’s (1) own power, extend rod end (4) of cylinder (5) into
outrigger beam bracket (6).
(10) Install pin (3) to secure rod end (4) of cylinder (5) to outrigger beam
bracket (6).
(11) Install roll pin (2) to secure pin (3).
20-81
TM 08780B-20
(12) Secure hydraulic hoses with nylon ties (12) as needed.
END OF TASK
NOTE
(para 2-16 or 2-25).

LO 9-2320-297-12
1. Crane (MK15 & MK17)

2. Roll Pin (2)
3. Pin
4. Rod End
5. Cylinder
6. Outrigger Beam Bracket
20-82
TM 08780B-20
20-14. RIGHT OUTRIGGER CYLINDER REPLACEMENT

c. Installation

Condition Condition
MK15 TM 08780B-20 Left outrigger
MK17 cylinder removed
(para 20-13).
Materials/Parts
Nylon ties (MS) item 12 Special Environmental Conditions
Cable tie (AR) (MS3367-1-9) item 12 Cleanliness is extremely important when
O-ring (2) (NSN 5330-00-477-2380) working on hydraulic equipment. Clean
items 20 and 23 all parts before disassembly and work in a
clean area.
Personnel Required
1 MOS 3521 General Safety Instructions
1 Assistant Block wheels of truck to prevent personal
injury.
References
TM 08780B-10
a. Removal
NOTE
(TM 08780B-10).
(1) Place crane (1) as shown.
(3) Remove pin (3) from rod end (4) of cylinder (5) and outrigger beam
bracket (6).
(4) Using crane’s (1) own power, retract rod end (4) of cylinder (5) into
20-83
TM 08780B-20
1. Crane 5. Cylinder
2. Roll Pin (2) 6. Outrigger Beam Bracket
3. Pin 7. Cylinder Barrel
4. Rod End
(6) Remove pin (9) from base end (10) of cylinder (5) and bracket (11).
(7) Cut and remove nylon ties (12) as needed to move hydraulic hoses out of
the way.
20-84
TM 08780B-20
(8) Tag and remove hydraulic line (13) and hydraulic line (14).

(9) With help from assistant lift and remove cylinder (5).
(10) Remove two clamps (15) and spacers (16).
(11) Disconnect and remove tubing (17) from elbow (18).
(12) Mark position and remove elbow (18) with boss nut (19). Discard O-ring
(23).
(13) Mark position and remove elbow (21) with boss nut (22). Discard O-ring
(23).
20-85
TM 08780B-20
c. Installation
(1) Install elbow (21) with new O-ring (23) and position as marked.
(2) Secure elbow (21) by tightening boss nut (22).
(3) Install elbow (18) with new O-ring (20) and position as marked.
(4) Secure elbow (18) by tightening boss nut (19).
(5) Connect tubing (17) to elbow (18).
(6) Install two clamps (15) and spacers (16) to secure tubing (17) to cylinder
(5).
5. Cylinder 19. Boss Nut

15. Clamp (2) 20. O-Ring
16. Spacer (2) 21. Elbow
17. Tubing 22. Boss Nut
20-86
TM 08780B-20
(7) With help from assistant position cylinder (5) into place.
(9) Install pin (9) to secure base end (10) of cylinder (5) to bracket (11).

(11) Using crane’s (1) own power, extend rod end (4) of cylinder (5) into
outrigger beam bracket (6).
(12) Install pin (3) to secure rod end (4) of cylinder (5) to outrigger beam
bracket (6).
20-87
TM 08780B-20
(14) Secure hydraulic hoses with nylon ties (12) as needed.
END OF TASK
NOTE
TM 08780B-20 Install left outrigger cylinder (para 20-13).

(para 2-16 or 2-25).

LO 9-2320-297-12
1. Crane
2. Roll Pin (2)
3. Pin
4. Rod End
5. Cylinder
6. Outrigger Beam
Bracket
20-88
TM 08780B-20
20-15. STABILIZER CYLINDER REPLACEMENT

c. Installation
INITIAL SETUP

Special Tools area.
3 mm Allen wrench
Lockwasher (4) (MS35338-44) injury.
items 6 and 14
O-ring (2) (NSN 5330-01-190-0294)
items 22 and 27
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
WARNING
STABILIZER CYLINDERS (1) ARE HEAVY. A SUITABLE LIFTING DEVICE MUST BE

USED TO PREVENT PERSONAL INJURY OR DAMAGE TO EQUIPMENT.
NOTE
This paragraph works for both the left and the right stabilizer cylinders (1). Repeat as needed
for either side. Only the left stabilizer cylinder (1) is shown.
(1) Position crane (2) as shown.
(2) Extend stabilizer cylinder (1) until it is just off of floor. This eases
handling during removal.
(3) Tag and disconnect hydraulic lines (3 and 4).
(4) Remove capscrew (5), lockwasher (6) and chain (7) from end plate (8).
20-89
TM 08780B-20
(5) Remove pin (9) and stabilizer stow pin (10).
CAUTION
DO NOT RIG SLING (11) AROUND HYDRAULIC LINES. DAMAGE TO LINES

DURING LIFT MAY RESULT.
(6) Secure sling (11) to base end (12) of stabilizer cylinder (1) as shown.
(7) Remove four capscrews (13), lockwashers (14) and end plate (8). Discard
lockwashers (14).
(8) Support sling (11) with overhead lifting device.
(9) With help from assistant walk stabilizer cylinder (1) off base pivot (15).
1. Stabilizer Cylinder
2. Crane
3. Hydraulic Line
4. Hydraulic Line
5. Capscrew
6. Lockwasher
7. Chain
8. End Plate
9. Pin
10. Stabilizer Stow Pin
11. Sling
12. Base End
13. Capscrew (4)
14. Lockwasher (4)
15. Base Pivot
20-90
TM 08780B-20
CAUTION
STABILIZER CYLINDER IS HEAVY. TO PREVENT PERSONAL INJURY, STABILIZER

CYLINDER SHOULD BE PLACED FLAT ON THE FLOOR WHERE IT CANNOT FALL
OVER.
(10) Remove stabilizer cylinder (1) and place flat on the floor.
(12) Disconnect and remove tubing (18) and tubing (19).
(13) Loosen nut (20) and remove elbow (21).
(14) Remove and discard O-ring (22).
(15) Disconnect tubing (23) from elbow (24) and adapter (25).
(16) Loosen nut (26) and turn elbow (24) to remove tubing (23).
(17) Remove elbow (24) and nut (26). Discard O-ring (27).
(18) Remove nut (28), star washer (29) and placard bracket (30) from adapter
(25).
(19) Remove adapter (25) from selector/locking valve (31). Remove

selector/locking valve (31).
(20) Remove capscrew (32), locknut (33) and clamp (34) from tubing (18 and
19). Discard locknut (33).
c. Installation
(1) Position selector/locking valve (31) onto bracket (35) and secure with
adapter (25).
20-91
TM 08780B-20
(2) Install placard bracket (30) onto adapter (25) with star washer (29) and nut
(3) Install elbow (24) with nut (26) and new O-ring (27). Do not tighten nut
(26).
(4) With elbow (24) turned to one side, position tubing (23) to adapter (25)
and elbow (24). Turn elbow (24) with wrench to properly position fittings (36 and 37).
(5) Hand tighten fittings (36 and 37).
(6) Secure elbow (24) by tightening nut (26).
(7) Install elbow (21) with new O-ring (22) and nut (20). Do not tighten nut
(20).
(8) Install tubing (18) and tubing (19). Tighten securely.
(10) Position two spacers (17) to tubing (18 and 19) and secure with clamp
(16). Tighten clamp (16) securely.
(11) Position clamp halves (34) to tubing (18 and 19) and secure with capscrew
(32) and new locknut (33).
(12) Tighten fittings (36 thru 41) securely.
20-92
TM 08780B-20
1. Stabilizer Cylinder 25. Adapter 33. Locknut

16. Clamp 26. Nut 34. Clamp Half (2)
17. Spacer (2) 27. 0-Ring 35. Bracket
18. Tubing 28. Nut 36. Fitting
19. Tubing 29. Starwasher 37. Fitting
20. Nut 30. Placard Bracket 38. Fitting
21. Elbow 31. Selector/Locking 39. Fitting
22. O-Ring Valve 40. Fitting
23. Tubing 32. Capscrew 41. Fitting
24. Elbow
CAUTION
DO NOT RIG SLING (11) AROUND HYDRAULIC LINES. DAMAGE TO LINES DURING
LIFT MAY RESULT
(13) Secure sling (11) to base end of stabilizer cylinder (1).
(14) Support sling (11) with overhead lifting device.
(15) With help from assistant slide stabilizer cylinder (1) onto base pivot (15).
(16) Secure end plate (8) with four capscrews (13) and new lockwashers (14).
Tighten securely.
20-93
TM 08780B-20
(17) Remove sling (11).
(18) Install stabilizer stow pin (10) and pin (9).
(19) Secure chain (7) to end plate (8) with capscrew (5) and new lockwasher
END OF TASK
NOTE
TM 08780B-10 Check stabilizer cylinder for operation
(para 2-16 or 2-25).
TM 08780B-20 Replace any hydraulic oil lost (para 22-3).
3. Hydraulic Line
4. Hydraulic Line
5. Capscrew
6. Lockwasher
7. Chain
8. End Plate
9. Pin
10. Stabilizer Stow Pin
11. Sling
13. Capscrew (4)
14. Lockwasher (4)
15. Base Pivot
20-94
TM 08780B-20
20-16. A-FRAME MAINTENANCE

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK15 TM 08780B-10 A-frame support
chains removed
Materials/Parts if installed
Adhesive (item 3, Appendix D) (para 2-17).
Lockwasher (8) (MS35338-44)
items 13, 21, 33.2, 69 Special Environmental Conditions
Locknut (MS51922-1) item 15 Cleanliness is extremely important when
O-ring (2) (NSN 5330-01-190-0294) working on hydraulic equipment. Clean all
items 37 and 41 parts before disassembly and work in a clean
O-ring (4) (NSN 5330-00-200-8125) area.
items 44, 46, 48 and 50
Locknut (MS51943-39) item 52 General Safety Instructions
Lockwasher (4) (MS35338-46) item 75 Block wheels of truck to prevent personal
Locknut (3) (MS51922-17) item 82 injury.
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
WARNING
IF USING MK15 CRANE (1) TO REMOVE A-FRAME (2), THERE MUST BE AMPLE
OVERHEAD AREA FREE OF OBSTRUCTIONS AND OVERHEAD ELECTRICAL
WIRES.
NOTE
Slacken winch cable. Winch clevis must be back and out of the way before A-frame is
removed.
(1) Attach sling to A-frame (2) and support with overhead lifting device (such
as crane).
20-95
TM 08780B-20
(2) Using overhead lifting device, lift A-frame (2) just enough to relax tension
on pins (4).
(3) Disconnect hydraulic lines (5 and 6) at quick disconnects (7 and 8).
(4) Pull two hair pin clips (9) from pins (4).
NOTE
(5) Remove two snap pins (9.1) from pins (4).
WARNING
DIRECT ALL PERSONNEL TO STAND CLEAR OF A-FRAME DURING REMOVAL
OPERATION.
(6) Remove two support straps (10).
(7) Remove two pins (4) from A-frame mounting brackets (11).
(8) Using overhead lifting device, remove A-frame (2) from mounting
brackets (11). Lower A-frame (2) to ground and place flat, supported by blocks of wood.
20-96
TM 08780B-20
1. MK15 Crane
2. A-Frame
4. Pin
5. Hydraulic Line
6. Hydraulic Line
7. Quick Disconnect
8. Quick Disconnect
9. Hair Pin Clip (2)
9.1. Snap Pin (2)*
10. Supporting Strap
11. Mounting Bracket (2)
* LVSAl Series Vehicles Only
b. Disassembly
(1) Remove two capscrews (12), two lockwashers (13) and four hose clamp
halves (14). Discard lockwashers (13).
(2) Remove locknut (15), flatwasher (16), capscrew (17) and two clamp
halves (18) from guard (19). Discard locknut (15).
20-97
TM 08780B-20
(3) Remove two capscrews (20), lockwashers (21), flatwashers (22) and guard
NOTE
Tag and mark hydraulic lines (5) and (6) prior to removal.
(4) Remove hydraulic line (5) by disconnecting fitting (23) from elbow (24).
(5) Remove hydraulic line (6) by disconnecting fitting (25) from elbow (26).
(6) Remove one end of tubing (27) by disconnecting fitting (28) from elbow
(29).
(7) Remove one end of tubing (30) by disconnecting fitting (31) from elbow
(32).
(8) Remove holding valve (33).
NOTE
(9) Remove two capscrews (33.1), lockwashers (33.2) and holding valve (33).
Discard lockwashers.
(10) Remove tubing (27) by disconnecting fitting (34) from elbow (35).
(11) Loosen nut (36) and remove elbow (35). Remove O-ring (37) from elbow
(35). Discard O-ring (37).
(12) Remove tubing (30) by disconnecting fitting (38) from elbow (39).
NOTE
Note position of and tag, elbows (24, 26, 29 and 32) to insure proper installation.
(14) Loosen nut (42) and remove elbow (32) from adapter (43). Remove
adapter (43) from holding valve (33). Remove O-ring (44) from adapter (43). Discard O-ring
(44).
20-98
TM 08780B-20
NOTE
(17) Loosen nut (47) and remove elbow (26) from adapter (48.1). Remove
adapter (48.1) from holding valve (33). Remove O-ring (44) from adapter (48.1). Discard O-
ring (44).
5. Hydraulic Line 25. Fitting 38. Fitting

6. Hydraulic Line 26. Elbow 39. Elbow
12. Capscrew (2) 27. Tubing 40. Nut
13. Lockwasher (2) 28. Fitting 41. O-Ring
14. Hose Clamp Halves (4) 29. Elbow 42. Nut
15. Locknut 30. Tubing 43. Adapter
16. Flatwasher 31. Fitting 44. O-Ring
17. Capscrew 32. Elbow 45. Nut
18. Clamp Halves (2) 33. Holding Valve 46. O-Ring
19. Guard 33.1. Capscrew (2)* 47. Nut
20. Capscrew (2) 33.2. Lockwasher (2)* 48. O-Ring
21. Lockwasher (2) 34. Fitting 48.1. Adapter*
22. Flatwasher (2) 35. Elbow 49. Nut
23. Fitting 36. Nut 50. O-Ring
20-99
TM 08780B-20
1. A-Frame 59. Flat Washer (2) 67. Clevis (2)

51. Capscrew 60. Spring (2) 68. Capscrew (2)
52. Locknut 61. Stop Block (2) 69. Lockwasher (2)
53. Pin 62. Capscrew (8) 70. Small Flat Washer (2)
54. Cylinder 63. Bearing Cap (2) 71. Chain Assembly (2)
55. Clevis Pin 64. Roller 71.1. Large Flat
56. Clevis 65. Grease Fitting (2) Washer (2)*
57. Spacer (2) 66. Clevis Pin (2) 71.2. Cable Assembly (2)*
58. Capscrew (2)
LVSA1 Series Vehicles Only
(19) Remove capscrew (51) and locknut (52). Discard locknut (52).
(20) Using a drift punch, drive pin (53) out of A-frame (2) and cylinder (54).
WARNING
CYLINDER IS HEAVY. STAND CLEAR OF CYLINDER DURING LIFTING

OPERATION.
(21) Attach a sling to cylinder (54). Using a lifting device, remove cylinder
(54) from A-frame (2).
(22) Remove clevis pin (55) and clevis (56) from cylinder (54).
20-100
TM 08780B-20
(23) Remove two spacers (57) from A-frame (2).
(24) Remove two capscrews (58), flat washers (59), springs (60) and stop
blocks (61).
(25) Remove eight capscrews (62), two bearing caps (63) and roller (64).
(26) Remove two grease fittings (65) from bearing caps (63).
(27) Remove two clevis pins (66) and clevises (67).
(28) Remove capscrew (68), lockwasher (69), flat washer (70) and chain
(29) Repeat step (28) for opposite chain assembly (71).
NOTE
(30) Remove capscrew (68), lockwasher (69), small flat washer (70), large flat
washer (71.1), cable assembly (71.2) and large flat washer (71.1). Discard lockwasher (69).
(31) Repeat step (30) for opposite cable assembly (71.2).
2. A-Frame
73. Pin (2)
74. Capscrew (4)
75. Lockwasher (4)
76. Flatwasher (4)
77. Retainer Plate (2)
78. Roller (2)
79. Bracket
80. Cotter Pin
80.1. Pin
80.2. Snatch Block Assembly
81. Capscrew (3)
82. Locknut (3)
83. Rubber Pad Strip (2)
84. Rubber Pad
20-101
TM 08780B-20
WARNING
A-FRAME IS HEAVY. STAND CLEAR OF A-FRAME DURING LIFTING OPERATION.
(32) Using a lifting device and sling, turn A-frame (2) over and set down on
wooden blocks.
(33) Remove four grease fittings (72) from two pins (73).
(34) Remove four capscrews (74), lockwashers (75), fiat washers (76) and two
retainer plates (77). Discard lockwashers (75).
(35) Using a soft drift punch, drive pin (73) out of roller (78). Remove roller
(78) from brackets (79).
(36) Repeat step (35) for second roller (78).
(37) Remove cotter pins (80), pin (80.1) and snatch block assembly (80.2).
(38) Remove three capscrews (81), locknuts (82), two rubber pad strips (83)
and rubber pad (84). Discard locknuts (82).
d. Assembly
(1) Position snatch block assembly (80.2) to A-frame (2) and secure with pin
(80.1) and cotter pins (80).
(2) Position roller (78) in brackets (79).
NOTE
Slotted end of pin (73) must be toward top of A-frame (2).
(3) Insert pin (73) through brackets (79) and roller (78). Tap pin (73) into
position with soft-faced hammer.
(4) Align slotted end of pin (73) with retainer plate (77). Align retainer plate
(77) with holes in bracket (79).
20-102
TM 08780B-20
(5) Secure retainer plate (77) to bracket (79) with two flat washers (76), new
lockwashers (75) and capscrews (74). Tighten securely.
(6) Install grease fittings (72) in pin (73).
(7) Repeat steps (2) thru (6) for other roller (78).
(8) Position rubber pad (84) to A-frame (2) with two rubber pad strips (83)
and secure with three capscrews (81) and new locknuts (82). Tighten securely.
WARNING
(9) Using a lifting device and sling, turn A-frame (2) over and lower onto
wooden blocks.
NOTE
(10) Position large washer (71.1) and cable assembly (71.2) to A-frame (2) and
secure with large washer (71.1), small washer (70), new lockwasher (69) and capscrew (68).
Tighten securely.
(11) Repeat step (10) for opposite side of cable assembly (70).
(12) Position chain assembly (71) to A-frame (2) and secure with flat washer
(70), new lockwasher (69) and capscrew (68). Tighten securely.
(13) Repeat step (12) for opposite side of chain assembly (70).
(14) Position two clevises (67) to A-frame (2) and secure with two clevis pins
(66).
(15) Install one grease fitting (65) into each bearing cap (63). Then position
both bearing caps (63) onto roller (64).
(16) Apply adhesive to threads of capscrews (62).
(17) Position roller (64) with caps (63) to A-frame (2) and secure with eight
capscrews (62). Tighten securely.
20-103
TM 08780B-20
2. A-Frame 68. Capscrew (2)

62. Capscrew (8) 69. Lockwasher (2)
63. Bearing Cap (2) 70. Small Flat Washer (2)
64. Roller 71. Chain Assembly (2)
65. Grease Fitting (2) 71.1. Large Flat Washer (4)*
66. Clevis Pin (2) 71.2. Cable Assembly (2)*
67. Clevis (2)
(18) Position stop block (61) to A-frame (2) and secure with capscrew (58), flat
washer (59) and spring (60). Tighten capscrew (58) until spring (60) compresses enough to hold
stop block (61) from swinging freely.
(19) Repeat step (18) for opposite stop block (61).
(20) Install two spacers (57) into A-frame (2).
WARNING
A-FRAME CYLINDER IS HEAVY. STAND CLEAR OF A-FRAME CYLINDER DURING

LIFTING OPERATION.
(21) Using a lifting device and sling, position cylinder (54) to A-frame (2).
(22) Install pin (53) to secure cylinder (54) to A-frame (2). Make sure holes in
pin (53) and A-frame (2) align.
(23) Install capscrew (51) and secure with new locknut (52). Tighten securely.
20-104
TM 08780B-20
(24) Position clevis (56) to cylinder (54) and secure with clevis pin (55).
2. A-Frame 54. Cylinder 58. Capscrew (2)

51. Capscrew 55. Clevis Pin 59. Flat Washer (2)
52. Locknut 56. Clevis 60. Spring (2)
53. Pin 57. Spacer (2) 61. Stop Block (2)
20-105
TM 08780B-20
24. Elbow 36. Nut 45. Nut

26. Elbow 37. O-Ring 46. O-Ring
29. Elbow 38. Fitting 47. Nut
32. Elbow 39. Elbow 48. O-Ring
33. Holding Valve 40. Nut 48.1. Adapter*
33.1. Capscrew (2)* 41. 0-Ring 49. Nut
33.2. Lockwasher (2)* 42. Nut 50. O-Ring
34. Fitting 43. Adapter 54. Cylinder

NOTE
Elbows (24, 26, 29 and 32) must be installed in same position as noted during disassembly
procedure.
(25) Install new O-rings (50, 48 and 46) on elbows (24, 26 and 29). Install
elbows (24, 26 and 29) into holding valve (33). Do not tighten nuts (49, 47 and 45) at this time.
NOTE
(26) Install new O-rings (50 and 46) on elbows (24 and 29). Install elbows (24
and 29) into holding valve (33). Do not tighten nuts (49 and 45) at this time.
(27) Install new O-ring (44) on adapter (48.1). Install adapter (48.1) into
holding valve (33). Install elbow (32) in adapter (48.1) in same position as noted during
disassembly procedure. Do not tighten nut (47) at this time.
20-106
TM 08780B-20
(28) Install new O-ring (44) on adapter (43). Install adapter (43) into holding
valve (33). Install elbow (32) in adapter (43) in same position as noted during disassembly
procedure. Do not tighten nut (42) at this time.
(29) Position holding valve (33) on cylinder (54).
NOTE
(30) Install holding valve (33) using two capscrews (33.1) and new
lockwashers (33.2). Tighten capscrews securely.
5. Hydraulic Line 23. Fitting 35. Elbow

6. Hydraulic Line 24. Elbow 36. Nut
12. Capscrew (2) 25. Fitting 37. O-Ring
13. Lockwasher (2) 26. Elbow 38. Fitting
14. Hose Clamp Halves (4) 27. Tubing 39. Elbow
15. Locknut 28. Fitting 40. Nut
16. Flatwasher 29. Elbow 41. O-Ring
17. Capscrew 30. Tubing 42. Nut
18. Clamp Halves (2) 31. Fitting 45. Nut
19. Guard 32. Elbow 47. Nut
20. Capscrew (2) 33. Holding Valve 49. Nut
21. Lockwasher (2) 34. Fitting 54. Cylinder
22. Flatwasher (2)
20-107
TM 08780B-20
(31) Install new O-ring (41) on elbow (39). Install elbow (39) into cylinder
(54). Do not tighten nut (40) at this time.
(32) Install new O-ring (37) on elbow (35). Install elbow (35) into cylinder
(54). Do not tighten nut (36) at this time.
(33) Install tubing (27) by connecting fitting (34) to elbow (35) and fitting (28)
to elbow (29). Tighten nuts (45 and 36) and fittings (34 and 28) securely.
(34) Install tubing (30) by connecting fitting (31) to elbow (32) and fitting (38)
to elbow (39). Tighten nuts (40 and 42) and fittings (31 and 38) securely.
(35) Install one end of hydraulic lines (6 and 5) by connecting fittings (25 and
23) to elbows(26 and 24). Tighten nuts (47 and 49) and fittings (25 and 23) securely.
(36) Install other end of hydraulic lines (6 and 5) by securing with four hose
clamp halves (14), two new lockwashers (13) and capscrews (12).
(37) Position guard (19) over holding valve (33). Align holes in guard (19) and
holding valve (33) and install two flat washers (22), new lockwashers (21) and capscrews (20).
(38) Secure hydraulic lines (5 and 6) inside guard (19) with two hose clamp
halves (18), one capscrew (17), flat washer (16) and new locknut (15).
e. Installation
(1) Secure sling to A-frame (2).
WARNING
(2) Using MK15 crane (1), raise A-frame (2) into position at rear of MK15.
(3) While assistant guides base of A-frame (2), install two support straps (10).
Do not tighten. This is for safety at this point. Leave a small amount of slack.
(4) Secure A-frame (2) to mounting brackets (11) with two pins (4). Lock
pins (4) in place with hair pin clips (9).
NOTE
(5) Secure A-frame (2) to mounting brackets (11) with two pins (4). Lock
pins (4) in place with snap pins (9.1).
20-108
TM 08780B-20
(6) Tighten support straps (10), making sure stop blocks (61) align with stops
(85).
(7) Relax overhead lifting device and remove sling from clevis (3).
(8) Connect hydraulic lines (5 and 6) by coupling quick disconnects (7 and 8).
END OF TASK
NOTE
Follow-0n Maintenance
TM 08780B-10 Check A-frame for proper operation
(para 2-18).
1. MK15 Crane 9. Hair Pin Clip

2. A-Frame 9.1. Snap Pin (2)*
3. Pin 10. Supporting Strap
5. Hydraulic Line 11. Mounting Bracket(2)
6. Hydraulic Line 61. Stop Block (2)
7. Quick Disconnect 85. Stops (2)
8. Quick Disconnect
20-109
TM 08780B-20
20-17. HOSE BREAKAGE VALVE REPLACEMENT
THIS TASK COVERS: a. Removal of No. 1 Extension Cylinder Breakage Valve

b. Removal of No. 2 Extension Cylinder Breakage Valve
d. Installation of No. 2 Extension Cylinder Breakage Valve
e. Installation of No. 1 Extension Cylinder Breakage Valve

Condition Condition
MK15 TM 08780B-10 Main boom extended
MK17 over vehicle
(para 2-16 or 2-25).
Materials/Parts
O-ring (2) (NSN 5330-00-193-0692) Special Environmental Conditions
items 9, 18 and 43 Cleanliness is extremely important when
working on hydraulic equipment. Clean all
References parts before disassembly and work in a
TM 08780B-10 clean area.

injury.
a. Removal of No. 1 Extension Cylinder Breakage Valve
(1) Loosen clamp (1). Loosen fittings (2 and 3). Slide tubing (4) to clear
breakage valve (5).
(2) Remove adapter (6) and breakage valve (5) from No. 1 extension cylinder
(7).
(3) Remove adapter (6) from reducer (8). Remove and discard O-ring (9)
from adapter (6).
(4) Remove reducer (8), small spring (10), ball (11) and long spring (12) from
breakage valve (5).
(5) Loosen fitting (13). Move tubing (14) to clear breakage valve (15).
(6) Remove adapter (16) and breakage valve (15) from No. 1 extension
cylinder (7).
from adapter (16).
20-110
TM 08780B-20
(8) Remove reducer (17), small spring (19), ball (20) and long spring (21)
from breakage valve (15).
1. Clamp 8. Reducer 15. Breakage Valve

2. Fitting 9. O-Ring 16. Adapter
3. Fitting 10. Small Spring 17. Reducer
4. Tubing 11. Ball 18. O-Ring
5. Breakage Valve 12. Long Spring 19. Small Spring
6. Adapter 13. Fitting 20. Ball
7. No. 1 Extension 14. Tubing 21. Long Spring
Cylinder
b. Removal of No. 2 Extension Cylinder Breakage Valve
(1) Loosen clamps (22, 23 and 24). Loosen fittings (25) at holding valve (26).
Loosen fitting (27). Slide tubing (28) to clear breakage valve (29).
cylinder (31).
(3) Remove adapter (30) from reducer (32). Remove and discard O-ring (33).
20-111
TM 08780B-20
(5) Loosen fitting (37) at holding valve (26). Loosen fitting (38). Slide
tubing (39) to clear breakage valve (40).
cylinder (31).
from adapter (41).
d. Installation of No. 2 Extension Cylinder Breakage Valve
(40). Make sure large end of spring (44) faces reducer (42). Install reducer (42) into breakage
valve (40).
adapter (42).
(3) Install adapter (42) and breakage valve (40) into No. 2 extension cylinder
(4) Slide tubing (39) and connect fitting (38) to breakage valve (40). Do not
tighten fitting (38).
(5) Connect fitting (37) to holding valve (26). Tighten securely. Tighten
fitting (38) securely.
(29). Make sure large end of spring (34) faces reducer (32) into breakage valve (29).
adapter (30).
20-112
TM 08780B-20
(9) Slide tubing (28) and connect fitting (27) to breakage valve (29). Do not
tighten fitting (27).
22. Clamp 31. No. 2 Extension 39. Tubing

23. Clamp Cylinder 40. Breakage Valve
24. Clamp 32. Reducer 41. Adapter
25. Fitting 33. O-Ring 42. Reducer
26. Holding Valve 34. Small Spring 43. O-Ring
27. Fitting 35. Ball 44. Small Ball
28. Tubing 36. Long Spring 45. Ball
29. Breakage Valve 37. Fitting 46. Long Spring
30. Adapter 38. Fitting
20-113
TM 08780B-20
(10) Connect fitting (25) to holding valve (26). Tighten securely. Tighten
fitting (27) securely.
(11) Tighten clamps (22, 23 and 24).
e. Installation of No. 1 Extension Cylinder Breakage Valve
(15). Make sure end of spring (19) faces reducer (17). Install reducer (17). Tighten securely.
adapter (16).
(4) Slide tubing (14) and connect fitting (13). Tighten securely.
(5). Make sure large end of spring (10) faces reducer (8). Install reducer (8). Tighten securely.
(6) Install adapter (6) onto reducer (8). Install new O-ring (9).
(7).
(8) Slide tubing (4) and connect fittings (3 and 2). Tighten securely.
(9) Tighten clamp (1).
END OF TASK
NOTE
LI 2320-12/9 Check hydraulic oil level
LO 9-2320-297-12
20-114
TM 08780B-20
1. Clamp 8. Reducer 15. Breakage Valve

2. Fitting 9. O-Ring 16. Adapter
3. Fitting 10. Small Spring 17. Reducer
4. Tubing 11. Ball 18. O-Ring
5. Breakage Valve 12. Long Spring 19. Small Spring
6. Adapter 13. Fitting 20. Ball
7. No. 1 Extension 14. Tubing 21. Long Spring
Cylinder
20-115
TM 08780B-20
20-18. MANIFOLD REPLACEMENT (MK17)

INITIAL SETUP

Materials/Parts parts before disassembly
Lockwasher (2) (MS35338-45) item 14 and work in a clean area.
O-ring (NSN 5330-01-190-0294)
items 18, 20, 24 and 26 General Safety Instructions
O-ring (NSN 5330-01-168-0885) item 22 Block wheels of truck to prevent personal
O-ring (NSN 5330-01-040-4772) item 30 injury.
O-ring (NSN 5330-00-228-7196)
items 28 and 29
References
TM 08780B-10
NOTE
1. Manifold
2. Crane
(1) Position crane (1) over bed to gain access to manifold (2). Refer to
paragraph 2-25 in TM 08780B-10.
(2) Tag and disconnect tubing (3) from fitting (4).
20-116
TM 08780B-20
(3) Tag and disconnect tubing (5) from fitting (6).
(4) Tag and remove hydraulic line (7) from elbow (8). Tag elbow (8).
3. Tubing 8. Elbow
4. Fitting 9. Hydraulic Line
5. Tubing 10. Elbow
7. Hydraulic Line 12. Elbow
(7) Remove two capscrews (13), lockwashers (14), flat washers (15) and
manifold (16). Discard lockwashers (14).
(8) Remove plug (17) and discard O-ring (18).
(9) Remove plug (19) and discard O-ring (20).
(10) Loosen nut (21) and remove elbow (12). Discard O-ring (22).
(11) Remove plug (23). Discard O-ring (24).
(14) Remove fitting (6) and discard O-ring (29).
20-117
TM 08780B-20
(15) Remove fitting (4) and discard O-ring (30).
(1) Position manifold (16) as shown.
(2) Install new O-ring (30) on fitting (4).
(3) Install fitting (4) into manifold (16). Tighten securely.
(5) Install fitting (6) in manifold (16). Tighten securely.
4. Fitting 16. Manifold 24. O-Ring

6. Fitting 17. Plug 25. Nut
10. Elbow 19. Plug 27. Nut
13. Capscrew (2) 21. Nut 29. O-Ring
14. Lockwasher (2) 22. O-Ring 30. O-Ring
15. Flat Washer (2) 23. Plug
20-118
TM 08780B-20
(6) Install new O-ring (28) on elbow (8).
(7) Install elbow (8) into manifold (16). Do not tighten nut (27).
(10) Install new O-ring (24) on plug (23).
(11) Install plug (23) into manifold (16). Tighten securely.
(18) Position manifold (16) so that fitting (4) aligns with tubing (3) and fitting
(6) aligns with tubing (5).
(19) Secure manifold (16) with two capscrews (13), new lockwashers (14) and
flat washers (15). Tighten securely.
(20) Connect tubing (5) to fitting (6). Tighten securely.
(21) Connect tubing (3) to fitting (4). Tighten securely.
(22) Position and align hydraulic line (11) to elbow (12). Connect hydraulic
line (11) to elbow (12). Tighten nut (21) and line (11) securely.
(23) Position and align hydraulic line (9) to elbow (10). Connect hydraulic line
(9) to elbow (10). Tighten nut (25) and line (9) securely.
(24) Position and align hydraulic line (7) to elbow (8). Tighten nut (27) and
line (7) securely.
END OF TASK
20-119
TM 08780B-20
NOTE
(para 2-16 or 2-24).

LO 9-2320-297-12
3. Tubing
4. Fitting
5. Tubing
6. Fitting
7. Hydraulic Line
8. Elbow
9. Hydraulic Line
10. Elbow
11. Hydraulic Line
12. Elbow
25. Nut
20-120
TM 08780B-20
20-19. MANIFOLD REPLACEMENT (MK15)

INITIAL SETUP

Materials/Parts parts before disassembly and work in a
Lockwasher (2) (MS35338-45) item 18 clean area.
O-ring (NSN 5330-00-288-7196)
O-ring (NSN 5330-01-190-0294 Block wheels of truck to prevent personal
items 22, 28, 32 and 34 injury.
O-ring (NSN 5330-01-040-4772) item 26
O-ring (NSN 5330-01-168-0885) item 30
References
TM 08780B-10
NOTE
• Position crane over bed.
• Place a container to catch hydraulic oil before disconnecting hydraulic lines.
20-121
TM 08780B-20
(1) Tag and remove hydraulic line (1) from tee (2). Tag tee (2).
(2) Tag and remove hydraulic line (3) from elbow (4) Tag elbow (4).
(3) Tag and remove hydraulic line (6) with elbow (5) from fitting (7). Tag
fitting (7).
(6) Tag and remove hydraulic line (12) from fitting (13). Tag fitting (13).
(8) Tag and remove hydraulic line (16) from tee (2).
(9) Remove two capscrews (17), lockwashers (18), flat washers (19) and
manifold (20). Discard lockwashers (18).
(10) Secure manifold (20) in a vise.
1. Hydraulic Line 8. Hydraulic Line 15. Elbow

2. Tee 9. Elbow 16. Hydraulic Line
3. Hydraulic Line 10. Hydraulic Line 17. Capscrew (2)
4. Elbow 11. Elbow 18. Lockwasher (2)
5. Elbow 12. Hydraulic Line 19. Flat Washer (2)
6. Hydraulic Line 13. Fitting 20. Manifold
20-122
TM 08780B-20
(11) Remove fitting (7). Remove and discard O-ring (21).
(12) Remove fitting (13). Remove and discard O-ring (22).
(13) Loosen nut (23) and remove elbow (4). Remove and discard O-ring (24).
(17) Remove plug (31) and remove and discard O-ring (32).
(18) Loosen nut (33) and remove tee (2). Remove and discard O-ring (34).
(1) Position manifold (20) in vise and secure.
(3) Install fitting (7) into manifold (20). Tighten securely.
(5) Install fitting (13) in manifold (20). Tighten securely.
20-123
TM 08780B-20
(15) Install plug (31) into manifold. Tighten securely.
(16) Install new O-ring (34) on tee (2).
(17) Install tee (2) into manifold (20). Do not tighten nut (33).
2. Tee 21. O-Ring 28. O-Ring

4. Elbow 22. O-Ring 29. Nut
7. Fitting 23. Nut 30. O-Ring
9. Elbow 24. O-Ring 31. Plug
11. Elbow 25. Nut 32. O-Ring
13. Fitting 26. 0-Ring 33. Nut
15. Elbow 27. Nut 34. O-Ring
20. Manifold
(18) Position manifold (20) to bracket (35).
20-124
TM 08780B-20
(19) Connect hydraulic line (14) to elbow (15). Tighten nut (29). Remove
tags. Tighten hydraulic line (14) securely.
(20) Connect hydraulic line (16) to tee (2). Tighten securely.
(21) Connect hydraulic line (1) to tee (2). Tighten nut (33). Remove tags.
Tighten hydraulic line (1) securely.
(22) Connect hydraulic line (12) to fitting (13). Remove tags. Tighten
securely.
(23) Connect hydraulic line (10) to elbow (11). Tighten nut (27). Remove
tags. Tighten hydraulic line (10) securely.
(24) Connect hydraulic line (8) to elbow (9). Tighten nut (25). Remove tags.
(25) Connect elbow (5) with hydraulic line (6) to fitting (7). Remove tags.
(26) Connect hydraulic line (3) to elbow (4). Tighten nut (23). Remove tags.
(27) Secure manifold (20) to bracket (35) with two capscrews (17), new
lockwashers (18) and flat washers (19).
2. Tee
4. Elbow
7. Fitting
9. Elbow
11. Elbow
13. Fitting
15. Elbow
20. Manifold
23. Nut
25. Nut
27 Nut
29. Nut
33. Nut
35. Bracket
END OF TASK
20-125
TM 08780B-20
NOTE
TM 08780B-10 Check crane for proper operation and
hydraulic leaks (para 2-16).

LO 9-2320-297-12
1. Hydraulic Line 8. Hydraulic Line 15. Elbow

2. Tee 9. Elbow 16. Hydraulic Line
3. Hydraulic Line 10. Hydraulic Line 17. Capscrew (2)
4. Elbow 11. Elbow 18. Lockwasher (2)
5. Elbow 12. Hydraulic Line 19. Flatwasher (2)
6. Hydraulic Line 13. Fitting 20. Manifold
7. Fitting 14. Hydraulic Line 35. Bracket
20-126
TM 08780B-20
20-20. BASIC SOLENOID VALVE MAINTENANCE

INITIAL SETUP

parts before disassembly and work in a
Materials/Parts clean area.
Nylon tie (AR) (MS3367-5-9) item 11 Block wheels of truck to prevent personal
Locknut (2) (MS51922-9) item 23 injury.
O-ring (NSN 5330-00-228-7196)
items 27, 28 and 32
NOTE
• Place a container or funnel, as necessary, to catch hydraulic oil before disconnecting
hydraulic lines.
• This task works for both cranes (MK15 and MK17). Differences are shown in
illustrations or noted.
(1) On MK15 only, remove four capscrews (1), washers (2) and locknuts (3)
from panel (4). Discard locknuts (3).
(2) Cut nylon tie (5), slide rubber boot (6) back and disconnect wire leads (7)
from neutral safety switch (8).
(3) Tag and unplug two wires (9) from two wires (10).
(4) Cut nylon ties (11) as needed.
20-127
TM 08780B-20
1. Capscrew (4) 7. Wire Lead (2)

2. Washer (4) 8. Neutral Safety Switch
3. Locknut (4) 9. Wire (2)
4. Panel 10. Wire (2)
5. Nylon Tie 11. Nylon Tie (A/R)
6. Rubber Boot
NOTE
If necessary, loosen nut (12) and turn elbow (13) to allow removal of tubing (14).
20-128
TM 08780B-20
(5) Disconnect two fittings (15 and 16) from tubing (14). Remove tubing
(14).
NOTE
If necessary, loosen nut (17) and turn elbow (18) to allow removal of tubing (19).
(6) Disconnect two fittings (20 and 21) from tubing (19). Remove tubing
(19).
12. Nut
13. Elbow
14. Tubing
15. Fitting
16. Fitting
17. Nut
18. Elbow
19. Tubing
20. Fitting
21. Fitting
(7) Remove two capscrews (22), locknuts (23) and four washers (24).
20-129
TM 08780B-20
(8) Remove basic solenoid valve assembly (25) and spacer (26) (MK17 only).
22. Capscrew (2)

23. Locknut (2)
24. Washer (4)
25. Basic Solenoid
Valve Assembly
26. Spacer
(MK17 Only)
20-130
TM 08780B-20
(9) Secure basic solenoid valve assembly (25) in a soft-jawed vise.
(10) Remove elbow (13). Remove and discard O-ring (27).
(11) Remove elbow (17). Remove and discard O-ring (28).
(12) Remove adapter (29) with electrical failure valve (30) from basic solenoid
valve (31). Remove and discard O-ring (32).
(13) Remove locknut (33). Discard locknut (33).
(14) Remove coil (34) and placard (35).
(3) Test coil (34) for continuity.
(1) Place coil (34) and placard (35) over cartridge (36) and secure with new
locknut (33).
(2) Install new O-ring (32) onto adapter (29).
(3) Install basic solenoid valve (31) onto adapter (29).
(5) Install elbow (17) into basic solenoid valve (31). Do not tighten.
(7) Install elbow (13) into electrical failure valve (30). Do not tighten.
20-131
TM 08780B-20
13. Elbow 29. Adapter 32. O-Ring

17. Elbow 30. Electrical Failure 33. Locknut
25. Basic Solenoid Valve 34. Coil
Valve Assembly 31. Basic Solenoid 35. Placard
27. O-Ring Valve 36. Cartridge
28. O-Ring
22 Capscrew (2) 25. Basic Solenoid 37. Bracket

23. Locknut (2) Valve Assembly
24. Washer (4) 26. Spacer (MK17 Only)
20-132
TM 08780B-20
(8) Position basic solenoid valve assembly (25) (with spacer (26), on MK17
only),to bracket (37) and secure with two capscrews (22), four washers (24) and new locknuts
(23).
(9) Position tubing (19) between elbow (18) and point A. Elbow (18) may be
turned as needed to accomplish connection.
(10) Connect fitting (20) to elbow (18). Connect fitting (21) to point A.
(11) Tighten nut (17) to lock elbow (18) in place. Tighten fittings (20 and 21)
to secure tubing (19).
(12) Position tubing (14) between elbow (13) and point B. Elbow (13) may be
turned to accomplish connection.
(13) Connect fitting (15) to elbow (13). Connect fitting (16) to point B.
(14) Tighten nut (12) to lock elbow (13) in place. Tighten fittings (15 and 16)
to secure tubing (14).
12. Nut
13. Elbow
14. Tubing
15. Fitting
16. Fitting
17. Nut
18. Elbow
19. Tubing
20. Fitting
21. Fitting
(15) Connect wires (9) to wires (10).
(16) Connect wire leads (7) to neutral safety switch (8).
(17) Install rubber boot (6) over neutral safety switch (8) and secure with nylon
tie (5).
(18) Secure all wires with nylon ties (11) as necessary.
(19) On MK15 only, install panel (4) using four capscrews (1), flat washers (2)
20-133
TM 08780B-20
END OF TASK
NOTE
LO 9-2320-297-12

(para 2-16 or 2-25).
TM 08780B-20 Secure electrical failure valve with seal

(para 20-21).
1. Capscrew (4)
2. Washer (4)
3. Locknut (4)
4. Panel
5. Nylon Tie
6. Rubber Boot
7. Wire Lead (2)
9. Wire (2)
10. Wire (2)
11. Nylon Tie Air
20-134
TM 08780B-20
20-21. ELECTRICAL FAILURE VALVE REPLACEMENT

c. Assembly
INITIAL SETUP

MK17 working on hydraulic equipment. Clean
all parts before disassembly and work in
Materials/Parts a clean area.
Sealant, pipe (item 48, Appendix D) General Safety Instructions
Locknut (MS51922-9) item 3 Block wheels of truck to prevent personal
Nylon tie (AR) (MS3367-1-9) item 5 injury.
Nylon tie (AR) (MS3367-5-9) item 11
O-ring (NSN 5330-00-228-7196) items 27 and 32
References
TM 08780B-10
LI 2320-12/9
LO 9-2320-297-12
a. Removal
NOTE
• Place a container to catch hydraulic oil before disconnecting hydraulic lines.
• This task works for both cranes (MK15 and MK17). Differences are shown in
illustrations or noted.
(1) On MK15 only, remove four capscrews (1), washers (2) and locknuts (3)
from panel (4). Discard locknuts (3).
(2) Cut nylon tie (5) and remove rubber boot (6) and disconnect wire leads (7)
from neutral safety switch (8).
(3) Tag and unplug two wires (9) from two wires (10).
(4) Cut nylon ties (11) as needed.
20-135
TM 08780B-20
1. Capscrew (4) 7. Wire Lead (2)

2. Washer (4) 8. Neutral Safety Switch
3. Locknut (4) 9. Wire (2)
4. Panel 10. Wire (2)
5. Nylon Tie 11. Nylon Tie A/R
6. Rubber Boot
5. Nylon Tie
6. Rubber Boot
7. Wire Lead (2)
9. Wire (2)
10. Wire (2)
11. Nylon Tie (A/R)
20-136
TM 08780B-20
(5) Disconnect two fittings (12 and 13) of tubing (14).
(6) Loosen nut (15) and turn elbow (16) to allow removal of tubing (14).
(7) Disconnect two fittings (17 and 18) of tubing (19).
12. Fitting 17. Fitting

14. Tubing 19. Tubing
15. Nut 20. Nut
16. Elbow 21. Elbow
22. Capscrew (2) 25. Basic Solenoid Valve Assembly

23 Locknut (2) 26. Spacer (MK17 Only)
24. Flat Washer (4)
20-137
TM 08780B-20
(9) Remove two capscrews (22), locknuts (23) and four flat washers (24).
(10) Remove basic solenoid valve assembly (25) and (on MK17 only) spacer
(26).
(11) Secure basic solenoid valve assembly (25) in a soft-jawed vise.
(12) Remove elbow (16) and discard O-ring (27).
(13) Remove elbow (28) with electrical failure valve (29) from pipe nipple
(30).
(14) Secure electrical failure valve (29) in a soft-jawed vise.
(15) Loosen nut (31) and remove elbow (28) from electrical failure valve (29).
Remove and discard O-ring (32).
16. Elbow 29. Electrical Failure Valve

25. Basic Solenoid Valve Assembly 30. Pipe Nipple
27 O-Ring 31. Nut
(16) Remove screw (33) and locknut (34). Discard locknut (34).
(17) Remove handle (35).
(18) Remove neutral safety switch (8).
20-138
TM 08780B-20
(19) Remove four Allen head screws (36), spacer (37) and housing (38) from
electrical failure valve (29).
(20) Separate cam (39) with shaft (40) from housing (38).
8. Neutral Safety Switch 36. Allen Head Screw (4)

29 Electrical Failure Valve 37. Spacer
33. Screw 38. Housing
34. Locknut 39. Cam
35. Handle 40. Shaft
c. Assembly
(1) Place electrical failure valve (29) in a soft-jaw vise.
(2) Using handle (35), place valve (29) in the closed position.
(3) Install new O-ring (32) onto elbow (28). Install new O-ring (27) onto
elbow (16).
20-139
TM 08780B-20
(4) On MK15, install elbow (28) into dowel (41) side of electrical failure
valve (29). Do not tighten nut (31).
(5) On MK15, install elbow (16) into opposite side of valve (29).
(6) On MK17, install elbow (16) into dowel (41) side of electrical failure
valve (29). Do not tighten nut (15).
(7) On MK17, install elbow (28) on opposite side of valve (29).
(8) Align housing (38) with dowel (41).
(9) Apply a light coat of grease to cam (39).
(10) Install cam (39) into housing (38) so that low lobe (42) is visible through
port (43) in housing (38).
(11) Install spacer (37) onto housing (38) and electrical failure valve (29) using
four Allen head screws (36). Tighten securely.
(12) Install neutral safety switch (36) into housing (38). Tighten securely.
8. Neutral Safety 29. Valve 37. Spacer

Switch 31. Nut 38. Housing
15. Nut 32. O-Ring 39. Cam
16. Elbow 35. Handle 41. Dowel
27. O-Ring 36. Allen Head 42. Lobe
28. Elbow Screw (4) 43. Port
20-140
TM 08780B-20
8. Neutral Safety Switch 29. Electrical Failure Valve

16. Elbow 30. Pipe Nipple
25. Basic Solenoid Valve Assembly 31. Nut
(13) Remove electrical failure valve (29) from vise. Place basic solenoid valve
assembly (25) in a soft-jaw vise.
(14) Apply sealant to threads of nipple (30). Install elbow (28) onto nipple
(30). Electrical failure valve (29) must face down. Tighten nut (31) to lock elbow (28) in
position.
(15) Position elbow (16) so it faces the same direction as neutral safety switch
(8).
(16) Position basic solenoid valve assembly (25) (with spacer (26), on MK17
only) to bracket (44) and secure with two capscrews (22), four flat washers (24) and new
locknuts (23).
22. Capscrew (2)

23. Locknut (2)
24. Flat Washer (4)
25. Basic Solenoid
Valve Assembly
26. Spacer
(MK17 Only)
44. Bracket
20-141
TM 08780B-20
(17) Position tubing (19) between elbow (21) and point A. Elbow (21) may be
turned as needed to accomplish connection.
(18) Connect two fittings (17 and 18). Connect fitting (18) to point A.
(19) Lock elbow (21) with nut (20). Tighten fittings (17 and 18) securely.
(20) Position tubing (14) between elbow (16) and point B. Elbow (16) may be
turned to accomplish connection.
(21) Connect fitting (12) to elbow (16). Connect fitting (13) to point B.
(22) Lock elbow (16) with nut (15). Tighten fittings (12 and 13) securely.
12. Fitting
13. Fitting
14. Tubing
15. Nut
16. Elbow
17. Fitting
18. Fitting
19. Tubing
20. Nut
21. Elbow
20-142
TM 08780B-20
(23) Connect two wires (9 and 10).
(24) Secure wires (9 and 10) with nylon ties (11) as needed.
(25) Connect wire leads (7) to neutral safety switch (8).
(26) Install rubber boot (6) over neutral safety switch (8) and secure with nylon
tie (5).
(27) Using handle (35), place electrical failure valve (29) into the open
position.
(28) Position handle (35) on valve (29) so handle points up.
(29) Secure handle (35) with screw (33) and new locknut (34).
(30) Wire handle (35) in the open position.
(31) On MK15 only, install panel (4) using four capscrews (1), washers (2) and
END OF TASK
NOTE
LO 9-2320-297-12

(para 2-16 or 2-25).
20-143
TM 08780B-20
1. Capscrew (4) 7. Wire Lead (2) 29. Electrical Failure

2. Washer (4) 8. Neutral Safety Valve
3. Locknut (4) Switch 33. Screw
4. Panel 9. Wire 34. Locknut
5. Nylon Tie 10. Wire 35. Handle
6. Rubber Boot 11. Nylon Tie A/R
20-144
TM 08780B-20
20-22. STABILIZER SELECTOR/LOCKING VALVE REPLACEMENT

c. Installation
INITIAL SETUP

parts before disassembly and work in a
Materials/Parts clean area.
O-ring (3) (NSN 5330-01-190-0294)
items 9, 22 and 24 General Safety Instructions
Locknut (MS51858-5) item 17 Block wheels of truck to prevent personal
injury.
a. Removal
NOTE
• This paragraph applies to either the right or the left stabilizer selector/locking valves
(1). Only the left stabilizer selector/locking valve is shown.
• Position container to catch hydraulic oil before disconnecting hydraulic lines.
(2) Unscrew two fittings (4 and 5) on tubing (6).
(4) Remove elbow (8) and discard O-ring (9).
(5) Unscrew fitting (10).
(6) Remove nut (11), star washer (12) and placard bracket (13) from adapter
(14).
(7) Remove adapter (14) from stabilizer/selector locking valve (1) and remove
stabilizer selector/locking valve (1) from bracket (15).
(8) Remove socket head capscrew (16) and locknut (17). Discard locknut
(17).
20-145
TM 08780B-20
(9) Remove handle (18), snapring (19) and cam washer (20)from stabilizer
selector/locking valve (1).
(10) Remove adapter (21) and O-ring (22) from stabilizer selector/locking
valve (1). Discard O-ring (22).
(11) Remove adapter (23) and O-ring (24) from stabilizer selector/locking
valve (1). Discard O-ring (24).
1. Stabilizer Selector/ 9. O-Ring 17. Locknut

Locking Valve 10. Fitting 18. Handle
2. Clamp 11. Nut 19. Snapring
3. Spacer (2) 12. Star Washer 20. Cam Washer
4. Fitting 13. Placard Bracket 21. Adapter
5. Fitting 14. Adapter 22. O-Ring
6. Tubing 15. Bracket 23. Adapter
7. Nut 16. Socket Head 24. 0-Ring
8. Elbow Capscrew
20-146
TM 08780B-20
c. Installation
(1) Install hew O-ring (24) onto adapter (23). Install adapter (23) into
stabilizer selector/locking valve (1).
(2) Install new O-ring (22) onto adapter (21). Install adapter (21) into
stabilizer selector/locking valve (1).
(3) Position stabilizer selector/ locking valve (1) onto bracket (15) and secure
with special adapter (14). Connect fitting (10) to adapter (23) and tighten securely.
(4) Install placard bracket (13), star washer (12) and nut (11). Tighten nut
(11) securely.
(6) Install elbow (8), leaving nut (7) loose.
(7) Position tubing (6) to adapter (14) and elbow (8).
(8) Turn elbow (8) with wrench to properly position fittings (4 and 5). Hand
tighten fittings (4 and 5).
(10) Install two spacers (3) and clamp (2). Tighten clamp (2) securely.
(11) Tighten fitting (4) and fitting (5) securely.
NOTE
Slot on shaft (25) is aligned with stabilizer selector/locking valve (1). When slot is straight up
and down, stabilizer selector/locking valve (1) is open.
(12) Position cam washer (20) on shaft (25) so stabilizer selector/locking valve
rotates clockwise to close and counterclockwise to open. Secure cam washer (20) with snapring
(19).
(13) Install handle (18) on shaft (25) to align with slot on shaft (25). Secure
handle (18) with socket head capscrew (16) and new locknut (17).
END OF TASK
20-147
TM 08780B-20
NOTE
LO 9-2320-297-12
TM 08780B-10 Check stabilizer cylinder for proper

operation (para 2-16 or 2-25).
1. Stabilizer Selector/ 9. O-Ring 17. Locknut

Locking Valve 10. Fitting 18. Handle
2. Clamp 11. Nut 19. Snapring
3. Spacer (2) 12. Star Washer 20. Cam Washer
4. Fitting 13. Placard Bracket 21. Adapter
5. Fitting 14. Adapter 22. O-Ring
6. Tubing 15. Bracket 23. Adapter
7. Nut 16. Socket Head 24. O-Ring
8. Elbow Capscrew 25. Shaft
20-148
TM 08780B-20
20-23. OUTRIGGER SELECTOR/LOCKING VALVE REPLACEMENT (MK15)

c. Installation
INITIAL SETUP

Locknut (MS51858-5) item 6 clean area.
O-ring (2) (NSN 5330-01-190-0294) item 15 General Safety Instructions
injury. Wear eye protection when working
on hydraulic system to prevent personal
injury.
a. Removal
WARNING
HYDRAULICS MAY BE UNDER PRESSURE AND CAN SPURT OUT WHEN LINES (1)
AND (2) ARE DISCONNECTED. CRACK ALL LINES SLOWLY AND KEEP YOUR FACE
CLEAR OF LINES.
NOTE
(1) Tag and disconnect two hydraulic lines (1 and 2).
NOTE
Note position of handle (3) to slot on shaft (4). This is for proper assembly.
(2) Remove socket head capscrew (5) and locknut (6). Discard locknut (6).
(3) Remove handle (3) and washer (7) from outrigger selector/locking valve
(8).
(4) Remove two capscrews (9), locknuts (10), washers (11) and retainer (12).
20-149
TM 08780B-20
1. Hydraulic Line 6. Locknut 9. Capscrew (2)

2. Hydraulic Line 7. Washer 10. Locknut (2)
3. Handle 8. Outrigger Selector/ 11. Washer
4. Shaft locking Valve 12. Retainer
5. Socket Head Capscrew
(5) Secure outrigger selector/ locking valve (8) in a soft-jawed vise.
NOTE
Left side outrigger selector/locking valve has two elbows (13). Right outrigger selector/locking
valve only has one elbow (13).
20-150
TM 08780B-20
(6) Remove elbow (13), two adapters (14) and O-rings (15). Discard O-rings
(15).
(7) Remove snapring (16) and cam washer (17).
c. Installation
(1) Secure outrigger selector/locking valve (8) in a soft-jawed vise.
NOTE
Left side outrigger selector/locking valve has two elbows (13). Right outrigger selector/locking
valve only has one elbow (13).
(2) Install two new O-rings (15), adapters (14) and elbow (13). Tighten
securely.
(3) Install cam washer (17) and snapring (16).
8. Outrigger Selector;
Locking Valve
13. Elbow (Left Side 2,
Right Side 1)
14. Adapter (2)
15. O-Ring (2)
16. Snapring
17. Cam Washer
(4) Position outrigger selector/locking valve (8) on fender (18).
(5) Secure outrigger selector/ locking valve (8) to fender (18) with two
capscrews (9), retainer (12), washers (11) and two new locknuts (10).
20-151
TM 08780B-20
(6) Install washer (7).
(7) Position handle (3) as noted.
(8) Secure handle (3) with socket head capscrew (5) and new locknut (6).
(9) Connect two hydraulic lines (1 and 2) as tagged. Tighten securely.
END OF TASK
NOTE
(para 2-16).

LO 9-2320-297-12
1. Hydraulic Line
2. Hydraulic Line
3. Handle
5. Socket Head
Capscrew
6. Locknut
7. Washer
8. Outrigger Selector
Locking Valve
9. Capscrew (2)
10. Locknut (2)
11. Washer
12. Retainer
18. Fender
20-152
TM 08780B-20
20-24. OUTRIGGER SELECTOR/LOCKING VALVE REPLACEMENT (MK17)

c. Installation
INITIAL SETUP

Locknut (MS51858-5) item 6 clean area.
O-ring (2) (NSN 5330-01-190-0294) item 14 General Safety Instructions
Wear eye protection when working on
hydraulic system to prevent personal injury.
injury.
a. Removal
WARNING
HYDRAULICS MAY BE UNDER PRESSURE AND CAN SPURT OUT WHEN LINES ARE
DISCONNECTED. CRACK ALL LINES SLOWLY AND KEEP YOUR FACE CLEAR OF
LINES.
NOTE
NOTE
Note position of handle (3) to slot on shaft (4). This is for proper assembly.
(2) Remove socket head capscrew (5) and locknut (6). Discard locknut (6).
(3) Remove handle (3) and washer (7) from outrigger selector/locking valve
(8).
(4) Remove two capscrews (9), lockwashers (10), retainer (11) and outrigger
selector/locking valve (8). Discard lockwashers (10).
(5) Secure outrigger selector/ locking valve (8) in a soft-jawed vise.
20-153
TM 08780B-20
1. Hydraulic Line 7. Washer

2. Hydraulic Line 8. Outrigger Selector/Locking Valve
3. Handle 9. Capscrew (2)
4. Shaft 10. Lockwasher (2)
5. Socket Head Capscrew 11. Retainer
6. Locknut
20-154
TM 08780B-20
8. Outrigger Selector/
Locking Valve
12. Elbow
13. Adapter (2)
14. O-Ring (2)
15. Snapring
16. Cam Washer
(6) Remove elbow (12) from adapter (13).
(7) Remove two adapters (13) and O-rings (14). Discard O-rings (14).
(8) Remove snapring (15) and cam washer (16).
c. Installation
(1) Secure outrigger selector/locking valve (8) in a soft-jawed vise.
(2) Install two new O-rings (14) and adapters (13).
(3) Install elbow (12) onto adapter (13).
(4) Install cam washer (16) and snapring (15).
(5) Position outrigger selector/locking valve (8) to bracket (17).
(6) Secure outrigger selector/locking valve (8) to bracket (17) with two
capscrews (9), new lockwashers (10) and retainer (11).
(7) Install washer (7).
20-155
TM 08780B-20
(8) Position handle (3) as noted.
(9) Secure handle (3) with socket head capscrew (5) and new locknut (6).
(10) Connect two hydraulic lines (1 and 2) as tagged. Tighten securely.
END OF TASK
NOTE
L1 2320-12/9 Check hydraulic oil level.
LO 9-2320-297-12

(para 2-25).
1. Hydraulic Line
2. Hydraulic Line
3. Handle
4. Shaft
5. Socket Head
Capscrew
6. Locknut
7. Washer
8. Outrigger Selector/
Locking Valve
9. Capscrew (2)
10. Lockwasher (2)
11. Retainer
17. Bracket
20-156
TM 08780B-20
20-25. STOWAGE BOX MAINTENANCE (MK15)

c. Installation
INITIAL SETUP
MK15
Materials/Parts
Locknuts (6) (MS51858-5) items 12 and 15
a. Removal
(1) Remove remote control unit (1) and umbilical cord (2) from stowage box
(3).
(2) Remove four Allen head capscrews (4) and remote control receptacle box
(5).
locknuts (6).
NOTE
Note location of washers (10) for proper installation.
(4) Remove stowage box (3), four spacers (9) and two washers (10).
(5) Remove four Allen head capscrews (11), locknuts (12) and bracket (13).
(6) Remove two Allen head capscrews (14), locknuts (15) and latch (16).
(7) Remove test receptacle (17) from holder (18).
(8) Remove two screws (19), locknuts (20), chain (21) and holder (18).
20-157
TM 08780B-20
c. Installation
(1) Install holder (18), two screws (19), chain (21) and new locknuts (20).
Tighten securely.
(2) Install test receptacle (17) into holder (18).
(3) Install latch (16), two Allen head capscrews (14) and two new locknuts
(4) Install bracket (13), four Allen head capscrews (11) and four new locknuts
(5) Position two washers (10) and four spacers (9).
(6) Install stowage box (3).
(7) Install four capscrews (8), washers (7) and new locknuts (6). Tighten
securely.
(8) Install remote control receptacle box (5) and four Allen head capscrews
(4) onto stowage box (3). Tighten securely.
(9) Install umbilical cord (2) and remote control unit (1).
20-158
TM 08780B-20
1. Remote Control 8. Capscrew (4) 15. Locknut (2)

Unit 9. Spacer (4) 16. Latch
2. Umbilical Cord 10. Washer (2) 17. Test Receptacle
3. Stowage Box 11. Allen Head 18. Holder
4. Allen Head Capscrew (4) 19. Screw (2)
Capscrew (4) 12. Locknut (4) 20. Locknut (2)
5. Receptacle Box 13. Bracket 21. Chain
6. Locknut (4) 14. Allen Head
7. Washer (4) Capscrew (2)
END OF TASK
20-159
TM 08780B-20
20-26. STOWAGE BOX MAINTENANCE (MK17)

c. Installation
INITIAL SETUP
MK17
Materials/Parts
Locknut 4 (MS51922-13) item 9
a. Removal
(1) Remove remote control unit (1) and umbilical cord (2) from stowage box
(3).
(2) Remove four Allen head capscrews (4) from receptacle box (5).
(3) Remove receptacle box (5) from stowage box (3).
(4) Remove four capscrews (6), washers (7), one clamp (8) and four locknuts
(9) from bottom of stowage box (3). Discard locknuts (9).
(5) Remove stowage box (3).
(6) Remove two screws (10), locknuts (11), chain (12) and receptacle (13)
with test plug (14). Discard locknuts (11).
(7) Remove two Allen head capscrews (15), locknuts (16) and door latch (17).
20-160
TM 08780B-20
c. Installation
(1) Install door latch (17), two Allen head capscrews (15) and new locknuts (16).
Tighten securely.
(2) Install test plug (14), receptacle (13), chain (12), screws (10) and new locknuts
(3) Install stowage box (3).
(4) Install four capscrews (6), washers (7), one clamp (8) and four new locknuts (9).
Tighten securely.
(5) Install receptacle box (5) and four Allen head capscrews (4) to stowage box (3).
Tighten securely.
(6) Install remote control unit (1) and umbilical cord (2).
1. Remote Control Unit

2. Umbilical Cord
3. Stowage Box
4. Allen Head Capscrew (4)
5. Receptacle Box
6. Capscrew (4)
7. Washer (4)
8. Clamp
9. Locknut (4)
10. Screw (2)
11. Locknut (2)
12. Chain
13. Receptacle
14. Test Plug
15. Allen Head Capscrew
16. Locknut (2)
17 Door Latch
END OF TASK
20-161
TM 08780B-20
20-27. PLACARD REPLACEMENT

c. Installation
INITIAL SETUP

MK17 injury.
Materials/Parts
Number 10 drive screws (MS21318-27) item 1
a. Removal
NOTE
• Placards are the metal labels attached to parts of the crane. They must be replaced if
they become damaged or when a part they were mounted on is replaced.
• The following procedure works for any of the crane’s placards.
(1) Using a small sharp chisel, remove four drive screws (1).
(2) Remove placard (2).
(3) Using a suitable punch, drive thread ends of drive screws (3) through
mounting surface (4). Drill out thread ends (3) of drive screw (1) if needed.
1. Drive Screw (4)

2. Placard
3. Thread End
4. Mounting Surface
20-162
TM 08780B-20
(1) Clean mounting surfaces.
(2) Inspect mounting surfaces for damage.
(3) Repair if necessary.
c. Installation
NOTE
Use the following illustrations to locate placards.
(1) Position placard (2) on mounting surface (4).
(2) Secure placard (2) to mounting surface (4) with four new drive screws (1).
(3) Tap drive screws (1) with a hammer to seat in place.
1. Drive Screw (4)

2. Placard
4. Mounting Surface
20-163
TM 08780B-20
A. Placard Comb O/R Aux Cont.

B. Placard Comb Storage Box
C. Placard “A” Frame Warning
D. Placard Face Plate-Hand Contr
E. Placard Electrical Warning
F. Placard Susp. Load Warning
G. Placard Angle Indicator (R.H.)
H. Placard Greasing Instr.
I. Placard O/R Cyl Lock/Unlock (RH
J. Placard Lifting Cap (RH
20-164
TM 08780B-20
K. Placard Stow Pin Caution

L. Placard Lifting Cap (L.H.)
M. Placard Susp. Load Warning
N. Placard Comb Actuator Box
O. Placard “A” Frame Warning
P. Placard Rot Stow Marker
Q. Placard Serial No.
R. Placard Comb Actuator Box
S. Placard Comb Main Controls
T. Placard O/R Ext Lock/Unlock
U. Placard Man/Off Rem. Switch
V. Placard Side Pull
W. Placard O/R Cyl. Lock/Unlock (L.H.)
X. Placard Angle Indicator (L.H.)
20-165
TM 08780B-20
A. Placard Susp. Load Warning

B. Placard Lifting Cap (R.H.)
C. Placard Angle Indicator
D. Placard Rot. Stow Marker
E. Placard Greasing Instrn.
F. Placard O/R Cyl. Lock/Unlock (R.H.)
G. Placard Comb/O/R Controls
H. Placard Face Plate Hand Contr.
I. Placard Act Switch Hand Contr.
20-166
TM 08780B-20
J. Placard Stow Pin Caution

K. Placard Lifting Cap (L.H.)
L. Placard Susp. Load Warning
M. Placard Rot. Stow Marker
N. Placard Man/Off Rem Switch
O. Placard Serial No.
P. Placard Comb/Main Controls
Q. Placard O/R Cyl. Lock/Unlock (L.H.)
R. Placard Elect. Failure
S. Placard Comb/Storage Box
T. Placard Angle Indicator
END OF TASK
20-167
TM 08780B-20
20-28. STABILIZER PAD MAINTENANCE

b. Disassembly
d. Assembly
e. Installation
INITIAL SETUP

MK17 injury.
a. Removal
NOTE
• To perform the following task, the crane must be operated under its own power. Hook
up an MK48 or slave lines from another vehicle, as explained in the operator’s manual
(TM 08780B-10).
• Position handle (1) so that you are in a comfortable position to perform the following
task.
(1) Extend stabilizer cylinder (2) as shown so that stabilizer pad (3) is
securely pinned against the ground.
(2) Using a hammer and suitable punch, drive two roll pins (4) out of
stabilizer pad (3).
(3) Retract stabilizer cylinder (2) out of stabilizer pad (3).
20-168
TM 08780B-20
1. Handle
3. Stabilizer Pad
4. Roll Pin (2)
b. Disassembly
NOTE
Stabilizer pad (3) does not have to be removed from vehicle to service stowing cable lock pin
assembly (5).
(1) Secure stabilizer pad (3) in a vise.
(2) Back jam nut (6) off and remove knob (7) from handle (1).
(3) Drive roll pin (8) out of handle (1), cam (9) and shaft (10).
(4) Pull handle (1) out of cam (9) and shaft (10).
(5) Remove cam (9) from shaft (10).
(6) Remove grease fitting (11).
20-169
TM 08780B-20
(2) Inspect stabilizer pad (3) for cracks, broken welds or other damage.
(3) Inspect shaft (10) for burrs and free movement. If spring action of shaft
(10) is not functional, replace stabilizer pad (3).
1. Handle
3. Stabilizer Pad
5. Stowing Cable Lock
Pin Assembly
6. Jam Nut
7. Knob
8. Roll Pin
9. Cam
10. Shaft
11. Grease Fitting
d. Assembly
(1) Push shaft (10) out as far as possible and jam in place with a wrench or
flat object as shown.
(2) Slide cam (9) onto shaft (10) aligning holes.
(3) Insert handle (1) into cam (9) and shaft (10) aligning holes.
(4) Secure handle (1) and cam (9) to shaft (10) by installing roll pin (8).
(5) Screw knob (7) onto handle (1) until handle (1) reaches bottom of screw
knob (7).
20-170
TM 08780B-20
(6) Lock knob (7) on handle (1) with jam nut (6).
(7) Install grease fitting (11).
1. Handle
3. Stabilizer Pad
6. Jam Nut
7. Knob
8. Roll Pin
9. Cam
10 Shaft
11. Grease Fitting
e. Installation
(1) Position stabilizer pad (3) on ground directly below stabilizer cylinder (2).
(2) Extend stabilizer cylinder (2) into its socket in stabilizer pad (3).
(3) Position stabilizer pad (3) so that you are in a comfortable position to
install two roll pins (4).
(4) Securely pin stabilizer pad (3) with stabilizer cylinder (2) to ground.
NOTE
Make sure split in roll pins (4) are not facing ball socket (12).
20-171
TM 08780B-20
(5) Install two roll pins (4) to secure stabilizer pad (3) to stabilizer cylinder
(2).
END OF TASK
NOTE
LI 2320-12/9 Lubricate stabilizer pad and locking pin.
LO 9-2320-297-12
TM 08780B-10 Stow stabilizers (para 2-16 or 2-25).
1. Handle
3. Stabilizer Pad
4. Roll Pin (2)
12. Ball Socket
20-172
TM 08780B-20
20-29. STOWING CABLE REPLACEMENT

c. Installation
INITIAL SETUP

MK17 injury.
Materials/Parts
Stowing cable (EZ-260 FSCM 35683)
a. Removal
(1) Release lower end of stowing cable (1) from stabilizer pad (2) using quick
release locking pin (3).
(2) Remove clip pin (4) from pin (5).
(3) Remove pin (5) and upper end of stowing cable (1) from bracket (6).
Discard stowing cable (1).
(2) Inspect all parts for burrs or damage.
c. Installation
(1) Secure one end of new stowing cable (1) to bracket (6) with pin (5).
(2) Secure pin (5) with clip pin (4).
(3) Secure other end of new stowing cable (1) to stabilizer pad (2) using quick
release locking pin (3).
END OF TASK
20-173
TM 08780B-20
NOTE
TM 08780B-10 Stow stabilizers (para 2-16 or 2-25).
1. Stowing Cable
2. Stabilizer Pad
3. Quick Release
Locking Pin
4. Clip Pin
5. Pin
6. Bracket
20-174
TM 08780B-20
20-30. MAIN CONTROL LEVER MAINTENANCE

c. Installation
INITIAL SETUP

MK17 injury.
Materials/Parts
a. Removal
NOTE
MK15 has six main levers located at the main control panel. MK17 has four main levers
located at the main control panel. Main levers are serviced the same except as noted.
(1) On MK15 only, remove four locknuts (1), washers (2) and capscrews (3)
from panel (4). Remove panel (4). Discard locknuts (1).
(2) Remove two capscrews (5), washers (6) and nuts (7)from guard (8).
Remove guard (8).
(3) Remove clip pin (9) from pin (10). Remove pin (10) from actuator rod
(11).
(4) Loosen jam nut (12). Remove knob (13) and jam nut (12) from control
lever (14).
(5) Remove set screw (15) from bracket (16). Remove bracket (16) from
control rod (14).
(6) Remove cotter pin (17) from pin (18). Remove retainer (19) and pin (18).
(7) Remove cotter pin (20) from pin (21). Remove pin (21) from valve spool
(22) and control lever (14). Discard cotter pin (20).
(8) Remove control lever (14).
20-175
TM 08780B-20
1. Locknut (4) 9. Clip Pin 16. Bracket

2. Washer (4) 10. Pin 17. Cotter Pin
3. Capscrew (4) 11. Actuator Rod 18. Pin
4. Panel 12. Jam Nut 19. Retainer
5. Capscrew (2) 13. Knob 20. Cotter Pin
6. Washer (2) 14. Control Lever 21. Pin
7. Nut (2) 15. Set Screw 22. Valve Spool
8. Guard
20-176
TM 08780B-20
c. Installation
(1) Position control lever (14) into valve spool (22). Install pin (21) into valve
spool (22) and control lever (14).
(2) Install new cotter pin (20) into pin (21).
(3) Install pin (18) into control rod (14) and casting (23). Install retainer (19)
onto pin (18). Install new cotter pin (17).
(4) Slide bracket (16) onto control lever (14). Position bracket (16) in
actuator rod (11). Install pin (10) into actuator rod (11) and bracket (16).
(5) Install clip pin (9) into pin (10).
(6) Install set screw (15) into bracket (16). Tighten securely.
(7) Install jam nut (12) onto control rod (14). Install knob (13) onto control
rod (14). Lock knob (13) in place by tightening jam nut (12) against knob (13).
(8) Install guard (8) using two capscrews (5), washers (6) and nuts (7).
(9) On MK15, install panel (4) using four capscrews (3) washers (2) and
locknuts (1).
20-177
TM 08780B-20
1. Locknut (4) 9. Clip Pin 17. Cotter Pin

2. Washer (4) 10. Pin 18. Pin
3. Capscrew (4) 11. Actuator Rod 19. Retainer
4. Panel 12. Jam Nut 20. Cotter Pin
5. Capscrew (2) 13. Knob 21. Pin
6. Washer (2) 14. Control Lever 22. Valve Spool
7. Nut (2) 15. Set Screw 23. Casting
8. Guard 16. Bracket
20-178
TM 08780B-20
5. Capscrew (2)
6. Washer (2)
7. Nut (2)
8. Guard
9. Clip Pin
10. Pin
11. Actuator Rod
12. Jam Nut
13. Knob
14. Control Lever
15. Set Screw
16. Bracket
17. Cotter Pin
18. Pin
19. Retainer
20. Cotter Pin
21. Pin
22. Valve Spool
23. Casting
END OF TASK
20-179
TM 08780B-20
20-31. AUXILIARY CONTROL LEVER MAINTENANCE

c. Installation
INITIAL SETUP
MK15
MK17
Materials/Parts
a. Removal
(1) On MK15 only, remove nut (1), washer (2) and capscrew (3) from guard
(4). Remove guard (4).
(2) Loosen jam nut (5). Remove knob (6) from auxiliary control lever (7).
(3) Remove cotter pin (8) from pin (9). Remove retainer (10) from pin (9).
(4) Remove pin (9) and retainer (10) from auxiliary control lever (7) and
casting (11).
(5) Remove cotter pin (12) from pin (13). Remove pin (13) from valve spool
(14) and auxiliary control lever (7). Remove control lever (7). Discard cotter pin (12).
c. Installation
(1) Position auxiliary control lever (7) in valve spool (14). Install pin (13)
into valve spool (14) and auxiliary control lever (7).
20-180
TM 08780B-20
(3) Install pin (9) into auxiliary control lever (7) and casting (11). Install
retainer (10) onto pin (9).
(5) Install jam nut (5) onto auxiliary control lever (7). Thread knob (6) onto
control lever (7).
(6) Lock knob (6) in place by tightening jam nut (5) against knob (6).
(7) On MK15 only, install guard (4) using capscrew (3), washer (2) and nut
1. Nut
2. Washer
3. Capscrew
4. Guard
5. Jam Nut
6. Knob
7. Auxiliary Control Lever
8. Cotter Pin
9. Pin
10. Retainer
11. Casting
12. Cotter Pin
13. Pin
14. Valve Spool
END OF TASK
20-181
TM 08780B-20
20-32. TRAVEL LOCK PIN MAINTENANCE

c. Installation

Condition Condition
MK15 TM 08780B-10 Unstow crane
MK17 (para 2-16 or 2-25).

Lockwasher (MS35338-44) item 3 Block wheels of truck to prevent personal
Lockwasher (3) (MS35338-51) item 10 injury.
References
TM 08780B-10
a. Removal
NOTE
Travel lock pins (1) on MK15 and MK17 differ only in position on rear module. Service for
each is the same.
(1) Remove capscrew (2), lockwasher (3), flatwasher (4), chain, pin and clip
pin assembly (5). Discard lockwasher (3).
(2) If damaged, remove chain (6) and clip pin (7) from travel lock pin (8).
(3) Remove three capscrews (9), lockwashers (10), washer plate (11) and
stow bracket (12) from folding boom assembly (13). Discard lockwashers (10).
c. Installation
(1) Install stow bracket (12) into folding boom assembly (13) using three
capscrews (9), new lockwasher (10) and washer plate (11). Hand tighten capscrews (9).
20-182
TM 08780B-20
(2) Install chains (6) and clip pin (7) onto travel lock pin (8) if removed.
(3) Secure end of chain (6) to base (14) using capscrew (2) new lockwasher
(3) and flatwasher (4). Tighten capscrew (2) securely.
(4) Stow crane. Refer to paragraph 2-16 or 2-25 (TM 08780B-10).
(5) Align stow bracket (12) with base (14) using pin (8).
(6) Torque capscrews (9) to 170-190 foot-pounds (230-257 N*m).
1. Travel Lock Pin

Assembly
2. Capscrew
3. Lockwasher
4. Flat Washer
5. Chain Pin And Clip
Pin Assembly
6. Chain
7. Clip Pin
8. Travel Lock Pin
9. Capscrew (3)
10. Lockwasher (3)
11. Washer Plate
12. Stow Bracket
13. Folding Boom
Assembly
14. Base
END OF TASK
20-183
TM 08780B-20
20-33. TESTING MAIN CRANE RELIEF PRESSURE
THIS TASK COVERS: a. Checking Main Relief Pressure

b. Adjusting Main Relief Pressure
INITIAL SETUP

MK17 injury.
Special Tools
Pressure gauge (S-111-25-28-51)
Materials/Parts
Wire seal (S000-25-2384) item 5
References
TM 08780B-10
a. Checking Main Relief Pressure
(1) Connect pressure gauge (1) to check port (2).
(2) Operate crane per operators manual (TM 08780B-10). Pull folding boom
lever (3) down to force pressure relief open. Read pressure gauge (1). Pressure reading should
be 2,950-3,050 psi (20,340-21,029 kPa).
(3) If pressure reading is above or below 2,950-3,050 psi (20,340-21,029

kPa), relief valve (4) needs adjusting. Refer to step b. below.
(4) Remove pressure gauge (1) from check port (2) when adjustment is
correct.
b. Adjusting Main Relief Pressure
(1) Connect pressure gauge (1) to check port (2).
(2) Remove and discard wire seal (5).
(3) Loosen nut (6).
(4) Back off set screw (7), three to four turns.
(5) Pull and hold folding boom lever (3) down.
20-184
TM 08780B-20
(6) Read pressure gauge (1).
(7) Adjust set screw (7) until pressure gauge (1) reads 2,950-3,050 psi
(20,340-21,029 kPa).
(8) Hold set screw (7) in position and tighten nut (6) securely.
(9) Recheck for correct pressure reading. Adjust if necessary.
(10) Install new wire seal (5).
(11) Remove pressure gauge (1) from check port (2).
1. Pressure Gauge
2. Check Port
3. Folding Boom Lever
4. Relief Valve
5. Wire Seal
6. Nut
7. Set Screw
END OF TASK
20-185
TM 08780B-20
20-34. HOLDING VALVE ADJUSTMENT
THIS TASK COVERS: a. Extension Boom Double Holding Valve

b. Folding Boom Holding Valve Adjustment
c. Main Boom Holding Valve Adjustment
d. A-Frame Holding Valve Adjustment (MK15 Only)
INITIAL SETUP

MK17 injury.
Materials/Parts Personnel Required

Wire seal (AR) (5000-25-2384) 1 MOS 3521
1 Assistant
References
TM 08780B-10
NOTE
Crane or A-Frame (MK15 or MK17) must be operated to perform the following tasks. Refer
to operator’s manual (TM 08780B-10) for correct procedure.
a. Extension Boom Double Holding Valve
(1) Unstow crane (1) to operating position. Extend extension booms (2) about
two feet (6.09 m).
1. Crane
2. Extension Booms
20-186
TM 08780B-20
(2) Install a 0-5,000 psi (0-34,475 kPa) pressure gauge (3) at main control
valve test port.
(3) Have assistant slowly pull extension boom control lever (4) down.
(4) Watch pressure gauge (3) and extension booms (2) for movement. When
extension booms (2) begin to move, note pressure reading. Pressure should be 1,000 psi ± 100
psi (6,895 kPa ± 689.5 kPa).
(5) Release extension boom control lever (4).
3. Pressure Gauge
4. Extension Boom Control Lever
20-187
TM 08780B-20
5. Jam Nut
6. Set Screw
(6) If pressure is below 1,000 psi (6,895 kPa) in step (4), adjust valve as
follows:
(a) Loosen jam nut (5) by turning counterclockwise several turns.
(b) Turn set screw (6) in (clockwise) a quarter of a turn.
(c) Check pressure reading.
(d) Repeat as needed to obtain 1,000 psi ±100 psi (6,895 kPa ±689.5
kPa).
(e) Lock set screw (6) in place with jam nut (5).
(7) If pressure is above 1,000 psi (6,895 kPa) in step (4), adjust valve as
follows:
(b) Turn set screw (6) out (counterclockwise) a quarter of a turn.
(d) Repeat as needed to obtain 1,000 psi ± 100 psi (6,895 kPa ± 689.5
kPa).
(8) Have assistant slowly push extension boom control lever (4) up.
20-188
TM 08780B-20
(9) Watch pressure gauge (3) and extension booms (2) for movement. When
extension booms (2) begin to move, note pressure reading. Pressure should be 1,000 psi ± 100
psi (6,895 kPa ± 689.5 kPa).
(10) Release extension boom control lever (4).
1. Crane 3. Pressure Gauge

2. Extension Boom 4. Extension Boom Control Lever
7. Jam Nut
8. Set Screw
(11) If pressure is below 1,000 psi (6,895 kPa) in step (9), adjust valve as
follows:
(b) Turn set screw (8) in (clockwise) a quarter of a turn.
20-189
TM 08780B-20
kPa).
(12) If pressure is above 1,000 psi (6,895 kPa) in step (9), adjust valve as
follows:
(b) Turn set screw (8) out (counterclockwise) a quarter of a turn.
kPa).
(13) Remove pressure gauge (3) from main control valve test port.
(14) Stow crane (1).
b. Folding Boom Holding Valve Adjustment
(1) Unstow crane (1) to operating position.
valve test port.
(3) Have assistant slowly pull folding boom control lever (9) down.
(4) Watch pressure gauge (3) and folding boom (10) for movement. When
folding boom (10) begins to move, note pressure reading. Pressure should be 1,000 psi ± 100 psi
(6,895 kPa ± 689.5 kPa).
(5) Release folding boom control lever (9).
20-190
TM 08780B-20
1. Crane 9. Folding Boom Control Lever

3. Pressure Gauge 10. Folding Boom
11. Seal
12. Jam Nut
13. Holding Valve
14. Adjusting Cap Nut
(6) If pressure is below 1,000 psi (6,895 kPa), adjust valve as follows:
(a) Remove and discard seal (11).
(b) Loosen jam nut (12) on holding valve (13) by turning clockwise
several turns.
(c) Turn adjusting cap nut (14) in (clockwise) a quarter of a turn.
(d) Check pressure reading.
(e) Repeat as needed to obtain 1,000 psi ± 100 psi (6,895 kPa ± 689.5
kPa).
(f) Lock adjusting cap nut (14) in place with jam nut (12).
(g) Install new seal (11).
(7) If pressure is above 1,000 psi (6,895 kPa), adjust valve as follows:
20-191
TM 08780B-20
(b) Loosen jam nut (12) on holding valve (13) by turning clockwise
several turns.
(c) Turn adjusting cap nut (14) out (counterclockwise) a quarter of a

turn.
kPa).
(9) Stow crane (1).
c. Main Boom Holding Valve Adjustment
(1) Unstow crane (1) to operating position.
valve test port.
(3) Have assistant slowly pull main boom control lever (15) down.
(4) Watch pressure gauge (3) and main boom (16) for movement. When main
boom begins to move, note pressure reading. Pressure should be 2,000 psi ± 100 psi (13,790 kPa
± 689.5 kPa).
(5) Release main boom control lever (15).
(6) If pressure is below 2,000 psi ± 100 psi (13,790 kPa ± 689.5 kPa), adjust
valve as follows:
(b) Turn jam nut (18) in (clockwise) several turns.
20-192
TM 08780B-20
1. Crane 15. Main Boom Control Lever

3. Pressure Gauge 16. Main Boom
(c) Turn adjusting cap nut (19) in (clockwise) a quarter of a turn.
kPa).
(7) If pressure is above 2,000 psi ± 100 psi (13,790 kPa ± 689.5 kPa), adjust
valve as follows:
(b) Turn jam nut (18) in (clockwise) several turns.
(c) Turn adjusting cap nut (19) out (counterclockwise) a quarter of a

turn.
kPa).
20-193
TM 08780B-20
(9) Stow crane (1).
17. Seal
18. Jam Nut
19. Adjusting Cap Nut
d. A-Frame Holding Valve Adjustment (MK15 Only)
(1) Unstow A-frame cylinder (20).
valve test port.
(3) Have assistant slowly pull A-frame cylinder control lever (21) down.
(4) Watch pressure gauge (3) and A-frame cylinder (20) for movement.
When A-frame cylinder begins to move, note pressure reading. Pressure should be 650 psi ± 50
psi (4,482 kPa ± 345 kPa).
(5) Release A-frame cylinder control lever (21).
(6) If pressure is below 650 psi ± 50 psi (4,482 kPa ± 345 kPa), adjust A-
frame cylinder holding valve (22) as follows:
(a) Remove plug (23).
(b) Turn adjusting screw (24) in (clockwise) a quarter of a turn.
(d) Repeat as needed to obtain 650 psi ± 50 psi (4,482 kPa ± 345 kPa).
(e) Install plug (23).
(7) If pressure is above 650 psi ± 50 psi (4,482 kPa ± 345 kPa), adjust valve
as follows:
20-194
TM 08780B-20
(a) Remove plug (23).
(b) Turn adjusting screw (24) out (counterclockwise) a quarter of a

turn.
(d) Repeat as needed to obtain 650 psi ± 50 psi (4,482 kPa ± 345 kPa).
(e) Install plug (23).
(f) Repeat adjustment procedure for other holding valve cartridge.
(9) Stow A-frame cylinder (20).
3. Pressure Gauge 22. A-Frame Cylinder Holding Valve

20. A-Frame Cylinder 23. Plug
21. A-Frame Cylinder Control Lever 24. Adjusting Screw
END OF TASK
20-195
TM 08780B-20
20-35. OUTRIGGER BEAM ADJUSTMENT
THIS TASK COVERS: a. Checking Outrigger Beam Alignment

b. Adjusting Outrigger Beam Alignment
INITIAL SETUP
MK15
MK17
References
TM 08780B-10
a. Checking Outrigger Beam Alignment
NOTE
Most of the following steps will require operation of the crane. Refer to paragraph 2-16 or 2-
25 in TM 08780B-10.
(1) Fully extend right and left outrigger beams (1 and 2).
(2) Swing right and left stabilizer cylinders (3 and 4) into position. DO NOT
allow pads on stabilizer cylinders (3 and 4) to contact the ground.
NOTE
The alignment of both outrigger beams is adjusted by leveling the right outrigger beam with its
housing.
(3) Clean the top surface of right outrigger beam housing (5). Place a level on
top surface of right outrigger beam housing (5). Note reading of level.
(4) Clean the top surface of the right outrigger beam (1). Place a level on top
surface of right outrigger beam (1). Compare this reading of the level to the reading taken in
step (3).
(5) If the level reads the same in steps (3) and (4) the outrigger beams (1 and
2) are properly aligned. If the readings are different, refer to step b in this paragraph to adjust the
outrigger beams.
b. Adjusting Outrigger Beam Alignment
(1) Make sure right and left outrigger beams (1 and 2) are fully extended.
(2) Loosen jam nut (6).
20-196
TM 08780B-20
(3) Turn adjusting screw (7) in or out while checking alignment of outrigger
beam (1) and outrigger beam housing (5) as described in step a.
(4) After the outrigger beam (1) and the outrigger beam housing (5) are
aligned, operate the outrigger beams several times to check for proper operation.
(5) Tighten jam nut (6) securely.
(6) Stow right and left stabilizer cylinders (3 and 4).
(7) Stow right and left outrigger beams (1 and 2).
1. Right Outrigger Beam 5. Right Outrigger Beam Housing

2. Left Outrigger Beam 6. Jam Nut
3. Right Stabilizer Cylinder 7. Adjusting Screw
4. Left Stabilizer Cylinder
END OF TASK
20-197/(20-198 blank)
TM 08780B-20
CHAPTER 21
CRANE
Maintenance level mechanics. The following sections cover maintenance and replacement
procedures for the vehicle’s crane.
a. General. The MK15A1 and MK17A1 cranes are the same, except for mounting
location and control locations. Both are telescopic cranes. Each crane is capable of lifting 9,000
lbs (4,086 kg) at 15 feet (4.5m). Beyond that, the crane is limited to lighter loads by an overload
shutdown system. Both cranes rotate 318 degrees, with a 42 degree safety limit that protects the
control stations. Both cranes have remote control functions. In the event of electrical failure,
both cranes can be manually operated by using the manual override located on the crane control
panel.
b. Electrical System. The crane’s electrical system operates on 24 volts DC,

supplied from the MK48A1. Electricity provides power for the remote control system.
Electricity also controls the overload shutdown system.
21-1
TM 08780B-20
(1) Junction Box. The junction box, located on the crane subframe, receives
power (24 volts DC) from the MK48A1. The junction box is the center for all of the crane’s
electrical connections.
(2) Hoist Layer Sensor. The hoist layer sensor is a proximity switch that
sends an ON/OFF signal to the microprocessor indicating the amount of cable that has been
spooled off of the hoist. It will cause the microprocessor to use a different calibration factor to
determine the actual load exerted on the tension load cell.
(3) Tension Load Cell. The tension load cell is a strain gauge that sends a
signal of the load exerted on the winch at its pivot point. It sends the signal to the
microprocessor which uses the information to determine if an overload condition exists. It works
in conjunction with three other sensors to initiate an overload lockout signal.
(4) Boom Length Sensor. The boom length sensor is a length potentiometer
that measures and sends a signal to the microprocessor on how far the boom is extended.
(5) Boom Angle Sensor. The boom angle sensor measures and sends a signal
to the microprocessor on what angle the boom is at.
21-2
TM 08780B-20
(6) Microprocessor. The microprocessor receives information from four

sensors to allow a comparison of the actual load and rated load. If the load is over the rated load,
the microprocessor will lockout all functions that would increase the load exerted on the crane.
These are boom up and down, hoist up and telescope out. All other functions are not affected by
the lockout signal.
(7) Main Power Switch. The main power switch allows electrical power from
the MK48A1 to power up the crane’s electrical circuits. This switch also serves as a circuit
breaker to prevent damage to the crane’s electrical system in the event of a short circuit.
(8) Shutdown Relay. The shutdown relay is located in the junction box and
relays a signal from the remote control emergency stop switch to cut power to the solenoid valve.
This will cause all hydraulic fluid to bypass the crane’s valve banks and return to the MK48A1
hydraulic reservoir.
(9) Tilt Alarm Sensor. The tilt alarm sensor will complete the tilt alarm
power circuit when the crane is out of level more than 4.5 degrees.
21-3
TM 08780B-20
(10) Tilt Alarm. The tilt alarm will sound when the crane is out of level more
than 4.5 degrees.
(11) Tilt Alarm Switch. Turns the tilt alarm circuit on or off.
c. Hydraulic System. The MK48A1 pumps hydraulic oil to the crane at a flow rate
of 11 gallons per minute. This flow of hydraulic oil is directed and controlled by several valves
on the crane. Opening these valves permits oil to flow to the crane’s hydraulic cylinders. Here,
hydraulic oil pressure builds until great enough to move the hydraulic cylinders. Relief valves
prevent this pressure from becoming too great. The relief valves release extra pressure and send
it back to the hydraulic reservoir on the MK48A1. Unwanted movement of the crane is
prevented by holding valves mounted on the crane’s booms.
All hydraulic oil eventually flows back to the MK48A1 through a return line. There, the
hydraulic oil is filtered and cooled. The hydraulic oil is then drawn into the hydraulic pump
where it begins the cycle again.
(1) Outrigger Extension Cylinders. The two outrigger extension cylinders

hydraulically extend or retract the extension beams.
(2) Outrigger Jack Cylinders. The two hydraulic jack cylinders are used
together with the outrigger beams to give the crane greater stability for handling loads.
21-4
TM 08780B-20
(3) A-Frame (MK15A1 Only). The A-frame provides hydraulic lifting

capability for towing.
(4) Solenoid Valve. The solenoid valve is electrically operated. It provides

the crane with hydraulic power by stopping oil flow back to the reservoir. This causes the oil to
go through the control valves. It incorporates a manual override in the event of an electrical
failure. Press and hold in the button to supply hydraulic oil to the crane control valves.
21-5
TM 08780B-20
(5) Double Holding Valve. The double holding valve prevents movement of
the mast erection cylinder until its preset safety pressure is overcome by hydraulic pressure from
operation of the crane’s control.
(7) Main Relief Valve. The main relief valve protects the crane’s components
from pressures that might exceed 3,200 psi.
(8) Hoist Pressure Relief Valve. The hoist pressure relief valve limits
pressure to 2400 psi in the HOIST UP circuit.
(6) Single Holding Valve. The single holding valve prevents movement in
one direction until its preset safety pressure is overcome by hydraulic pressure from operation of
the crane’s controls.
21-6
TM 08780B-20
d. Accessories. The following items are needed for safe, convenient operation of the
crane.
(1) Stowage Box. The stowage box on both cranes (MK15A1 or MK17A1),
houses the remote control unit and remote control cable.
(2) Placards. The placards, which are located at prominent positions on the
crane, provide instructions and/or warnings.
(3) Stabilizer Pads. The stabilizer pads provide the base support for the crane
while working.
(4) Main Control Levers. The main and auxiliary levers provide the
mechanical linkage for operation of the control valves.
21-7
TM 08780B-20
21-8
TM 08780B-20
21-3. JUNCTION BOX MAINTENANCE

c. Installation

Condition Condition
MK17A1 disconnected
(para 7-46).
Materials/Parts
Decal (P/N 7376008622) item 121 General Safety Instructions
Lockwasher (16) (P/N 7950060350) item 22 Block wheels of truck to prevent personal
Lockwasher (2) (P/N 7950080050) item 100 injury. To prevent personal injury, make
Lockwasher (5) (P/N 7950060050) sure batteries are disconnected before
items 112 and 117 working on electrical components.
Locknut (2) (P/N 7659000205) item 82
Locknut (2) (P/N 7659000047) item 84
Star washer (8) (P/N 7950160350) item 5
O-ring (3) (P/N MS9068-021) item 31
O-ring (P/N MS9068-025) item 24
Rivet (17) (P/N 7760000027) item 122
(1) Loosen four capscrews (1) and open cover (2).
(2) Remove four capscrews (3), nuts (4), eight star washers (5) and four
washers (6) from junction box (7). Discard star washers (5).
21-9
TM 08780B-20
1. Capscrew (4) 5. Star Washer (8)

2. Cover 6. Washer (4)
3. Capscrew (4) 7. Junction Box
4. Nut (4)
NOTE
and legend.
• All wires are installed on terminal block with a capscrew. Capscrew must be removed
prior to removal of wires from terminal block.
(3) Remove two black wires (8 and 9) from grounding block (10).
(4) Remove white wire (11) from no. 19 position and white wire (12) from no.
5 position of terminal block (13).
(5) Remove two solenoid cables (14 and 15) from junction box (7).
(6) Remove green wire (16) from grounding block (10).
(7) Remove black wire (17) from no. 1 position, red wire (18) from no. 17
position and white wire (19) from no. 19 position of terminal block (13).
(8) Remove four nuts (20), capscrews (21), lockwashers (22) and OSS cable
(23) from junction box (7). Discard lockwashers (22) and O-ring (24).
21-10
TM 08780B-20
(9) Remove black wire (25) from grounding block (10) and green wire (26)
from no. 2 position of tilt alarm switch (27).
(10) Remove red wire (28) from no. 1 position of terminal block (13) and white
wire (29) from no. 3 position of tilt alarm switch (27).
(11) Remove four nuts (20), capscrews (21), lockwashers (22) and tilt sensor
cable (30) from junction box (7). Discard lockwashers (22) and O-ring (31).
7. Junction Box 16. Green Wire 24. O-Ring

8. Black Wire 17. Black Wire 25. Black Wire
9. Black Wire 18. Red Wire 26. Green Wire
10. Grounding Block 19. White Wire 27. Tilt Alarm Switch
11. White Wire 20. Nut (8) 28. Red Wire
12. White Wire 21. Capscrew (8) 29. White Wire
13. Terminal Block 22. Lockwasher (8) 30. Tilt Sensor Cable
14. Solenoid Cable 23. OSS Cable 31. O-Ring
15. Solenoid Cable
21-11
TM 08780B-20
(13) Remove red wire (33) from no. 4 position, black wire (34) from no. 2
position and white wire (35) from no. 3 position of terminal block (13).
(14) Remove four nuts (20), capscrews (21), lockwashers (22) and main power
cable (36) from junction box (7). Discard lockwashers (22) and O-ring (31).
(15) Remove two black wires (37 and 38) from grounding block (10).
(16) Remove white wire (39) from no. 19 position and white wire (40) from no.
(17) Remove two solenoid cables (41 and 42) from junction box (7).
(18) Remove violet wire (43) from no. 7 position, grey wire (44) from no. 8
position, red wire (45) from no. 9 position, tan wire (46) from no. 10 position and yellow wire
(47) from no. 11 position of terminal block (13).
(19) Remove white wire (48) from no. 12 position, pink wire (49) from no. 13
position, brown wire (50) from no. 14 position, black wire (51) from no. 15 position and orange
wire (52) from no. 16 position of terminal block (13).
(20) Remove blue wire (53) from no. 17 position and red/blue striped wire (54)
from no. 18 position of terminal block (13).
(22) Remove four nuts (20), capscrews (21), lockwashers (22) and remote
control cable (56) from junction box (7). Discard lockwashers (22) and O-ring (24).
21-12
TM 08780B-20
7. Junction Box 35. White Wire 46. Tan Wire

10. Grounding Block 36. Main Power Cable 47. Yellow Wire
13. Terminal Block 37. Black Wire 48. White Wire
20. Nut (8) 38. Black Wire 49. Pink Wire
21. Capscrew (8) 39. White Wire 50. Brown Wire
22. Lockwasher (E) 40. White Wire 51. Black Wire
24. O-Ring 41. Solenoid Cable 52. Orange Wire
31. O-Ring 42. Solenoid Cable 53. Blue Wire
32. Green Wire 43. Violet Wire 54. Red/Blue Striped Wire
33. Red Wire 44. Grey Wire 55. Green Wire
34. Black Wire 45. Red Wire 56. Remote Control Cable
(23) Remove four black wires (57, 58, 59 and 60) from grounding block (10).
21-13
TM 08780B-20
(24) Remove white wire (61) from no. 12 position, white wire (62) from no. 9
position, white wire (63) from no. 10 position and white wire (64) from no. 11 position of
(25) Remove four solenoid cables (65, 66, 67 and 68) from junction box (7).
(26) Remove four black wires (69, 70, 71 and 72) from grounding block (10).
position, white wire (75) from no. 13 position and white wire (76) from no. 14 position of
(28) Remove four solenoid cables (77, 78, 79 and 80) from junction box (7).
7. Junction Box 63. White Wire 72. Black Wire

10. Grounding Block 64. White Wire 73. White Wire
13. Terminal Block 65. Solenoid Cable 74. White Wire
57. Black Wire 66. Solenoid Cable 75. White Wire
59. Black Wire 68. Solenoid Cable 77. Solenoid Cable
60. Black Wire 69. Black Wire 78. Solenoid Cable
61. White Wire 70. Black Wire 79. Solenoid Cable
21-14
TM 08780B-20
(29) Remove junction box (7) from brackets (81).
(30) Remove two locknuts (82) and connectors (83) from junction box (7).
(31) Remove two locknuts (84) and connectors (85 and 86) from junction box
(32) Remove nut (87), lockwasher (88), washer (89) and tilt alarm switch (28)
from junction box (7).
(33) Remove nut (90), lockwasher (91), washer (92) and main power switch
(93) from junction box (7).
(34) Remove two capscrews (94), lockwashers (95), white wire (96) and black
wire (97) from main power switch (93).
7. Junction Box 86. Connector 92. Washer

28. Tilt Alarm Switch 87. Nut 93. Main Power Switch
81. Bracket (2) 88. Lockwasher 94. Capscrew (2)
82. Locknut (2) 89. Washer 95. Lockwasher (2)
83. Connector (2) 90. Nut 96. White Wire
84. Locknut (2) 91. Lockwasher 97. Black Wire
85. Connector
21-15
TM 08780B-20
7. Junction Box 101. Washer (2)

10. Grounding Block 102. Fiber Washer (2)
98. Green Wire 103. Capscrew (2)
99. Nut (2) 104. White Wire (3)
100. Lockwasher (2) 105. Diode
(36) Remove two nuts (99), lockwashers (100), washers (101), fiber washers
(102), capscrews (103) and grounding block (10) from junction box (7). Discard lockwashers
(100).
(37) Remove three white wires (104) from diode (105).
(38) Remove red wire (106) from no. 8 position and black wire (107) from no.
position and blue wire (110) from no. 6 position of terminal block (13).
NOTE
Note position of terminal block (13) and label (115) prior to removal to ensure proper
installation.
(40) Remove two nuts (111), lockwashers(112), washers (113), capscrews

(114), terminal block (13) and label (115) from junction box (7). Discard lockwashers (112).
21-16
TM 08780B-20
NOTE
Bracket (120) will need to be bent upward to allow removal of shutdown relay (119).
(41) Remove three nuts (116), lockwashers (117), washers (118) and shutdown
relay (119) from bracket (120). Discard lockwashers (117).
(42) If required, remove and discard decal (121) from cover (2).
2. Cover 110. Blue Wire 116. Nut (2)

7. Junction Box 111. Nut (2) 117. Lockwasher (3)
13. Terminal Block 112. Lockwasher (2) 118. Washer (3)
106. Red Wire 113. Washer (2) 119. Shutdown Relay
107. White Wire 114. Capscrew (2) 120. Bracket
108. White Wire 115. Label 121. Decal
109. White Wire
(43) Remove three rivets (122) and bracket (120) from junction box (7).
Discard rivets (122).
21-17
TM 08780B-20
(44) Remove two rivets (122), washers (123) and diode (105) from junction
box (7). Discard rivets (122).
(45) Remove four rivets (122) and bracket (124) from junction box (7).
Discard rivets (122).
(46) Remove eight rivets (122) and two panels (125 and 126) from junction
box (7). Discard rivets (122).
c. Installation
(1) Install two panels (126 and 125) in junction box (7) using eight rivets
(122).
(2) Install bracket (124) in junction box (7) using four rivets (122).
(3) Install diode (105) in junction box (7) using two washers (123) and rivets
(122).
(4) Install bracket (120) in junction box (7) using three rivets (122).
7. Junction Box
105. Diode
120. Bracket
122. Rivet (17)
123. Washer (2)
124. Bracket
125. Panel
126. Panel
21-18
TM 08780B-20
(5) Install shutdown relay (119) on bracket (120) using three washers (118),
new lockwashers (117) and nuts (116).
(6) If removed, install new decal (121) on cover (2).
CAUTION
ENSURE LABEL (115) AND TERMINAL BLOCK (13) ARE INSTALLED IN SAME
POSITION AS NOTED DURING REMOVAL OR DAMAGE TO EQUIPMENT MAY
RESULT.
(7) Install label (115) and terminal block (13) in junction box (7) using two
capscrews (114), washers (113), new lockwashers (112) and nuts (111).
(8) Install blue wire (110) in no. 6 position, white wire (109) in no. 5 position,
white wire (108) in no. 2 position, black wire (107) in no. 17 position and red wire (106) in no. 8
position of terminal block (13).
2. Cover 110. Blue Wire 116. Nut (3)

7. Junction Box 111. Nut (2) 117. Lockwasher (3)
13. Terminal Block 112. Lockwasher (2) 118. Washer (3)
106. Red Wire 113. Washer (2) 119. Shutdown Relay
107. White Wire 114. Capscrew (2) 120. Bracket
108. White Wire 115. Label 121. Decal
109. White Wire
21-19
TM 08780B-20
(9) Install three white wires (104) on diode (105).
(10) Install grounding block (10) in junction box (7) using two capscrews
(103), fiber washers (102), washers (101), new lockwashers (100) and nuts (99).
(11) Install green wire (98) on grounding block (10).
7. Junction Box 100. Lockwasher (2) 103. Capscrew (2)

10. Grounding Block 101. Washer (2) 104. White Wire (3)
98. Green Wire 102. Fiber Washer (2) 105. Diode
99. Nut (2)
21-20
TM 08780B-20
7. Junction Box 86. Connector 92. Washer

27. Tilt Alarm Switch 87. Nut 93. Main Power Switch
81. Bracket (2) 88. Lockwasher 94. Capscrew (2)
82. Locknut (2) 89. Washer 95. Lockwasher (2)
83. Connector (2) 90. Nut 96. White Wire
84. Locknut (2) 91. Lockwasher 97. Black Wire
85. Connector
(12) Install black wire (97) and white wire (96) on main power switch (93)
using two lockwashers (95) and capscrews (94).
(13) Install main power switch (93) in junction box (7) using washer (92),
lockwasher (91) and nut (90).
(14) Install tilt alarm switch (28) in junction box (7) using washer (89),
lockwasher (88) and nut (87).
(15) Install two connectors (86 and 85) in junction box (7) using two new
locknuts (84).
(16) Install two connectors (83) in junction box (7) using two new locknuts
(82).
21-21
TM 08780B-20
(17) Position junction box (7) on brackets (81).
(18) Position four solenoid cables (80, 79, 78 and 77) in junction box (7).
NOTE
All wires are installed on terminal block using a capscrew. Capscrew must be installed upon
installation of wire on terminal block.
(19) Install white wire (76) on no. 14 position, white wire (75) on no. 13
position, white wire (74) on no. 16 position and white wire (73) on no. 15 position of terminal
block (13).
(20) Install four black wires (72, 71, 70 and 69) on grounding block (10).
(21) Position four solenoid cables (68, 67, 66 and 65) in junction box (7).
(22) Install white wire (64) on no. 11 position, white wire (63) on no. 10
position, white wire (62) on no. 9 position and white wire (61) on no. 12 position of terminal
block (13).
(23) Install four black wires (60, 59, 58 and 57) on grounding block (10).
21-22
TM 08780B-20
7. Junction Box 63. White Wire 72. Black Wire

10. Grounding Block 64. White Wire 73. White Wire
13. Terminal Block 65. Solenoid Cable 74. White Wire
59. Black Wire 68. Solenoid Cable 77. Solenoid Cable
60. Black Wire 69. Black Wire 78. Solenoid Cable
(24) Install remote control cable (56) and new O-ring (24) in junction box (7)
using four new lockwashers (22), capscrews (21) and nuts (20).
(26) Install red/blue striped wire (54) on no. 18 position and blue wire (53) on
no. 17 position of terminal block (13).
21-23
TM 08780B-20
(27) Install orange wire (52) on no. 16 position, black wire (51) on no. 15
position, brown wire (50) on no. 14 position, pink wire (49) on no. 13 position and white wire
(48) on no. 12 position of terminal block (13).
(28) Install yellow wire (47) in no. 11 position, tan wire (46) in no. 10 position,
red wire (45) in no. 9 position, grey wire (44) in no. 8 position and violet wire (43) in no. 7
(29) Install two solenoid cables (42 and 41) in junction box (7).
(30) Install white wire (40) in no. 19 position and white wire (39) in no. 19
(31) Install two black wires (38 and 37) in grounding block (10).
(32) Install main power cable (36) and new O-ring (31) in junction box (7)
using four new lockwashers (22), capscrews (21) and nuts (20).
(33) Install white wire (35) in no. 3 position, black wire (34) in no. 2 position
and red wire (33) in no. 4 position on terminal block (13).
21-24
TM 08780B-20
7. Junction Box 35. White Wire 46. Tan Wire

10. Grounding Block 36. Main Power Cable 47. Yellow Wire
13. Terminal Block 37. Black Wire 48. White Wire
20. Nut (4) 38. Black Wire 49. Pink Wire
21. Capscrew (4) 39. White Wire 50. Brown Wire
22. Lockwasher (4) 40. White Wire 51. Black Wire
24. O-Ring 41. Solenoid Cable 52. Orange Wire
31. O-Ring 42. Solenoid Cable 53. Blue Wire
32. Green Wire 43. Violet Wire 54. Red/Blue Striped Wire
33. Red Wire 44. Grey Wire 55. Green Wire
34. Black Wire 45. Red Wire 56. Remote Control Cable
21-25
TM 08780B-20
(35) Install tilt sensor cable (30) and new O-ring (31) in junction box (7) using
four new lockwashers (22), capscrews (21) and nuts (20).
(36) Install white wire (29) in no. 3 position of tilt alarm switch (27) and red
wire (28) in no. 1 position of terminal block (13).
(37) Install green wire (26) in no. 2 position of tilt alarm switch (27) and black
wire (25) on grounding block (10).
(38) Install OSS cable (23) and new O-ring (24) in junction box (7) using four
new lockwashers (22), capscrews (21) and nuts (20).
(39) Install white wire (19) in no. 19 position, red wire (18) in no. 17 position
and black wire (17) in no. 1 position of terminal block (13).
(41) Position two solenoid cables (15 and 14) in junction box (7).
(42) Install white wire (12) in no. 5 position and white wire (11) in no. 19
(43) Install two black wires (9 and 8) on grounding block (10).
21-26
TM 08780B-20
7. Junction Box 16. Green Wire 24. O-Ring

8. Black Wire 17. Black Wire 25. Black Wire
9. Black Wire 18. Red Wire 26. Green Wire
10. Grounding Block 19. White Wire 27. Tilt Alarm Switch
11. White Wire 20. Nut (8) 28. Red Wire
12. White Wire 21. Capscrew (8) 29. White Wire
13. Terminal Block 22. Lockwasher (8) 30. Tilt Sensor Cable
14. Solenoid Cable 23. OSS Cable 31. O-Ring
15. Solenoid Cable
(44) Install junction box (7) using four washers (6), eight new star washers (5),
four nuts (4) and capscrews (3).
(45) Close cover (2) and tighten four capscrews (1).
END OF TASK
NOTE

(para 2-17 or 2-26).
21-27
TM 08780B-20
1. Capscrew (4)
2. Cover
3. Capscrew (4)
4. Nut (4)
5. Star Washer (B)
6. Washer (4)
7. Junction Box
21-28
TM 08780B-20
21-4. CRANE REMOTE CONTROL STOWAGE BOX REPLACEMENT

c. Installation
INITIAL SETUP
MK15A1
MK17A1
Materials/Parts
Locknut (4) (1598030) item 1
Door seal (52 in) (125865A) item 11
Plug, hole (2) (DP-250) item 13
Adhesive, silicone sealant (A/R) (item 5, Appendix D)
a. Removal
(1) Remove four locknuts (1), capscrews (2) and remote control stowage box
(3) from bracket (4). Discard locknuts (2).
NOTE
(2) Remove five locknuts (5), washers (6), capscrews (7) and mounting
bracket (4). Discard locknuts (5).
(3) Remove two locknuts (8), capscrews (9) and rubber hooks (10). Discard
locknuts (8).
(4) Remove seal (11) from door frame (12). Discard seal (11).
(5) Remove two hole plugs (13) as necessary.
21-29
TM 08780B-20
c. Installation
(1) If removed, install two new hole plugs (13) using silicone sealant.
(2) Apply silicone sealant to door frame edge (12).
(3) Position seal (11) with gap to right edge of box.
(4) Apply silicone sealant to joint.
(5) Install rubber hooks (10) using two capscrews (9) and new locknuts (8).
NOTE
(6) Install mounting bracket (4) using five capscrews (7), washers (6) and new
(7) Install remote control stowage box (3) on bracket (4) using capscrews (2)
END OF TASK
21-30
TM 08780B-20
1. Locknut (4) 5. Locknut (5) 10. Rubber Hook

2. Capscrew (4) 6. Washer (6) 11. Seal (52 In)
3. Remote Control 7. Capscrew (5) 12. Door Frame
Stowage Box 8. Locknut (2) 13. Hole Plug (2)
4. Bracket 9. Capscrew (2)
21-31
TM 08780B-20
21-5. TILT SENSOR AND ALARM REPLACEMENT

c. Installation
d. Adjustment

Condition Condition
MK15A1 TM 08780B-10 Truck on level
MK17A1 surface (para 2-13).
Materials/Parts TM 08780B-20 Junction box removed

Star washer (4) (P/N 7950160350) item 4 (para 21-3, step 2).
a. Removal
(1) Disconnect three connectors (1).
(2) Remove four nuts (2), washers (3), star washers (4), capscrews (5) and tilt
sensor (6) from bracket (7). Discard star washers (4).
(3) Disconnect two terminals (8) from tilt alarm (9).
(4) Remove nut (10) and tilt alarm (9) from bracket (11).
c. Installation
(1) Install tilt alarm (9) on bracket (11) with nut (10).
(2) Connect two terminals (8) to tilt alarm (9).
(3) Install tilt sensor (6) on bracket (7) using four capscrews (5), star washers
(4), washers (3) and nuts (2).
(4) Connect three connectors (1).
21-32
TM 08780B-20
d. Adjustment
(1) Level crane subframe (12) left to right and front to rear.
(2) Adjust tilt sensor (6) as follows:
NOTE
• Adjust tilt alarm slowly. Tilt alarm has a delayed response.
• After initial adjustment of nut (13) is made, do not re-adjust during the remainder of
the procedure. Nut (13) provides the reference dimension to which nuts (14) and (15)
will be adjusted.
• Three to four threads should be showing on top of nuts (13, 14 and 15) after bubble
(16) is centered in the window (17).
(a) Tighten nuts (13, 14 and 15) until bubble (16) is centered in the
window (17).
(b) Turn crane power and tilt alarm switch on (TM 08780B-10).
(c) Slowly tighten nut (14) until tilt alarm (9) sounds.
(d) Slowly loosen nut (14) until tilt alarm (9) quits.
(e) Continue to loosen nut (14), while counting the number of turns,
until tilt alarm (9) again sounds. Record number of turns.
(f) Slowly tighten nut (14), while counting the number of turns, until
tilt alarm (9) quits. Record number of turns.
(g) Subtract number of turns recorded in step (f) from number of turns
recorded in step (e). Record resulting number of turns.
(h) Divide resulting number of turns obtained in step (g) by two.

Record resulting number of turns.
(i) Tighten nut (14) by number of turns determined in step (h).
(j) Repeat steps (c) thru (i) for nut (15).
(k) Test tilt sensor (6) adjustment by pushing corners down, one at a
time, near nuts (13, 14 and 15). Tilt alarm (9) should sound at each location. If tilt alarm (9)
does not sound in all three attempts, loosen nut (13) and repeat steps (a) thru (j).
END OF TASK
21-33
TM 08780B-20
NOTE
TM 08780B-20 Install junction box (para 21-3, step 44).
1. Connector (3) 7. Bracket 13. Window

2. Nut (4) 8. Terminal (2) 14. Nut
3. Washer (4) 9. Tilt Alarm 15. Nut
4. Lockwasher (4) 10. Nut 16. Bubble
5. Capscrew (4) 11. Bracket 17. Window
6. Tilt Sensor 12. Crane Subframe
21-34
TM 08780B-20
21-6. CRANE TUBING REPLACEMENT (MK15A1)
THIS TASK COVERS: Hydraulic Tubing Locations
INITIAL SETUP

MK15A1 To avoid personal injury, always assume
hydraulic lines have pressure. Slowly crack
hydraulic lines open to allow all pressure to
escape. Always wear safety glasses.
Hydraulic Tubing Locations
NOTE
• Place a container to catch hydraulic oil during tube removal.
• Plug all tubes after removal to prevent dirt from entering the hydraulic system.
• Tag and mark all tubes prior to removal.
• Note location of plastic cable ties prior to removal.
• Remove plastic cable ties as required.
• Remove clamps and support brackets as required.
• Inspect all tubing and fittings for cracks, kinks, nicks, dents, stripped threads and cuts.
Replace damaged parts.
21-35
TM 08780B-20
Tube Name From To

Supply Tube Inside fitting (1) Pressure supply fitting (2)
Return Tube Outside elbow (3) Return fitting (4)
Return Tube Tee (5) Tee (6)
Supply Tube Tee (7) Tee (8)
Supply Tube Top of tee (8) Four function electric control
valve top elbow (9)
Return Tube Top of tee (6) Four function electric control
rear fitting (10)
Supply Tube Tee (8) Four function manual control
bottom front fitting (11)
Supply Tube Top of tee tube (12) Two way solenoid valve
fitting (13)
Return Tube Tee (6) Four function manual control
valve bottom rear elbow (14)
Return Tube Two way solenoid valve rear Tee tube (16)
fitting (15)
Hydraulic Tube Four function manual control Four function electric control
rear fitting (17) bottom elbow (18)
Supply Tube Accumulator bottom elbow Four function electric control
(19) rear fitting (20)
Supply Tube Tube (21) Tube (22)
Supply Tube Tube (22) Three way manual control
valve bottom front fitting (23)
Return Tube Tube (24) Tube (25)
Return Tube Tube (25) Three way manual control
21-36
TM 08780B-20
1. Fitting 10. Fitting 19. Elbow

2. Fitting 11. Fitting 20. Fitting
3. Elbow 12. Tube 21. Tube
4. Fitting 13. Fitting 22. Tube
5. Tee 14. Elbow 23. Fitting
6. Tee 15. Fitting 24. Tube
7. Tee 16. Tube 25. Tube
8. Tee 17. Fitting 26. Elbow
9. Elbow 18. Elbow
21-37
TM 08780B-20
27. Tube
28. Tube
29. Tube End
30. Tube End
31. Tube
32. Tube
Tube Name From To

Boom Tube Hoist boom tube right end (27) Hoist boom tube left end (28)
Boom Tube Hoist boom right welded Hoist boom left welded elbow
elbow (29) (30)
Boom Tube Hoist boom right tube (31)
Boom Tube Hoist boom left tube (32)
END OF TASK
21-38
TM 08780B-20
21-7. CRANE TUBING REPLACEMENT (MK17A1)
THIS TASK COVERS: Hydraulic Tubing Locations
INITIAL SETUP

Hydraulic Tubing Locations
NOTE
Tube Name From To

Main Supply Tube Tube (1) Tee tube end (2)
Main Return Tube Tube (3) Tee tube end (4)
Tube Assembly Two-way solenoid valve rear Four function electric control
tee (5) valve rear tee (6)
Tube Assembly Two-way solenoid valve Tube tee (8)
bottom elbow (7)
Tube Assembly Tube tee (8) Four function electric control
valve top elbow (9)
Tube Assembly Four function manual control Tee (11)
valve bottom elbow (10)
21-39
TM 08780B-20
1. Tube
2. Tee Tube End
3. Tube
4. Tee Tube End
5. Tee
6. Tee
7. Elbow
8. Tube Tee
9. Elbow
10. Elbow
11. Tee
21-40
TM 08780B-20
12. Fitting
13. Fitting
14. Welded Elbow
15. Welded Elbow
16. Tube
17. Tube
Tube Name From To

Boom Tube Hoist boom right tube fitting Hoist boom right tube fitting
(12) (13)
Boom Tube Hoist boom right welded Hoist boom left welded elbow
elbow (14) (15)
Boom Tube Hoist boom right tube (16)
Boom Tube Hoist boom left tube (17)
END OF TASK
21-41
TM 08780B-20
21-8. CRANE HOSES REPLACEMENT (MK15A1)
THIS TASK COVERS: Hydraulic Hose Locations
INITIAL SETUP

Hydraulic Hose Locations
NOTE
21-42
TM 08780B-20

2. Tee 5. Tee 8. Fitting
3. Fitting 6. Tee
Hose Name From To

Outrigger Extend Extension cylinder bottom Extension cylinder supply
fitting (1) fitting (2) on holding valve
Outrigger Extend Extension cylinder supply Right and left outrigger
fitting (2) on holding valve extension manual control rear
fitting (3 and 4) “A” Port
Outrigger Retract Extension cylinder tee (5) Extension cylinder supply
fitting (6) on holding valve
Outrigger Retract Extension cylinder supply Right and left outrigger
fitting (6) on holding valve extension manual control front
fitting (7 and 8) “B” Port
21-43
TM 08780B-20

10. Tee 13. Tube 16. Fitting
11. Fitting 14. Tee
Hose Name From To

Right Outrigger Jack Cylinder, Extension cylinder rear fitting Outrigger supply tee (10)
Down (9)
Right Outrigger Jack Cylinder, Outrigger supply tee (10) Right and left outrigger
Down (up/down) jack manual control
front fittings (11 and 12) “B”
Port
Right Outrigger Jack Cylinder, Extension cylinder tube (13) Outrigger supply tee (14)
Up
Up (up/down) jack manual control
rear fittings (15 and 16) “A”
Port
21-44
TM 08780B-20
17. Tube 20. Fitting 23. Fitting

19. Fitting 22. Tee
Hose Name From To

Left Outrigger Jack Cylinder, Extension cylinder tube (17) Outrigger supply tee (18)
Down
Left Outrigger Jack Cylinder, Outrigger supply tee (18) Right and left outrigger jack
Down LH (up/down) manual control
front fittings (19 and 20) “A”
Port
Up
Up LH (up/down) manual control
rear fittings (23 and 24)
21-45
TM 08780B-20

26. Fitting 29. Tube 32. Tee
27. Fitting 30. Tube
Hose Name From To

Left and Right Jack Cylinder, Left and right cartridge valve Left and right beam lower
Extend bottom fitting (25) bulkhead fitting (26)
Left and right Jack Cylinder, Left and right cartridge valve Left and right beam upper
Retract side fitting (27) bulkhead fitting (28)
Left and Right Jack Cylinder Left and right beam lower Extension cylinder tube (29)
bulkhead fitting (26)
Left and Right Jack Cylinder Left and right beam upper Extension cylinder tube (30)
Left and Right Extension Left and right extension Cylinder center tee (32)
Cylinder, Retract cylinder bottom fitting (31)
21-46
TM 08780B-20
33. Fitting
34. Fitting
35. Fitting
36. Fitting
Hose Name From To

Mast Erection Up Mast erection manual control Mast erection cylinder holding
valve front fitting (33) valve bottom fitting (34)
Mast Erection Down Mast erection manual control Mast erection cylinder holding
valve rear fitting (35) valve top fitting (36)
21-47
TM 08780B-20
37. Fitting
38. Fitting
39. Fitting
40. Fitting
41. Fitting
42. Fitting
Hose Name From To

Telescope Out Telescope electric control Bulkhead upper fitting on
valve front fitting (37) front of crane (38)
Telescope Out Bulkhead upper fitting on Telescope cylinder lower
front of crane (38) fitting (39)
Telescope In Telescope electric control Bulkhead upper fitting on rear
valve rear fitting (40) of crane (41)
Telescope In Bulkhead upper fitting on rear Telescope cylinder upper
of crane (41) fitting (42)
21-48
TM 08780B-20

45. Tee Fitting 49. Fitting 53. Fitting
Hose Name From To

Boom Up Boom manual control valve Boom holding valve left
front fitting (43) fitting (44)
Boom Down Boom manual control valve Bulkhead fitting (46)
rear tee fitting (45)
Boom Down Bulkhead fitting (46) Boom holding valve fitting
(47)
Boom Holding Valve Inside Boom holding valve inside left Boom holding valve inside
Left fitting (48) right fitting (49)
Boom Holding Valve Inside Boom holding valve inside Boom holding valve inside
Center center fitting (50) center fitting (51)
Boom Holding Valve Inside Boom holding valve inside Boom holding valve inside left
Right right fitting (52) fitting (53)
21-49
TM 08780B-20
54. Fitting
55. Fitting
56. Fitting
57. Fitting
58. Fitting
59. Fitting
60. Fitting
61. Fitting
62. Fitting
63. Fitting
Hose Name From To

Hoist Up Lower Hoist manual control valve Hoist mast tube left lower
Hoist Up Upper Hoist mast tube left upper Hoist boom left upper tube
fitting (56) rear fitting (57)
Hoist Up Boom Hoist boom left upper tube Hoist motor control valve
forward fitting (58) upper fitting (59)
Hoist Down Lower Hoist manual control valve Hoist mast tube right lower
rear fitting (60) fitting (61)
Hoist Down Upper Hoist mast tube right upper Hoist boom tube right rear
fitting (62) fitting (63)
21-50
TM 08780B-20
64. Fitting
65. Fitting
66. Fitting
67. Fitting
68. Fitting
69. Fitting
70. Fitting
71. Fitting
72. Fitting
73. Fitting
Hose Name From To

Hoist Down Hoist boom left lower tube Hoist motor control valve
forward fitting (64) lower fitting (65)
Hoist Motor Brake Release Hoist motor control valve Hoist motor right bottom
bottom fitting (66) forward fitting (67)
Hoist Motor Brake Engage Hoist motor left side fitting Hoist motor right bottom
(68) fitting (69)
Hoist Motor Return Outer Hoist motor right top fitting Hoist boom right top tube
(70) fitting (71)
Hoist motor return lower Hoist boom right top tube rear Main return tube tee fitting
fitting (72) (73)
21-51
TM 08780B-20
74. Fitting
75. Fitting
76. Fitting
77. Fitting
78. Fitting
79. Fitting
80. Fitting
81. Tee
82. Tube Fitting
Hose Name From To

Swing, Clockwise Swing manual control valve Swing motor cross-over with
front fitting (74) shuttle valve left fitting (75)
Swing, Counter-clockwise Swing manual control valve Swing motor cross-over with
rear fitting (76) shuttle valve right fitting (77)
Swing Motor Brake Release Swing motor cross-over with Swing motor fitting (79)
shuttle valve front fitting (78)
Swing Motor Drain Swing orbit motor bottom Tee (81)
fitting (80)
Swing Motor Drain Tee (81) Tank supply tube (82)
21-52
TM 08780B-20
83. Fitting
84. Fitting
85. Fitting
86. Fitting
87. Fitting
88. Fitting
Hose Name From To

Valve Hose Three way manual control Four way electric control
valve top fitting (83) valve rear fitting (84)
Main Supply Tube fitting (85) Tube fitting (86)
Main Return Tube fitting (87) Tube fitting (88)
END OF TASK
21-53
TM 08780B-20
21-9. CRANE HOSES REPLACEMENT (MK17A1)
THIS TASK COVERS: Hydraulic Hose Locations
INITIAL SETUP

Hydraulic Hose Locations
NOTE
21-54
TM 08780B-20

2. Tee 5. Tee 8. Fitting
3. Fitting 6. Tee
Hose Name From To

Outrigger Extend Extension cylinder bottom Extension cylinder supply
fitting (1) fitting (2) on holding valve
Outrigger Extend Extension cylinder supply Right and left outrigger
fitting (2) on holding valve extension manual control rear
fitting (3 and 4) “A” Port
Outrigger Retract Extension cylinder tee (5) Extension cylinder supply
fitting (6) on holding valve
Outrigger Retract Extension cylinder supply Right and left outrigger
fitting (6) on holding valve extension manual control front
fitting (7 and 8) “B” Port
21-55
TM 08780B-20

11. Fitting 14. Tee
Hose Name From To

Right Outrigger Jack Cylinder, Extension cylinder rear fitting Outrigger supply tee (10)
Down (9)
Down (up/down) jack manual control
front fittings (11 and 12) “B”
Port
Right Outrigger Jack Cylinder, Extension cylinder tube (13) Outrigger supply tee (14)
Up
Up (up/down) jack manual control
rear fittings (15 and 16) “A”
Port
21-56
TM 08780B-20
17. Tube 20. Fitting 23. Fitting

19. Fitting 22. Tee
Hose Name From To

Down
Down LH (up/down) manual control
front fittings (119 and 20) “A”
Port
Up
Up LH (up/down) manual control
rear fittings (23 and 24) “B”
Port
21-57
TM 08780B-20
25. Fitting
26. Fitting
27. Fitting
28. Fitting
29. Tube
30. Tube
31. Fitting
32. Tee
Hose Name From To

Left and Right Jack Cylinder, Left and right cartridge valve Left and right beam lower
Extend bottom fitting (25) bulkhead fitting (26)
Left and right Jack Cylinder, Left and right cartridge valve Left and right beam upper
Retract side fitting (27) bulkhead fitting (28)
Left and Right Jack Cylinder Left and right beam lower Extension cylinder tube (29)
Left and Right Jack Cylinder Left and right beam upper Extension cylinder tube (30)
Left and Right Extension Left and right extension Cylinder center tee (32)
Cylinder, Retract cylinder bottom fitting (31)
21-58
TM 08780B-20
33. Fitting
34. Fitting
35. Fitting
36. Fitting
Hose Name From To

Mast Erection Up Mast erection manual control Mast erection cylinder holding
valve front fitting (33) valve bottom fitting (34)
Mast Erection Down Mast erection manual control Mast erection cylinder holding
valve rear fitting (35) valve top fitting (36)
21-59
TM 08780B-20
37. Fitting
38. Fitting
39. Fitting
40. Fitting
41. Fitting
42. Fitting
Hose Name From To

Telescope Out Telescope electric control Bulkhead fitting on front of
valve front fitting (37) crane (38)
Telescope Out Bulkhead upper fitting on Telescope cylinder lower
front of crane (38) fitting (39)
Telescope In Telescope electric control Bulkhead fitting on rear of
valve rear fitting (40) crane (41)
Telescope In Bulkhead upper fitting on rear Telescope cylinder upper
of crane (41) fitting (42)
21-60
TM 08780B-20

45. Tee Fitting 49. Fitting 53. Fitting
Hose Name From To

Boom Up Boom manual control valve Boom holding valve left
Boom Down Boom manual control valve Bulkhead on turntable (46)
rear tee fitting (45)
Boom Down Bulkhead on turntable (46) Boom holding valve fitting
(47)
Boom Holding Valve Inside Boom holding valve inside left Boom holding valve inside
Left fitting (48) right fitting (49)
Boom Holding Valve Inside Boom holding valve inside Boom holding valve inside
Center center fitting (50) center fitting (51)
Boom Holding Valve Inside Boom holding valve inside Boom holding valve inside left
Right right fitting (52) fitting (53)
21-61
TM 08780B-20
54. Fitting
55. Fitting
56. Fitting
57. Fitting
58. Fitting
59. Fitting
60. Fitting
61. Fitting
62. Fitting
63. Fitting
Hose Name From To

Hoist Up Lower Hoist manual control valve Hoist mast hose left lower
Hoist Up Upper Hoist mast hose left upper Hoist boom left upper tube
fitting (56) rear fitting (57)
Hoist Up Boom Hoist boom left upper tube Hoist motor control valve
forward fitting (58) upper fitting (59)
Hoist Down Lower Hoist manual control valve Hoist mast tube right lower
rear fitting (60) fitting (61)
Hoist Down Upper Hoist mast tube right upper Hoist boom tube right rear
fitting (62) fitting (63)
21-62
TM 08780B-20
64. Fitting
65. Fitting
66. Fitting
67. Fitting
68. Fitting
69. Fitting
70. Fitting
71. Fitting
72. Fitting
73. Fitting
Hose Name From To

Hoist Down Boom Hoist boom left lower tube Hoist motor control valve
forward fitting (64) lower fitting (65)
Hoist Motor Brake Release Hoist motor control valve Hoist motor right bottom
bottom fitting (66) forward fitting (67)
Hoist Motor Brake Engage Hoist motor left side fitting Hoist motor right bottom
(68) fitting (69)
Hoist Motor Return Boom Hoist motor right top fitting Hoist boom right top tube
Outer (70) fitting (71)
Hoist motor return lower Hoist boom right top rear Main return tube tee fitting
fitting (72) (73)
21-63
TM 08780B-20

Hose Name From To

Swing, Clockwise Swing manual control valve Swing motor cross-over with
front fitting (74) shuttle valve left fitting (75)
Swing, Counter-clockwise Swing manual control valve Swing motor cross-over with
rear fitting (76) shuttle valve right fitting (77)
Swing Motor Brake Release Swing motor cross-over with Swing motor fitting (79)
shuttle valve front fitting (78)
Swing Motor Drain Swing orbit motor bottom Main return tube tee fitting
fitting (80) (73)
21-64
TM 08780B-20
81. Elbow
82. Elbow
83. Tee
84. Elbow
85. Elbow
86. Adapter
87. Elbow
88. Fitting
89. Elbow
90. Elbow
Hose Name From To

Accumulator Supply Hose Accumulator bottom elbow Four function electric control
(81) valve rear elbow (82)
Hose Assembly Two-way solenoid valve rear Four function manual control
tee (83) valve bottom elbow (84)
Hose Assembly Four function electric control Four function manual control
valve bottom elbow (85) valve rear adapter (86)
Supply Hose Welded elbow (87) Three way manual control
valve bottom front fitting (88)
Return Hose Welded elbow (89) Three way manual control
END OF TASK
21-65
TM 08780B-20
21-10. HOIST CABLE REPLACEMENT

c. Installation

Condition Condition
MK15A1 TM 08780B-10 Boom erected
MK17A1 (para 2-17 or 2-26).
Hoist cable fully

payed out (para 2-17
or 2-26).
TM 08780B-20 Hoist block assembly

a. Removal
WARNING
CABLE CAN BECOME FRAYED OR CONTAIN BROKEN WIRES. WEAR HEAVY

LEATHER PALMED GLOVES WHEN HANDLING CABLE. FRAYED OR BROKEN
WIRES CAN INJURE HANDS. FAILURE TO COMPLY MAY RESULT IN INJURY TO
PERSONNEL.
(1) Drive cable wedge (1) and cable (2) out of sleeve (3).
(2) Pull cable (2) from sleeve (3).
(3) Remove cable (2) from drum (4).
21-66
TM 08780B-20
1. Cable Wedge
2. Cable
3. Sleeve
4. Drum
1. Cable Wedge
Cable
2. Cable
3. Sleeve
4. Drum
c. Installation
(1) Route cable (2) over and around drum (4).
(2) Route cable (2) up through sleeve (3) and back down into sleeve (3),
making a loop.
21-67
TM 08780B-20
(3) Insert wedge (1) in cable (2) loop and pull cable (2) and wedge (1) into
sleeve (3).
(4) Drive wedge (1) and cable (2) into sleeve (3) until fully seated.
(5) Start engine.
NOTE
After one complete layer of cable is on drum, provide tension on cable so that cable spools on
tightly. Leave enough cable unspooled to allow installation of hook block.
(6) Install cable (2) onto drum (4) (para 2-17 or 2-26).
END OF TASK
NOTE
TM 08780B-20 Install hook block assembly (para 21-11).
TM 08780B-10 Stow crane (para 2-17 or 2-26).
21-68
TM 08780B-20
21-11. HOOK BLOCK ASSEMBLY MAINTENANCE

b. Disassembly
d. Assembly
e. Installation

Condition Condition
MK15A1 TM 08780B-10 Crane erected
MK17A1 (para 2-17 or 2-26).
Materials/Parts Hoist cable extended

Grease (item 23, Appendix D) until hook block rests
Cotter pin (P/N 7690143210) item 1 on ground (para 2-17
Cotter pin (8) (P/N 7690081610) item 10 or 2-26).
Cotter pin (P/N 7690143210) item 24
Locknut (P/N 7660081600) item 30
Lockwasher (P/N 7950220050) item 17
a. Removal
WARNING

PERSONNEL.
(1) Remove and discard cotter pin (1) from nut (2).
(2) Remove nut (2), two washers (3), screws (4) and wedge socket (5) from
boom (6).
21-69
TM 08780B-20
1. Cotter Pin
2. Nut
3. Washer (2)
4. Screw (2)
5. Wedge Socket
6. Boom
(3) Place wedge socket (5) in vise.
(4) Remove wedge (7) and cable (8) from wedge socket (5).
(5) Remove hook block (9) from cable (8).
21-70
TM 08780B-20
5. Wedge Socket
7. Wedge
8. Cable
9. Hook Block
b. Disassembly
(1) Remove and discard eight cotter pins (10) from four straight pins (11).
(2) Remove four straight pins (11) from hook block (9).
(3) Remove lubrication fitting (12) from shouldered shaft (13).
(4) Bend down tabs of starwasher (14).
(5) Remove locknut (15) and starwasher (14) from hook block (9).
(6) Remove capscrew (16), lockwasher (17), washer (18) and bushing (19)
from hook block (9). Discard lockwasher (17).
(7) Remove eye bolt (20) from shouldered shaft (13) and remove shouldered
shaft (13) from hook block (9).
(8) Remove cable pulley (21) and sleeve spacer (22) from hook block (9).
(9) Remove two roller bearings (23) from cable pulley (21).
21-71
TM 08780B-20
9. Hook Block 14. Starwasher 19. Bushing

10. Cotter Pin (8) 15. Locknut 20. Eye Bolt
11. Straight Pin (4) 16. Capscrew 21. Cable Pulley
12. Lubrication Fitting 17. Lockwasher 22. Sleeve Spacer
13. Shouldered Shaft 18. Washer 23. Roller Bearing (2)
(10) Remove and discard cotter pin (24) from slotted nut (25).
(11) Remove slotted nut (25), washer (26), thrust bearing (27) and swivel hook
(28) from hook block (9).
(12) Remove safety pin (29) from swivel hook (28).
(13) Remove locknut (30), capscrew (31) and lanyard (32) from latch (33).
(14) Remove latch (33) and spring (34) from swivel hook (28).
21-72
TM 08780B-20
d. Assembly
(1) Install latch (33) on swivel hook (28) with spring (34), lanyard (32),
capscrew (31) and new locknut (30).
(2) Install safety pin (29) in latch (33).
(3) Apply a light coat of grease to inner diameter of thrust bearing (27) and
install swivel hook (28) on hook block (9) with thrust bearing (27), washer (26) and slotted nut
(25).
(4) Install new cotter pin (24) in slotted nut (25).
9. Hook Block 27. Thrust Bearing 31. Capscrew

24. Cotter Pin 28. Swivel Hook 32. Lanyard
25. Slotted Nut 29. Safety Pin 33. Latch
26. Washer 30. Locknut 34. Spring
(5) Pack two roller bearings (23) with grease.
(6) Install two roller bearings (23) in cable pulley (21).
(7) Install cable pulley (21) and sleeve bushing (22) in hook block (9) with
shouldered shaft (13), starwasher (14) and locknut (15). Hand tighten locknut (15).
21-73
TM 08780B-20
(8) Bend up tabs of starwasher (14) in slots of nut (15).
(9) Install lubrication fitting (12) in shouldered shaft (13).
(10) Install eye bolt (20) in shouldered shaft (13).
(11) Install bushing (19), washer (18), new lockwasher (17) and capscrew (16)
in hook block (9).
(12) Install four straight shafts (11) in hook block (9).
(13) Install eight new cotter pins (10) in four straight shafts (11).
9. Hook Block 14. Starwasher 19. Bushing

10. Cotter Pin (8) 15. Locknut 20. Eye Bolt
11. Straight Pin (4) 16. Capscrew 21. Cable Pulley
12. Lubrication Fitting 17. Lockwasher 22. Sleeve Spacer
13. Shouldered Shaft 18. Washer 23. Roller Bearing (2)
e. Installation
(1) Route cable (8) through hook block sheave (9).
(2) Place wedge socket (5) in vise.
(3) Position cable (8) and wedge (7) in wedge socket (5).
21-74
TM 08780B-20
5. Wedge Socket
7. Wedge
8. Cable
9. Hook Block
(4) Install wedge socket (5) on boom (6) with capscrew (4), two washers (3)
and nut (2).
(5) Install new cotter pin (1) in nut (2).
1. Cotter Pin
2. Nut
3. Washer (2)
4. Capscrew
5. Wedge Socket
6. Boom
NOTE
Attach suitable weight (250-500 lbs) to hook block to seat cable and wedge in wedge socket.
(6) Seat cable (8) and wedge (7) in wedge socket (5).
21-75
TM 08780B-20
5. Wedge Socket
7. Wedge
8. Cable
END OF TASK
NOTE
LI 2320-12/9 Lube hook block.
LO 9-2320-297-12
21-76
TM 08780B-20
21-12. BOOM SHEAVE REPLACEMENT

c. Installation

Condition Condition
MK15A1 TM 08780B-10 Hoist cable extended
MK17A1 approximately 10 feet
(para 2-17 or 2-26).
Materials/Parts
a. Removal
(1) Remove grease fitting (1) from sheave pin (2).
(2) Straighten tab on key washer (3) from detent in nut (4).
(3) Remove nut (4) and key washer (3).
(4) Remove capscrew (5), lockwasher (6), washer (7) and bushing (8) from
sheave pin (9). Discard lockwasher (6).
(5) Remove sheave (10) from sheave pin (2).
NOTE
Support sheave (10) during removal of sheave pin (2). Sheave (10) has two roller bearing
assemblies (12) inside hub which may fall out.
(6) Remove sheave pin (2) and sheave (10) from boom (11).
(7) Remove two roller bearing assemblies (12) and bearing spacer (13) from
sheave (10).
NOTE
Perform step (8) only if bearing cups (14) are damaged.
(8) Remove two bearing cups (14) and bearing cup spacer (15) from sheave
(10).
21-77
TM 08780B-20
1. Grease Fitting 7. Washer 12. Roller Bearing

2. Sheave Pin 8. Bushing Assembly (2)
3. Key Washer 9. Lock Pin 13. Bearing Spacer
4. Nut 10. Sheave 14. Bearing Cup (2)
5. Capscrew 11. Boom 15. Bearing Cup Spacer
6. Lockwasher
c. Installation
(1) If removed, install bearing cup spacer (15) and two bearing cups (14) on
sheave (10).
(2) Pack two roller bearing assemblies (12) with grease.
(3) Install bearing spacer (13) and two roller bearing assemblies (12) in
sheave (10).
WARNING

21-78
TM 08780B-20
PERSONNEL. NEVER LET MOVING CABLE SLIDE THROUGH HANDS EVEN WHEN
WEARING GLOVES. A BROKEN WIRE COULD PIERCE THROUGH GLOVE AND CUT
HANDS.
(4) Install sheave (10) and sheave pin (2) into boom (11) with cable (16)
routed over top of sheave (10) and through groove.
(5) Position lock pin (9) in sheave pin (2).
(6) Position key washer (3) and nut (4) on sheave pin (2).
(7) Apply sealing compound to threads of capscrew (5).
(8) Install washer (7), lockwasher (6), bushing (8) and capscrew (5) in sheave
pin (2).
(9) Tighten nut (4) until snug.
(10) Bend tang of key washer (3) so that the tang lines up with one of four slots
on nut (4).
(11) Install grease fitting (1) in sheave pin (2).
END OF TASK
NOTE
Follow-O Maintenance
TM 08780B-34 Load test crane (para 19-62).
21-79
TM 08780B-20
1. Grease Fitting 7. Washer 12. Roller Bearing Assembly (2)

2. Sheave Pin 8. Bushing 13. Bearing Spacer
3. Key Washer 9. Lock Pin 14. Bearing Cup (2)
4. Nut 10. Sheave 15. Bearing Cup Spacer
5. Capscrew 11. Boom 16. Cable
6. Lockwasher
21-80
TM 08780B-20
21-13. POWER CABLE REPLACEMENT

c. Installation

Condition Condition
MK17A1 disconnected
(para 7-46).
Power cable harness

removed from
junction box
(para 21-3).
General Safely Instructions

injury.

a. Removal
NOTE
• Cut cable ties as required.
• Remove cushion clamps as required.
(1) Disconnect power cable connector (1).
(2) Remove power cable harness (2) from crane (3).
21-81
TM 08780B-20
1. Power Cable Connector

2. Power Cable Harness
3. Crane
c. Installation
NOTE
Install cable ties and cushion clamps as required.
(1) Position power cable harness (2) on crane (3).
(2) Connector power cable connector (1).
END OF TASK
21-82
TM 08780B-20
NOTE
Connect power cable harness to junction box

(para 21-3).

(para 2-17 or 2-26).
1. Power Cable Connector

2. Power Cable Harness
3. Crane
21-83
TM 08780B-20
21-14. REMOTE CONTROL HARNESS REPLACEMENT

c. Installation

Condition Condition
MK17A1 disconnected
(para 7-46).
Materials/Parts
Lockwasher (P/N 6294006281) item 3 Remote control
harness removed from
junction box
(para 21-3).

injury.

a. Removal
NOTE
• Wire and harness removal from junction box is covered in junction box replacement
(para 21-3).
(1) Remove dust cap (1), nut (2), lockwasher (3) and remote control harness
(4) from bracket (5). Discard lockwasher (3).
(2) Remove remote control harness (4) from crane (6).
21-84
TM 08780B-20
1. Dust Cap 4. Remote Control Harness

2. Nut 5. Bracket
3. Lockwasher 6. Crane
c. Installation
NOTE
(1) Position remote control harness (4) on crane (6).
(2) Install remote control harness (4) in bracket (5) with new lockwasher (3),
nut (2) and dust cap (1).
END OF TASK
21-85
TM 08780B-20
NOTE
TM 08780B-20 Install remote control harness on junction
box (para 21-3).

(para 2-17 or 2-26).
1. Dust Cap 4. Remote Control Harness

2. Nut 5. Bracket
3. Lockwasher 6. Crane
21-86
TM 08780B-20
21-15. OVERLOAD SHUTDOWN CABLE REPLACEMENT

c. Installation

Condition Condition
MK17A1 disconnected
(para 7-46).
Overload shutdown
cable removed from
junction box
(para 21-3).

injury.

a. Removal
NOTE
(1) Disconnect overload shutdown cable (1) from overload shutdown box (2).
NOTE
Note routing of cable before removing.
(2) Remove overload shutdown cable (1) from crane (3).
21-87
TM 08780B-20
1. Overload Shutdown Cable

2. Overload Shutdown Box
3. Crane
c. Installation
NOTE
(1) Position overload shutdown cable (1) on crane (3).
(2) Connect overload shutdown cable (1) to overload shutdown box (2).
END OF TASK
21-88
TM 08780B-20
NOTE
TM 08780B-20 Install overload shutdown cable in junction
box (para 21-3).

(para 2-17 or 2-26).
1. Overload Shutdown Cable

2. Overload Shutdown Box
3. Crane
21-89
TM 08780B-20
21-16. CONTROL SOLENOID CABLE REPLACEMENT

c. Installation

Condition Condition
MK17A1 disconnected
(para 7-46).
Materials/Parts
Lockwasher (6) (P/N 7950140050) item 9 Tilt sensor alarm
Lockwasher (4) (P/N 7950140050) item 4 removed (para 21-5)
Gasket (12) (P/N 731740-002) item 15 (MK17A1 only).

injury.

a. Removal
NOTE
• Wire and harness removal from junction box is covered in junction box maintenance
(para 21-3).
• There are 12 solenoid cables in the junction box. All solenoid cables are removed the
same way. Refer to key for functions of solenoid cables.
(1) Remove solenoid cable (1) from junction box (2).
21-90
TM 08780B-20
1. Solenoid Cable
2. Junction Box
NOTE
Perform step (2) if working on MK17A1. Perform step (3) if working on MK15A1.
(2) Remove four capscrews (3), lockwashers (4), washers (5) and cover (6)
(3) Remove six capscrews (8), lockwashers (9), washers (10) and cover (11)
NOTE
There are 12 control valves; wiring to all control valve connectors is removed the same way.
(4) Loosen screw (13) and remove connector (14) and gasket (15) from
control valve (16). Discard gasket (15).
(5) Remove solenoid cable (1) from crane (17) and truck (18).
21-91
TM 08780B-20
1. Solenoid Cable 8. Capscrew (8) 14. Connector

3. Capscrew (4) 9. Lockwasher (6) 15. Gasket (12)
4. Lockwasher (4) 10. Washer (8) 16. Control Valve
5. Washer (4) 11. Cover 17. Crane
6. Cover 12. Bracket 18. Truck
7. Bracket 13. Screw
c. Installation
NOTE
(1) Position solenoid cable (1) on truck (18) and crane (17).
NOTE
Wires to all control valves are installed the same way.
(2) Install new gasket (15) and connector (14) and tighten screw (13).
NOTE
Perform step (3) if working on MK15A1. Perform step (4) if working on MK17A1.
21-92
TM 08780B-20
(3) Install cover (11) on bracket (12) with six washers (10), new lockwashers
(9) and capscrews (8).
(4) Install cover (6) on bracket (7) with four washers (5), new lockwashers (4)
and capscrews (3).
1. Solenoid Cable 8. Capscrew (6) 14. Connector

3. Capscrew (4) 9. Lockwasher (6) 15. Gasket (12)
4. Lockwasher (4) 10. Washer (6) 16. Control Valve
5. Washer (4) 11. Cover 17. Crane
6. Cover 12. Bracket 18. Truck
7. Bracket 13. Screw
NOTE
Installation of harness and wires in junction box is covered in junction box replacement
(para 21-3).
(5) Install solenoid cable (1) in junction box (2).
END OF TASK
21-93
TM 08780B-20
NOTE
TM 08780B-20 Install tilt sensor alarm (para 21-5)
(MK17A1 only).
Connect batteries(para 7-46).

(para 2-17 or 2-26).
1. Solenoid Cable
2. Junction Box
21-94
TM 08780B-20
21-17. TILT SENSOR HARNESS REPLACEMENT

c. Installation

Condition Condition
MK17A1 disconnected
(para 7-46).
Tilt sensor harness

removed from
junction box
(para 21-3).

injury.

a. Removal
NOTE
• Tag and mark all wires prior to removal.
(1) Disconnect two terminals (1) from tilt alarm (2).
(2) Disconnect three connectors (3) from tilt alarm sensor (4).
(3) Remove tilt sensor harness (5) from crane (6).
21-95
TM 08780B-20
1. Terminal (2) 4. Tilt Alarm Sensor

2. Tilt Alarm 5. Tilt Sensor Harness
3. Connector (3) 6. Crane
c. Installation
NOTE
(1) Position tilt sensor harness (5) on crane (6).
(2) Connect three connectors (3) on tilt alarm sensor (4).
(3) Connect two terminals (1) on tilt alarm (2).
END OF TASK
21-96
TM 08780B-20
NOTE
TM 08780B-20 Install tilt sensor harness in junction box
(para 21-3).

(para 2-17 or 2-26).
1. Terminal (2) 4. Tilt Alarm Sensor

2. Tilt Alarm 5. Tilt Sensor Harness
3. Connector (3) 6. Crane
21-97
TM 08780B-20
21-18. REMOTE CONTROL BOX REPAIR

c. Assembly
INITIAL SETUP
MK15A1
MK17A1
Materials/Parts
Compound, silicone (item 14.1, Appendix D)
Sealant, silicone (item 45.1, Appendix D)
Gasket (P/N A/281) item 8
Locknut (16) (P/N 7-660-082504) item 3
Lockwasher (P/N 16FW008032)
Lockwasher (3) (P/N 114021)
O-ring (P/N A-103) item 11
Washer, plastic (P/N 16FW008032)
Washer, rubber (P/N 8-325N300-90)
a. Disassembly
NOTE
• All controllers are removed the same way.
• Tag and mark all connectors, switches and wires prior to removal.
(1) Remove shoulder strap (1) from remote control box (2).
1. Shoulder Strap
2. Remote Control Box
21-98
TM 08780B-20
(2) Remove and discard four locknuts (3) from studs (4).
(3) Lift swing controller (5) away from remote control box (2).
(4) Disconnect swing controller connector (6) from connector (7).
(5) Remove gasket (8) and swing controller (5) from remote control box (2).
Discard gasket (8).

3. Locknut (4)
4. Stud (4)
5. Swing Controller
6. Swing Controller Connector
7. Connector
8. Gasket
NOTE
Note position of screw (9) and lever assembly (10) prior to removal.
(6) Remove screw (9), lever assembly (10) and O-ring (11) from swing
controller (5). Discard O-ring (11).
(7) Loosen nut (12) and remove knob (13) and nut (12) from lever assembly
(10).
(8) Repeat steps (2 thru 7) for telescope controller, hoist controller and boom
controller.
9. Screw
10. Lever Assembly
11. O-Ring
12. Nut
13. Knob
21-99
TM 08780B-20
(9) Disconnect switch (14) from connector (15).
(10) Remove two screws (16), switch (14) and insulator (17) from controller
(18).
(11) Disconnect switch (19) from connector (20).
(12) Remove two screws (21), switch (19), insulator (22) and spacer (23).
14. Switch 18. Controller 21. Screw (2)

15. Connector 19. Switch 22. Insulator
16. Screw (16) 20. Connector 23. Spacer
17. Insulator
NOTE
Do not remove spacer (28) from circuit card (29) if circuit card (29) is not being replaced.
(13) Remove screws (24 and 25), lockwashers (26), heat sink (27) and spacer
(28) from circuit card (29). Discard lockwashers (26).
(14) Remove circuit card (29) from controller (18).
NOTE
If circuit card is not being replaced, go to step (16).
(15) Remove heat sink (30) from circuit card (29).
(16) Repeat steps (9 thru 15) for telescope controller, hoist controller and boom
controller.
21-100
TM 08780B-20
18. Controller
24. Screw
25. Screw
26. Lockwasher (2)
27. Heat Sink
28. Spacer
29. Circuit Card
30. Heat Sink
(17) Remove locknut (31), washer (32), chain (33) and washer (34) from stud
(35). Discard locknut (31) and washers (32 and 34).
(18) Remove cap (36) then note position and remove nut (37) and lockwasher
(38) from receptacle (39). Discard lockwasher (38).
(19) Push receptacle (39) into remote control box (2) and remove and discard
rubber washer (40).
2. Remote Control Box 34. Washer 38. Lockwasher

31. Locknut 35. Stud 39. Receptacle
32. Washer 36. Cap 40. Rubber Washer
33. Chain 37. Nut
(20) Lift switch guard (41) and mark position.
21-101
TM 08780B-20
(21) Remove nut (42), switch guard (41), nylon washer (43), washer (44) and
washer (45) from ON/OFF switch (46).
(22) Pull ON/OFF switch (46) out of remote control box (2) through controller
hole.
(23) Remove four connectors (47) from ON/OFF switch (46).
2. Remote Control Box 44. Rubber Washer

41. Switch Guard 45. Washer
42. Nut 46. On/Off Switch
43. Nylon Washer 47. Connector (4)
(24) Remove ground wire (48) from ground terminal (49).
(25) Remove wire harness (50) from remote control box (2).
NOTE
Perform step (26) only if data plate (52) is damaged or if replacing remote control box.
(26) Drill out and remove four rivets (51), data plate (52) and ground terminal
(49) from remote control box (2).
21-102
TM 08780B-20
c. Assembly
NOTE
Perform step (1) only if 47 data plate (52) was removed.
(1) Install data plate (52) and ground terminal (49) on remote control box (2)
with four rivets (51).
(2) Apply sealant to four rivets (51) only on inside of remote control box (2).
(3) Position wiring harness (50) in remote control box (2).
(4) Install ground wire (48) on ground terminal (49).
2. Remote Control Box 50. Wiring Harness

48. Ground Wire 51. Rivet (4)
49. Ground Terminal 52. Data Plate
(5) Install four connectors (47) on ON/OFF switch (46).
NOTE
OFF position of switch points to rubber key of washer.
(6) Apply sealant between washer (45) and ON/OFF switch (46) and install
ON/OFF switch (46) in remote control box (2) with washer (45), washer (44), nylon washer (43),
switch guard (41) and nut (42).
21-103
TM 08780B-20
2. Remote Control Box 44. Rubber Washer

41. Switch Guard 45. Washer
42. Nut 46. On/Off Switch
43. Nylon Washer 47. Connector (4)
(7) Install new rubber washer (40) and receptacle (39) in remote control box
(2) with new lockwasher (38) and nut (37).
(8) Install cap (36) on receptacle (39).
(9) Install plastic washer (34), chain (33) and plastic washer (32) on stud (35)
with new locknut (31).
2. Remote Control Box 34. Washer 38. Lockwasher

31. Locknut 35. Stud 39. Receptacle
32. Washer 36. Cap 40. Rubber Washer
33. Chain 37. Nut
21-104
TM 08780B-20
NOTE
If circuit card was not replaced, go to step (11).
(10) Position heat sink (30) on circuit card (29).
(11) Install circuit card (29) on controller (18).
NOTE
Spacer (28) is installed only if circuit card was replaced.
(12) Install spacer (28) and heat sink (27) on circuit card (29) with three new
lockwashers (26) and screws (24 and 25).
18. Controller 26. Lockwasher (2) 29. Circuit Card

24. Screw 27. Heat Sink 30. Heat Sink
25. Screw 28. Spacer
(13) Install spacer (23), insulator (22) and switch (19) on controller (18) with
two screws (21).
(14) Connect connector (20) on switch (19).
(15) Install insulator (17) and switch (14) on controller (18) with two screws
(16).
(16) Connect connector (15) on switch (14).
(17) Repeat steps (13 thru 16) for telescope controller, hoist controller and
boom controller.
21-105
TM 08780B-20
14. Switch 18. Controller 21. Screw (2)

15. Connector 19. Switch 22. Insulator
16. Screw (16) 20. Connector 23. Spacer
17. Insulator
(18) Install nut (12) and knob (13) on lever assembly (10).
(19) Apply silicone compound to shaft of lever assembly (10).
(20) Install new O-ring (11) on lever assembly(10).
(21) Apply sealant to underside of head on screw (9).
(22) Install lever assembly (10) on swing controller (5) with screw (9).
9. Screw 11. O-Ring

5. Controller 12. Nut
10. Lever Assembly 13. Knob
21-106
TM 08780B-20
(23) Coat both sides of new gasket (8) with sealant and install new gasket (8)
on swing controller (5).
(24) Connect swing controller connector (6) to connector (7).
(25) Install swing controller connector (6) on studs (4) and remote control box
(2) with four new locknuts (3).
NOTE
The inner two controllers must be installed before the outer two controllers.
(26) Repeat steps (18 thru 25) for telescope controller, hoist controller and
boom controller in that order
(27) Install shoulder strap (1) on remote control box (2).
END OF TASK
NOTE
TM 08780B-10 Operate crane to test remote control
operation (para 2-17 or 2-26).
1. Shoulder Strap
3. Locknut (4)
4. Stud (4)
5. Swing Controller
6. Swing Controller
Connector
7. Connector
8. Gasket
21-107
TM 08780B-20
21-19. HOLDING VALVE REPLACEMENT

b. Installation

Condition Condition
MK15A1 TM 08780B-10 Crane unstowed
MK17A1 (para 2-17 or 2-26).

O-ring (8) item 12 Cleanliness is extremely important when
O-ring (4) item 22 working on hydraulic equipment. Clean all
Seal Kit (9-926-105593) parts before disassembly and work in a
items 26, 27 and 28 clean area.
Cap and plug set
Lubricating oil General Safety Instructions
injury.
a. Removal
NOTE
• Holding valve on MK15A1 and MK17A1 is removed the same way. MK15A1 shown.
• Tag and mark hoses prior to removal to ensure proper installation.
• Cap and plug all hoses and fittings upon removal.
(1) Raise boom (1) and turn turntable (2) on crane (3) approximately 45° or
until turntable (2) clears access hole (4) for holding valve manifold (5).
(2) Position drain pan under holding valve manifold (5) to catch excess oil.
(3) Disconnect three hydraulic hoses (6, 7 and 8).
(4) Remove two hoses (9 and 10) from tee (11). Discard two O-rings (12).
(5) Remove two hoses (13 and 14) from tee (15). Discard two O-rings (12).
(6) Remove two tees (16 and 17) from holding valve manifold (5).
Discard two O-rings (12).
(7) Remove two hoses (18 and 19) from elbows (20 and 21) and remove
holding valve manifold (5) from crane (3). Discard two O-rings (12).
21-108
TM 08780B-20
(8) Position holding valve manifold (5) in soft-jawed vise.
NOTE
Matchmark two elbows prior to removal to ensure proper installation.
(9) Remove two elbows (20 and 21) from holding valve manifold (5).
(10) Remove two fittings (23 and 24) from holding valve manifold (5).
(11) Remove holding valve (25) from holding valve manifold (5).
(12) Remove and discard backup ring (26), O-ring (27) and O-ring (28) from
holding valve (25).
b. Installation
NOTE
Apply lubricating oil to all new O-rings and backup ring prior to installation.
(1) Install new O-ring (28), O-ring (27) and backup ring (26) on holding valve
(25).
(2) Install holding valve (25) in holding valve manifold (5).
(3) Install two new O-rings (22) and fittings (23 and 24) in holding valve
manifold (5).
(4) Align matchmarks and install two new O-rings (22) and elbows (21 and
20) on holding valve manifold (5).
(5) Position holding valve manifold (5) in crane (3) and install two new O-
rings (12) and hoses (19 and 18) on elbows (21 and 20).
(6) Install two new O-rings (12) and tees (17 and 16) in holding valve
manifold (5).
(7) Install two new O-rings (12) and hoses (14 and 13) on tee (15).
(8) Install two new O-rings (12) and hoses (10 and 9) on tee (11).
(9) Connect three hydraulic hoses (8, 7 and 6).
END OF TASK
21-109
TM 08780B-20
NOTE
TM 08780B-10 Operate crane and check for leaks
(para 2-17 or 2-26).
Stow crane (para 2-17 or 2-26).
1. Boom 10. Hose 20. Elbow

2. Turntable 11. Tee 21. Elbow
3. Crane 12. O-Ring (8) 22. O-Ring (4)
4. Access Hole 13. Hose 23. Fitting
5. Holding Valve 14. Hose 24. Fitting
Manifold 15. Tee 25. Holding Valve
6. Hydraulic Hose 16. Tee 26. Backup Ring
7. Hydraulic Hose 17. Tee 27. O-Ring
8. Hydraulic Hose 18. Hose 28. O-Ring
9. Hose 19. Hose
21-110
TM 08780B-20
CHAPTER 22
BODY ACCESSORY ITEMS
Maintenance level mechanics. The following chapter covers repair and replacement procedures
for body accessory items.
a. General. The body accessories on the LVS are provided for the safety,
convenience and comfort of the operating personnel.
b. Windshield Wipers and Motors. The LVS is equipped with two variable speed,
air operated windshield wiper motors. The windshield wiper motors are located under the
dashboard and console. Both windshield wiper motors (1) are individually controlled.
Windshield wiper blades (2) must be replaced if worn or damaged to insure safe, clear vision.
c. Heater. Heater (3) is located under the console (4) in the center of the cab. A two
speed motor controls the amount of heat blown out of heater (3). There is also ducting to direct
heated air to the windshield for defrosting and defogging.
d. Horns. There are two sets of horns - electric horns (5) and air horns (6). The
electric horn is operated by a horn button in the center of the steering wheel. The air horns are
supplied with air from the vehicle's air system. The air horns are activated by pulling a chain
that opens a valve and supplies air to the air horns.
1. Windshield Wiper Motors
2. Windshield Wiper Blades
3. Heater
4. Console
5. Electric Horns
6. Air Horns
22-1
TM 08780B-20
22-3. WINDSHIELD WIPER MOTOR REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (MS35338-46) item 10 disconnected
(para 7-45).
Windshield wiper
blades removed (para
22-4).
Instrument panel


a. Removal
NOTE
Removal procedures are the same for both the right and left windshield wiper motors.
(1) Remove knurled driver (1), rubber shield (2), nut (3), washer (4) and seal
washer (5) from wiper motor shaft (6).
(2) Remove two capscrews (7).
(3) Remove capscrew (8), nut (9) and lockwasher (10) from defroster hose
guard (11) to gain access to right side wiper motor only. Discard lockwasher (10).
(4) Tag and remove two air lines (12) from fittings (13).
22-2
TM 08780B-20
(5) Tag and remove hose (14) from fitting (13).
(6) Remove wiper motor (15).
(7) Mark locations of fittings (13) and remove three fittings (13) from wiper
motor (15).
c. Installation
(1) Lightly coat threads of fittings (13) with pipe sealant.
(2) Install fittings (13) in wiper motor (15).
(3) Install wiper motor (15) and install hose (14) on fitting (13).
(4) Install two air lines (12) on fittings (13).
(5) Install two capscrews (7) and tighten securely.
(6) For right side only, install nut (9), new lockwasher (10) and capscrew (8)
to secure defroster hose guard (11). Tighten nut (9) securely.
(7) Install seal washer (5), washer (4), nut (3), rubber shield (2) and knurled
driver (1) on wiper motor shaft (6). Tighten nut (3) securely.
END OF TASK
22-3
TM 08780B-20
NOTE
Install windshield wiper blades and arms

(para 22-4).
Install instrument dash panel (para 7-11).
TM 08780B-10 Operate windshield wipers and check for

1. Knurled Driver 7. Capscrew (2) 12. Air Line (2)

2. Rubber Shield 8. Capscrew 13. Fitting (3)
3. Nut 9. Nut 14. Hose
4. Washer 10. Lockwasher 15. Wiper Motor
5. Seal Washer 11. Defroster Hose
6. Wiper Motor Shaft Guard
22-4
TM 08780B-20
22-4. WINDSHIELD WIPER MOTOR REPLACEMENT (LVSA1 SERIES

VEHICLES ONLY)

c. Installation

Condition Condition
MK48A1 TM 08780B-10 Air system
drained (para 3-5).
Materials/Parts
Pipe Sealant (item 48, Appendix D) TM 08780B-20 Batteries
Lockwasher (MS35338-46) item 10 disconnected
Self-locking nut (2) (C-1483) item 16 (para 7-46).
Windshield wiper
blades removed (para
22-5).
Instrument panel


a. Removal
NOTE
Removal procedures are the same for both the right and left windshield wiper motors.
(1) Remove arm driver (1), rubber cap (2), nut (3), washer (4) and leather
gasket (5) from wiper motor shaft (6).
(2) Remove two capscrews (7).
(3) On the right side motor only, remove capscrew (8), lockwasher (9) and nut
(10) from defroster hose guard (11) to gain access to right side wiper motor. Discard lockwasher
(10).
22-5
TM 08780B-20
(4) Tag and remove two air lines (12) from fittings (13).
(5) Tag and remove hose (14) from fitting
(6) Remove two screws (15), self-locking nuts (16) and mounting plate (17)
from wiper motor (18).
(7) Mark locations of fittings (13) and remove three fittings (13) from wiper
motor (18).
c. Installation
(1) Lightly coat threads of fittings (13) with pipe sealant.
(2) Install fittings (13) in wiper motor (18).
(3) Install mounting plate (17) on wiper motor (18) using two self-locking
nuts (16) and screws (15). Torque nuts to 60-70 inch-pounds (7-8 N*m).
(4) Install wiper motor (18) using two capscrews (7).
(5) Connect hose (14) on fitting (13).
(6) Connect air lines (12) on fittings (13).
(7) On right side motor only, install defroster hose guard (11) using nut (10),
lockwasher (9) and capscrew (8).
(8) Install leather gasket (5), washer (4), nut (3), rubber cap (2) and arm driver
(1) on wiper motor shaft (6).
END OF TASK
22-6
TM 08780B-20
NOTE
Install windshield wiper blades and arms

(para 22-5).
Install instrument dash panel (para 7-11).
TM 08780B-10 Operate windshield wipers and check for

1. Arm Driver 7. Capscrew (2) 13. Fitting (3)

2. Rubber Cap 8. Capscrew 14. Hose
3. Nut 9. Lockwasher 15. Screw (2)
4. Washer 10. Nut 16. Self-Locking Nut (2)
5. Leather Gasket 11. Defroster Hose Guard 17. Mounting Plate
6. Wiper Motor Shaft 12. Air Line (2)
18. Wiper Motor
22-7
TM 08780B-20
22-5. WINDSHIELD WIPER ARM AND BLADE REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Lockwasher (C-1423) item 2.1
a. Removal
(1) Remove locknut (1) and lockwasher (2) from wiper arm drive stud (3).
Discard locknut (1) and lockwasher (2).
NOTE
(2) Remove acorn nut (1.1) and lockwasher (2.1) from wiper arm drive stud
(3). Discard lockwasher (2.1).
(3) Remove hose (4) from connector (5).
(4) Remove wiper arm (6) from wiper arm drive stud (3).
(5) Remove screw (7) and nut (8).
(6) Remove wiper blade (9) from wiper arm (6).
(7) Remove hose (4) from nozzle (10).
22-8
TM 08780B-20
c. Installation
(1) Install hose (4) on nozzle (10).
NOTE
Do not over tighten nut. Tighten enough to allow for movement of blade in bracket without
excessive play.
(2) Install wiper blade (9) on wiper arm (6) and tighten screw (7) and nut (8).
(3) Install wiper arm (6) on wiper arm drive stud (3).
(4) Install hose (4) on connector (5).
(5) Install new lockwasher (2) and new locknut (1) on wiper arm drive stud
(3). Tighten locknut (1) securely.
NOTE
(6) Install new lockwasher (2.1) and acorn nut (1.1) on wiper arm drive stud
(3). Torque acorn nut (1.1) to 90-110 inch-pounds (10-12 N*m).
END OF TASK
NOTE
TM 08780B-10 Check wiper arm and blade for proper
22-9
TM 08780B-20
1. Locknut 3. Wiper Arm Drive Stud 7. Screw

1.1. Acorn Nut* 4. Hose 8. Nut
2. Lockwasher 5. Connector 9. Wiper Blade
2.1. Lockwasher* 6. Wiper Arm 10. Nozzle
22-10
TM 08780B-20
22-6. WIPER CONTROL VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Pipe sealant (item 48, Appendix D) TM 08780B-20 Access cover
Lockwasher (NSN 5310-01-155-1846) item 7 removed (para 18-15),
Lockwasher (C-1353) item 7.1 item 3.

a. Removal
NOTE
Perform steps (4), (6) and (8) for LVSA1 series vehicles only.
(1) Tag and remove three air lines (1) from three elbow fittings (2).
(2) Remove three elbow fittings (2) from wiper control valve (3).
(3) Remove set screw (4) and knob (5).
(4) Remove knob (5.1).
(5) Remove nut (6) and lockwasher (7) from wiper control valve (3). Discard
lockwasher (7). Discard lockwasher (7.1).
(6) Remove nut (6.1) and lockwasher (7.1) from windshield wiper control
valve (3.1).
(7) Remove wiper control valve (3) from panel (9).
(8) Remove wiper control valve (3.1) from panel (9).
22-11
TM 08780B-20
c. Installation
NOTE
Perform steps (2), (4), (6) and (9) for LVSA1 series vehicles only.
(1) Install new lockwasher (7) and position wiper control valve (3) in place.
(2) Position wiper control valve (3.1) on panel (9).
(3) Install nut (6) on wiper control valve (3). Tighten securely.
(4) Install new lockwasher (7.1) and nut (6.1) on wiper control valve(3.1).
Torque nut (6.1) to 40-50 inch-pounds (5-6 N*m).
(5) Install knob (5) and tighten set screw (4).
(6) Install knob (5.1).
(7) Coat three elbow fitting threads (8) with pipe sealant.
(8) Install three elbow fittings (2) on wiper control valve (3).
(9) Install three elbow fittings (2) on wiper control valve (3.1). Torque
fittings (2) to 25-40 inch-pounds (3-5 N*m).
(10) Install three air lines (1) on three elbow fittings (2).
END OF TASK
22-12
TM 08780B-20
NOTE
TM 08780B-20 Install access cover (para 18-15), item 3.
TM 08780B-10 Check windshield wipers for proper

1. Air Line (3) 5. Knob 7. Lockwasher

2. Elbow Fitting (3) 5.1. Knob* 7.1. Lockwasher*
3. Wiper Control Valve 6. Nut 8. Threads
3.1. Wiper Control Valve* 6.1. Nut* 9. Panel
4. Set Screw
22-13
TM 08780B-20
22-7. WINDSHIELD WASHER CONTROL VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
item 3.

a. Removal
(1) Remove air line (1) from washer control valve (2).
(2) Remove spring clamp (3) and hose (4) from washer control valve (2).
(3) Remove elbow fitting (5) from washer control valve (2).
(4) Remove set screw (6) and remove knob (7).
NOTE
(5) Remove knob (7.1).
(6) Remove nut (8) from washer control valve (2).
(7) Remove washer control valve (2).
22-14
TM 08780B-20
c. Installation
(1) Position washer control valve (2) in place.
(2) Install nut (8) on washer control valve (2). Tighten securely.
(3) Install knob (7) and set screw (6). Tighten set screw (6).
NOTE
(4) Install knob (7.1).
(5) Coat threads (9) of elbow fitting (5) with pipe sealant and install in washer
control valve (2).
(6) Install hose (4) and spring clamp (3) on washer control valve (2).
(7) Install air line (1) on washer control valve (2).
END OF TASK
NOTE
TM 08780B-10 Check windshield washer for proper

22-15
TM 08780B-20
1. Air Line 5. Elbow Fitting 7.1. Knob*

2. Washer Control Valve 6. Set Screw 8. Nut
3. Spring Clamp 7. Knob 9. Threads
4. Hose
22-16
TM 08780B-20
22-8. WASHER RESERVOIR HOSE AND NOZZLE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Access cover
Lockwasher (MS35338-46) item 10 Instrument panel
Personnel Required
1 MOS 3521 General Safety Instructions
1 Assistant To prevent personal injury, make sure
a. Removal
(1) Slide spring clamps (1) back on hoses (2 and 3).
(2) Tag and remove hoses (2 and 3) from reservoir (4).
(3) Slide reservoir (4) off bracket (5).
(4) Remove two capscrews (6), nuts (7) and lockwashers (8) from bracket (5).
(5) Remove capscrew (9), lockwasher (10) and nut (11) from defroster duct
cover (12). Discard lockwasher (10).
(6) Remove defroster duct cover (12).
(7) Remove spring clamp (13) and hose (3) from washer control valve (14).
(8) Remove hose (2) from T-fitting (15).
(9) Remove hose (16) from T-fitting (15) and left nozzle (17).
(10) Remove hose (18) from T-fitting (15) and right nozzle (19).
22-17
TM 08780B-20
NOTE
Both right and left side nozzles are removed in the same manner.
(11) While assistant holds right nozzle (19) in place, remove nut (20) from
right nozzle (19).
(12) Remove right nozzle (19) and gasket (21).
(13) Remove hose (22) from right nozzle (19).
c. Installation
(1) Install hose (22) on right nozzle (19).
(2) Install right nozzle (19) and gasket (21).
(3) While assist hold right nozzle (19), install nut (20).
(4) Install hose (18) on T-fitting (15) and right nozzle (19).
(5) Install hose (16) on T-fitting (15) and left nozzle (17).
(6) Install hose (2) on T-fitting (15).
(8) Position defroster duct cover (12) and install new lockwasher (10),
capscrew (9) and nut (11). Tighten securely.
(9) Position bracket (5) and install two capscrews (6), new lockwashers (8)
and nuts (7). Tighten securely.
(10) Install reservoir (4) on bracket (5).
(11) Install hoses (2 and 3) in tagged locations with spring clamps (1) on
reservoir (4).
END OF TASK
22-18
TM 08780B-20
NOTE
Install access cover (para 18-15), item 3.

1. Spring Clamp (2) 9. Capscrew 15. T-Fitting

2. Hose 10. Lockwasher 16. Hose
3. Hose 11. Nut 17. Left Nozzle
4. Reservoir 12. Defroster Duct 18. Hose
5. Bracket Cover 19. Right Nozzle
6. Capscrew (2) 13. Spring Clamp 20. Nut (2)
7. Nut (2) 14. Washer Control 21. Gasket (2)
8. Lockwasher (2) Valve 22. Hose
22-19
TM 08780B-20
22-9. WASHER RESERVOIR HOSE AND NOZZLE REPLACEMENT (LVSA1


c. Installation

Condition Condition
MK48A1 TM 08780B-20 Access cover
Lockwasher (354AX) item 13 Instrument panel
Locknut (3) (66419AX) item 18 removed (para 7-11).
Personnel Required Main air manifold

1 MOS 3521 removed (para 13-26),
1 Assistant items 12.1 and 13.1.

a. Removal
(1) Tag and remove hoses (1 and 2) from reservoir bottle (3).
(2) Remove reservoir bottle (3).
(3) Remove capscrew (4), lockwasher (5) and nut (6) from defroster duct
cover (7). Discard lockwasher (5).
(4) Remove defroster duct cover (7).
(5) Remove capscrew (8), washer (9) and clamp (10) from main air manifold
(11). Remove hoses (1 and 2) from clamp (10).
(6) Remove two capscrews (12), lockwashers (13), washers (14), washer
bottle bracket (15) and vertical washer bottle bracket (16). Discard lockwashers (13).
(7) Remove three capscrews (17), locknuts (18), gasket slip (19) and vertical
washer bottle bracket (16) from washer bottle bracket (15). Discard locknuts (18).
22-20
TM 08780B-20
(8) Remove spring clip (20) and hose (1) from washer control valve (21).
(9) Remove hose (2) from connection tee (22).
(10) Remove hose (23) from connection tee (22) and left washer elbow (24).
(11) Remove hose (25) from connection tee (22) and right washer elbow (26).
NOTE
Both right and left side washer elbows are removed in the same manner.
(12) While assistant holds right washer elbow (26) in place, remove nut (27)
from right washer elbow (26).
(13) Remove right washer elbow (26) and gasket (28).
(14) Remove hose (29) from right washer elbow (26).
c. Installation
(1) Install hose (29) on right washer elbow (26).
(2) Install right washer elbow (26) and gasket (28).
(3) While assistant holds right washer elbow (26), install nut (27).
(4) Install hose (25) on connection tee (22) and right washer elbow (26).
(5) Install hose (23) on connection tee (22) and left washer elbow (24).
(6) Install hose (2) on connection tee (22).
22-21
TM 08780B-20
1. Hose 12. Capscrew (2) 20. Spring Clamp

2. Hose 13. Lockwasher (2) 21. Washer Control Valve
3. Reservoir 14. Washer (2) 22. Connection Tee
4. Capscrew 15. Washer Bottle 23. Hose
5. Lockwasher Bracket 24. Left Elbow
6. Nut 16. Vertical Washer 25. Hose
7. Defroster Duct Cover Bottle Bracket 26. Right Elbow
8. Capscrew 17. Capscrew (3) 27. Nut
9. Washer 18. Locknut (3) 28. Gasket
10. Clamp 19. Gasket Strip 29. Hose
11. Main Air Manifold
22-22
TM 08780B-20
(8) Install vertical washer bottle bracket (16) onto washer bottle bracket (15)
using gasket slip (19), three new locknuts (18) and capscrews (17). Tighten locknuts (18)
securely.
(9) Install vertical washer bottle bracket (16) and washer bottle bracket (15)
using two washers (14), new lockwashers (13) and capscrews (12). Tighten capscrews (12)
securely.
(10) Install washer reservoir bottle (3).
(11) Secure hoses (1 and 2) to main air manifold (11) using clamp (10), washer
(9) and capscrew (8). Tighten capscrew (8) securely.
(12) Position defroster duct cover (7) and install new lockwasher (5), capscrew
(13) Install hoses (1 and 2) in tagged locations on reservoir bottle (3).
END OF TASK
NOTE
TM 08780B-20 Install main air manifold (para 13-26),
items 12.1 and 13.1.
Install instrument panel (para 7-11).

22-23
TM 08780B-20
22-10. MIRROR REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Star washer (2) (MS35335-61) items 4 and 12
a. Removal
NOTE
Removal of both the left and the right mirror assemblies is performed in the same manner.
(1) Remove nut (1), lockwasher (2), spacer (3), star washer (4) and capscrew
(5) from top of mirror (6). Discard lockwasher (2) and star washer (4).
(2) Remove nut (7), lockwasher (8) and flat washer (9) from bottom of mirror
(3) Remove mirror and bracket assembly (10).
(4) Remove spacer (11), star washer (12), capscrew (13) and mirror (6).
(5) Remove nut (14), two flat washers (15), capscrew (16) and mirror (17)
from bracket (18).
c. Installation
(1) Install mirror (17) on bracket (18) with capscrew (16), two flat washers
22-24
TM 08780B-20
(2) Position mirror (6) on bracket (19). Install capscrew (5), new star washer
(4), spacer (3), new lockwasher (2) and nut (1) at top of mirror (6). Hand tighten nut (1) and
capscrew (5).
(3) Position mirror and bracket assembly (10) and mirror (6) on bracket (19).
(4) Install capscrew (13), new star washer (12), spacer (11), flat washer (9),
new lockwasher (8) and nut (7) at bottom of mirror (6). Hand tighten capscrew (13) and nut (7).
(5) Adjust mirrors (6 and 17). Tighten nuts (1 and 7) and capscrews (5 and
13) securely.
1. Nut 8. Lockwasher 14. Nut

2. Lockwasher 9. Flat Washer 15. Flat Washer (2)
3. Spacer 10. Mirror and 16. Capscrew
4. Star Washer Bracket Assembly 17. Mirror
5. Capscrew 11. Spacer 18. Bracket
6. Mirror 12. Star Washer 19. Bracket
7. Nut 13. Capscrew
END OF TASK
22-25
TM 08780B-20
22-11. AIR HORN REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (MS35338-50) item 8 removed (para 18-15)
Lockwasher (MS35338-45) item 13 item 23.
Gasket (NSN 5330-00-885-3921) item 14
a. Removal
(1) Remove two capscrews (1) and lockwashers (2) from bracket (3).
(2) Pull air horns (4) through access hole.
(3) Remove air line (5) from elbow fitting (6) and remove air horns (4).
(4) Remove elbow fitting (6).
(5) Remove nut (7), lockwasher (8) and washer (9). Discard lockwasher (8).
(6) Remove capscrew (10), washer (11), nut (12) and lockwasher (13).
(7) Remove air horns (4) and gasket (14), from bracket (3). Discard gasket
(14).
c. Installation
(1) Position air horns (4) and new gasket (14) on bracket (3).
22-26
TM 08780B-20
(2) Install washer (11), capscrew (10), new lockwasher (13) and nut (12).
(3) Install washer (9), new lockwasher (8) and nut (7).
(4) Coat threads of elbow fitting (6) with pipe sealant and install in air horns
(4).
(5) Install air line (5) on elbow fitting (6).
(6) Slide air horns (4) through access hole.
(7) Position air horns (4) and bracket (3).
(8) Install two capscrews (1) and new lockwashers (2). Tighten securely.
(9) To adjust tone, loosen nut (15) and turn adjusting screw (16). Tighten nut
(15) securely.
END OF TASK
NOTE
TM 08780B-20 Install access panel (para 18-15), item 23.
22-27
TM 08780B-20
1. Capscrew (2) 7. Nut 12. Nut

2. Lockwasher (2) 8. Lockwasher 13. Lockwasher
3. Bracket 9. Washer 14. Gasket
4. Air Horns 10. Capscrew 15. Nut
5. Air Line 11. Washer 16. Adjusting Screw
6. Elbow Fitting
22-28
TM 08780B-20
22-12. AIR HORN REPAIR

c. Assembly

Condition Condition
MK48 TM 08780B-20 Air horn removed
(para 22-11).
Materials/Parts
Diaphragm (2) (NSN 2590-00-753-9234) item 8
Screw with captive lockwasher (4) (113205) item 1
a. Disassembly
NOTE
Cover (3) mounting hardware has changed from a screw and lockwasher to a screw with
captive lockwasher. When repairing a non-A1 series vehicle use the new style hardware to
replace the old style hardware. Refer to TM 08780B-24P for correct parts identification.
(1) Remove four screws with captive lockwasher (1) and cover (3). Discard
screws with captive lockwasher (1).
(2) Remove nut (4), spring seat (5), spring (6), contact (7) and diaphragm (8).
Discard diaphragm (8).
(3) Remove horn bell (9) from body (10).
(4) Repeat steps (1) thru (3) for other side.
c. Assembly
(1) Install contact (7) on spring (6).
(2) Install spring (6) on spring seat (5).
22-29
TM 08780B-20
(3) Install spring seat (5) into cover (3). Install nut (4) finger tight to secure
spring seat (5).
(4) Install new diaphragm (8) into body (10).
(5) Install cover (3) and four new screws with captive lockwasher (1).
Tighten screws with captive lockwasher (1) securely.
(6) Install horn bell (9) into body (10).
(7) Repeat steps (1) thru (6) for other side.
END OF TASK
NOTE
TM 08780B-20 Install air horn (para 22-11).
1. Screw With Captive

Lockwasher (4)
3. Cover
4. Nut
5. Spring Seat
6. Spring
7. Contact
8. Diaphragm
9. Horn Bell
10. Body
22-30
TM 08780B-20
22-13. AIR HORN VALVE REPLACEMENT

c. Installation

Condition Condition
drained (para 3-5).
Materials/Parts
Lockwasher (2) (MS35338-43) item 6 To prevent personal injury, drain all
a. Removal
(1) Tag and remove two airlines (1) from valve (2).
(2) Spread chain link (3) and disconnect chain (4) from valve (2).
(3) Remove two screws (5) and lockwashers (6) from valve (2). Discard
lockwashers (6).
(4) Remove valve (2) from vehicle.
(5) Remove fittings (7) from valve (2).
(6) Remove screw (8) and chain (4).
c. Installation
(1) Install screw (8) through chain (4). Tighten securely.
(2) Coat threads of fittings (7) with pipe sealant and install in valve (2).
22-31
TM 08780B-20
(3) Install two new lockwashers (6) and screws (5) to secure valve (2) to
vehicle.
(4) Install chain link (3) to connect chain (4) on valve (2).
(5) Install two air lines (1) on valve (2) in tagged locations.
END OF TASK
NOTE
TM 08780B-10 Start engine and build air pressure
(para 2-13).
Check operation of air horn (para 2-1).
22-32
TM 08780B-20
1. Air Line (2) 5. Screw (2)

2. Valve 6. Lockwasher (2)
3. Chain Link 7. Fitting (3)
4. Chain 8. Screw
22-33
TM 08780B-20
22-14. ELECTRIC HORN REPLACEMENT

c. Installation

Condition Condition
Materials/Parts
a. Removal
(1) Tag and remove two wires (1) from electric horn (2).
(2) Remove capscrew (3), two wires (4), star washer (5) and electric horns
(3) Remove two nuts (6) from electric horns (2).
(4) Remove electric horns (2) from brackets (7).
c. Installation
(1) Position electric horns (2) on brackets (7).
(2) Install two nuts (6) on electric horns (2). Torque nuts (6) to 10 foot-
pounds (13.6 N*m).
(3) Install new star washer (5), two wires (4) and capscrew (3) on bracket (7).
(4) Install two wires (1) on electric horns (2) in tagged locations.
END OF TASK
22-34
TM 08780B-20
NOTE
TM 08780B-10 Check operation of electric horn (para 2-1).
1. Wire
2. Electric Horn (2)
3. Capscrew
4. Wire (2)
5. Star Washer
6. Nut (2)
7. Bracket (2)
22-35
TM 08780B-20
22-15. HEATER REPLACEMENT

c. Installation

Condition Condition
Materials/Parts items 3, 29, 30 and
31.
Nylon ties (4) (MS3367-7-9) item 13
Adhesive, weatherstrip (item 5.1, Appendix D)
a. Removal
NOTE
Hose clamps (3) have changed from a worm type clamp to a constant torque “Breeze” type
clamp. When repairing a non-A1-vehicle, use the new style constant torque clamp to replace
the old style clamp. Refer to TM 08780B-24P for correct part identification.
(1) Tag two heater hoses (1 and 2). Loosen two clamps (3).
(2) Remove hoses (1) and (2) and immediately plug with 5/8 x 1 capscrew (4).
Tighten clamps (3).
(4) Remove retainer (6) and control cable (7) from control arm (8).
(5) Remove capscrew (9) and lockwasher (10) to remove clamp (11) from
bracket (12). Discard lockwasher (10).
(6) Remove nylon ties (13) and disconnect four defroster ducts (14) from
heater (15). Discard nylon ties (13).
(7) Remove six screws (16) and lockwashers (17) from bracket (18). Discard
lockwashers (17).
(8) Remove heater (15).
22-36
TM 08780B-20
b. Cleaning/Installation
c. Installation
(1) Position heater (15) in compartment and install six screws (16) and new
lockwashers (17). Tighten six screws (16) securely.
(2) Apply weatherstrip adhesive to four defroster ducts (14) and install with
new nylon ties (13).
(3) Install control cable (7) on control arm (8).
(4) Install retainer (6) on control arm (8).
(5) Install capscrew (9) and new lockwasher (10) to secure clamp (11) and
control cable (7) to bracket (12). Tighten capscrew (9) securely.
(7) Loosen two clamps (3). Remove two 5/8 x 1 capscrews (4) and
immediately install heater hoses (1 and 2) in tagged locations. Tighten clamps (3) to 40 inch-
pounds (4.5 N*m).
(8) Fill cooling system. Refer to paragraph 6-2 in this manual.
(9) Start engine. Check operation of heater. Refer to paragraph 2-13

(TM 08780B-10).
(10) Check for leaks at heater hose connections.
END OF TASK
22-37
TM 08780B-20
NOTE
TM 08780B-20 Install access covers (para 18-15), items 3,
29, 30 and 31.
1. Heater Hose 7. Control Cable 13. Nylon Tie (4)

2. Heater Hose 8. Control Arm 14. Defroster Duct (4)
3. Clamp (2) 9. Capscrew 15. Heater
4. 5/8x1 Capscrew 10. Lockwasher 16. Screw (6)
5. Plug 11. Clamp 17. Lockwasher (6)
6. Retainer 12. Bracket 18. Bracket
22-38
TM 08780B-20
22-16. HEATER BLOWER REPLACEMENT

c. Installation

Condition Condition
a. Removal
(1) Remove six capscrews (1), lockwashers (2) and washers (3) from heater
cover (4). Discard lockwashers (2).
(2) Remove heater cover (4).
(3) Remove two capscrews (5), lockwashers (6) and washers (7) from blower
motor housing assembly (8). Discard lockwashers (6).
(4) Remove capscrew (9), lockwasher (10), washer (11), ground wire (12) and
star washer (13) from blower motor housing assembly (8). Discard washers (10 and 13).
(5) Remove tape (14) and unplug wire quick disconnect (15).
(6) Remove blower motor housing assembly (8) from heater housing (16).
c. Installation
(1) Position blower motor housing assembly (8) in heater housing (16).
(2) Connect wire quick disconnect (15). Wrap tape (14) around connection.
22-39
TM 08780B-20
(3) Install new star washer (13), ground wire (12), washer (11), new
lockwasher (10) and capscrew (9) on blower motor housing assembly (8).
(4) Install two washers (7), new lockwashers (6) and capscrews (5) on blower
motor housing assembly (8).
(5) Install heater cover (4).
(6) Install six capscrews (1) with new lockwashers (2) and washers (3).
Tighten securely.
END OF TASK
NOTE
TM 08780B-10 Check operation of heater blower motor

(para 2-1).
1. Capscrew (6)
2. Lockwasher (6)
3. Washer (6)
4. Heater Cover
5. Capscrew (2)
6. Lockwasher (2)
7. Washer (2)
8. Blower Motor
Housing Assembly
9. Capscrew
10. Lockwasher
11. Washer
12. Ground Wire
13. Star Washer
14. Tape
15. Wire Quick Disconnect
16. Heater Housing
22-40
TM 08780B-20
22-17. HEATER BLOWER REPAIR

c. Assembly

Condition Condition
MK48 TM 08780B-20 Heater blower motor
a. Disassembly
(1) Remove three capscrews (1) and end plate (2) from each end of blower
housing (3).
(2) Mark arrows on motor (4), blower housing (3) and each fan wheel (5) all
in the same direction. This will insure that motor (4) and fan wheels (5) are installed in the
correct rotation direction.
(3) Remove capscrew (6), washer (7) and bracket (8) from fan motor (4).
(4) Remove inner and outer spring clamps (9) from one fan wheel (5).
(5) Remove inner and outer spring clamps (9) from other fan wheel (5).
(6) Remove fan wheels (5) from blower housing (3).
(7) Slide motor (4) out of blower housing (3).
(1) Wipe inside of blower housing (3) clean. Remove any dirt that has
accumulated.
(2) Blow or wipe fan wheels (5) clean.
(3) Inspect fan wheels (5) for cracks or broken fins.
22-41
TM 08780B-20
c. Assembly
(1) Slide motor (4) in blower housing (3).
(2) Install inner and outer spring clamps (9) and slide one fan wheel (5) in
blower housing (3).
(3) Slide other fan wheel (5) in blower housing (3) and install inner and outer
spring clamps (9).
(4) Install washer (7) and capscrew (6) to secure bracket (8) on motor (4).
(5) Install end plates (2) with three capscrews (1) and tighten securely.
END OF TASK
NOTE
TM 08780B-20 Install heater blower (para 22-16).
1. Capscrew (3)
2. End Plate (2)
3. Blower Housing
4. Motor
5. Fan Wheel (2)
6. Capscrew
7. Washer
8. Bracket
9. Spring Clamp (4)
22-42
TM 08780B-20
22-18. HEATER CORE REPLACEMENT

c. Installation

Condition Condition
a. Removal
NOTE
Hose clamp (3) has changed from a worm type clamp to a constant torque “Breeze” type
clamp. When repairing a non-A1 vehicle, use the new style constant torque clamp to replace
the old style clamp. Refer to TM 08780B-24P for correct part identification.
(1) Tag two heater hoses (1 and 2). Loosen two hose clamps (3).
(2) Remove and immediately plug hoses (1 and 2) with 5/8 x 1 capscrews (4).
Tighten clamps (3).
(3) Remove six capscrews (5), lockwashers (6) and washers (7) from heater
cover (8). Discard lockwashers (6).
(4) Remove heater cover (8).
(5) Lift heater core (9) out of heater housing.
c. Installation
(1) Install heater core (9) in heater housing.
22-43
TM 08780B-20
(2) Install heater cover (8).
(3) Install six washers (7), new lockwashers (6) and capscrews (5) on heater
cover (8).
(4) Loosen two clamps (3) and remove capscrew (4) from hoses (1 and 2).
Immediately install hoses (1 and 2). Tighten clamps (3) to 40 inch-pounds.
(5) Fill cooling system to proper level. Refer to paragraph 6-3 of this manual.
END OF TASK
NOTE
TM 08780B-20 Access cover installed (para 18-15).
TM 08780B-10 Start engine (para 2-13) and check heater

core for leaks.
1. Hose
2. Hose
3. Hose Clamp (2)
4. Capscrew (2)
5. Capscrew (6)
6. Lockwasher (6)
7. Washer (6)
8. Heater Cover
9. Heater Core
22-44
TM 08780B-20
22-19. HEATER HOSE AND FITTING REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Cooling system
drained (pare 6-3).
Materials/Parts
Pipe sealant (item 48, Appendix D) Access panels
Lockwasher (MS35338-44) item 5 removed (para 18-15)
items 16 and 23.
a. Removal
NOTE
• Remove nylon ties as needed to remove hoses. Note location for replacement during
installation.
• Hose clamps (1, 2, 9, 10 and 11) have changed from a worm type clamp to a constant
torque “Breeze” type clamp. When repairing a non-A1 vehicle, use the new style
constant torque clamp to replace the old style clamp. Refer to TM 08780B-24P for
correct part identification.
(1) Loosen two hose clamps (1).
(2) Loosen hose clamp (2).
(3) Tag and remove hose (3).
(4) Remove capscrew (4), lockwasher (5), washer (6) and nut (7) from clamp
(5) Loosen hose clamps (9, 10 and 11).
(6) Tag and remove hose (12) and hose (13).
(7) Remove heater control valve (14) from bracket (15).
(8) Remove two nipple fittings (16) from bracket (15).
(9) Remove elbow fitting (17) and reducer bushing (18).
22-45
TM 08780B-20
(10) Remove fitting (19) and reducer bushing (20).
1. Hose Clamp (2) 8. Clamp 15. Bracket

2. Hose Clamp 9. Hose Clamp 16. Nipple Fitting (2)
3. Hose 10. Hose Clamp 17. Elbow Fitting
4. Capscrew 11. Hose Clamp 18. Reducer Bushing
5. Lockwasher 12. Hose 19. Fitting
6. Washer 13. Hose 20. Reducer Bushing
7. Nut 14. Heater Control Valve
22-46
TM 08780B-20
c. Installation
NOTE
Before installing fittings and reducer bushings, coat all threads with pipe sealant.
(1) Install and tighten reducer bushing (20) and fitting (19).
(2) Install and tighten reducer bushing (18) and elbow fitting (17).
(3) Install and tighten two nipple fittings (16) on bracket (15).
(4) Install heater control valve (14) on bracket (15).
NOTE
Route hoses in the same positions that they were in before removal.
(5) Install hose (13) and hose (12).
(6) Tighten hose clamps (9, 10 and 11) to 40 inch-pounds (4.5 N*m).
(7) Install washer (6), new lockwasher (5), capscrew (4) and nut (7) on clamp
(8).
(8) Install hose (3).
(9) Tighten hose clamp (2) to 40 inch-pounds (4.5 N*m).
(10) Tighten two hose clamps (1) to 40 inch-pounds (4.5 N*m).
END OF TASK
NOTE
TM 08780B-20 Cooling system filled to proper level
(para 6-3).
Install access panels (para 18-15) items

16 and 23.
TM 08780B-10 Operate engine and check for leaks

(para 2-13).
22-47
TM 08780B-20
1. Hose Clamp (2) 8. Clamp 15. Bracket

2. Hose Clamp 9. Hose Clamp 16. Nipple Fitting (2)
3. Hose 10. Hose Clamp 17. Elbow Fitting
4. Capscrew 11. Hose Clamp 18. Reducer Bushing
5. Lockwasher 12. Hose 19. Fitting
6. Washer 13. Hose 20. Reducer Bushing
7. Nut 14. Heater Control Valve
22-48
TM 08780B-20
22-20. DEFROSTER HOSE, PLENUMS AND CONTROL CABLE REPLACEMENT

c. Installation

Condition Condition
Nylon ties (MS3367-7-9)
Lockwasher (MS35338-46) item 8 Instrument panel
Star washer (MS35335-61) item 14 opened (para 7-11),
Star washer (MS35333-76) item 18 step 1.
Adhesive, weatherstrip (item 5.1, Appendix D)
a. Removal
NOTE
Remove nylon ties as needed to remove defroster hoses. Note location for installation.
(1) Disconnect four defroster hoses (1, 2, 3 and 4) from heater box (5).
(2) Remove two defroster hoses (2 and 3).
(3) Remove defroster hose (4).
(4) Remove capscrew (6), nut (7) and lockwasher (8) from defroster hose
guard (9). Discard lockwasher (8).
(5) Remove defroster hose guard (9).
(6) Remove defroster hose (1).
(7) Remove retainer (10) and pull control cable (11) off defroster control arm
(12).
(8) Remove capscrew (13), star washer (14) and clamp (15) from bracket
(9) Remove clamp (15) from control cable (11).
(10) Remove nut (17) and star washer (18). Discard star washer (18).
22-49
TM 08780B-20
(11) Remove control cable (11) from mounting hole (19).
1. Defroster Hose 8. Lockwasher 14. Star Washer

2. Defroster Hose 9. Defroster Hose Guard 15. Clamp
3. Defroster Hose 10. Retainer 16. Bracket
4. Defroster Hose 11. Control Cable 17. Nut
5. Heater Box 12. Defroster Control Arm 18. Star Washer
6. Capscrew 13. Capscrew 19. Mounting Hole
7. Nut
22-50
TM 08780B-20
(12) Remove three screws (20) and washers (21) from right side plenum (22).
(13) Remove right side plenum (22).
(14) Remove three screws (23) and washers (24) from left side plenum (25).
(15) Remove left side plenum (25).
c. Installation
CAUTION
TO PREVENT PARTS DAMAGE, ROUTE DEFROSTER HOSES AWAY FROM MOVING

PARTS AND ELECTRICAL CONNECTIONS.
(1) Apply silicone sealant to left side plenum (25) and position left side
plenum.
(2) Install three washers (24) and screws (23) on left side plenum.
(3) Apply silicone sealant to right side plenum (22) and position right side
plenum.
(4) Install three washers (21) and screws (20) on right side plenum.
(5) Install control cable (11) in mounting hole (19).
(6) Install new star washer (18) and nut (17).
(7) Slide clamp (15) on control cable (11).
(8) Install capscrew (13), new star washer (14) and clamp (15) on bracket
(16).
(9) Slide control cable (11) on defroster control arm (12).
(10) Install retainer (10) on defroster control arm (12).
22-51
TM 08780B-20
(11) Install defroster hose (1).
(12) Position defroster hose guard (9).
(13) Install capscrew (6), new lockwasher (8) and nut (7) on defroster hose
guard (9).
(14) Install defroster hose (4).
(15) Install two defroster hoses (2 and 3).
(16) Apply weatherstrip adhesive to four defroster hoses (1, 2, 3 and 4) and
connect four defroster hoses to heater box (5).
(17) Install nylon ties as needed to secure defroster hoses (1, 2, 3 and 4) in
proper position.
END OF TASK
NOTE
TM 08780B-10 Check heater for proper operation

(para 2-1).
22-52
TM 08780B-20
1. Defroster Hose 10. Retainer 18. Star Washer

2. Defroster Hose 11. Control Cable 19. Mounting Hole
3. Defroster Hose 12. Defroster Control Arm 20. Screw (3)
4. Defroster Hose 13. Capscrew 21. Washer (3)
5. Heater Box 14. Star Washer 22. Right Side Plenum
6. Capscrew 15. Clamp 23. Screw (3)
7. Nut 16. Bracket 24. Washer (3)
8. Lockwasher 17. Nut 25. Left Side Plenum
9. Defroster Hose Guard
22-53
TM 08780B-20
22-21. HEATER CONTROL CABLE REPLACEMENT

c. Installation

Condition Condition
Materials/Parts items 3 and 23.
a. Removal
(1) Remove screw (1) from clamp (2).
(2) Slide cable (3) off pin (4).
(3) Remove nut (5) and lockwasher (6) from control knob (7).
(4) Pull cable (3) from mounting hole (8) and remove from vehicle. Discard
lockwasher (6).
c. Installation
(1) Install cable (3) in hole (8).
(2) Install control knob (7) in mounting hole (8).
(3) Install new lockwasher (6) and nut (5) on control knob (7).
(4) Route cable (3) through hole (9).
(5) Install cable (3) on pin (4).
(6) Install screw (1) on clamp (2) to secure cable (3) in clamp (2).
22-54
TM 08780B-20
END OF TASK
NOTE
TM 08780B-20 Install access panels (para 18-15),
items 3 and 23.
TM 08780B-10 Check heater control for proper operation

(para 2-1).
1. Screw
2. Clamp
3. Cable
4. Pin
5. Nut
6. Lockwasher
7. Control Knob
8. Mounting Hole
9. Hole
22-55
TM 08780B-20
22-22. TIRE WINCH CABLE REPLACEMENT

c. Installation
INITIAL SETUP
MK48
a. Removal
(1) Deploy tire winch cable (1).
(2) Remove nut (2) and clamp (3).
(3) Remove tire winch cable (1).
c. Installation
(1) Thread tire winch cable (1) over pulley (4) to winch (5).
(2) Place end of tire winch cable (1) through hole in winch (5).
(3) Loop tire winch cable (1), as shown and install in clamp (3).
(4) Install clamp (3) and nut (2). Tighten nut (2) securely.
(5) Reel in tire winch cable (1).
22-56
TM 08780B-20
1. Tire Winch Cable

2. Nut
3. Cable Clamp
4. Pulley
5. Winch
END OF TASK
22-57
TM 08780B-20
22-23. TIRE WINCH REPAIR

c. Installation

Condition Condition
MK48 TM 08780B-20 Tire winch cable
Materials/Parts
a. Removal
(1) Remove capscrews (1), washers (2), lockwashers (3) and nuts (4). Discard
lockwashers (3).
(2) Remove winch (5) from upper column (6).
(3) Remove two retaining pins (7) from clevis pins (8).
(4) Pull two clevis pins (8) out of upper column (6).
(5) Pull three sections of column assembly (9) apart and remove from vehicle.
(6) Remove retaining pin (10), washer (11) and clevis pin (12).
(7) Remove nut (13), spacer (14), pulley (15), three washers (16) and
capscrew (17).
c. Installation
(1) Install pulley (15), spacer (14), three washers (16), capscrew (17) and nut
(13). Tighten capscrew (17) and nut (13) securely.
(2) Install clevis pin (12), washer (11) and retaining pin (10).
22-58
TM 08780B-20
(3) Install three sections of column assembly (9) on vehicle.
(4) Install two pins (8) into upper column (6).
(5) Install two retaining pins (7).
(6) Install winch (5), four capscrews (1), washers (2), new lockwashers (3)
and nuts (4). Tighten capscrews (1) and nuts (4) securely.
END OF TASK
NOTE
TM 08780B-20 Install tire winch cable (para 22-22).
22-59
TM 08780B-20
1. Capscrew (3)
2. Washer (3)
3. Lockwasher (3)
4. Nut (3)
5. Winch
6. Upper Column
7. Retaining Pin (2)
8. Clevis Pin (2)
9. Column Assembly
10. Retaining Pin
11. Washer
12. Clevis Pin
13. Nut
14. Spacer
15. Pulley
16. Washer (3)
17. Capscrew
22-60
TM 08780B-20
CHAPTER 23
HYDRAULIC SYSTEM
maintenance and replacement procedures for the vehicle's hydraulic system.
a. General Description. The hydraulic system consists of an engine-driven tandem

pump, an oil reservoir with filter, a power steering gear, two yaw cylinders and controlling
valves as described below.
b. Reservoir. A holding tank for hydraulic fluid - to supply the hydraulic system.
c. Oil Filter. A six micron oil straining device. Removes small impurities for longer
system life.
d. Auxiliary Hydraulic Selector Valve. Directs oil supply to either auxiliary

hydraulics or the yaw steering valve.
23-1
TM 08780B-20
e. Oil Cooler. Cools oil to minimize excessive heat buildup in the hydraulic system.
This will prolong the life of both the oil and the system components.
f. Hydraulic Fan Motor. Draws air through the radiator to control engine water,
transmission oil and hydraulic oil temperatures.
g. Pressure Relief Valve. Relieves oil flow to tank to limit system pressure.
23-2
TM 08780B-20
h. Tandem Hydraulic Pump. Two pumps in one housing with a common inlet port,
supplying two outlets with different volumes of oil.
i. Demand Valve. Divides oil flow to the fan motor or steering/auxiliary hydraulic
system upon demand.
j. Steering Gear. Converts hydraulic pressure to rotational motion for steering the
vehicle.
23-3
TM 08780B-20
k. Motion Control Valve. Prevents motion of the yaw cylinders when the yaw
control valve is in the neutral position, thereby preventing road wander.
l. Yaw Cylinders. Steer the rear module through hydraulic pressure.
23-4
TM 08780B-20
m. Priority Flow Valve. Divides oil flow between steering gear and demand valve.
n. Yaw Control Valve. Flow directional valve that controls the yaw cylinders.
o. Accumulator. Absorbs pressure spikes when steering the vehicle.
p. High Pressure Filter. A high pressure straining device. Removes small impurities
for longer system life.
23-5
TM 08780B-20
23-3. HYDRAULIC SYSTEM SERVICE
THIS TASK COVERS: a. Hydraulic Oil Change

b. Hydraulic System Clean Up
c. Adjust Auxiliary Selector Relief Valve
INITIAL SETUP

Test Equipment parts before disassembly and work in a
Pressure test kit (S111-25-3238) clean area.
Pressure test kit (S111-25-2851)
Hydraulic oil (AR) (item 34, Appendix D) injury.
O-ring (FF9446-232) item 12
Personnel Required
1 MOS 3521
1 Assistant
a. Hydraulic Oil Change
NOTE
Place a container to catch hydraulic oil before disconnecting hydraulic lines or removing
fittings.
(1) Remove plug (1) from bottom of reservoir (2).
(2) Drain hydraulic oil from reservoir (2).
(3) Remove filler cap (3) from filler neck (4).
NOTE
(4) Remove filler cap and dipstick (3.1) from filler neck (4).
(5) After all hydraulic oil has drained from reservoir (2) replace plug (1).
(6) Replace hydraulic oil in reservoir (2). Fill to level line in sight glass (5).
23-6
TM 08780B-20
(7) Replace filler cap (3) on filler neck (4).
NOTE
(8) Replace filler cap and dipstick (3.1) on filler neck (4).
(9) Replace hydraulic oil filter. Refer to paragraph 23-6 of this manual.
1. Plug
2. Reservoir
3. Filler Cap
3.1. Filler Cap And Dipstick*
4. Filler Neck
5. Sight Glass
23-7
TM 08780B-20
b. Hydraulic System Clean Up
NOTE
Place a container to catch hydraulic oil before disconnecting hydraulic lines or fittings.
(1) Remove plug (1) from bottom of reservoir (2).
(2) Drain hydraulic oil from reservoir (2).
(3) Remove access panel. Refer to paragraph 18-15, item 23 of this manual.
(4) Remove four capscrews (7), lockwashers (8), two split flanges (9) and
pump supply line (10) from tandem pump (11). Discard lockwashers (8) and O-ring (12).
(5) Remove 12 locknuts (13), access cover (14) and gasket (15) from reservoir
(2). Discard locknuts (13). Inspect gasket (15) for rips or tears. Replace gasket (15) as needed.
(6) Replace hydraulic oil filter. Refer to paragraph 23-6 of this manual.
1. Plug
2. Reservoir
13. Locknut (12)
14. Access Cover
15. Gasket
23-8
TM 08780B-20
(7) Using clean, lint free rags, wipe inside of reservoir (2) clean.
NOTE
Place container under pump supply line (10) to catch hydraulic oil.
(8) Using clean hydraulic oil, flush reservoir (2) down through pump supply
line (10) until all visible debris has been removed.
(9) Secure pump supply line (10) to tandem pump (11) with new O-ring (12),
two split flanges (9), four capscrews (7) and new lockwashers (8).
(10) Position gasket (15) and access cover (14) to reservoir (2).
(11) Secure access cover (14) to reservoir (2) with 12 new locknuts (13).
(12) Install plug (1) in bottom of reservoir (2).
(13) Fill reservoir (2) with clean hydraulic oil to fill level.
(14) Start engine to cycle hydraulic oil. Refer to paragraph 2-13

(TM 08780B-10).
(15) Replace hydraulic oil filter as often as needed. Refer to paragraph 23-6 in
this manual.
(16) Replace access panel. Refer to paragraph 18-15, item 23 of this manual.
7. Capscrew (4)
8. Lockwasher (4)
9. Split Flange (2)
10. Pump Supply Line
11. Tandem Pump
12. O-Ring
23-9
TM 08780B-20
c. Adjust Auxiliary Selector Relief Valve
WARNING
ALL CONNECTING OR DISCONNECTING OF HYDRAULIC LINES OR TEST

EQUIPMENT MUST BE DONE WITH ENGINE TURNED OFF. RUN ENGINE ONLY
WHILE PERFORMING TEST NEEDED. AT ALL OTHER TIMES, SHUT ENGINE
DOWN TO AVOID PERSONAL INJURY OR SERIOUS DAMAGE TO EQUIPMENT.
(1) Disconnect quick coupler (16) of auxiliary lines to trailer.
CAUTION
MAKE SURE SELECTOR VALVE LEVER (21) IS PUSHED IN TO THE STEERING

POSITION BEFORE STARTING ENGINE.
NOTE
All quick couplers (16, 17 and 18) may be disconnected. To perform the following task,
however, only quick coupler (16) needs to be disconnected.
(2) Install gauge (19) to test port (20).
(3) Start engine. Refer to paragraph 2-13 (TM 08780B-10). Allow hydraulic
oil to warm up to operating temperature.
16. Quick Coupler

17. Quick Coupler
18. Quick Coupler
23-10
TM 08780B-20
CAUTION
• Engine must be tuned and low idle set at 690 rpm before starting test. If low idle is
higher than 690 rpm, refer unit out to third echelon maintenance. Attempting to go
further will cause parts damage.
• When performing step (4), do not hold selector valve lever (21) in the AUXILIARY
HYDRAULICS position for more than 15 to 20 seconds. While adjusting or testing the
auxiliary selector relief valve do not hold auxiliary selector valve lever (21) in the
AUXILIARY HYDRAULICS position if pressure is above 3,250 psi. Serious damage
will result to the tandem pump if pressure is above the recommended relief setting or
held for a longer length of time at lower pressures.
(4) Position yourself to read gauge (19) as assistant pulls selector valve lever
(21) OUT to the AUXILIARY HYDRAULICS position. This should be 3,150-3,250 psi. If
reading falls above or below this range, the auxiliary selector relief valve (22) must be adjusted.
Adjust pressure as follows:
(a) Loosen jam nut (23) on auxiliary selector relief valve (22).
(b) Turn set screw (24) clockwise to increase pressure or

counterclockwise to decrease pressure settings as needed.
19. Gauge 22. Auxiliary Selector Relief Valve

20. Test Port 23. Jam Nut
21. Auxiliary Selector Valve Lever 24. Set Screw
23-11
TM 08780B-20
(7) Repeat step (4) until pressure setting is within limits.
(8) Lock set screw (24) with jam nut (23).
(9) Repeat step (4) to assure setting has not changed.
WARNING
ENGINE MUST BE SHUT DOWN TO DISCONNECT OR CONNECT HYDRAULIC

LINES.
(10) Remove gauge (19) from test port (20).
(11) Connect quick coupler (16) of auxiliary lines to trailer.
NOTE
If pressure exists in line of quick coupler, wait several minutes for pressure to bleed before
connecting. If after several minutes the pressure is still present, it will be necessary to crack
line (25) open at auxiliary selector valve.
16. Quick Coupler
23-12
TM 08780B-20
19. Gauge
20. Test Port
21. Selector Valve Lever
23. Jam Nut
24. Set Screw
25. Line
END OF TASK
23-13
TM 08780B-20
23-4. SELECTOR VALVE REPLACEMENT

b. Disassembly
d. Assembly
e. Installation
INITIAL SETUP

Lockwashers (4) (NSN) items 6 and 12 clean area.
O-ring (2) (NSN 5330-01-168-0885)
O-ring (NSN 5330-00-228-7196) item 21 Block wheels of truck to prevent personal
O-ring (NSN 5330-01-190-0294) item 22 injury.
a. Removal
NOTE
When disconnecting hydraulic lines, a container is needed to catch hydraulic fluid.
(1) Tag and disconnect four hydraulic lines (1, 2, 3 and 4).
(2) Remove three nuts (5) and lockwashers (6) from below fender (7).
(3) Lift selector valve (8) and remove three capscrews (9) and flat washers
(10).
23-14
TM 08780B-20
1. Hydraulic Line 6. Lockwasher (3) 11. Capscrew

2. Hydraulic Line 7. Fender 12. Lockwasher
3. Hydraulic Line 8. Selector Valve 13. Flat Washer
4. Hydraulic Line 9. Capscrew (3) 14. Bracket
5. Nut (3) 10. Flat Washer (3)
(4) Remove capscrews (11), lockwasher (12), flatwasher (13) and bracket (14)
from selector valve (8). Discard lockwasher (12).
(5) Remove selector valve (8) from fender (7).
b. Disassembly
(1) Tag and remove four fittings (15, 16, 17 and 18) from selector valve (8).
(2) Remove four O-rings (19, 20, 21 and 22) from fittings (15, 16, 17 and 18).
Discard O-rings (19, 20, 21 and 22).
d. Assembly
(1) Install four new O-rings (19, 20, 21 and 22) onto fittings (15, 16, 17 and
18).
23-15
TM 08780B-20
(2) Install four fittings (15, 16,17 and 18) into selector valve (8) as tagged.
Tighten securely.
e. Installation
(1) Position bracket (14) to selector valve (8). Secure bracket (14) to selector
valve (8) with capscrew (11), flat washer (13) and new lockwasher (12). Tighten securely.
(2) Position selector valve (8) on fender (7) with three capscrews (9) and flat
washers (10).
(3) Secure selector valve (8) to fender (7) with three new lockwashers (6) and
(4) Connect four hydraulic lines (1, 2, 3 and 4) to fittings (15, 16, 17 and 18)
as tagged. Tighten securely.
END OF TASK
NOTE
TM 08780B-20 Replace lost hydraulic fluid (para 23-3).
Adjust auxiliary selector relief valve

(para 23-3).

LO 9-2320-297-12
8. Selector Valve
15. Fitting
16. Fitting
17. Fitting
18. Fitting
19. O-Ring
20. O-Ring
21. O-Ring
22. O-Ring
23-16
TM 08780B-20
23-5. YAW CONTROL VALVE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Wheels straight
(para 15-17).
Materials/Parts
Cotter pin (MS24665-360) item 6 Fuse link assembly
Special Environmental Conditions

Cleanliness is extremely important when
area.

Block front and rear tires to prevent personal
injury.
a. Removal
WARNING
LINES.
NOTE
All lines must be plugged quickly as they are removed to prevent loss of hydraulic fluid.
(1) Tag hydraulic lines (1, 2, 3 and 4) so that they can be installed in same
position as removed.
(2) Place container under yaw control valve (5) to catch hydraulic fluid.
(3) Remove and plug line (1).
(4) Remove and plug three lines (2, 3 and 4).
(5) Remove cotter pin (6) from ball stud (7). Discard cotter pin (6).
23-17
TM 08780B-20
(6) Remove castle nut (8).
(7) Remove yaw control valve (5) from bell crank (9).
(8) Remove three nipples (10, 11 and 12) from yaw control valve (5).
(9) Remove elbow (13) from yaw control valve (5).
(2) Inspect all parts for wear or damage. Refer to paragraph 2-12.
c. Installation
(1) Install elbow (13) in yaw control valve (5). Tighten securely.
(2) Install three nipples (10, 11 and 12) into yaw control valve (5). Tighten
securely.
(3) Insert ball stud (7) through bellcrank (9) from chassis side.
(4) Install castle nut (8) and torque to 185-200 foot-pounds (250-271 N*m).
(5) Install new cotter pin (6). Do not back off castle nut (8) to align hole for
cotter pin (6). Tighten castle nut (8) further if necessary.
(6) Remove plug and install line (4) on yaw control valve (5). Tighten
securely.
securely.
securely.
securely.
END OF TASK
23-18
TM 08780B-20
NOTE
TM 08780B-20 Install fuse link assembly (para 15-15).
LI 2320-1219 Check hydraulic oil level.

LO 9-2320-297-12
1. Line
2. Line
3. Line
4. Line
5. Yaw Control
Valve
6. Cotter Pin
7. Ball Stud
8. Castle Nut
9. Bell Crank
10. Nipple
11. Nipple
12. Nipple
13. Elbow
23-19
TM 08780B-20
23-6. HYDRAULIC FILTER REPLACEMENT

c. Installation
INITIAL SETUP

Seal ring (1199479) item 3 clean area.
Oil filter (145744C FSCM 45152) item 6
References Block wheels of truck to prevent personal
TM 08780B-10 injury.
a. Removal
(1) Loosen six capscrews (1).
WARNING
COVER (2) IS UNDER SPRING PRESSURE. REMOVE WITH CARE TO PREVENT

PERSONAL INJURY.
(2) Turn cover (2) counterclockwise and remove.
(3) Remove and discard seal ring (3).
(4) Remove spring (4) and by-pass manifold (5).
(5) Remove oil filter (6) with two O-rings (7) from oil filter housing (8).
Discard oil filter (6) and O-rings (7).
23-20
TM 08780B-20
c. Installation
(1) Position two new O-rings (7) on new oil filter (6).
(2) Install oil filter (6) into oil filter housing (8).
(3) Install by-pass manifold (5) with spring (4) over oil filter (6).
(4) Install new seal ring (3) into cover (2).
(5) Position cover (2) onto oil filter housing (8). Depress cover (2) and turn
clockwise to latch cover (2) on capscrews (1).
(6) Tighten six capscrews (1) securely.
NOTE
If STE/ICE is not available, use of a 0-100 psi gauge is required. Install gauge at quick
disconnect fitting on filter housing.
(7) Remove plug (9) from filter housing (8). Connect blue STE/ICE
transducer (10) to port. With vehicle power OFF, perform transducer calibration test using test
0050, then re-enter test 0050. Refer to Chapter 2, paragraph 2-6 in this manual for general
STE/ICE operating instructions.
(8) Start engine to cycle hydraulic oil. Refer to operators manual

(TM 2320-20/11B), paragraph 2-13.
(9) Allow hydraulic oil temperature to reach 130° - 140°F (54°C - 60°C).
Shut down engine.
(10) With vehicle power OFF, perform transducer calibration test again, using
test 0050.
(11) Start engine and increase engine speed to maximum and record reading.
(a) If pressure reading is 12 psi (83 kPa) or less, oil filter (6) is clean
and operating correctly.
NOTE
If the hydraulic oil is excessively contaminated, it may be necessary to replace the hydraulic
filter more than once to insure the hydraulic oil pressure is not over 20 psi (138 kPa).
(b) If pressure reading is more than 20 psi (138 kPa) replace oil filter
(6).
23-21
TM 08780B-20
(c) If pressure reading is between 13 psi (90 kPa) and 20 psi (138 kPa)
perform steps (d) through (f) below.
CAUTION
TO PREVENT SERIOUS ENGINE DAMAGE, DO NOT ALLOW ENGINE TO RUN AT

MAXIMUM SPEED FOR OVER 3 MINUTES.
(d) Increase engine speed to maximum and allow to run for 3 minutes.
(e) Reduce engine speed to approximately 1,500 rpm for 7 minutes.
(f) Increase engine speed briefly to maximum and read hydraulic oil
pressure. If pressure reading is greater than 12 psi (83 kPa) replace oil filter (6) and repeat steps
C.1-11 until hydraulic oil pressure is 12 psi (83 kPa) or less.
(12) If STE/ICE was used, remove STE/ICE transducer (10) from oil filter
housing (8).
(13) Install plug (9) and tighten securely.
(14) If gauge was used, remove gauge and replace dust cap at quick disconnect.
END OF TASK
23-22
TM 08780B-20
1. Capscrew (6)
2. Cover
3. Seal Ring
4. Spring
5. Bypass Manifold
6. Oil Filter
7. O-Ring (2)
8. Oil Filter Housing
9. Plug
10. STE/ICE Transducer
23-23
TM 08780B-20
23-7. HYDRAULIC FILTER REPLACEMENT (LVSA1 SERIES VEHICLES

ONLY)

c. Installation
INITIAL SETUP

MK48A1 Cleanliness is extremely important when
working on hydraulic equipment. Clean
Materials/Parts all parts before disassembly and work in a
Capscrew with captive clean area.
Lockwasher (4) (LFT-1138) item 1
Oil filter (G1397) item 4 General Safety Instructions
O-ring (LFT-908)item 3 Block wheels of truck to prevent personal
Pipe sealant (item 48, Appendix D) injury.
References
TM 08780B-10
a. Removal
WARNING
COVER ASSEMBLY (2) IS UNDER SPRING PRESSURE. REMOVE WITH CARE TO

PREVENT PERSONAL INJURY.
CAUTION
HYDRAULIC OIL FILTERS ARE NOT INTERCHANGEABLE. WHEN REPLACING

FILTER ON A1 VEHICLES, NEW STYLE FILTER MUST BE USED. FAILURE TO
COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT.
(1) Remove four capscrews with captive lockwashers (1) and cover assembly
(2). Discard four capscrews with captive lockwashers (1).
23-24
TM 08780B-20
(2) Inspect all parts for damage. Refer to 2-12.
c. Installation
(3) Install new O-ring (3) on cover assembly (2).
(4) Position cover assembly (2) onto oil filter housing (6). While depressing
cap (3) install four capscrews with captive lockwashers (1).
(5) Tighten four capscrews (1) securely.
NOTE
If STE/ICE is not available, use of a 0-100 psi gauge is required. Install gauge at quick
disconnect fitting on filter housing.
(6) Remove oil sampling valve (7) from filter housing (6). Connect blue
STE/ICE transducer (8) to port. With vehicle power OFF, perform transducer calibration test
using test 0050, then re-enter test 0050. Refer to Chapter 2, paragraph 2-6 in this manual for
general STE/ICE operating instructions.
(7) Start engine to cycle hydraulic oil. Refer to operators manual

(TM 08780B-10), paragraph 2-13.
(8) Allow hydraulic oil temperature to reach 130°-140° F (54°C - 60°). Shut
down engine.
(9) With vehicle power OFF, perform transducer calibration test again, using
test 0050.
(10) Start engine and increase engine speed to maximum and record reading.
(a) If pressure reading is 12 psi (83 kPa) or less, oil filter (4) is clean
and operating correctly.
NOTE
If the hydraulic oil is excessively contaminated, it may be necessary to replace the hydraulic
filter more than once to insure the hydraulic oil pressure is not over 20 psi (138 kPa).
23-25
TM 08780B-20
(b) If pressure reading is more than 20 psi (138 kPa) replace oil filter
(4).
(c) If pressure reading is between 13 psi (90 kPa) and 20 psi (138 kPa)
perform steps (d) through (f) below.
CAUTION
TO PREVENT SERIOUS ENGINE DAMAGE, DO NOT ALLOW ENGINE TO RUN AT

MAXIMUM SPEED FOR OVER 3 MINUTES.
(d) Increase engine speed to maximum and allow to run for 3 minutes.
(e) Reduce engine speed to approximately 1,500 rpm for 7 minutes.
(f) Increase engine speed briefly to maximum and read hydraulic oil
pressure. If pressure reading is greater than 12 psi (83 kPa) replace oil filter (4) and repeat steps
C.1-11 until hydraulic oil pressure is 12 psi (83 kPa) or less.
(11) If STE/ICE was used, remove STE/ICE transducer (8) from oil filter
housing (6).
(12) Coat threads of ail sampling valve (7) with pipe sealant and install.
Tighten securely.
(13) If gauge was used, remove gauge and replace dust cap at quick disconnect.
END OF TASK
NOTE
TM 08780B-20 Replace high pressure hydraulic filters
(para 23-20 and 23-21).
23-26
TM 08780B-20
1. Capscrew with
Captive Lockwasher
2. Cover Assembly
3 O-Ring
4 Oil Filter
5. O-Ring (2)
8. STE/ICE Transducer
23-27
TM 08780B-20
23-8. YAW CYLINDER REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-10 Locking strut
installed (para 2-15).

working with hydraulic equipment. Clean
all parts before disassembly and work in a
clean area.

injury.
a. Removal
WARNING
LINES.
NOTE
• Steps are the same for the left or the right yaw cylinder.
• Lines must be plugged quickly to prevent loss of hydraulic fluid. You will need to have
plugs for lines within reach as you disconnect them.
(1) Tag hydraulic lines (1 and 2) so they can be installed in same position as
removed.
(2) Place container under yaw cylinder (3) to catch hydraulic fluid.
(3) Remove nylon tie and loosen and remove line (1). Plug line (1) to prevent
loss of hydraulic fluid.
(4) Loosen and remove line (2). Plug line (2).
23-28
TM 08780B-20
(5) Remove two cotter pins (4), one from each end.
(6) Remove two castle nuts (5) and washers (6), one from each end.
(7) Remove two yaw cylinder pins (7), one from each end and remove yaw
cylinder (3).
(8) Remove nipple (8), plug (9) and elbow (10) from yaw cylinder (3).
NOTE
Perform step (9) for LVSA1 series vehicles only, with black surfaced cylinder rod.
(9) Remove nipple (8) and elbow (10) from yaw cylinder (3).
(10) Remove four bushings (11) if needed.
(11) Remove two grease fittings (12) from yaw cylinder (3).
WARNING
BE SURE TO WEAR SAFETY GLASSES WHEN SERVICING HYDRAULIC SYSTEM.
c. Installation
(1) If removed, install four new bushings (11).
(2) Install elbow (10), plug (9) and nipple (8) into yaw cylinder (3).
NOTE
Perform step (3) for LVSA1 series vehicles only, with black surfaced cylinder rod.
(3) Install elbow (10) and nipple (8) into yaw cylinder (3).
(4) Extend yaw cylinder (3) to length needed for installation.
(5) Install yaw cylinder (3) with main body towards front of unit.
23-29
TM 08780B-20
(6) Secure yaw cylinder (3) with two yaw cylinder pins (7).
(7) Install two washers (6) and castle nuts (5) on yaw cylinder pins (7).
Secure tightly.
(8) Install two new cotter pins (4).
NOTE
Lines must be connected quickly after removing plugs to prevent loss of fluid.
(9) Remove plug from line (2) and quickly connect line (2) to nipple (8) so as
not to lose hydraulic fluid.
(10) Remove plug from line (1) and quickly connect line (1) to elbow (10).
Install nylon tie.
(11) Install two grease fittings (12) on yaw cylinder (3).
END OF TASK
NOTE
LO 9-2320-297-12
TM 08780B-10 Stow locking strut (para 2-15).
1. Line 5. Castle Nut (2) 9. Plug*

2. Line 6. Washer (2) 10. Elbow
3. Yaw Cylinder 7. Yaw Cylinder Pin (2) 11. Bushing (4)
4. Cotter Pin (2) 8. Nipple 12. Grease Fitting (2)
* Deleted On LVSA1 Series Vehicles Only
23-30
TM 08780B-20
23-9. HYDRAULIC RESERVOIR REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Muffler removed
(para 5-3).
Materials/Parts
Lockwasher (6) (MS35338-46) items 3 and 12 Access panel
Lockwasher (MS35338-43) item 20 removed (para 18-15).
Personnel Required Hydraulic oil

1 MOS 3521 drained (para 23-3).
1 Assistant
Hydraulic oil level
gauge removed (para
23-10).
Hydraulic oil filter

housing removed
(para 23-12).

area.

injury.
a. Removal
(1) Remove two capscrews (1), nuts (2) and lockwashers (3). Discard
lockwashers (3).
(2) Push manifold (4) back and away from reservoir (5). Tie manifold (4) out
of the way. Remove hydraulic line (6).
(3) Cut nylon ties (7) as necessary. Disconnect plug (8). Remove sending
unit (9) from reservoir (5).
23-31
TM 08780B-20
(4) Remove four capscrews (10), nuts (11), lockwashers (12) and one ground
wire (13). Discard lockwashers (12).
(5) Tie engine oil fill tube (14) out of the way.
(6) Remove hydraulic oil supply line (15), adapter (16), elbow (17) and elbow
(18).
(7) Remove nut (19), lockwasher (20), wire (21) and sending unit (22).
1. Capscrew (2)
2. Nut (2)
3. Lockwasher (2)
4. Manifold
5. Reservoir
6. Hydraulic Line
7. Nylon Ties
8. Plug
9. Sending Unit
10. Capscrew (4)
11. Nut (4)
12. Lockwasher (4)
13. Ground Wire
14. Engine Oil Fill Tube
15. Hydraulic Oil
Supply Line
16. Adapter
17. Elbow
18. Elbow
19. Nut
20. Lockwasher
21. Wire
22. Sending Unit
23-32
TM 08780B-20
(8) With assistant at one end, lift and remove reservoir (5) from vehicle.
c. Installation
(1) Apply pipe sealant to two elbows (17 and 18). Install two elbows (17 and
18) into reservoir (5). Install adapter (16) into elbow (17).
(2) With help from assistant, place reservoir (5) into position.
NOTE
It will be necessary for assistant working through access opening in cab to position wrench
while mechanic working between cab and hydraulic reservoir turns wrench to install
hydraulic oil supply line.
(3) Connect hydraulic oil supply line (15) to adapter (16). Connect hydraulic
line (6) to elbow (18). Tighten securely.
(4) Coat threads of sending unit (22) with pipe sealant and install into
reservoir (5). Tighten securely.
(5) Connect wire (21) with new lockwasher (20) and nut (19). Tighten nut
(19) securely.
CAUTION
DO NOT TIGHTEN SENDING UNIT (9) ABOVE 15 FOOT-POUNDS (20.34 N*M).
(6) Install sending unit (9) into reservoir (5). Torque to 15 foot-pounds (20.34
N*m).
(7) Place engine oil fill tube (14) into position.
(8) Secure reservoir (5), engine oil fill tube (14) and ground wire, using four
capscrews (10), new lockwashers (12) and nuts (11). Tighten nuts (11) securely.
(9) Install manifold (4) onto reservoir (5) using two capscrews (1), new
23-33
TM 08780B-20
END OF TASK
NOTE
TM 08780B-20 Install hydraulic oil filter housing
(para 23-12).
Install hydraulic oil level gauge

(para 23-10).
Install access panel (para 18-15).
Install muffler (para 5-3).
LI 2320-12/9 Replace hydraulic oil.

LO 9-2320-297-12
TM 08780B-10 Start engine and check hydraulic system for

proper operation and leaks (para 2-13).
23-34
TM 08780B-20
1. Capscrew (2)
2. Nut (2)
3. Lockwasher (2)
4. Manifold
5. Reservoir
6. Hydraulic Line
7. Nylon Ties
8. Plug
9. Sending Unit
10. Capscrew (4)
11. Nut (4)
12. Lockwasher (4)
13. Ground Wire
14. Engine Oil Fill
Tube
15. Hydraulic Oil
Supply Line
16. Adapter
17. Elbow
18. Elbow
19. Nut
20. Lockwasher
21. Wire
22. Sending Unit
23-35
TM 08780B-20
23-10. HYDRAULIC OIL LEVEL GAUGE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-20 Hydraulic oil
drained (para 23-3).
Materials/Parts
Self-locking nut (12) (MS35338-44) item 1 Special Environmental Conditions
O-ring (2) (NSN 5330-01-155-4277) item 7 Cleanliness is extremely important when
area.

injury.
a. Removal
(1) Remove 12 self-locking nuts (1). Discard self-locking nuts (1).
(2) Remove access plate (2) with filler neck (3).
(3) Remove gasket (4) carefully and save.
(4) Remove two nuts (5) through access hole.
(5) Remove hydraulic oil level gauge (6) with two O-rings (7). Discard O-
rings (7).
(2) Inspect hydraulic oil level gauge (6) for breaks or leaks.
(3) Inspect gasket (4) for condition.
23-36
TM 08780B-20
c. Installation
(1) Position hydraulic oil level gauge (6) with two new O-rings (7) into
reservoir (8).
(2) Secure hydraulic oil level gauge (6) with two nuts (5). Tighten securely.
(3) Install gasket (4).
(4) Position access plate (2) so that filler neck (3) is at the front of reservoir
(8).
(5) Secure access plate (2) with 12 new self-locking nuts (1). Tighten
securely.
END OF TASK
NOTE
TM 08780B-20 Replace hydraulic oil and check for leaks
(para 23-3).
23-37
TM 08780B-20
1. Self-Locking Nut (12) 5. Nut (2)

2. Access Plate 6. Hydraulic Oil Level Gauge
3. Filler Neck 7. O-Ring (2)
4. Gasket 8. Reservoir
23-38
TM 08780B-20
23-11. HYDRAULIC OIL COOLER REPLACEMENT


Condition Condition
MK48 TM 08780B-20 Radiator grille
removed (para 6-4).
Materials/Parts
Lockwasher (4) (MS35338-46) item 5 Special Environmental Conditions
O-ring (NSN 5330-00-228-7196) Cleanliness is extremely important when
items 10 and 12 working on hydraulic equipment. Clean all
Personnel Required area.
1 MOS 3521
1 Assistant General Safety Instructions
injury.
NOTE
When disconnecting hydraulic lines, a container is needed to catch hydraulic fluid.
(1) Disconnect hydraulic line (1).
(2) Disconnect hydraulic line (2).
(3) Remove four capscrews (3), nuts (4), lockwashers (5) and eight flat
washers (6). Discard lockwashers (5).
(4) With assistant helping at one side of oil cooler (7), lift and remove oil
cooler (7) from mounting brackets (8).
(5) Remove elbow (9). Discard O-ring (10).
(6) Remove elbow (11). Discard O-ring (12).
23-39
TM 08780B-20
(1) Install elbow (11) with new O-ring (12) into oil cooler (7). Tighten
securely.
(2) Install elbow (9) with new O-ring (10) into oil cooler (7). Tighten
securely.
(3) With help from assistant, position oil cooler (7) onto mounting bracket (8).
(4) Secure oil cooler (7) to mounting brackets (8) with four capscrews (3),
eight flat washers (6), four new lockwashers (5) and nuts (4). Tighten securely.
(5) Connect two hydraulic lines (1 and 2). Tighten securely.
END OF TASK
NOTE
TM 08780B-20 Replace radiator grille (para 6-4).

LO 9-2320-297-12
23-40
TM 08780B-20
1. Hydraulic Line 5. Lockwasher (4) 9. Elbow

2. Hydraulic Line 6. Flat Washer (8) 10. O-Ring
3. Capscrew (4) 7. Oil Cooler 11. Elbow
4. Nut (4) 8. Mounting Bracket (2) 12. O-Ring
23-41
TM 08780B-20
23-12. HYDRAULIC OIL FILTER HOUSING MAINTENANCE

b. Disassembly
d. Assembly
e. Installation
INITIAL SETUP

Pipe sealant (item 48, Appendix D) clean area.
O-ring (NSN 5330-00-228-7196) items 6 and 7
Gasket (1199478) item 11 Block wheels of truck to prevent personal
Oil filter (145744C FSCM 45152) item 17 injury.
O-ring (NSN 5330-01-155-4277) item 22
a. Removal
NOTE
The hydraulic oil filter housing (1) can be disassembled without removing it from the
reservoir. Perform only tasks needed.
(2) Remove two adapters (4 and 5).
(3) Remove and discard two O-rings (6 and 7).
23-42
TM 08780B-20
1. Oil Filter Housing 5. Adapter

2. Hydraulic Line 6. O-Ring
4. Adapter

8. Nut (4)
9. Lockwasher (4)
10. Reservoir
11. Gasket
23-43
TM 08780B-20
(4) Remove four nuts (8) and lockwashers (9). Discard lockwashers (9).
(5) Remove oil filter housing (1) from reservoir (10).
b. Disassembly
(1) Loosen six capscrews (12).
WARNING
COVER (13) IS UNDER SPRING PRESSURE. REMOVE WITH CARE TO PREVENT

PERSONAL INJURY.
(2) Turn cover (13) counterclockwise and remove.
(3) Remove seal ring (14).
(4) Remove spring (15) and by-pass manifold (16).
(6) Remove plug (19).
(7) Remove pressure check valve (20), protective cap (21) and O-ring (22).
(3) Inspect seal ring (14) for wear or damage.
23-44
TM 08780B-20

12. Capscrew (6)
13. Cover
14. Seal Ring
15. Spring
16. By-Pass Valve
17. Oil Filter
18. O-Ring (2)
19. Plug
20. Pressure Check Valve
21. Protective Cap
22. O-Ring
d. Assembly
(1) Install pressure check valve (20) with new O-ring (22) and protective cap
(2) Coat threads of plug (19) with pipe sealant and install. Tighten securely.
(5) Install by-pass manifold (16) with spring (15) over oil filter (17).
(6) Install seal ring (14) into cover (13).
(7) Position cover (13) onto oil filter housing (1). Depress cover (13) and turn
clockwise to latch cover (13) on capscrews (12).
(8) Tighten six capscrews (12) securely.
23-45
TM 08780B-20
1. Oil Filter Housing 15. Spring 19. Plug

12. Capscrew (6) 16. By-Pass Valve 20. Pressure Check Valve
13. Cover 17. Oil Filter 21. Protective Cap
14. Seal Ring 18. O-Ring (2) 22. O-Ring

8. Nut (4)
9. Lockwasher (4)
10. Reservoir
11. Gasket
23-46
TM 08780B-20
e. Installation
(1) Place new gasket (11) in position on reservoir (10).
(2) Install oil filter housing (1) onto reservoir (10) so that plug (19) and
pressure check valve (20) face right side of vehicle.
(3) Secure oil filter housing (1) with four new lockwashers (9) and nuts (8).
(4) Install two new O-rings (6 and 7) on adapters (4 and 5).
(5) Install two adapters (4 and 5) into oil filter housing (1). Tighten securely.
(6) Connect two hydraulic lines (2 and 3) in tagged locations. Tighten

securely.
END OF TASK
NOTE
LO 9-2320-297-12
1. Oil Filter Housing 4. Adapter 6. O-Ring

2. Hydraulic Line 5. Adapter 7. O-Ring
3. Hydraulic Line
23-47
TM 08780B-20
23-13. HYDRAULIC FILTER HOUSING MAINTENANCE (LVSA1 SERIES

VEHICLES ONLY)

b. Disassembly
d. Assembly
e. Installation
INITIAL SETUP

MK48A1 Cleanliness is extremely important when
Capscrew with captive clean area.
Lockwasher (4) (LFT-1138) item 12
Gasket (LFT 642) General Safety Instructions
Adhesive (item 3, Appendix D) Block wheels of truck to prevent personal
Pipe sealant (item 48, Appendix D) injury.
Oil filter (G1397) item 18
O-ring (2) (NSN 5330-00-228-7196) items 6 and 7
O-ring (LFT-908) item 14
O-ring (NSN 503-01-155-4277) item 23
a. Removal
NOTE
The hydraulic oil filter housing (1) can be disassembled without removing it from the
reservoir. Perform only tasks needed.
(1) Disconnect two hydraulic lines (2 and 3).
(2) Remove two adapters (4 and 5).
(3) Remove and discard two O-rings (6 and 7).
23-48
TM 08780B-20

2. Hydraulic Line
3. Hydraulic Line
4. Adapter
5. Adapter
6. O-Ring
7. O-Ring

8. Nut (4)
9. Lockwasher (4)
10. Reservoir
11. Gasket
(4) Remove four nuts (8) and lockwashers (9). Discard lockwashers (9).
(5) Remove oil filter housing (1) from reservoir (10).
23-49
TM 08780B-20
b. Disassembly
WARNING
COVER ASSEMBLY (13) IS UNDER SPRING PRESSURE. REMOVE WITH CARE TO

(1) Remove four capscrews with captive lockwashers (12) and cover
assembly (13). Discard four capscrews with captive lockwashers (12).
WARNING
BY-PASS VALVE (16) IS UNDER SPRING PRESSURE. REMOVE WITH CARE TO

(3) Remove three capscrews (15), by-pass valve (16) and spring (17) from
cover assembly (13).
(5) Remove oil sampling valve (20).
(6) Remove pressure check valve (21), protective cap (22) and O-ring (23).

12. Capscrew With
Captive Lockwasher (4)
13. Cover Assembly
14. O-Ring
15. Capscrew (3)
16. By-Pass Valve
17. Spring
18. Oil Filter
19. O-Ring (2)
22. Cap
23. O-Ring
23-50
TM 08780B-20
d. Assembly
(1) Install new O-ring (23), pressure check valve (21) and protective cap (22).
Tighten securely.
(2) Coat threads of oil sampling valve (20) with pipe sealant and install.
Tighten securely.
(3) Install new oil filter (18) with two new O-rings (19) in oil filter housing
(1).
(4) Coat threads of three capscrews (15) with adhesive.
(5) Position spring (17) and by-pass valve (16) on cover assembly (13).
While depressing by-pass valve (16) and spring (17) install three capscrews (15). Torque
capscrews to 9 foot-pounds (12 N*m).
(6) Install new O-ring (14) in cover assembly (13).
(7) Position cover assembly (13) onto oil filter housing (1). While depressing
cover assembly (13) install four new capscrews with captive lockwashers (12). Tighten
capscrews securely.
23-51
TM 08780B-20

12. Capscrew With
Captive Lockwasher (4)
13. Cover Assembly
14. O-Ring
15. Capscrew (3)
16. Bypass Valve
17. Spring
18. Oil Filter
19. O-Ring (2)
22. Cap
23. O-Ring

8. Nut (4)
9. Lockwasher (4)
10. Reservoir
11. Gasket
23-52
TM 08780B-20
e. Installation
(1) Position new gasket (11) on reservoir (10).
(2) Install oil filter housing (1) onto reservoir (10) so that oil sampling valve
(20) and pressure check valve (21) face right side of vehicle.
(3) Install four new lockwashers (9) and nuts (8). Tighten nuts securely.
(4) Install two new O-rings (6 and 7) on adapters (4 and 5).
(5) Install two adapters (4 and 5) into oil filter housing (1). Tighten securely.
(6) Connect two hydraulic lines (2 and 3) to adapters (4 and 5). Tighten
securely.
END OF TASK
NOTE
LO 9-2320-297-12
1. Oil Filter Housing 5. Adapter

4. Adapter
23-53
TM 08780B-20
23-14. HYDRAULIC HOSE AND FITTING REPLACEMENT
THIS TASK COVERS: a. Hose Replacement

b. Fitting Replacement
c. Pipe Thread Fittings
d. Straight Thread Fittings
e. Boss Fittings
f. J.I.C. Flared Fittings
g. Quick Couplers
h. Flange Block
i. O-ring Replacement
INITIAL SETUP

MK16 parts before disassembly and work in a
MK17 clean area.

Hydraulic oil (item 33, Appendix D) To prevent personal injury, carefully loosen
Pipe sealant (item 48, Appendix D) fittings to relieve all pressure from hydraulic
Thread sealing tape (item 58, Appendix D) hoses.
a. Hose Replacement
(1) Clean fitting connections before removing hoses (1).
NOTE
• Hydraulic oil will leak from fittings when hoses (1) are removed. Plug all fittings and
openings to prevent oil leakage.
• Note hose (1) routings and clamps for proper installation.
(2) Tag and remove hoses (1) that need replacement. Discard hoses (1).
CAUTION
ONLY USE REPLACEMENT HOSES (1) WITH THE SAME INSIDE DIAMETERS,
PRESSURE RATINGS, LENGTHS AND FITTINGS.
(3) When installing replacement hoses (1), do not twist or exceed the
maximum bend radius or change hose (1) routing. Hoses (1) must be routed in their original
positions.
23-54
TM 08780B-20
(4) Install all clamps or brackets and tighten hose fittings securely.
(5) Check for leaks.
b. Fitting Replacement
(1) Use proper size wrenches. Place wrenches on hex portion of straight
fittings and on wrench pad of shaped fittings. Never use pipe wrenches.
(2) Tighten all fittings securely. If a connection leaks, tighten fittings until
leak stops. Do not over tighten.
(3) If a fitting has an elbow or has to align with tubing or a hose, always
complete an extra turn to align. Never loosen. If another turn cannot be completed, remove
fittings. Apply pipe sealant and reinstall. If fitting still does not align, use another fitting.
c. Pipe Thread Fittings
NOTE
Fittings with pipe threads have a slight taper on the threaded portion of the fitting.
(1) Apply pipe sealant to male end of pipe thread fitting (2). Do not apply
pipe sealant on first thread.
(2) Install pipe thread fitting (2). Tighten securely.
1. Hose
2. Pipe Thread Fitting
23-55
TM 08780B-20
3. Straight Threads
4. O-Ring
d. Straight Thread Fittings
NOTE
Fittings with straight threads (3) will be straight on threaded end of fitting. Some straight
threaded fittings will have an O-ring (4) to aid in sealing.
(1) If there is no O-ring (4), apply thread sealing tape.
(2) Install and tighten fitting securely.
e. Boss Fittings
NOTE
Each boss fitting (5) has an O-ring (6), washer (7) and nut (8).
(1) Install boss fitting (5) into straight thread boss until washer (7) contacts
face of boss.
(2) Position boss fitting (5) as needed.
(3) Hold boss fitting (5) in position and tighten nut (8) securely.
5. Boss Fitting
6. O-Ring
7. Washer
8. Nut
23-56
TM 08780B-20
9. J.I.C. Flared Fitting
f. J.I.C. Flared Fittings
NOTE
J.I.C. flared fittings (9) have 37 degree flared ends. These fittings do not need pipe sealant.
(1) Install J.I.C. flared fitting (9).
(2) Tighten securely.
g. Quick Couplers
NOTE
Quick couplers (10) are used to ease connection and disconnection of hoses. They also
prevent the loss of hydraulic oil when disconnected.
(1) To disconnect, pull locking ring (11) back and pull quick couplers (10)
apart.
(2) To connect, pull back on locking ring (11) and push quick couplers (10)
together. Release locking ring (11) and continue pushing until it locks into place, securing quick
couplers (10).
10. Quick Coupler

11. Locking Ring
23-57
TM 08780B-20
h. Flange Block
NOTE
The flange block (12) is used where hoses have to be mounted to a flat surface.
(1) Lubricate O-ring (13) with clean hydraulic oil.
(2) Install O-ring (13) and flange (14) onto flange block (12).
(3) Install two flange halves (15), four capscrews (16) and lockwashers (17).
Tighten four capscrews (16) securely.
12. Flange Block 15. Flange Halve (2)

13. O-Ring 16. Capscrew (4)
14. Flange 17. Lockwasher (4)
i. O-Ring Replacement
NOTE
If replacement of an O-ring is needed, follow steps (1) thru (5).
(1) Remove and discard old or damaged O-ring.
23-58
TM 08780B-20
(2) Wrap tape around threads of fitting so that new O-ring (18) will not be
damaged during installation.
(3) Lubricate new O-ring (18) with clean hydraulic oil.
(4) Stretch and carefully roll O-ring (18) onto fitting.
(5) Remove tape covering threads.
18. O-Ring
END OF TASK
23-59
TM 08780B-20
23-15. HYDRAULIC HOSE REEL REPLACEMENT

c. Installation
d. Spring Tension Adjustment

Condition Condition
MK15 TM 08780B-20 Auxiliary hydraulic
hoses removed
Locknut (4) (MS51943-35) item 15 Special Environmental Conditions
Personnel Required working on hydraulic equipment. Clean all
1 MOS 3521 parts before disassembly and work in a clean
1 Assistant area.
a. Removal
(1) Remove stowed items from cover (1) if still in place.
(2) Remove 22 capscrews (2) and cover (1).
(3) Carefully release spring tension on hose reel (3).
CAUTION
TO PREVENT LOSS OF HYDRAULIC OIL, MAKE SURE AUXILIARY HYDRAULIC

CIRCUIT CONTROL (4) AND FLOW CONTROL VALVE (5) ARE BOTH OFF.
(4) Tag and remove hoses (6 and 7) from adapters (8 and 9). To prevent loss
of hydraulic oil, wire hoses (6 and 7) up.
(5) Remove adapters (8 and 9) from fittings (10 and 11) if damaged.
23-60
TM 08780B-20
4. Auxiliary Hydraulic Circuit Control

5. Flow Control Valve
(6) Remove quick disconnect ends (12 and 13) from hose reel (3).
(7) Have assistant hold capscrews (14).
locknuts (15).
23-61
TM 08780B-20
1. Cover 8. Adapter 13. Quick Disconnect End

2. Capscrew (22) 9. Adapter 14. Capscrew (4)
3. Hose Reel 10. Fitting 15. Locknut (4)
6. Hose 11. Fitting 16. Washer (4)
7. Hose 12. Quick Disconnect End
23-62
TM 08780B-20
3. Hose Reel
17. Lifting Sling
(9) Attach a lifting sling (17) to hose reel (3).
(10) Using an overhead lifting device, remove hose reel (3) and place it on the
floor.
c. Installation
(1) Attach lifting sling (17) to hose reel (3).
(2) Using an overhead lifting device, place hose reel (3) into its compartment.
(3) Remove lifting sling (17).
(4) Have assistant install and hold four capscrews (14).
23-63
TM 08780B-20
(5) Install four washers (16) and new locknuts (15). Tighten locknuts (15)
securely.
NOTE
(6) Install quick disconnect ends (12 and 13) onto hose reel (3).
(7) Install adapters (8 and 9) onto fittings (10 and 11) if removed. Tighten
securely.
(8) Connect hoses (6 and 7) to adapters (8 and 9). Tighten securely.
(9) Adjust spring tension. Refer to section d of this paragraph.
3. Hose Reel 9. Adapter 13. Quick Disconnect End

6. Hose 10. Fitting 14. Capscrew (4)
7. Hose 11. Fitting 15. Locknut (4)
8. Adapter 12. Quick Disconnect End 16. Washer (4)
23-64
TM 08780B-20
d. Spring Tension Adjustment
WARNING
HOSE REEL (3) IS UNDER STRONG SPRING TENSION. TO PREVENT PERSONAL

INJURY, KEEP LOOSE CLOTHING, TOOLS AND YOUR HANDS AWAY FROM HOSE
REEL AS IT UNWINDS.
NOTE
To insure proper adjustment, start with spring tension released.
(1) Have assistant hold hose reel (3) firmly.
WARNING
TO PREVENT PERSONAL INJURY, DO NOT USE YOUR HANDS TO RELEASE PAWL

(18). USE A TOOL SUCH AS A SMALL PRY BAR.
(2) Using a tool, release pawl (18) from ratchet wheel (19). Allow hose reel
(3) to unwind completely.
CAUTION
TO PREVENT PARTS DAMAGE, DO NOT WIND HOSE REEL (3) MORE THAN 24
TURNS.
(3) Set spring tension by turning hose reel (3) 24 turns in the direction shown.
Lock pawl (18) into ratchet wheel (19) after each turn.
(4) Connect auxiliary hoses (20) to hose reel (3).
(5) Have assistant hold auxiliary hoses (20).
(6) Rotate hose reel (3) far enough in the direction shown to release pawl (18).
(7) Have assistant slowly rewind auxiliary hoses (20).
(8) Operate an auxiliary tool. Refer to paragraph 2-21 (TM 08780B-10).

Check all hoses for leaks.
(9) Remove auxiliary tool and rewind auxiliary hoses (20). Make sure hoses
(20) rewind properly.
(10) Install cover (1) with 22 capscrews (2). Tighten capscrews (2) securely.
23-65
TM 08780B-20
(11) Stow items onto cover (1) if necessary. Refer to Appendix E

(TM 08780B-10).
1. Cover
2. Capscrew (22)
3. Hose Reel
18. Pawl
19. Ratchet Wheel
20. Auxiliary Hose (2)
END OF TASK
23-66
TM 08780B-20
23-16. AUXILIARY HYDRAULIC HOSE REPLACEMENT

c. Installation

Condition Condition
MK15 TM 08780B-20 Cover removed
(para 23-15 item 1).
Materials/Parts
Pipe sealant (item 48, Appendix D) Special Environmental Conditions
Band clamps (AR) (NSN 4730-01-116-4056) Cleanliness is extremely important when
item 9 working on hydraulic equipment. Clean all
area.
a. Removal
(1) Unwind hoses (1 and 2) fully.
WARNING
TO PREVENT PERSONAL INJURY, MAKE SURE HOSES (1 AND 2) ARE LOCKED IN

PLACE BEFORE DISCONNECTING THEM.
(2) Disconnect hoses (1 and 2) from hose reel (3).
(3) Remove quick disconnect ends (4 or 5) from the hose (1 or 2) that will be
replaced.
(4) Remove two screws (6), nuts (7) and ball stop halves (8).
(5) Cut and remove band clamps (9) only if hose (1 or 2) is damaged.
(6) Remove hose (1 or 2).
(2) Inspect quick disconnect ends (4 and 5) for smooth separation by

connecting them together several times.
23-67
TM 08780B-20
c. Installation
NOTE
(1) Lay hoses (1 and 2) next to each other.
(2) If removed, install band clamp (9) every 30 inches (76.2 cm).
(3) Install stop ball halves (8) with two screws (6) and nuts (7). Tighten
securely.
(4) Install quick disconnect ends (4 and 5) onto hose (1 or 2) as shown.

Tighten securely.
(5) Connect hoses (1 and 2) onto hose reel (3).
(6) Rewind hoses (1 and 2) onto hose reel (3).
END OF TASK
NOTE
TM 08780B-20 Install cover (para 23-15 item 1).
23-68
TM 08780B-20
1. Hose 6. Screw (2)

2. Hose 7. Nut (2)
3. Hose Reel 8. Stop Ball Half (2)
4. Quick Disconnect End 9. Band Clamp (A/R)
5. Quick Disconnect End
23-69
TM 08780B-20
23-17. AUXILIARY HYDRAULIC HOSE REEL ROLLER REPLACEMENT

c. Installation

Condition Condition
MK15 TM 08780B-20 Auxiliary hydraulic
hoses removed (para
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Remove stowed items from cover (1) if still in place. Remove 22
capscrews (2) and cover (1).
(2) Have assistant hold capscrews (3). Remove four locknuts (4) and washers
(3) Remove roller assembly (6).
(4) Drive out pin (7).
(5) Remove shaft (8) and roller (9).
(6) Remove trunnion bearings (10 and 11) from roller (9).
(7) Repeat steps (4) thru (6) for remaining rollers (12, 13 and 14).
(2) Inspect pins (7). Replace if damaged.
23-70
TM 08780B-20
c. Installation
(1) Seat trunnion bearings (10 and 11) into roller (9).
(2) Install roller (9) with shaft (8).
(3) Line up hole in shaft (8) and install pin (7).
(4) Repeat steps (1) thru (3) for rollers (12, 13 and 14).
(5) Install roller assembly (6).
(6) Have assistant hold capscrews (3) and install four washers (5) and new
(7) Install cover (1) and 22 capscrews (2). Tighten capscrews (2) securely.
END OF TASK
NOTE
TM 08780B-20 Install auxiliary hydraulic hoses
(para 23-16).
23-71
TM 08780B-20
1. Cover
2. Capscrew (22)
3. Capscrew (4)
4. Locknut (4)
5. Washer (4)
6. Roller Assembly
7. Pin
8. Shaft
9. Roller
10. Trunnion Bearing
11. Trunnion Bearing
12. Roller
13. Roller
14. Roller
23-72
TM 08780B-20
23-18. AUXILIARY HYDRAULIC HOSE REEL ROLLER REPLACEMENT (LVSA1


c. Installation

Condition Condition
MK15A1 TM 08780B-20 Auxiliary hydraulic
hoses removed (para
Spinlock nut (4) (9904-6200) item 7
Personnel Required
1 MOS 3521
1 Assistant
a. Removal
(1) Remove stowed items from cover (1) if still in place. Remove 22
capscrews (2) and cover (1).
(2) Have assistant hold capscrews (3). Remove four locknuts (4) and washers
(3) Remove roller assembly (6).
(4) Remove four spinlock nuts (7) and capscrews (8). Discard spinlock nuts
(7).
(5) Remove roller mounting blocks (9).
(6) Remove roller rods (10 and 11) from roller tubing (12 and 13).
(7) Remove trunnion bearings (14) from roller tubing (12 and 13).
23-73
TM 08780B-20
c. Installation
(1) Seat trunnion bearings (14) into roller tubing (12 and 13).
(2) Install roller rods (10 and 11) into roller tubing (12 and 13).
(3) Install roller mounting block (9) with capscrews (8) and new spinlock nuts
(7).
(4) Install roller assembly (6).
(5) Have assistant hold capscrews (3) and install four washers (5) and new
(6) Install cover (1) and 22 capscrews (2).
END OF TASK
NOTE
TM 08780B-20 Install auxiliary hydraulic hoses
(para 23-16).
23-74
TM 08780B-20
1. Cover 7. Spinlock Nut (4) 11. 1/2” Dia. Roller Rod (2)
2. Capscrew (22) 8. Capscrew 12. 1 1/2” Dia. Roller Tubing (2)
3. Capscrew (4) 9. Roller Mounting 13. 1 1/2” Dia. Roller Tubing (2)
4. Locknut (4) Block (4) 14. Trunnion Bearing (8)
5. Washer (4) 10. 1/2” Dia. Roller Rod (2) 15. Roller Mounting Bracket
6. Roller Assembly
23-75
TM 08780B-20
23-19. DIRECTIONAL RELIEF VALVE FILTER SCREEN REPLACEMENT

c. Installation
INITIAL SETUP

Hydraulic oil (item 46, Appendix C) clean area.

To avoid personal injury, always assume
hydraulic lines have pressure. Crack
hydraulic lines open slowly to allow all
pressure to escape. Always wear safety
glasses.
a. Removal
NOTE
• Place a container below hydraulic lines as they are disconnected.
• To aid in later installation, be sure to plug all lines as necessary and tag all lines and
their connection points.
(2) Remove tee (3) and filter screen (4).
c. Installation
(1) Install filter screen (4).
(2) Install tee (3) and tighten securely.
23-76
TM 08780B-20
(3) Connect hydraulic lines (1 and 2) and tighten securely.
END OF TASK
NOTE
TM 08780B-10 Check for proper steering operation
(para 2-13).
1. Hydraulic Line
2. Hydraulic Line
3. Tee
4. Filter Screen
23-77
TM 08780B-20
23-20. Hl-PRESSURE HYDRAULIC FILTER AND HEAD REPLACEMENT (MKl5A1/

MK17A1-LVSA1 SERIES VEHICLES ONLY)
THIS TASK COVERS: a. Filter Element Removal

b. Head Assembly/Bracket Removal
d. Head Assembly/Bracket Installation
e. Filter Element Installation

Condition Condition
MK15A1 TM 08780B-20 Hydraulic reservoir
MK17A1 filter replaced
(para 23-7).

Hydraulic oil (item 46, Appendix C) Cleanliness is extremely important when
Back-up ring (MS27595-146) item 7 working on hydraulic equipment. Clean all
Element, filter (G1482) item 4 parts before disassembly and work in a clean
Lockwasher (4) (352AX) item 13 area.
O-ring (ARP568-904) item 2 General Safes Instructions
O-ring (DF-681) item 6 Block wheels of truck to prevent personal
O-ring (2) (3-916) items 15 and 16 injury.
a. Filter Element Removal
NOTE
• There are two styles of head assemblies. Filter element removal and head assembly
removal is the same for both.
• Plug hoses after removal to prevent dirt from entering hydraulic system.
• Place a container to catch hydraulic oil during hose removal.
• The hi-pressure filter can be replaced without removing head assembly. Perform only
tasks needed.
(1) Remove drain plug (1) and O-ring (2) from bowl (3) by turning
counterclockwise. Drain bowl (3) completely. Discard O-ring (2).
(2) Remove bowl (3) and filter element (4) from head assembly (5). Discard
filter element (4).
23-78
TM 08780B-20
NOTE
Perform Step 3 only if bowl (3) was leaking.
(3) Remove O-ring (6) and back-up ring (7) from head assembly (5). Discard
O-ring (6) and back-up ring (7).
(1) Remove inlet hose (8) from adapter (9).
(2) Remove outlet hose (10) from elbow (11).
(3) Remove four capscrews (12) and lockwashers (13) while supporting head
assembly (5). Remove head assembly (5) from bracket (14). Discard lockwashers (13).
(4) Remove adapter (9) and elbow (11) from head assembly (5). Discard
O-rings (15 and 16).
(5) Remove by-pass valve assembly (17) from head assembly (5).
(6) Remove three locknuts (18) and capscrews (19) while supporting bracket
(14). Remove bracket (14). Discard locknuts (18).
23-79
TM 08780B-20
1. Drain Plug
2. O-Ring
3. Bowl
4. Filter Element
5. Head Assembly
6. O-Ring
7. Back-Up Ring
8. Inlet Hose
9. Adapter
10. Outlet Hose
11. Elbow
12. Capscrew (4)
13. Lockwasher (4)
14. Bracket
15. O-Ring
16. O-Ring
17. By-Pass Valve
Assembly
18. Locknut (3)
19. Capscrew (3)
23-80
TM 08780B-20
(1) Install bracket (14) using three capscrews (19) and new locknuts (18).
Tighten locknuts securely.
(2) Install by-pass valve assembly (17) in head assembly (5). Tighten
securely.
(3) Install new O-ring (15) and adapter (9) on head assembly (5). Tighten
adapter securely.
(4) Install new O-ring (16) and elbow (11) on head assembly (5). Tighten
elbow securely.
(5) Install head assembly on bracket (14) using four capscrews (12) and new
lockwashers (13). Tighten capscrews securely.
(6) Install outlet hose (10) on elbow (11). Tighten securely.
(7) Install inlet hose (8) on adapter (9). Tighten securely.
NOTE
Perform step (1) only if O-ring (6) and back-up ring (7) were removed.
(1) Install new O-ring (6) and new back-up ring (7) on head assembly (5).
NOTE
Place a suitable container under filter to catch hydraulic oil.
(2) Install new filter element (4) and bowl (3) on head assembly (5). Tighten
securely.
(3) Install new O-ring (2) and drain plug (1) on bowl (3). Tighten plug
securely.
END OF TASK
23-81
TM 08780B-20
1. Drain Plug
2. O-Ring
3. Bowl
4. Filter Element
5. Head Assembly
6. O-Ring
7. Back-Up Ring
8. Inlet Hose
9. Adapter
10. Outlet Hose
11. Elbow
12. Capscrew (4)
13. Lockwasher (4)
14. Bracket
15. O-Ring
16. O-Ring
17. By-Pass Valve
Assembly
18. Locknut (3)
19. Capscrew (3)
23-82
TM 08780B-20
23-21. HI-PRESSURE HYDRAULIC FILTER AND HEAD REPLACEMENT (MK48A1-

LVSA1 SERIES VEHICLES ONLY)
THIS TASK COVERS: a. Filter Element Removal


Condition Condition
MK48A1 TM 08780B-20 Hydraulic reservoir
filter replaced (pare
Hydraulic oil (item 46, Appendix C)
Back-up ring (DF-779) item 7 Special Environmental Conditions
Element, filter (G1482) item 4 Cleanliness is extremely important when
Lockwasher (4) (352-A) item 13 working on hydraulic equipment. Clean all
Locknut (2) (110312A) item 18 parts before disassembly and work in a
O-ring (ARP568-904) item 2 clean area.
O-ring (DF-681) item 6
O-ring (22617-12) item 15 and 16 General Safety Instructions
injury.
a. Filter Element Removal
NOTE
• Place a container to catch hydraulic oil during hose removal.
• Plug hoses after removal to prevent dirt from entering hydraulic system.
• The hi-pressure filter can be replaced without removing head assembly. Perform only
tasks needed.
(1) Remove drain plug (1) and O-ring (2) from bowl (3) by turning
counterclockwise. Drain bowl (3) completely. Discard O-ring (2).
(2) Remove bowl (3) and filter element (4) from head assembly (5). Discard
filter element.
NOTE
Perform step (3) only if bowl (3) was leaking.
23-83
TM 08780B-20
(3) Remove O-ring (6) and back-up ring (7) from head assembly (5). Discard
O-ring (6) and buck-up ring (7).
(1) Remove inlet hose (8) from elbow (9).
(2) Remove outlet hose (10) from adapter (11).
(3) Remove four capscrews (12) and lockwashers (13) while supporting head
assembly (5). Remove head assembly (5) from bracket (14). Discard lockwashers (13).
(4) Remove elbow (9) and adapter (11) from head assembly (5). Discard O-
rings (15 and 16).
(5) Remove by-pass valve assembly (17) from head assembly (5).
(6) Remove two locknuts (18) and capscrews (19) while supporting bracket
(14). Remove bracket (14). Discard locknuts (18).
23-84
TM 08780B-20
1. Drain Plug 8. Inlet Hose 15. O-Ring

2. O-Ring 9. Elbow 16. O-Ring
3. Bowl 10. Outlet Hose 17. By-Pass Valve
4. Filter Element 11. Adapter Assembly
5. Head Assembly 12. Capscrew (4) 18. Locknut (2)
6. O-Ring 13. Lockwasher (4) 19. Capscrew (2)
7. Back-Up Ring 14. Bracket
23-85
TM 08780B-20
(1) Install bracket (14) using two capscrews (19) and new locknuts (18).
Tighten capscrews securely.
(2) Install by-pass valve assembly (17) in head assembly (5). Tighten
securely.
adapter securely.
adapter securely.
(5) Install head assembly on bracket (14) using four capscrews (12) and new
lockwashers (13). Tighten capscrews securely.
(6) Install outlet hose (10) on adapter (11). Tighten securely.
(7) Install inlet hose (8) on elbow (9). Tighten securely.
NOTE
Perform step (1) only if bowl (3) was leaking.
(1) Install back-up ring (7) and O-ring (6) on head assembly (5).
NOTE
Place a suitable container under filter to catch hydraulic oil.
(2) Install filter element (4) and bowl (3) on head assembly (5). Tighten
securely.
(3) Install O-ring (2) and drain plug (1) on bowl (3) by turning
counterclockwise.
END OF TASK
23-86
TM 08780B-20
1. Drain Plug 8. Inlet Hose 15. O-Ring

2. O-Ring 9. Elbow 16. O-Ring
3. Bowl 10. Outlet Hose 17. By-Pass Valve
4. Filter Element 11. Adapter Assembly
5. Head Assembly 12. Capscrew (4) 18. Locknut (2)
6. O-Ring 13. Lockwasher (4) 19. Capscrew (2)
7. Back-Up Ring 14. Bracket
23-87/(23-88 blank)
TM 08780B-20
CHAPTER 24
SPECIAL PURPOSE KITS
Maintenance level mechanics. The following chapter covers replacement procedures for special
purpose kits used on the LVS.
a. Machine Gun Mount. The machine gun mount kit consists of a machine gun ring,
platform and roof hatch. The machine gun ring is attached to the cab by three braces. The ring
allows 360 degree rotation of attached weapon. The roof hatch is used to cover the roof opening
when the weapon is not in use. The roof hatch is a spring-hinged panel mounted on a slide. The
machine gun platform provides a solid platform for the operation of the machine gun. The
platform is a steel plate with a support leg that folds against the rear bulkhead when not in use.
b. Extended Pintle Kit. The extended pintle kit is used to tow and position the M198
Howitzer. The kit consists of a front extended pintle and a rear extended pintle. When the rear
extended pintle is not in use, it is stowed on a carrier located at the spare tire. When the front
extended pintle is not in use, it is secured in the up position by the use of a pin and a quick
release pin.
c. Rear Body Tow Unit. The rear body tow unit permits any of the four trailers to be
towed, once separated from an MK48, by a vehicle of sufficient capacity. The rear body tow
unit is attached to the trailer at the guide assembly. The tow unit is secured in place with 12
hardened capscrews. The rear body tow unit also provides inter-vehicle electrical cables and air
lines to permit the operation of the trailer lights and brakes while being towed.
24-1
TM 08780B-20
24-3. MACHINE GUN MOUNT REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Locknut (4) (TLA-1213-GRC, FSCM 82458) item 5
a. Removal
WARNING
MACHINE GUN RING (1) IS HEAVY. TO AVOID PERSONAL INJURY OR DEATH USE
A LIFTING DEVICE OF ADEQUATE CAPACITY TO SUPPORT AND REMOVE RING.
(1) Remove twelve locknuts (2) twelve washers (3) twelve capscrews (4) and
remove machine gun ring (1). Discard locknuts (2).
(2) Remove four locknuts (5), eight washers (6) and four capscrews (7) from
rear support (8). Discard locknuts (5).
(3) Remove rear support (8).
(4) Remove four nuts (9), washers (10), lockwashers (11) and capscrews (12)
from front support channel (13). Discard lockwashers (11).
(5) Remove front support channel (13).
(6) Remove two nuts (14), washers (15) and capscrews (16) from right front
support (17).
(7) Remove two nuts (18) washers (19) and capscrews (20) from right front
support (17).
(8) Remove right front support (17).
(9) Remove four nuts (21), washers (22) and capscrews(23)from left front
support (24).
24-2
TM 08780B-20
(10) Remove two nuts (25) washers (26) and capscrews (27) from left front
support (24).
(11) Remove left front support (24).
b. Installation
NOTE
To aid assembly, do not fully tighten mounting hardware until all mounting hardware has
been installed.
(1) Install left front support (24) using two capscrews (27), washers (26) and
nuts (25).
(2) Install two capscrews (23) washers (22) and nuts (21).
(3) Install right front support (17) using two capscrews (20), washers (19) and
nuts (18).
(4) Install two capscrews (16) washers (15) and nuts (14).
(5) Install front support channel (13) behind right front support (17) and left
front support (24) using four capscrews (12), new lockwashers (11), washers (10) and nuts (9).
(6) Install rear support (8) using four capscrews (7), eight washers (6) and
four new locknuts (5).
WARNING
MACHINE GUN RING (1) IS HEAVY. TO AVOID PERSONAL INJURY OR DEATH USE
A LIFTING DEVICE OF ADEQUATE CAPACITY TO SUPPORT AND INSTALL RING.
(7) Install machine gun ring (1) using twelve capscrews (4) washers (3) and
new locknuts (2).
END OF TASK
24-3
TM 08780B-20
1. Machine Gun Ring 11. Lockwasher (4) 19. Washer (2)

3. Washer (12) 13. Front Support 21. Nut (2)
4. Capscrew (12) Channel 22. Washer (2)
5. Locknut (4) 14. Locknut (2) 23. Capscrew (2)
6. Washer (8) 15. Washer (2) 24. Left Front Support
7. Capscrew (8) 16. Capscrew (2) 25. Nut (2)
8. Rear Support 17. Right Front 26. Washer (2)
9. Nut (4) Support 27. Capscrew (2)
10. Washer (4) 18. Nut (2)
24-4
TM 08780B-20
24-4. MACHINE GUN PLATFORM REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Locknut (6) (21NTE-058) item 1
a. Removal
(1) Remove six locknuts (1) and capscrews (2) from hinge (3). Discard
locknut (1).
(2) Remove quick release pin (4) from stud (5). Remove platform assembly
(6).
(3) Remove two cotter pins (7) from pins (8). Discard cotter pins (7).
(4) Remove two pins (8) and leg (9) from platform (6).
(5) Remove two nuts (10), washers (11) and stud (5) from bulkhead (12).
c. Installation
(1) Install stud (5) into bulkhead (12) using two nuts (10) and washers (11).
(2) Install platform assembly (6) onto stud (5). Install quick release pin (4).
(3) Install six capscrews (2) and new locknuts (1). Torque locknuts (1) to 22
24-5
TM 08780B-20
(4) Install leg (9) using two pins (8) and new cotter pins (7).
1. Locknut (6) 5. Stud 9. Leg

2. Capscrew (6) 6. Platform Assembly 10. Nut (2)
3. Hinge 7. Cotter Pin (2) 11. Washer (2)
4. Quick Release Pin 8. Pin (2) 12. Bulkhead
END OF TASK
24-6
TM 08780B-20
24-5. MACHINE GUN HATCH REPLACEMENT

c. Installation
INITIAL SETUP
MK48
Materials/Parts
Silicone Sealant (item 5, Appendix D)
Locknut (4) (21NE-066, FSCM 72962) item 7
Spring pin (4) (59-040-187-0620, FSCM 72962) item 12
Locknut (21NTE-058, FSCM 72962) item 13
Locknut (4) (AN365-1024A, FSCM 88044) item 18
a. Removal
NOTE
• If machine gun hatch is being installed for first time, go to task C.
• Tag all parts with the vehicle's serial number. This will ensure that all parts remain
with the correct vehicle.
(1) Open hatch cover (1). Remove four capscrews (2) and four washers (3 and
4) from hatch ring (5).
(2) Slide hatch cover guide assembly (6) to the right and remove from hatch
ring (5).
(3) Remove four locknuts (7) from capscrews (8). Discard locknuts (7).
WARNING
PINS (9) ARE UNDER SPRING PRESSURE. TO PREVENT PERSONAL INJURY,

REMOVE EACH CAPSCREW (8), ONE AT A TIME, WHILE HOLDING PIN (9) IN
PLACE.
(4) While holding pin (9) in place, remove capscrew (8) from hatch cover
guide (6).
(5) Slowly remove pin (9) and spring (10) from hatch cover (1).
24-7
TM 08780B-20
(6) Repeat steps (4) and (5) for remaining three pins (9).
(7) Remove four levers (11) from pins by removing spring pin (12) from pin
(9).
(8) Remove locknut (13), washer (14), pull strap (15) and capscrew (16) from
hatch cover (1).
(9) Remove seal (17) from hatch ring (5).
(10) Remove four locknuts (18), washers (19) and capscrews (20) from base
supports (21 and 22).
(11) Remove 36 capscrews (23) from hatch ring (5).
(12) Remove hatch ring (5) and base supports (21 and 22).
(13) Remove base supports (21 and 22) from hatch ring (5).
(14) Remove two set screws (24) from hatch ring (5).
(15) Remove two wear strips (25) from hatch ring (5).
24-8
TM 08780B-20
1. Hatch Cover 9. Pin (4) 18. Locknut (4)

2. Capscrew (2) 10. Spring (4) 19. Washer (4)
3. Washer (2) 11. Lever (4) 20. Capscrew (4)
4. Washer (2) 12. Spring Pin (4) 21. Base Support
5. Hatch Ring 13. Locknut 22. Base Support
6. Hatch Cover 14. Washer 23. Capscrew (36)
Guide Assembly 15. Pull Strap 24. Set Screw (2)
7. Locknut (4) 16. Capscrew 25. Wear Strip (2)
8. Capscrew (4) 17. Seal
24-9
TM 08780B-20
c. Installation
(1) Install two set screws (24) into hatch ring (5).
(2) Install base supports (21 and 22) onto hatch ring (5). Position base
support brackets (26) facing each other.
(3) Apply silicone sealant to hatch ring (5) and base support brackets (26).
NOTE
Apply adhesive to the threads of all capscrews (20 and 23) before installation.
(4) Install hatch ring (5) and base supports (21 and 22) using 40 capscrews
(23 and 20), four washers (19) and new locknuts (18). Tighten capscrews (23 and 20) securely.
NOTE
If a new seal (17) is being installed, join ends of seal with seal plug (17.1).
(5) Install two wear strips (25) onto hatch ring (5). Apply adhesive
completely around seal (17) and install seal (17) with seal plug (17.1) onto hatch ring (5).
(6) Install four levers (11) onto pins (9) using spring pins (12).
(7) Install spring (10) into hatch cover (1). Insert pin (9) into hatch cover (1).
(8) While holding pin (9) in place, install capscrew (8) and new locknut (7)
into cover guide (6).
(9) Repeat steps (7) and (8) for remaining three pins (9).
(10) Install hatch cover guide assembly (6) onto hatch ring (5).
(11) Install two capscrews (2) and two washers (3) onto hatch ring (5). Torque
capscrews (2) to 28 foot-pounds (37.9 N*m).
(12) Install two capscrews (2) and washers (4) onto base supports (21 and 22).
Torque capscrews (2) to 28 foot-pounds (37.9 N*m).
24-10
TM 08780B-20
(13) Install pull strap (15) using capscrew (16), washer (14) and locknut (13).
1. Hatch Cover 10. Spring (4) 18. Locknut (4)

2. Capscrew (2) 11. Lever (4) 19. Washer (4)
3. Washer (2) 12. Spring Pin (4) 20. Capscrew (4)
4. Washer (2) 13. Locknut 21. Base Support
5. Hatch Ring 14. Washer 22. Base Support
6. Hatch Cover 15. Pull Strap 23. Capscrew (36)
Guide Assembly 16. Capscrew 24. Set Screw (2)
7. Locknut (4) 17. Seal 25. Wear Strip (2)
8. Capscrew (4) 17.1 Seal Plug 26 Base Support Bracket
9. Pin (4)
END OF TASK
24-11/(24-12 blank)
TM 08780B-20
CHAPTER 25
NON-ELECTRIC GAUGES
Maintenance level mechanics. The following chapter covers replacement procedures for non-
electric gauges on the vehicle.
25-2. DESCRIPTION AND DATA. The air pressure gauge is the only non-electrical gauge
in the MK48. The air pressure gauge houses two needles that indicate air pressure in the primary
and the secondary air systems. The green needle indicates the air pressure in the primary air
system and the red needle indicates the air pressure in the secondary air system. Since the
needles operate independently, using direct air pressure, a pressure change in one system will
only affect one needle. Each needle has a range of 0-150 psi.
Air Pressure Gauge
25-1
TM 08780B-20
25-3. AIR PRESSURE GAUGE REPLACEMENT

c. Installation

Condition Condition
MK48 TM 08780B-10 Drain air
reservoirs (para 3-5).
Materials/Parts
Star washer (2) (1L051275) item 10 disconnected
(para 7-45).


a. Removal
NOTE
Air lines are compression type lines. These air lines have sleeves inserted into the ends to help
support line. They also use eyelets to seal lines. When removing air lines the eyelets may stay
with the line or may stay with the fitting. Refer to paragraph 13-23 for air line repair
procedures.
(1) Remove six screws (1) from instrument panel (2). Lean instrument panel
(2) against steering wheel (3).
(2) Pull light socket (4) from air pressure gauge (5).
(3) Tag and remove two air lines (6 and 7) from adapters (8).
(4) Remove two adapters (8) from air pressure gauge (5).
(5) Remove two nuts (9), star washers (10) and bracket (11) from air pressure
gauge (5). Remove air pressure gauge (5) from instrument panel (2). Discard star washers (10).
(6) Remove two nuts (12) from air pressure gauge (5).
25-2
TM 08780B-20
c. Installation
(1) Install two nuts (12) on air pressure gauge (5).
(2) Install air pressure gauge (5) in instrument panel (2).
(3) Install bracket (11) using two new star washers (10) and nuts (9).
(4) Apply pipe sealant to threads (13) of air pressure gauge (5). Install two
adapters (8) onto air pressure gauge (5).
(5) Install two air lines (6 and 7) onto air pressure gauge (5).
(6) Install light socket (4) into air pressure gauge (5).
(7) Install instrument panel (2) using six screws (1).
END OF TASK
NOTE
TM 08780B-10 Operate engine and check air pressure gauge

25-3
TM 08780B-20
1. Screw (6) 6. Air Line 10. Star Washer (2)

2. Instrument Panel 7. Air Line 11. Bracket
3. Steering Wheel 8. Adapter (2) 12. Nut (2)
4. Light Socket 9. Nut (2) 13. Threads
25-4
TM 08780B-20
APPENDIX A
REFERENCES
A-1. INDEXES. The following indexes should be consulted frequently for latest changes to,
or revisions of, references given in this appendix and for new publications or instructions relating
to materiel covered in this manual.
Military Publications:
Consolidated Index of Army Publications and Blank Forms ...............................DA PAM 310-1
A-2. SUPPLY MANUALS. The following Marine Corps Supply Manuals pertain to this
material:
a. Demolition of Material To Prevent Enemy Use
Explosives, Bulk, Propellants, and Explosive Devices..................... SM 9-5-1375

Land Mines and Components ........................................................... SM 9-5-1345
Pyrotechnics, Military, All Types..................................................... SM 9-5-1370
b. Maintenance and Repair
Tool Kit, Mechanic’s General (NSN 5180-00-606-3566)............... SL-3-00456A
Shop Equipment, Automotive Maintenance and Repair:

Organizational Maintenance, Common No. 1, Less Power,
(NSN 4910-00-7540654) and Shop Equipment, Automotive
Maintenance and Repair: Organizational Maintenance,
Common No. 1 Map Only (NSN 4910-00-919-0098)..........SC 4910-95-CL-A74
A-3. FORMS. Refer to TM 4700-15/1 for pertinent maintenance forms and explanation on
use.
A-4. OTHER PUBLICATIONS. The following publications contain information pertinent

to major item materiel and associated equipment:
a. Vehicle
Operator’s Manual for Trucks, 8 x 8,

Logistics Vehicle System (DIESEL) ............................................TM 08780B-10
Lubrication Order for Trucks, 8 x 8, LI 2320-12/9

Logistics Vehicle System (DIESEL) ....................................... LO 9-2320-297-12
A-1
TM 08780B-20
Organizational Maintenance and Direct Support/General

Support Maintenance Repair Parts and Special Tools List
for Trucks, 8 x 8, Logistics Vehicle System (DIESEL) ............ TM 2320-24P/14
b. Camouflage
Camouflage ................................................................................................FM5-20
Color, Marking and Camouflage Painting of Military Vehicles,

Construction Equipment, and Materials Handling Equipment ........... TB 43-0209
c. Decontamination
Chemical, Biological, Radiological, and Nuclear Defense.....................FM 21-40
d. General
Accident Reporting and Records ..........................................................AR 385-40

Manual for the Wheeled Vehicle Driver...............................................FM 21-305
Deep-Water Fording of Ordnance Material........................................... TM 9-238
Northern Operations................................................................................FM 31-72
Operation and Maintenance of Army Material in Extreme
Cold Weather (0°F to -65°F) ..................................................................FM 9-207
Principles of Automotive Vehicles ...................................................... TM 9-8000
Prevention of Motor Vehicle Accidents ...............................................AR 385-55
Functional Grouping Codes ...............................................................TB 750-93-1
e. Maintenance and Repair
Winterization Kits for Army Tank-Automotive Materiel......................... SB 9-16

Inspection, Care and Maintenance of Antifriction Bearings ................. TM 9-214
Operation and Organizational Field and Depot Maintenance
Storage Batteries, Lead-Acid Type..........................................TM 9-6140-200-14
Load-Testing Vehicle Used to Handle Missiles and Rockets................. TB 9-352
Welding Theory and Application........................................................... TM 9-237
f. Shipment and Limited Storage
Color and Marking of Army Materiel Preservation,

Packaging, and Packing of Military Supplies and
Equipment ............................................................TM 38-230-1 and TM 38-230-2
Shipment and Limited Storage....................................................MIL-V-62038
Storage Serviceability Standard: Tracked Vehicles, Wheeled
Vehicles, and Components Parts........................................................ SB 740-98-1
A-2
TM 08780B-20
APPENDIX B
MAINTENANCE ALLOCATION CHART
Section I. Introduction
B-1. GENERAL
a. General. This section provides a general explanation of all maintenance and

repair functions authorized at various maintenance categories.
b. The Maintenance Allocation Chart (MAC) in Section II. Designates overall

authority and responsibility 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 categories.
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 II.
d. Section IV. Contains supplemental instructions and explanatory notes for a

particular maintenance function.
B-2. MAINTENANCE FUNCTIONS. Maintenance functions will be limited to and defined

as follows: (except for ammunition MAC).
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 touch).
b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic,

or electrical characteristics of an item and comparing those characteristics with prescribed
standards.
c. Service. Operations required periodically to keep an item in proper operating

condition, i.e., 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

or exact position, or by setting the operating characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum

or desired performance.
B-1
TM 08780B-20
f. Calibrate. To determine and cause corrections to be made or to be adjusted on

instruments or test, measuring, and diagnostic equipments used in precision measurement.
Consists of comparisons of two instruments, 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
into 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 and install a serviceable counterpart in

its place. “Replace” is authorized by the MAC and is shown as the 3d position code of the SMR
code.
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
appropriate technical publications. Overhaul is normally the highest degree of maintenance
performed. Overhaul does not normally return an item to like new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of

unserviceable equipment to a like new condition in accordance with original manufacturing
standards. Rebuild is the highest degree of materiel maintenance applied to equipment. The
rebuild operation includes the act of returning to zero those age measurements (hours/miles, etc.)
considered in classifying equipment/components.
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II
a. Column 1, Group Number. Lists functional group code numbers, the purpose of
which is to identify maintenance significant components, assemblies, subassemblies, and
modules with the next higher assembly. End item group number shall be 00'.
b. Column 2, Component/Assembly. Contains the names of components,

assemblies, subassemblies, and modules for which maintenance is authorized.
c. Column 3, Maintenance Function. Lists the functions to be performed on the item

listed in Column 2. (For detailed explanation of these functions, see paragraph B-2).
d. Column 4, Maintenance Category. Specifies, by the listing of a work time figure

in the appropriate subcolumn(s), the category of maintenance authorized to perform the function
listed in Column 3. This figure represents the active time required to perform that maintenance
B-2
TM 08780B-20
function at the indicated category of maintenance. If the number or complexity of the tasks
within the listed maintenance function varies at different maintenance categories, appropriate
work time figures will be shown for each category. The work time figure represents the average
time required to restore an item (assembly, subassembly, component, module, end item, or
system) to a serviceable condition under typical field operating conditions. This time includes
preparation time (including any typical field operating conditions). This time includes
preparation time (including any necessary assurance/quality control time in addition to the time
required to perform the specific tasks identified for the maintenance functions authorized in the
maintenance allocation chart. The symbol designations for the various maintenance categories
are as follows:
C.................................Operator or crew
O.................................Organizational Maintenance
F .................................Direct Support Maintenance
H.................................General Support Maintenance
L .................................Specialized Repair Activity (SRA)
D.................................Depot Maintenance
e. Column 5, Tools and Equipment. Specifies, by code, those common tool sets (not
individual tools) and special tools, TMDE, and support equipment required to perform the
designated function.
f. Column 6, Remarks. This column shall, when applicable, contain a letter code, in
alphabetic order, which shall be keyed to the remarks contained in Section IV.
B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT

REQUIREMENTS, SECTION III
a. Column 1, Reference Code. The tool and test equipment reference code
correlates with a code used in the MAC, Section II, Column 5.
b. Column 2, Maintenance Category. The lowest category 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.
B-3
TM 08780B-20
B-5. EXPLANATION OF COLUMN IN REMARKS, SECTION IV
a. Column 1, Reference Code. The code recorded in column 6, Section II.
b. Column 2, Remarks. This column lists information pertinent to the maintenance

function being performed as indicated in the MAC, Section It.
B-4
TM 08780B-20
Section II. LVS Maintenance Allocation Chart
(1) (2) (3) (4) (5) (6)

MAINTENANCE CATEGORY
GROUP COMPONENT/ MAINT. TOOLS REMARKS
NO. ASSEMBLY FUNC. C O F H D AND
EQPT.
01 Engine
0100 Engine Assembly Inspect .4

Test 1.5
Adjust 3.4
Service 1.0 65.4
Repair
Engine/Transmission Replace 18.0
0101 Cylinder Block Replace 37.7

Repair 3.0
0102 Crankshaft Replace 5.6
Vibration Damper and Replace 11.4

Front Cover
Front Oil Seal Replace 7.3
Rear Oil Seal Replace 8.2
0103 Flywheel Housing Replace 1.8
Flexplate Assembly Replace 3.0
0104 Piston/Connecting Rod Replace 9.4

Assembly Repair .4
0105 Rocker Cover & Gaskets Replace .3
Rocker Arm Replace 1.5

Valves Adjust 2.0
Cam Follower Valve Replace 5.5
Bridge Guide Repair 2.5
Camshaft Replace 7.8

Repair 3.5
Cylinder Head Replace 6.8

Repair 7.9
0106 Oil Filter Replace .9
Oil Filter Adapter Replace 2.0
B-5
TM 08780B-20
Section II. LVS Maintenance Allocation Chart (Continued)
(1) (2) (3) (4) (5) (6)

EQPT.
01 Engine (Continued)
Oil Cooler/Housing Replace 1.5
Oil Pan and Gasket Replace 1.5
Oil Pump Replace 11.4

Repair .3
Oil Pressure Regulator/ Replace .2

Relief Valve
0108 Exhaust Manifold and Replace .5

Gasket
0109 Idler Gear Replace .3

Repair 3.0
Water Pump Drive Gear Replace 1.6
0112 Engine Brake Adjust 2.0

Replace 1.0
Repair 1.5
03 Fuel System
0301 Injector Adjust 2.0

Replace 1.8
Repair .8
Test .2
Injector Control Tube Adjust 2.0

Lever Replace 1.0
Repair 1.5
0302 Fuel Supply Pump Replace 1.3

Repair .4
Hand Priming Pump Replace .5

Service .2
0304 Air Cleaner Assembly Replace 1.0
Air Cleaner Element Replace .2
B-6
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
03 Fuel System (Continued)
Air Restriction Indicator Inspect .1

Replace .3
Intake Ducting Replace .3
0305 Blower Assembly Replace 6.9

Repair 1.9
Blower Drive Shaft and Replace .5
Hub
Turbocharger Replace 1.1

Repair 1.5
Air Inlet Housing Replace 1.5
0306 Fuel Tank (each) Replace 2.0
Fuel Lines, Vents & Inspect .5

Fittings
Replace 1.5
0308 Governor Assembly Adjust 1.0

Replace 8.2
Repair 2.1
Shutdown Solenoid Adjust .5

Replace .5
Throttle Control Solenoid Replace .2
Throttle Cylinder Replace .5

Repair .5
B-7
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
03 Fuel System (Continued)
0309 Fuel Water Separator Inspect .1

Service .3
Replace .5
Repair 1.5
Secondary Fuel Filter Replace .1
Fuel Strainer Service .1
0311 Ether Starting Aid Inspect .1

Replace .3
0312 Throttle Treadle Valve Replace .8

Repair .5
Test .2
04 Exhaust System
0401 Muffler/Pipe Assembly Inspect .1

Replace 2.0
05 Cooling system D
0501 Radiator Service .7

Test .2
Replace 4.0
Repair A A
Radiator Grille Replace 2.0
Coolant Filter Replace .3
0502 Fan Shroud Replace 5.0
0503 Thermostats Replace 1.2
Cooling System Hoses Inspect .1

and Tubes Replace 2.0
0505 Fan Assembly Inspect .1

Replace .6
B-8
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
05 Cooling System (Continued)
0507 Engine Aftercooler Replace 7.9
06 Electrical System
0601 Alternator Test .3

Replace 1.7
Repair 1.9
0602 Voltage Regulator Adjust .1

Replace .4
0603 Starter Test .3

Replace 1.9
Repair 2.8
Starter Relay Replace .2
0606 Cooling System Switch Replace .5
Oil Pressure Switches Replace .5
0607 Instrument Panel Replace 2.5

Harness Repair A A
Circuit Breaker Replace .2
Instrument Panel Replace .5
Toggle Switches Replace .3
Turn Signal Switches Replace .3
Electrical Gauges Inspect .1

Replace .5
Magnetic Switch Replace .5
Ether Start Switch Replace .5
Ignition Switch Replace .5
Blackout Light Switch Replace .5
B-9
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
06 Electrical System (Continued)
Stoplight Switches Replace .3
Neutral Safety Switch Adjust .2

Replace .5
Relays Replace .5
Warning Lights Replace .5
0609 Headlights Inspect .1

Adjust .5
Replace .2
Lights, Dome, Blackout, Inspect .1

Indicator Clearance, Replace .4
Composite, Work Repair .2
0610 Sending Units Test .2

Replace .2
Buzzer Warning System Inspect .1

Replace .2
Low Air Pressure Inspect .1

Switches Replace .2
Fuel Restriction Sensor Replace .3
0612 Batteries Inspect .1

Test .3
Service .1
Replace 1.0
Battery Box Inspect .1

Replace 1.4
Battery Cables and Service .3

Terminals Replace .7
NATO Connector Replace .5
B-10
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
06 Electrical System (Continued)
0613 Cab Wiring Harness Test B B

Replace 16.0
Repair A,C A A,C
Engine Wiring Harness Test B

Repair 6.0 B
Replace A,C A A,C
Chassis Wiring Harness Test B B

Replace 14.0
Repair A,C A A,C
Chassis/Engine Test B B
Wiring Harness Replace 4.0
Repair A,C A A,C
Trailer Connector Inspect .1

Test .1
Replace .4
Repair .6
07 Transmission
0705 1 Shift Control Replace 1.0

Repair 1.5
Shift Cable Inspect .1

Adjust .4
Replace 1.1
0710 Transmission Assembly Inspect .1 .9

Test
Service .8
Adjust 2.0
Replace 16.0
Repair 20.4
Output Range Replace .6
Output Shaft Dustshield Replace .3

& Oil Seal
B-11
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
07 Transmission (Continued)
0714 Governor Replace .4
Modulator Valve Replace .5
0721 Filter Element, Spin-0n Replace .2
Oil Filter Bracket Replace .3
Oil Pan and Gasket Replace 1.1
Internal Filter Element Replace 1.2
Transmission Cooler Replace 2.5
Breather Inspect .1
Service .3
Replace .2
08 Transfer Case
0801 Transfer Case Assembly Inspect .1

Service .3
Replace 4.0
Repair 6.0
0803 2-Speedshift Linkage Adjust .5

Replace .8
Shift Lever Replace .8
Lock-Up Air Chamber Replace .3

Repair .3
0804 Lube Pump Replace .1
Lube Line Replace .1
Breather Inspect .1
Service .2
Replace .2
B-12
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
09 Propeller Shafts
0900 Propeller Shafts/ Inspect .2

Universal Joint Service .1
Replace .6
Repair .6
Cardan Joint Inspect .2

Repair 1.0
Pillow Block Inspect .1

Replace 1.0
10 Front Axle
1000 #1 Axle Assembly Inspect .1

Service .6
Replace 3.0
Repair 5.0
Axle Shaft/Cage Ring Replace 2.0

Assembly Repair .5
Lockout Chamber Replace 1.0

Repair 3.0
Axle Shift Unit Replace .5

Repair .6
Axle Breather Inspect .1

Service .2
Housing Oil Seal Replace 2.2
1002 Nose Box/Carrier Replace 5.0

Assembly Repair 9.0
Nose Box Breather Replace .5
Nose Box Lube Pump Replace .6
Nose Box Companion Replace 1.0

Flange
B-13
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
10 Front Axle (Continued)
Oil Seals Replace 1.0
1004 Ball Socket Replace 2.6
Ball Socket Bushing Replace 2.6
Trunnion Bearing Inspect .4

Replace 1.0
Steering Arm Replace 1.2
11 Rear Axles
1100 #2, 3, and 4 Axles Inspect .1

Service .5
Replace 3.0
Repair 4.0
Axle Shaft Replace .4
Lockout Chamber Replace 1.0

Repair 3.0
#3 Axle Shift Unit Replace .5

Repair .6
Axle Breather Inspect .1

Service .2
1102 #3 Axle Differential Replace 5.0

Carrier Repair 4.0
#3 Axle Housing Cover Replace 1.0

Repair .5
#3 Axle Differential Replace 2.0

Carrier Cover Repair 1.5
#3 Axle Companion Replace .8

Flange
B-14
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
11 Rear Axles (Continued)
#2 and 4 Axle Replace 2.0

Differential Carrier Repair 3.0
#2 and 4 Axle Carrier Replace .8

Yokes
#2 and 4 Axle Carrier Oil Replace .5

Seals
12 Brake System
1202 Brakes Inspect .2

Adjust .3
Brake Shoes Replace 1.2

Repair 1.0
#1 Axle Wedge Replace 3.0

Assembles
#1 Axle Brake Spider Replace 1.5
#2, 3, and 4 Axle Replace 2.4

Camshaft & Slack
Adjusters
Spider Bracket Replace 1.5
1208 Brake Chambers Replace .5

Repair .5
Brake Treadle Valve Replace 1.7

Repair .5
Relay Valve Replace .6

Repair .3
Quick Release Valve Replace .3
Pressure Protection Valve Replace .3
B-15
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
12 Brake System (Continued)
Spring Brake Control Replace .5

Valve
Parking Brake Valve Replace .3

Repair .3
Tractor Protection Valve Replace .3
Air Hoses and Tubing Inspect .1

Replace .2
Quick Disconnect Replace .3

Fittings
Air Reservoir and Valves Replace 1.5
Glad Hands Replace .2
1209 Air Compressor Inspect .1

Replace 1.5
Repair 2.0
Air Governor Adjust .2

Replace .3
Air Dryer Service 1.4

Replace .4
Repair 1.0
1211 Hand Control Valve Replace .6

Repair .6
Trailer Air Supply Valve Replace .3
Traction Control Valve Replace 1.0
13 Wheels and Tires
1311 Drum Assembly Replace 2.0

Repair 2.0
B-16
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
13 Wheels and Tires (Continued)
Wheel Bearing Service 1.0

Replace .8
Wheel with Tire Inspect .1

Replace .8
1313 Tire Replace .4

Repair A A
14 Steering System
1401 Steering Wheel Replace .6
Steering Column Replace .9

Repair 1.0
Steering Linkage & Inspect .5

Universal Joint Adjust 1.0
Replace 1.3
Draglink Inspect .1
Adjust 1.0
Replace 1.0
Repair 1.0
Tie Rod Inspect .1

Adjust 1.0
Replace .2
Repair 1.0
Pitman Arm Inspect .1

Replace 1.0
Bell Crank Inspect .1

Replace 1.6
Repair 1.0
90° Gear Box Replace 1.5

Repair 1.0
B-17
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
14 Steering System (Continued)
Fuse Link Assembly Replace .5

Repair 1.0
Yaw Feedback Linkage Inspect .1

Adjust .5
Replace 1.5
Steering Shaft Replace 1.0

Assemblies Repair .5
1407 Steering Gear Inspect .1

Adjust .5
Replace 2.6
Repair 2.0
1411 Steering System Hoses Replace .3

and Fittings
15 Frame
1501 Frame Assembly Inspect .4

Repair A A
Rear Cab Support Replace 1.2
Front Cab Support Replace 5.0
Radiator Support Replace 8.0
Engine Support Replace 3.0
Suspension Brackets Replace 10.0
Inner Suspension Replace 2.0

Brackets
Suspension Bracket Cross Replace 2.0

Tube
Rear Crossmember Replace 3.0
B-18
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
15 Frame (Continued)
Rear Intermediate Replace 3.0

Crossmember
1503 Pintle Hitch Service .1

Replace .4
Articulation Joint Replace 10.0

Repair 3.0
1506 Fifth Wheel Inspect .1

Service .3
Adjust .5
Replace 1.0
Repair 3.0
Fifth Wheel Ramps Inspect .1

Service .1
Replace .4
1507 Landing Leg Assembly Replace 1.5

Repair 1.0
Support Leg Assembly Replace .5
16 Springs and Shock Absorbers
1601 Spring Assembly Inspect .1

Replace 4.0
Spring Seat Assembly Replace 6.0

Repair 2.0
1604 Shock Absorber and Inspect .1

Bushings Replace .3
1605 Torque Rods (each) Inspect .1

Replace 1.0
B-19
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
18 Cab and Body
1801 Cab Inspect .1

Service .1
Replace 4.0
1801 Door Adjust .3

Replace 1.0
Repair 3.0
Mud Flaps Replace .5
Skid Plate/Grille Replace 2.0

Assembly
Engine Access Door Replace 1.2
Engine Access Panels Replace .2
1802 Cab Glass Inspect .1

Replace 1.2
Door Glass and Glass Inspect .1

Regulator Replace .5
1806 Seat Cushions Replace .3
Seat and Frame Assembly Replace .3
1808 Stowage Boxes Replace .4
1810 Cargo Body Replace 4.0
Cargo Body Sides Replace .2

Cargo Tie Downs Replace .2
20 Winches and Cranes
2001 Winch Assemblies Inspect .1

Replace 1.2
Repair 4.0
B-20
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
20 Winches and Cranes (Continued)
Counterbalance Valve Replace 1.0

Repair 1.0
Hydraulic Motor Replace 1.0

Repair 1.0
Winch Brake Replace 1.2

Repair 1.0
Crane Assemblies Replace 6.0

Repair 30.0
Number One Boom Replace 2.0

Extension Repair 1.5
Number Two Boom Replace 2.5

Extension Repair 1.5
Wear Pads Replace .6
Folding Boom Replace 4.0

Repair 2.0
Main Boom Replace 6.0

Repair 2.0
Outrigger Beam Replace 1.2

Repair 1.0
Number One Extension Replace 1.5

Cylinder Repair 1.0
Number Two Extension Replace 1.5

Cylinder Repair 1.0
Folding Boom Cylinder Replace 1.5

Repair 1.0
Slewing Cylinder Replace 2.5

Repair 2.0
B-21
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
Outrigger Cylinder Replace 1.5

Repair 1.0
Stabilizer Cylinder Replace 1.0

Repair 1.0
A-Frame Cylinder Replace .8

Repair 1.2
Main Control Valve Replace 3.0

Repair 4.0
Holding Valve Replace .8
Capacity Alert Dump Replace 1.0

Valve
Needle Adjustment Valve Replace .3
Pre-Tension Valve Replace .5
Right Side Control Replace 1.2

Valve Repair 1.0
Accumulator Replace .6
Repair .6
Actuator Box Replace 1.0

Repair 2.0
Selector/Locking Valve Replace .4
Electrical Failure Valve Replace .4

Repair .4
Overload Protection Adjust 1.0
Remote Control Replace .1

Assembly
(MK15 and MK17) Repair 2.0
B-22
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
Remote Control Replace .1

Assembly (MK16) Repair 1.0
Junction Box Replace 1.5
Proximity Switch Replace .5
Crane Assemblies Inspect 0.1

(LVSA1) Service 2.0
Test 0.2 0.2
Replace 4.0
Repair 0.5
Boom Assembly Replace 8.0
Erection Cylinder Replace 4.0

Repair 4.0
Lift Cylinder Replace 2.0

Repair 4.0
A-Frame Cylinder Repair 2.0
Tension Link Cylinder Replace 0.2
Mast Assembly Replace 0.6
Extension Cylinder Replace 0.7

Repair 0.8
Jack Cylinder Replace 3.0

Repair 5.0
Outrigger Beam Replace 3.0
Boom Mid-Section/ Adjust 0.3

Telescopic Cylinder Replace 2.0
Repair 4.0
Boom Fly Section Adjust 0.6

Replace 0.8
B-23
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
Boom Base Section Replace 3.0
Hoist Assembly Replace 1.4

Repair 5.3
Hoist Hydraulic Motor Replace 0.2

Repair 5.3
Oil Filled Disc Brake Replace 2.0

Assembly Repair 1.0
Gear Set Repair 1.7
Cross Relief Valve Replace 0.1

Repair 0.1
Two-way Solenoid Replace 1.3

Valve Repair 2.1
Four Function Electric Replace 0.8

Control Valve (MK15A1) Repair 1.1
Four Function Electric Replace 0.8

Four Function Manual Replace 0.8

Four Function Manual Replace 0.8

Three Function Manual Replace 0.8

Control Valve Repair 1.1
Unloader Valve Replace 0.3

Repair 0.3
Hoist Control Valve Replace 0.3
Holding Valve Replace 0.2
B-24
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
Accumulator Service 0.2

Replace 0.2
Turntable Replace 1.7
Turntable Bearing Replace 2.4
Tension Load Cell Replace 0.8
Overload Shutdown Replace 1.3
Cable Follower Replace 0.7

Repair 0.6
Proximity Sensor Replace 0.8
Swing Drive Assembly Replace 4.0

Repair 4.0
Swing Drive Orbit Replace 1.0

Assembly Repair 3.0
Swing Drive Brake Replace 2.0

Repair 1.0
Junction Box Replace 0.4
Remote Control Stowage Replace 0.3

Box (MK17A1)
Tilt Sensor and Alarm Replace 0.8
Hoist Cable Replace 1.0
Hook Block Assembly Replace 0.5

Repair 0.5
Boom Sheave Replace 0.4
Power Cable Replace 0.4
B-25
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
Remote Control Harness Replace 0.3
Overload Shutdown Replace 0.4

Cable
Control Solenoid Cable Replace 0.3
Tilt Sensor Harness Replace 0.3
Remote Control Box Replace 1.0

Repair 0.4
22 Body Accessory Items
2202 Windshield Wiper Motor Replace .6
Windshield Wiper Arm Replace .2
Windshield Wiper Blade Replace .1
Wiper Control Valve Replace .3
Windshield Washer Replace 1.0

Control Valve
Washer Reservoir Hoses Replace 1.0

and Nozzles
Mirrors Replace .3
Air Horn Replace .2

Repair .2
Air Horn Valve Replace .5
Electric Horn Replace .2
Heater Replace 1.5
Heater Core Replace .8
B-26
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
22 Body Accessory Items (Continued)
Heater Hoses and Fittings Replace .5
Defroster Hoses, Replace 1.0

Plenums, and Controls
24 Hydraulic System
2400 Hydraulic System Inspect .2

Service 1.0
Test 2.0
2401 Hydraulic Pump Inspect .1

Replace 1.7
Repair 1.0
Pump Driveshaft Replace 1.0

Repair .5
Fan Drive Motor Replace 4.0

Repair 2.0
Accumulator Service 1.0

Replace 1.5
2402 Priority Flow Valve Replace 1.5

Repair 1.0
Flow Control Valve Replace 1.0

Repair 1.3
Steering/Auxiliary Replace .6
Selector Valve Repair 1.0
Yaw Relief Valve Replace .3

Repair .3
Fan Control Valve Replace 1.5

Repair 1.0
Motion Control Replace 1.5

Repair 1.0
B-27
TM 08780B-20
(1) (2) (3) (4) (5) (6)

EQPT.
24 Hydraulic System (Continued)
Demand Valve Replace 1.5

Repair 1.0
Yaw Control Valve Inspect .1

Replace 1.0
Repair 1.0
Hydraulic Manifold Replace 1.5
Hydraulic Oil Cooler Replace 1.0

Repair A A
Selector Relief Valve Replace .8

Assembly Repair .5
2406 Hydraulic Filter Replace .2
Hydraulic Lines and Replace .3

Fittings
2407 Yaw Cylinders Inspect .1

Replace 1.0
Repair 1.0
2408 Hydraulic Reservoir Service .5

Replace 3.0
34 Special Purpose Kits
3401 Machine Gun Kit Replace .4
47 Non-Electrical Gauges
4702 Air Pressure Gauge Inspect .1

Replace .2
B-28
TM 08780B-20
Section III. Tool and Test Equipment Requirements
(1) (2) (3) (4) (5)

Reference Maintenance National/NATO Tool
Code Level Nomenclature Stock Number Number
ENGINE
O Tool Set, Fuel Pump 5180-00-219-8407 J 1508 D

O Camshaft, Gear Puller 5120-00-219-8397 J 1902-01
F Stud Set, Alignment (Set of 4) 5120-00-629-9781 J 1927-01
H Piston to Liner Feeler Gauge Set 5120-00-116-1631 J 5438-01
H Cam Follower Service Fixture 2815-00-705-9278 J 5840-01
H Blower Service Tool Set 5120-00-936-4376 J 6270-F
H Remover, Valve Guide 5120-00-733-8880 J 6569
F Compression Gauge and Hose Assy 4910-00-785-6437 J 6692
H Valve Spring Compressor 5120-00-733-8888 J 7455
H Installer, Bridge Guide 5120-00-999-8616 J 7482
H Magnetic Base Dial Indicator 5120-00-402-9619 J 7872
F Compression Gauge Adapter 5120-00-254-5276 J 7915-02
F Remover, Camshaft Gear & Water Pump 5120-00-733-8890 J 7932
Pulley
H Brass Wire Brush 5130-00-937-7281 J 7944
H Piston Ring Remover and Installer 5120-00-494-1846 J 8128
F Expander, Crankshaft Rear Oil Seal 5120-00-336-0445 J 4239
H Water Pump Oil Seal Installer 5120-00-937-7267 J 8501
F Wrench, Fuel Line Nut 5120-00-019-5232 J 8932-01
F Governor Cover and Bearing Installer 4910-00-779-6078 J 21068
H Flywheel Housing Seal Installer 5120-01-166-5422 J 21112-B
H Reamer, Injector Body 5110-00-937-7628 J 21089
H Installer, Valve Guide 5120-00-999-8617 J 2152
F Fixture, Lifting, Cylinder Head 4910-00-456-7620 J 22062-01
H Lapping Block Set 5220-00-020-5116 J 22090-A
H Micrometer Ball Attachment 5120-00-494-1738 GGG-C-105
H Injector Vise & Rack Freeness Tester 4910-00-950-3119 J 22396-A
H Tool Set, Injector Tube Reconditioning 2910-00-146-9619 J 22525-A
F Injector Test Kit 4940-01-148-7876 J 23010-A
H Cylinder Block Plug Remover/ Installer 5120-00-130-8864 J 23019
H Injector Service Kit 5220-01-038-0251 J 23435-02
H Valve Seat Insert Remover Set 5120-01-165-1935 J 23479-D
H Needle Valve Lift Gauge 5120-00-937-7285 J 9462-02
H Tool, Piston Pin Retainer 5120-00-127-7727 J 23762-A
H Piston Pin Retainer Leak Detector 5120-01-158-3982 J 23987-01
H Installer, Valve Seat Insert 5120-01-048-3118 J 24357
H Cylinder Liner Remover Assembly 4910-01-158-3982 J 24563-A
H Cylinder Liner Hold Down 4910-01-158-3984 J 24565-02
F Cylinder Head Guide Stud Set 4910-01-162-3630 J 24748
H Installer, Water Nozzle 5120-01-048-3119 J 24857-A
H Cylinder Liner Depth Gauge 5210-01-174-4498 J 24898
H Installer, Water Pump Drive Gear 5120-00-033-8902 J 25257
F Installer & Remover, Aftercooler Water 5120-01-048-2180 J 25275
Inlet Adapter
H Piston Crown I-D Gauge 5120-00-130-8869 J 25397
F Gauge, Pin Throttle Delay Cylinder 5120-00-138-7558 J 25558
B-29
TM 08780B-20
Section III. Tool and Test Equipment Requirements (Continued)
(1) (2) (3) (4) (5)

ENGINE (Continued)
F Gauge Throttle Delay Cylinder 5120-00-138-7559 J 25560

F Cylinder Head Test Fixture 4910-01-158-3958 J 28454
H Sled Gauge 5220-01-170-4918 J 29091
H Injector Tip Concentricity Gauge 5210-00-990-3327 J 29584
F Tool, Blower Shaft Aligner 4910-01-158-3991 J 33001
H Piston Groove Gauge 5220-00-028-1109 J 24599
F Idler Gear Bearing Installation Plate 5180-01-167-4285 2SK900
H Cylinder Block Pressure Kit 2SK737
H Crankshaft Front Oil Seal Installer 5120-00-936-4377 J 9783
H Cylinder Hone and Glaze Breaker 5130-00-629-9782 J 5902-01
H Valve Bridge Guide Remover 5120-00-999-8614 J 7091-01
F Driver, Handle 3/4 In. 5120-00-677-2259 J 8092
H Dial Gauge J 8165-2
F Rear Oil Seal Sleeve Installer J 21983
F Spring Tester 5120-00-937-7265 J 9666
F Injector Rack Gauge (.454) 5120-00-538-8465 J 23190
F Guide Studs 5120-01-048-2155 J 25002
H Water Pump Seal Remover 5120-01-163-0333 J 22150-B
F Injector Timing Gauge (1.466) 5110-01-160-2614 J 26888
F Injector Nut Seal Ring Installer 5120-01-170-4924 J 29197
O Tester, Cooling System J 24460-01
H Ring Compressor 4910-01-158-3974 J 24227
F Injector Nut Socket 5120-00-219-8409 J 4983-01
TRANSMISSION
F Seal and Dust Shield Remover (Puller 5120-01-048-2153 J 24171

Kit)
H Mainshaft Lifting Bracket 4120-01-115-1157 J 24196
H Front Support Hub Needle Bearing 5120-01-115-1160 J 24197
Installer
H Dust Shield (Front Seal) Inst. 5120-01-054-4049 J 24198
H Collector Ring Installer & Staker 5120-01-048-3124 J 24200
F Output Shaft Seal Installer 5120-01-054-4042 J 24202-1A
F Drive Handle 5120-01-054-4048 J 24202-4
H Output Shaft Bushing Installer 5120-01-115-9174 J 24203
H Clutch Spring Compressor Set 5120-01-048-3129 J 24204
H Center Support Compressor Assembly 5120-01-116-5016 J 24208-D
H Low and First Clutch Piston Inner Seal 5120-01-048-2156 J 24210
Protector
H Forward Clutch Seal Protector 5120-01-048-2157 J 24216-01
H Stator Cam Spring & Roller Retainer 5120-01-115-1158 J 24218-2
Ring
H Lock-Up Valve & Main Pressure 5120-01-048-2160 J 24219
Regulator Spring Compressor
H Fourth Clutch Alignment Fixture 5120-01-115-1156 J 24221
H Transmission Holding Fixture 61373
B-30
TM 08780B-20
(1) (2) (3) (4) (5)

TRANSMISSION (Continued)
H Valve Ring Adjustment Tool 5120-01-048-9917 J 24314

H Flywheel Lifting Bracket 5120-01-116-6049 J 24365
H Rear Bearing Installer 5120-01-054-4054 J 24447
H Shift Lever Seal Installer 5120-01-115-1161 J 26282
H Center Support Bushing Installer and 4910-01-158-3971 J 28525
Staking Set
F Flange Yoke Holding Bar J 3453
H Guide Pin Set 5120-01-115-1163 J 24315
H Remover/Installer Converter Pump Snap 4910-01-158-3996 J 26598-A
Ring
H Spring Tester J 9666
H Fourth Clutch Lifting Fixture J 24209
PTO Gear Removing Fixture 4910-00-158-3969 J 26899
FRONT AXLE
O Wrench, Wheel Bearing, Front 14139

H Socket, Nose Box 2CB157
F Torque Multiplier J 6985
O Cramp Angle Tool 1532210
O Run Flat Tool 1818
REAR AXLE
O Handle, Seal Installer Rd296

O Adapter, Seal Installer Rd291
O Pilot, Seal Installer Rd414
BRAKE SYSTEM
H Unloader Bore Bushing Removal Tool 12BF829
TRANSFER CASE
H Socket 2CS641
H Flywheel Lifting Device 5120-00-132-5447 J 25026
H Lifting Eye 2CS638
H Differential Assembly Lifting Device 2CS639
H 2 Speed Shift Shaft Assy Spacer from 2CS640
Main Helical Gear to End of Shaft
CRANE
F Chain Wrench CW24

H Adjustable Hook Spanner Wrench Set 304AHSK
H Snap Ring Pliers Set S111-25-2923
F Long Nose Pliers S111-25-2848
B-31
TM 08780B-20
(1) (2) (3) (4) (5)

CRANE (Continued)
F Accumulator Charging & Gauge S111-25-3096

Assembly
F Dowel Pin Wrench 1266
O Test Hose 4720-01-373-9871 HFF20-060
O 0-6000 PSI Gauge 6685-01-373-7976 151469
O Gauge Adapter 4730-01-373-0474 GAH20-1/4
NPTV
O Pressure Test Coupling 4820-01-312-9207 TCM20-1/4
NPTV
O Quick Disconnect 4730-01-264-0689 FD90-1021-04-
04
F Test Hose Assembly 2HP877
F ORS/SAE Reducer Adapter 4730-01-373-0096 FF2281T-0812S
F ORS/SAE Reducer Adapter 4730-01-373-0097 FF2281T-0612S
F Coupling Half, Quick Disconnect 4730-01-416-1641 TCM20-9/16
UNF-V
F Adapter 4730-01-213-1017 FF2031T-0404S
F ORS/NPTF Adapter FF2000T-0404S
F ORS/ORS Adapter FF2000T-0606S
F ORS/ORS Adapter FF2000T 0808S
F Fitting F090-1034-04-
04
F ORS/SAE Reducer Adapter FF228T-0412S
F Test Adapter 031-300-060-014
COMMON
F Outside Micrometer Set (0-6) 5210-00-554-7134 GGG-C-105

F Inside Micrometer Set (0-6) 5210-00-473-9350 GGG-B-17
O Jack Stands 10 Ton 93525
H Torx Socket (E-10) FLE100
O 7/8 in. Torque Adapter 1/2 in. dr. SRES28
O Crimping Tool (Deutsch) HDT 48-00
O Square, Carpenter 5210-00-810-3490 GGG-S-656
O Chalk Line 5210-00-273-9793 GGG-C-291
O Plumb Bob 5210-00-234-8949 GGG-P501
O Extraction Tool (Deutsch) 5120-01-158-4707 114010
O Vacuum Pump Kit 2217
O Reservoir Cap 4549
O Terminal Remover, Weatherpack 5120-01-374-8969 J36400-5
O Crimper, Weatherpack 5120-01-374-8936 J38852
B-32
TM 08780B-20
Section IV. Remarks
REFERENCE REMARKS
CODE
A No specific times established. Times required for replacement or repair will
depend on extent of work required.
B No specific times established. Times required for test will depend on the
extent of testing required.
C In the “O” category repair is limited to splicing of wires, taping of the
harness or wires, and the replacement of wire ends.
D Fan Drive Motor and Fan Control Valve are located in the Hydraulic System.
B-33/(B-34 blank)
TM 08780B-20
APPENDIX C
REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
Repair parts, special tools and equipment for Organizational Maintenance are listed in
TM 08780B-24P, which is the authority for requesting replacements.
C-1/(C-2 blank)
TM 08780B-20
APPENDIX D
EXPENDABLE SUPPLIES AND MATERIALS LIST
Section I. Introduction
D-1. SCOPE. This appendix lists expendable supplies and materials you will need to operate
and maintain the LVS.
D-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 to identify the materials (e.g., “Retaining compound, item 13,
Appendix D”).
b. Column(2)-Level. This column identifies the lowest level of maintenance that

requires the listed item.
C - Operator/Crew
O - Organizational Maintenance
F - Direct Support Maintenance
H - General Support Maintenance
c. Column (3)-National Stock Number. This is the National stock number assigned
to the item; use it to request or requisition the item.
d. Column(4)-Description. Indicates the Federal item name and, if required, a

description to identify the item. The last line for each item indicates the Federal Supply Code for
Manufacturer (FSCM) in parentheses followed by the part number.
e. Column (5)-Unit of Measure (U/M). Indicates the measure used in performing

the actual maintenance function. 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, requisition the
lowest unit of issue that will satisfy your requirements.
D-1
TM 08780B-20
Section II. Expendable Supplies and Material List
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK
NUMBER LEVEL NUMBER DESCRIPTION U/M
1 O Additives for Depot MIL-S-53021
Fuel System Biocide (45152) 111198A
2 O Adhesive (45152) 32167AX
2.1 O Adhesive, Jetmelt (45152) 1502520
3 F 8030-01-135-0685 Adhesive, Loctite 242 (45152) 65270AX 50 ml
4 F Adhesive, Sikaflex 221 (45152) 1414680
4.1 O Adhesive, Sikaflex 255 FC Black (45152) 3145938 OZ
5 O Adhesive-Sealant, Silicone. RTV

MIL-A-46106A (45152) 24758FX
5.1 O Adhesive, Weatherstrip (45152) 32167-AX OZ
6 O Alcohol, Isopropyl MIL-A-10-428 (45152) 144553 OZ
7 C Anti-Freeze, Coolant AFC Ethylene Glycol

MIL-A-11755
1 Gallon Can GAL
55 Gallon Drum GAL
8 C Anti-Freeze, Coolant AFC Ethylene Glycol MIL-

A-46153
1 Gallon Can GAL
55 Gallon Drum GAL
8.1 O Biobor JF MIL-S-53021 QT
9 O Cement, General Purpose, Synthetic Base

MIL-C-4003
(45152) 25431 AX
10 O 8030-00-616-7694 Compound, Antiseize, High Temperature LB

MIL-A-907D
(45152) 1302130
11 O Compound, Corrosion Preventive (45152) 65123

BX
11.1 O Compound, Corrosion Preventive (45152) 1388330
D-2
TM 08780B-20
Section II. Expendable Supplies and Material List (Continued)
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK
11.2 O
Compound, Anti-corrosion Conductive OZ
(71984) DC4-20
12 F Compound, Electrical Joint

Sheller Globe Corp. (35510)
13 F 8030-00-180-6222 Compound, Retaining (08028) Loctite 609 50 ml
14 F Compound Retaining 50 ml
Loctite 680 (45152) 84151 AX
14.1 O 6850-00-294-0860 Compound Silicone (72984) DCIII OZ

5 Ounce Tube
15 O Crocus Cloth ROLL
15.1 O Electricor VCI-238 (44695) OZ
16 O Epoxy Primer (Catalyst Component)

MIL-P-52192B (45152) 126224AX
17 O Epoxy Primer (Resin Component)

MIL-P-52192B (45152) 126223AX
18 F Epoxy, Red Air Dry Westinghouse

(89481) B-6-66S
19 F Grease, Chevron (58867) SRI-2
20 C Grease, Aircraft (81349) M81322
21 C Grease, General Purpose NLGI #2 MIL-G-23549C
22 C Grease. General Purpose NLGI #2 MIL-G-10924C
23 O Grease, Lithium Lubriplate (07748) 5555
24 F Grease, Moly (96584)
25 O Grease, Oil Soluble (Petroleum Jelly)
26 F Lubricant, Silicone Dow-Corning (71984) 55-M
D-3
TM 08780B-20
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK
27 C Oil, Fuel, Diesel DF-1 Winter VV-F-800
9140-00-286-2594 Bulk GAL
9140-00-286-2595 5 Gallon Can GAL
9140-00-286-2596 55 Gallon Drum, 16 Gauge GAL
28 C Oil, Fuel, Diesel DF-2 Regular VV-F-800

9140-00-286-2586 Bulk GAL
9140-00-286-2587 5 Gallon Can GAL
29 C Oil, Fuel, Diesel DF-A Arctic

9150-00-286-5283 Bulk GAL
9150-00-286-5282 5 Gallon Can GAL
30 C Oil, Gear 85/140 API GL-5 SAE BSW/140

MIL-L-2105C
1 Qt. Can QT
5 Gallon Drum GAL
55 Gallon Drum GAL
31 C Oil, Gear 80/90 API GL-S SAE 80W/90

MIL-L-2105C
1 Qt. Can QT
5 Gallon Drum GAL
55 Gallon Drum GAL
32 C Oil, Gear 75 SAE 75W MIL-L-2105C

1 Qt. Can QT
5 Gallon Drum GAL
55 Gallon Drum GAL
33 C Oil, Lubricating, Engine, OE/HDO 10 C-3

Trans Fluid, SAE 10W MIL-L2104D
1 Qt. Can QT
5 Gallon Drum GAL
55 Gallon Drum, 16 Gauge GAL
D-4
TM 08780B-20
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK
34 C Oil, Lubricating, Engine, OE/HDO-10 API
CD-SF, SAE 10W MIL-L-2104D
1 Qt. Can QT
5 Gallon Drum GAL
Bulk GAL

CD-SF, SAE 30 MIL-L-2104D
1 Qt. Can QT
5 Gallon Drum GAL
Bulk GAL

SE-CC, SAE 50
1 Qt. Can QT
5 Gallon Drum GAL
Bulk GAL
37 C Oil, Lubricating, Engine API CD-SF,

SAE 10W-30 MIL-L-46152B
1 Qt. Can QT
5 Gallon Drum GAL
Bulk GAL
38 C Oil, Lubricating, Engine OEA MIL-L-46167

1 Qt. Can QT
5 Gallon Drum GAL
39 F 5330-01-051-3373 Plastic Gasket, Loctite 510, (45152) 25824AX 50 ml
40 O Polyurethane Paint, Black MIL-C-46168

(For Stenciling) (45152) 1475970
D-5
TM 08780B-20
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK
41 O Polyurethane Paint (Catalyst Component)
MIL-C-46168 (B) (MR) (45152) 1351440
42 O Polyurethane Paint (Resin Component)

Lusterless Forest Green MIL-C-46168 (B) (MR)
(45152) 1351430
43 O Polyurethane Paint, White

MIL-C-46168B (45152) 1430270
43.1 O Primer, Sikaflex, Cleaner 205, (45152) 3145939 OZ
44 O Sandpaper (000)
45 O 8030-01-137-6964 Sealant, Loctite 515 (45152) 25824AX 50 ml
45.1 O Sealant, Ultra Blue 587
46 O 8030-00-339-0310 Sealant, Hydraulic, Loctite 569 (45152) 5643AX
47 Sealant, Metal 3M, 2084, (45152) 1317520
48 O 8030-01-054-0740 Sealant, Pipe, Loctite 592, (45152) 46642AX 50 ml
49 O Sealer, Permatex #2, (45152) 702348X OZ
50 O 8030-01-058-6070 Sealing, Lubricating and Wicking Compounds,

Thread Locking, Anaerobic, Single Component
MIL-S-46163 (Type I, Grade L)
Loctite 271, (45152) 45244AX 50 ml
51 C Sodium Bicarbonate LB
52 F Solder 96/4 ROLL
53 O Solvent, Dry Cleaning (81348) P-D 680

1 Qt. Can QT
1 Gallon Can GAL
5 Gallon Can GAL
D-6
TM 08780B-20
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK
54 O Solution, Soap
55 O Tape, Electrical Roll
56 O Tape Filament, Motor Wheel (18850) 8985 ROLL
57 O Tape, Masking ROLL
58 O Tape, Thread Sealing (Teflon) FT

50-Ft. Roll, 1/2 Inch Wide
59 O Thinner, Aliphatic, Polyurethane Coating

MIL-T-81772 (45152) 1351450
60 O Walkway Compound, Nonslip

Walkway Matting, Nonslip
MIL-W-5044C (45152) 1330480
60.1 O VCI-326 (44695) GAL
60.2 O VCI-329 (44695) GAL
60.3 O VCI-386 (44695) GAL
61 O Vegetable Based Tire Bead Lubricant
D-7/(D-8 blank)
TM 08780B-20
APPENDIX E
ILLUSTRATED LIST OF MANUFACTURED ITEMS
An illustrated list of manufactured items is not applicable to this manual.
E-1/(E-2 blank)
TM 08780B-20
APPENDIX F
TORQUE LIMITS
F-1. GENERAL. This section provides general torque limits for fasteners used on this truck.
Special torque limits are indicated in the maintenance procedures for applicable components.
The general torque limits given in this appendix shall be used when specific torque limits are not
indicated in the maintenance procedure. These general torque limits cannot be applied to screws
that retain rubber components. The rubber components will be damaged before. the correct
torque limit is reached. If a special torque limit is not given in the maintenance instructions,
tighten the screw or nut until it touches the metal bracket, then tighten it one more turn.
F-2. HOW TO USE TORQUE TABLE. Table F-1 lists dry torque limits. Dry torque limits
are used on screws that do not have lubricants applied to the threads. Table F-2 lists wet torque
limits. Wet torque limits are used on screws that have high pressure lubricants applied to the
threads. Table F-3 lists wet torque limits for Spiralock flange nuts. All flange nuts used on this
vehicle use Spiralock threads. Use the charts as follows:
NOTE
Use diameter and thread pitch gauges if available.
a. Measure the diameter of the screw you are installing.
b. Count the number of threads per inch.
F-1
TM 08780B-20
c. Under the heading SIZE, look down the left hand column until you find the
diameter of the screw you are installing (there will usually be two lines beginning with the same
size).
d. In the second column under SIZE, find the number of threads per inch that
matches the number of threads you counted in step (2).
e. To find the grade screw you are installing, match the markings on the head to the
correct picture of CAPSCREW HEAD MARKINGS on the torque table.
f. Look down the column under the picture you found in step (5) until you find the
torque limit (in foot-pound or N*m) for the diameter and threads per inch of the screw you are
installing.
F-2
TM 08780B-20
Table F-1. Torque Limits for Dry Fasteners
BOLT HEAD MARKINGS. Manufacturer’s marks may vary Three of the markings on heads
shown below, for example, indicate SAE Grade 5.
TORQUE
SIZE SAE GRADE SAE GRADE SAE GRADE SAE GRADE
No. 1 or 2 NO. 5 NO. 6 or 7 NO. 8
DIA THREADS MILLI- POUNDS NEWTON POUNDS NEWTON POUNDS NEWTON POUNDS NEWTON
INCHES PER INCH METERS FEET METERS FEET METERS FEET METERS FEET METERS
1/4 20 6.35 5.5 7.5 8 10.8 10 13.6 12 16.3

1/4 28 6.35 6.3 8.5 10 13.6 12 16.3 14 19.0
5/16 18 7.94 11 15 17 23.1 21 28.5 25 33.9
5/16 24 7.94 12 16.3 19 25.8 24 32.5 25 33.9
3/8 16 9.53 20 27.1 30 40.7 40 54.2 45 61.0
3/8 24 9.53 23 31.2 35 47.5 45 61.0 50 67.8
7/16 14 11.11 30 40.7 50 67.8 60 81.4 70 94.9
7/16 20 35 47.5 55 74.6 70 94.9 80 108.5
1/2 13 12.70 50 67.8 75 101.7 95 128.8 110 149.2
1/2 20 55 74.6 90 122.0 110 149.2 120 162.7
9/16 12 14.29 65 88.1 110 149.2 135 183.1 150 203.4
9/16 18 75 101.7 120 162.7 150 203.4 170 230.5
5/8 11 15.88 90 122.0 150 203.4 190 257.6 220 298.3
5/8 18 100 135.6 180 244.1 210 284.8 240 325.4
3/4 10 19.05 160 217.0 260 352.6 320 433.9 380 515.3
3/4 16 180 244.1 300 406.8 360 488.2 420 569.5
7/8 9 22.23 140 189.8 400 542.4 520 705.1 600 813.6
7/8 14 155 210.2 440 596.6 580 786.5 660 895.0
1 8 25.40 220 298.3 580 786.5 800 1084.8 900 1220.4
1 12 240 325.4 640 867 8 860 1166.2 1000 1356.0
1-1/8 7 25.58 300 406.8 800 1084.8 1120 1518.7 1280 1735.7
1-1/8 12 340 461.0 880 1193.3 1260 1708.6 1440 1952.6
1-1/4 7 31.75 420 569 5 1120 1518.7 1580 2142.5 1820 2467.9
1-1/4 12 460 623.8 1240 1681.4 1760 2386.6 2000 2712.0
1-3/8 6 34.93 560 759.4 1460 1979.8 2080 2820.5 2380 3227.3
1-3/8 12 640 867.8 1680 2278.1 2380 3227.3 2720 3688.3
1-1/2 6 38.10 740 1003.4 1940 2630.6 2780 3769 7 3160 4284.9
1-1/2 12 840 1139.0 2200 2983.2 3100 4203.6 3560 4827.4
F-3
TM 08780B-20
Table F-2. Torque Limits for Wet Fasteners
BOLT HEAD MARKINGS. Manufacturer’s marks may vary Three of the markings on heads
shown below, for example. indicate SAE Grade 5.
TORQUE
SIZE SAE GRADE SAE GRADE SAE GRADE SAE GRADE
No. 1 or 2 NO. 5 NO. 6 or 7 NO. 8
DIA THREADS MILLI- POUNDS NEWTON POUNDS NEWTON POUNDS NEWTON POUNDS NEWTON
INCHES PER INCH METERS FEET METERS FEET METERS FEET METERS FEET METERS
1/4 20 6.35 4 5.4 6.25 8.5 8 10.8 9 12.2

1/4 28 6.35 4.7 6.4 7 9.5 9 12.2 10 13.6
5/16 18 7.94 8 10.8 13 17.6 16 21.7 18 24.4
5/16 24 7.94 9 12.2 14 19.0 18 24.4 20 27.1
3/8 16 9.53 15 20.3 23 31.2 30 40.7 35 47.5
3/8 24 9.53 17 23.1 25 33.9 30 40.7 35 47.5
7/16 14 11.11 24 32.5 35 47.5 45 61.0 55 74.6
7/16 20 25 33.9 40 54.2 50 67.8 60 81.4
1/2 13 12.70 35 47.5 55 74.6 70 94.9 80 108.5
1/2 20 40 54.2 65 88.1 80 108.5 90 122.0
9/16 12 14.29 50 67.8 80 108.5 100 135.6 110 149.2
9/16 18 55 74.6 90 122.0 110 149.2 130 176.3
5/8 11 15.88 70 94.9 110 149.2 140 189.8 170 230.5
5/8 18 80 108.5 130 176.3 160 217.0 180 244.1
3/4 10 19.05 120 162.7 200 271.2 240 325.4 280 379.7
3/4 16 140 189.8 220 298.3 280 379.7 320 433.9
7/8 9 22.23 110 149.2 300 406.8 400 542.4 460 623.8
7/8 14 120 162.7 320 433.9 440 596.6 500 678.0
1 8 25.40 160 217.0 440 596.6 600 813.6 680 922.1
1 12 170 230.5 480 650.9 660 895.0 740 1003.4
1-1/8 7 25.58 220 298.3 600 813.6 840 1139.0 960 1301.8
1-1/8 12 260 352.6 660 895.0 940 1274.6 1080 1464.5
1-1/4 7 31.75 320 433.9 840 1139.0 1100 1491.6 1360 1844.2
1-1/4 12 360 488.2 920 1247.5 1320 1789.9 1500 2034.0
1-3/8 6 34.93 420 569.5 1100 1491.6 1560 2115.4 1780 2413.7
1-3/8 12 460 623.8 1260 1708.6 1780 2413.7 2040 2766.2
1-1/2 6 38.10 560 759.4 1460 1979.8 2080 2820.5 2360 3200.2
1-1/2 12 620 840.7 1640 2223.8 2320 3145.9 2660 3606.9
F-4
TM 08780B-20
Table F-3. Wet Torque Limits for Grade 8 Spiralock Flange Nuts
TORQUE
SIZE THREADS POUNDS NEWTON
PER INCH FEET METERS
1/4 20 15 20.3
5/16 18 25 33.9
3/8 16 44 59.7
1/2 13 107 145.1
5/8 11 212 287.5
3/4 10 375 508.5
F-5/(F-6 blank)
TM 08780B-20
APPENDIX G
SCHEMATIC AND WIRING DIAGRAMS
G-1. INTRODUCTION. The following foldouts illustrate the air, electrical and
hydraulic systems of the LVS and LVSA1 series vehicles.
G-2. FOLDOUTS
a. Air System. The following foldouts illustrate the LVS and LVSA1 series
vehicles air system.
FO-1 Air System (1 of 2)

FO-2 Air System (2 of 2)
FO-18 Air System (1 of 3) LVSA1 series vehicles only
FO-36 Air System (1 of 2) ABS modified vehicles only
FO-37 Air System (2 of 2) ABS modified vehicles only
b. Electrical System. The following schematics illustrate the LVS and

LVSA1 series vehicles electrical system.
FO-3 Electrical System (1 of 4)

FO-7 Instrument Panel Wiring
FO-8 Crane Electrical System MK15
FO-9 Crane Electrical System MK17
FO-14 Actuator Box Electronics MK15
FO-15 Actuator Box Electronics MK17
FO-16 Remote Controller MK15
FO-17 Remote Controller MK17
FO-21 LVSA1 Electrical System (1 of 9)
FO-30 Crane Electrical MK15A1/MK17A1 (1 of 2)
FO-31 Crane Electrical MK15A11MK17A1 (2 of 2)
FO-38 ABS Electrical System
G-1
TM 08780B-20
c. Hydraulic System. The following foldouts illustrate the LVS and LVSA1
series vehicles hydraulic system.
FO-10 Hydraulic System (1 of 2)

FO-11 Hydraulic System (2 of 2)
FO-12 Crane Hydraulic MK 15
FO-13 Crane Hydraulic MK 17
FO-32 LVSA1 Hydraulic System (1 of 3)
FO-35 LVSA1 Crane Hydraulics MK15A1/MK17A1 (1 of 1)
G-2
TM 08780B-20
APPENDIX H
STE/ICE CARD
LVS SERIES VEHICLE TEST CARD-VID 18-DCA6
H-1/(H-2 blank)
LVS SERIES VEHICLE TEST CARD-VID 18-DCA6
H-3/(H-4 blank)
TM 08780B-20
TM 08780B-20
APPENDIX I. LVS EXTENDED STORAGE MAINTENANCE PROCEDURES
a. Placing Vehicle in Extended Storage (Vehicle Inactive)
CAUTION
WHEN VEHICLE IS TO REMAIN INACTIVE FOR MORE THAN 12 MONTHS,

EXTENDED STORAGE PROCEDURES MUST BE PERFORMED TO PREVENT
DAMAGE DUE TO RUST, CORROSION OR ORGANIC GROWTH IN THE FLUIDS.
NOTE
When the vehicle is to remain inactive for more than 12 months, extended storage procedures
must be performed to maintain the vehicle warranty.
(1) Chassis and Ancillary Equipment
NOTE
• Completely lubricate the chassis and all ancillary equipment in accordance with
LI 2320-12/9A.
• Push in auxiliary selector valve. Coat shaft with grease.
(2) Crane extended storage (LVSA1 series vehicles only)
a. Apply liberal amounts of grease to the solenoid valve override

button.
CAUTION
TO AVOID OVERFILLING, DRAIN OIL EQUAL TO THE AMOUNT THAT IS BEING

ADDED BEFORE ADDING ADDITIVE OR DAMAGE TO EQUIPMENT MAY RESULT.
b. Drain 2 fl oz (60 ml) of oil from hoist gearbox.
c. Add 2 fl oz (60 ml) of VCI-326 vapor corrosion inhibitor (item

60.1, Appendix D) to the hoist gearbox.
d. Unwind hoist cable from drum, clean and lube with lubricant
(Brilube or equivalent) and rewind cable on drum.
e. Drain .8 fl oz (24 ml) of oil from swing drive gearbox.
f. Add .8 fl oz (24 mi) of VCI-326 vapor corrosion inhibitor (item

60.1, Appendix D) to the crane swing drive gearbox.
g. Operate crane swing and hoist functions to allow additive to coat

all moving parts.
I-1
TM 08780B-20
h. If additional storage time is required, repeat steps (c) thru (g) at

yearly intervals.
(3) Heavy duty winch gearbox extended storage. None required.
(4) Main hydraulic/steering hydraulic system extended storage
CAUTION

a. Drain 4.75 qts (4.5L) of oil from main hydraulic reservoir.
b. Add 4.75 qts (4.5L) of VCI-326 vapor corrosion inhibitor (item

60.1, Appendix D) to main hydraulic reservoir.
c. Operate all hydraulic equipment and hydraulic steering as follows:
1. Heavy Duty Winch - winch out approximately ten feet of

cable, then winch in. Repeat procedure twice.
2. Crane - completely cycle each crane function two times.
3. A-Frame Cylinder - completely extend and retract cylinder

two times.
4. Steering System - with yaw steering activated, turn steering

wheel to full right and then full left. Repeat this cycle three times.
5. If additional storage time is required, repeats steps (a), (b)

and (c) at yearly intervals.
(5) Axle and Nose Box Extended Storage
CAUTION

a. Drain oil from axles and nose box as follows:
1. Axles No. 1, 2 and 4 - 1.65 Pts (.8L).
2. Axle No. 3 - 2 Pts (.94L).
I-2
TM 08780B-20
3. Nose Box - .4 Pts (.19L).
b. Add VCI-326 vapor corrosion inhibitor (item 60.1, Appendix D) at

the following amounts:
1. Axles No. 1, 2 and 4 - 1.65 Pts (.8L).
2. Axle No. 3 - 2 Pts (.94L).
3. Nose Box - .4 Pts (.19L).
c. Drive vehicle approximately 1 mile (1.6 Km) to mix additive.
d. If additional storage time is required, repeat steps (a), (b) and (c) at
yearly intervals.
(6) Transfer Case Extended Storage
CAUTION

a. Drain 1 pt (.5L) of oil from transfer case.
b. Add 1 pt (.5L) of VCI-326 vapor corrosion inhibitor (item 60.1,

Appendix D) to transfer case.
c. If vehicle can be driven, drive vehicle approximately 1 mile (1.61

Km) to mix additive. If vehicle can not be driven, shift transfer case to neutral, start engine and
with parking brake applied, select (D) on transmission shift selector. Increase engine speed as
required to allow transmission to automatically upshift through all gear ranges.
WARNING
ENSURE TRANSFER CASE IS COOL BEFORE PROCEEDING. FAILURE TO COMPLY

MAY RESULT IN INJURY TO PERSONNEL.
d. When transfer case is cool enough to touch by hand, seal breather

with moisture proof tape.
(7) Transmission Extended Storage
a. Drain oil from transmission (TM 08780B-20).
I-3
TM 08780B-20
b. Add two qts (1.9L) of VCI-329 vapor corrosion inhibitor (item

60.2, Appendix D) and then fill transmission to operating level with transmission fluid. Add 1.5
teaspoons of Biobor JF (MIL-S-53021) (item 8.1, Appendix D) or equivalent as a fungus
inhibitor to transmission oil.
c. Run the engine for approximately five minutes at 1,500 rpm with
the transmission in neutral (N).
d. Drive the vehicle. Make sure the transmission shifts through all
ranges. If vehicle can not be driven, shift transfer case to neutral, start engine and, with parking
brakes applied, select (D) on transmission shift selector. Increase engine speed as required to
allow transmission to automatically upshift through all gear ranges.
e. Run the engine at 1,500 rpm with the transmission and transfer
case in neutral until normal operating temperature is reached.
CAUTION
DO NOT ALLOW TRANSMISSION OIL TEMPERATURE TO EXCEED 225 DEGREES F

(107 DEGREES C) OR DAMAGE TO TRANSMISSION MAY RESULT.
f. If normal operating temperature is less than 225 degrees F (107

degrees C) shift the transmission to forward range and stall the converter. Do not exceed 225
degrees F (107 degrees C). Run engine at 800-1,000 rpm in neutral (N) for 4-5 minutes. Reduce
engine speed to idle for 30 seconds. Apply Engine Stop switch until engine has stopped.
WARNING
ENSURE TRANSMISSION IS COOL BEFORE PROCEEDING. FAILURE TO COMPLY

MAY RESULT IN INJURY TO PERSONNEL.
g. As soon as transmission is cool enough to touch, seal all openings

and the breather with moisture-proof tape.
h. If additional storage time is required, repeat steps (b) thru (g) at

yearly intervals. It is not necessary to drain the oil completely, just drain 2 qts (1.9L) of oil to
leave room for 2 qts (1.9L) of VCI-329 and 1.5 teaspoons of Biobor JF.
(8) Fuel System Extended Storage
a. Drain fuel tanks.
b. Change all fuel filters.
I-4
TM 08780B-20
c. All fuel should be treated with Biobor JF (MIL-S-53021) (item 8.1,

Appendix D) or equivalent as a fungus inhibitor. The addition of 3 teaspoons of Biobor to 20
gallons of fuel will provide adequate protection against fungus growth. When storing a vehicle
in freezing conditions, the addition of 3 oz (88.7 ml) of isopropyl alcohol (MIL-A-10-428) (item
6, Appendix D) to 20 gallons of diesel fuel will help prevent fuel line freeze up.
d. Run engine 5 minutes to circulate clean treated fuel throughout the

fuel system.
e. Cap off fuel system.
(9) Engine Extended Storage
a. Change oil and filter (LO 9-2320-297-12). Add preservative

lubricating oil (MIL-L-21260C), Grade 2.
b. Seal off turbocharger inlet and outlet connections with moisture

proof tape.
c. Seal off air cleaner openings with moisture proof tape.
b. Removing Vehicle from Extended Storage
(1) Install batteries (TM 08780B-20).
WARNING
DO NOT CHECK TIRE PRESSURE WITHOUT FIRST REFERRING TO PARA 3-8 (TM
08780B-20), PROPER TIRE PRESSURE CHECKING PROCEDURE. PERSONAL INJURY
OR DEATH COULD RESULT.
(2) Conduct a visual inspection of the vehicle and remove all moisture proof
tape from engine, transmission, transfer case and fuel system. Check lubricant levels and tire
pressures. Correct any discrepancies.
(3) Lubricate the chassis, ancillary equipment and oil can points.
I-5/(I-6 blank)
TM 08780B-20
GLOSSARY
AC Alternating Current
amp Ampere
AR As Required
CB Circuit Breaker
Cm Centimeter
DC Direct Current
e.g. For Example
EIR Equipment Improvement Recommendation
FO Fold Out
ID Inner Diameter
i.e. That Is
k x 1000
km Kilometer
kPa Kilopascal
m Meter
MAC Maintenance Allocation Chart
mm Millimeter
N*m Newton Meter
No. Number
OD Outside Diameter
para Paragraph
PMCS Preventive Maintenance Checks and Services
psi Pounds Per Square Inch
PT Prevailing Torque
RPM Revolutions Per Minute
STE/ICE Simplified Test Equipment for Internal Combustion Engines
TMDE Test, Measurement and Diagnostic Equipment
Glossary-1/(Glossary-2 blank)
TM 08780B-20
ALPHABETICAL INDEX
Subject Para
Access Cover and Panel Replacement.............................................................................. 18-15

A-Frame Maintenance ...................................................................................................... 20-16
Air Cleaner Assembly Replacement................................................................................. 4-6
Air Cleaner Element Replacement.................................................................................... 4-7
Air Dryer Maintenance ..................................................................................................... 13-38
Air Governor Maintenance ............................................................................................... 13-37
Air Horn Repair ................................................................................................................ 22-12
Air Horn Replacement ...................................................................................................... 22-11
Air Horn Valve Replacement............................................................................................ 22-13
Air Line and Fitting Replacement..................................................................................... 13-23
Air Manifold Replacement (Front) ................................................................................... 13-24
Air Manifold Replacement (Left Instrument Panel)......................................................... 13-27
Air Manifold Replacement (Main) ................................................................................... 13-26
Air Manifold Replacement (Rear) .................................................................................... 13-25
Air Manifold Replacement (Right Instrument Panel)....................................................... 13-30
Air Pressure Gauge Replacement ..................................................................................... 25-3
Air Pressure Switch Replacement (Low Air) ................................................................... 7-43
Air Reservoir Replacement (Left) .................................................................................... 13-34
Air Reservoir Replacement (Quick Build-Up) ................................................................. 13-32
Air Reservoir Replacement Unit (Rear) ........................................................................... 13-35
Air Reservoir Replacement (Right) .................................................................................. 13-33
Air Restrictor Indicator Replacement ............................................................................... 4-8
Alarm Replacement .......................................................................................................... 7-42
Alternator Circuit Breaker and Diode Replacement......................................................... 7-3
Alternator Replacement .................................................................................................... 7-4
Antilocking Brake System Sensor Replacement .............................................................. 13-43
Auxiliary Control Lever Maintenance .............................................................................. 20-31
Auxiliary Hydraulic Hose Replacement ........................................................................... 23-16
Auxiliary Hydraulic Hose Reel Roller Replacement........................................................ 23-17
Auxiliary Hydraulic Hose Reel Roller Replacement (LVSA1 Series Vehicles Only)..... 23-18
Axle Breather Service (No. 1 Axle).................................................................................. 11-4
Axle Breather Service (Rear Axles) ................................................................................. 12-5
Axle Oil Change (No. 1 Axle) .......................................................................................... 11-3
Axle Oil Change (No. 2, 3 and 4 Axles)........................................................................... 12-3
Axle Shaft Maintenance (No. 1 Axle) .............................................................................. 11-6
Axle Shaft Replacement (No. 2, 3 and 4 Axles)............................................................... 12-4
INDEX-1
TM 08780B-20
ALPHABETICAL INDEX (Continued)
Subject Para
Ball Valve Replacement ................................................................................................... 13-29

Basic Solenoid Valve Maintenance .................................................................................. 20-20
Battery and Battery Box Replacement.............................................................................. 7-45
Battery and Battery Box Replacement (LVSA1 Series Vehicles Only)........................... 7-46
Beacon Light Replacement ............................................................................................... 7-36
Bell Crank Maintenance ................................................................................................... 15-10
Blower Repair, Heater ...................................................................................................... 22-16
Boom Sheave Replacement (MK15A1 and MK17A1) .................................................... 21-12
Brake Adjustment (No. 1 Axle) ........................................................................................ 13-4
Brake Chamber Replacement (No. 1 Axle) ...................................................................... 13-13
Brake Chamber Replacement (No. 2, 3 and 4 Axles)....................................................... 13-12
Brake Inspection and Adjustments (No. 2, 3 and 4 Axles)............................................... 13-5
Brake Maintenance (No. 1 Axle) ...................................................................................... 13-6
Brake Shoe Replacement (No. 1 Axle)............................................................................. 13-6
Brake Shoe Replacement (No. 2, 3 and 4 Axles) ............................................................. 13-7
Brake Spider and Bracket Replacement ........................................................................... 13-11
Brake Spider and Skein Replacement............................................................................... 13-9
Brake Treadle Valve Replacement ................................................................................... 13-14
Cab Step Replacement ...................................................................................................... 18-6

Camshaft and Slack Adjuster Replacement (No. 2, 3 and 4 Axles) ................................. 13-10
Cardan Joint Repair........................................................................................................... 10-4
Check Valve Replacement................................................................................................ 13-28
Circuit Breaker Replacement............................................................................................ 7-14
Circuit Breaker Replacement (Junction Box) ................................................................... 20-10
Clearance Light Mounting Bracket Replacement............................................................. 7-32
Clearance Light Replacement ........................................................................................... 7-31
Composite Light Replacement (Front) ............................................................................. 7-34
Composite Light Replacement (Rear) .............................................................................. 7-36
Control Lever Maintenance (Auxiliary) ........................................................................... 20-31
Control Lever Maintenance (Main) .................................................................................. 20-30
Control Solenoid Cable Replacement (MK15A1 and MK17A1)..................................... 21-16
Coolant Filter and Adapter Replacement.......................................................................... 6-5
Coolant System Hose and Tube Replacement .................................................................. 6-7
Coolant System Switch Replacement ............................................................................... 7-9
Crane Hoses Replacement (MK15A1) ............................................................................. 21-8
Crane Hoses Replacement (MK17A1) ............................................................................. 21-9
INDEX-2
TM 08780B-20
Subject Para
C (Continued)
Crane Remote Control Stowage Box Replacement (MK15A1 and MK17A1)................ 21-4
Crane Tubing Replacement (MK15A1)............................................................................ . 21-6
Crane Tubing Replacement (MK17A1)............................................................................ 21-7
Dashboard Warning and/or Indicator Light Replacement ................................................ 7-29

Defroster Hose, Plenums and Control Cable Replacement .............................................. 22-20
Destruction of Material to Prevent Enemy Use ................................................................ 1-4
Dimmer Switch Replacement ........................................................................................... 7-52
Diode Replacement........................................................................................................... 7-3
Directional Relief Valve Filter Screen Replacement........................................................ 23-19
Dome Light Replacement ................................................................................................. 7-33
Door Glass and Regulator Replacement ........................................................................... 18-10
Door Repair....................................................................................................................... 18-4
Door Replacement ............................................................................................................ 18-3
Drag Link Maintenance .................................................................................................... 15-7
Drum Replacement (No. 1 Axle) ...................................................................................... 14-4
Drum Replacement (No. 2, 3 and 4 Axle) ........................................................................ 14-3
Electrical Failure Valve Replacement .............................................................................. 20-21

Electronic Control Unit/Air Control Valve Replacement................................................. 13-42
Engine Access Door Replacement.................................................................................... 18-19
Engine Oil Sample Valve (LVSA1 Series Vehicles Only)............................................... 3-8
Engine Oil Service ............................................................................................................ 3-3
Ether Start Switch Replacement ....................................................................................... 7-22
Ether Starting Aid Replacement ....................................................................................... 4-22
Exhaust Crossover Tube Maintenance.............................................................................. 5-4
Exhaust Manifold and Gasket Replacement ..................................................................... 3-7
Extension Cylinder No. 1 Replacement............................................................................ 20-11
Extension Cylinder No. 2 Replacement............................................................................ 20-12
Fifth Wheel Ramp Replacement....................................................................................... 16-3

Fuel Filter and Adapter Replacement ............................................................................... 4-21
Fuel Level Sender Replacement ....................................................................................... 7-40
Fuel Line, Vent and Fitting Replacement ......................................................................... 4-12
INDEX-3
TM 08780B-20
Subject Para
F (Continued)
Fuel Restriction Sensor Replacement ............................................................................... 7-44

Fuel Supply Pump Repair ................................................................................................. 4-4
Fuel Supply Pump Replacement....................................................................................... 4-3
Fuel Tank Replacement (Left) .......................................................................................... 4-10
Fuel Tank Replacement (Right)........................................................................................ 4-11
Fuel/Water Separator Repair............................................................................................. 4-20
Fuel/Water Separator Replacement .................................................................................. 4-19
Fuel/Water Separator Service ........................................................................................... 4-18
Fuse Link Maintenance..................................................................................................... 15-15
Gauge Replacement (Air) ................................................................................................. 25-3

Gauge Replacement (Electric) .......................................................................................... 7-20
General Assembly Instructions ......................................................................................... 2-14
General Cleaning Instructions........................................................................................... 2-11
General Disassembly Instructions..................................................................................... 2-10
General Inspection Instruction.......................................................................................... 2-12
General Removal Instruction ............................................................................................ 2-9
General Repair Instruction................................................................................................ 2-13
Glad Hand Replacement ................................................................................................... 13-36
Governor Maintenance (Air)............................................................................................. 13-37
Governor Replacement (Transmission) ............................................................................ 8-10
Grab Handle Replacement (LVSA1 Series Vehicles Only) ............................................. 18-23
Hand Control Valve Replacement .................................................................................... 13-39

Hand Priming Pump Replacement.................................................................................... 4-5
Headlight Maintenance ..................................................................................................... 7-30
Heater Blower Repair ....................................................................................................... 22-17
Heater Blower Replacement ............................................................................................. 22-16
Heater Control Cable Replacement .................................................................................. 22-21
Heater Core Replacement ................................................................................................. 22-18
Heater Hose and Fitting Replacement .............................................................................. 22-19
Heater Replacement .......................................................................................................... 22-15
Hi Idle Neutral Switch Replacement ................................................................................ 7-27
Hi Pressure Hydraulic Filter and Head Replacement (MK15A1/MK17A1).................... 23-20
Hi-Pressure Hydraulic Filter and Head Replacement (MK48A1).................................... 23-21
INDEX-4
TM 08780B-20
Subject Para
H (Continued)
Hoist Cable Replacement (MK15A1 and MK17A1)........................................................ 21-10

Holding Valve(s) Adjustment ........................................................................................... 20-34
Holding Valve Replacement ............................................................................................. 21-19
Hook Block Assembly Maintenance (MK15A1 and MK17A1) ...................................... 21-11
Horn Repair....................................................................................................................... 22-12
Horn Replacement (Electric) ............................................................................................ 22-14
Horn Valve Replacement.................................................................................................. 22-13
Hose Breakage Valve Replacement.................................................................................. 20-17
Hub, Drum, Toner Ring and Wheel Bearing Replacement (No. 1 Axle)......................... 14-4
Hub, Drum, Toner Ring and Wheel Bearing Replacement (No. 2, 3 and 4 Axle) ........... 14-3
Hydraulic Filter Replacement ........................................................................................... 23-6
Hydraulic Filter Replacement (LVSA1 Series Vehicles Only) ........................................ 23-7
Hydraulic Hose and Fitting Replacement ......................................................................... 23-14
Hydraulic Hose Reel Replacement ................................................................................... 23-15
Hydraulic Oil Cooler Replacement................................................................................... 23-11
Hydraulic Oil Filter Housing Maintenance....................................................................... 23-12
Hydraulic Filter Housing Maintenance (LVSA1 Series Vehicles Only).......................... 23-13
Hydraulic Oil Level gauge Replacement.......................................................................... 23-10
Hydraulic Reservoir Replacement .................................................................................... 23-9
Hydraulic System Service................................................................................................. 23-3
Ignition Switch Replacement............................................................................................ 7-23

Instrument Panel Assembly Replacement ........................................................................ 7-11
Instrument Panel Harness Replacement............................................................................ 7-12
Instrument Panel Harness Replacement (LVSA1 Series Vehicles Only)......................... 7-13
Intake Ducting Replacement............................................................................................. 4-9
Junction Box Maintenance (MK15).................................................................................. 20-3

Junction Box Maintenance (MK17).................................................................................. 20-4
Junction Box Maintenance (MK15A1 and MK17A1)...................................................... 21-3
INDEX-5
TM 08780B-20
Subject Para
Landing Leg Assembly Repair ......................................................................................... 16-5

Landing Leg Assembly Replacement ............................................................................... 16-4
Left Outrigger Cylinder Replacement .............................................................................. 20-13
Light Switch Replacement (Master) ................................................................................. 7-24
Lockup Air Chamber Replacement .................................................................................. 9-9
Lubrication Lines and Fitting Replacement...................................................................... 9-6
Main Power Wiring Replacement..................................................................................... 20-7

Maintenance Allocation Chart .............................................................................. Appendix B
Maintenance Forms, Records and Reports ....................................................................... 1-3
Machine Gun Hatch Replacement .................................................................................... 24-5
Machine Gun Mount Replacement ................................................................................... 24-3
Machine Gun Platform Replacement................................................................................ 24-4
Magnetic Switch Replacement ......................................................................................... 7-21
Manifold Replacement (MK15)........................................................................................ 20-19
Manifold Replacement (MK17)........................................................................................ 20-18
Map Light Replacement.................................................................................................... 7-35
Master Light Switch Replacement.................................................................................... 7-24
Mirror Replacement .......................................................................................................... 22-10
Modulator Valve Replacement ......................................................................................... 8-11
Mud Flap Replacement ..................................................................................................... 18-5
Muffler/Pipe Replacement ................................................................................................ 5-3
90 Degree Gear Box Replacement (Cab Mounted) .......................................................... 15-11

90 Degree Gear Box Replacement (Frame Mounted) ...................................................... 15-12
Neutral Safety Switch Maintenance.................................................................................. 7-26
Neutral Switch Replacement............................................................................................. 20-8
Nose Box Breather Maintenance ...................................................................................... 11-5
Oil Filter Adapter Replacement ........................................................................................ 3-5

Oil Filter Bracket Replacement (Transmission) ............................................................... 8-12
Oil Filter Bracket Replacement (Transmission) (LVSA1 Series Vehicles Only) ............ 8-13
Oil Pan and Gasket Replacement...................................................................................... 3-6
Oil Pan, Gasket and Internal Filter Replacement (Transmission) .................................... 8-14
INDEX-6
TM 08780B-20
Subject Para
O (Continued)
Oil Pressure Switch Replacement..................................................................................... 7-10

One Way Check Valve Replacement................................................................................ 13-28
Optic Ribbon Light Source Replacement ......................................................................... 7-49
Optic Ribbon Replacement ............................................................................................... 7-50
Outrigger Beam Adjustment ............................................................................................. 20-35
Outrigger Selector/Locking Valve Replacement (MK15)................................................ 20-23
Outrigger Selector/Locking Valve Replacement (MK17)................................................ 20-24
Overload Shutdown Cable Replacement (MK15A1 and MK17A1) ................................ 21-15
Parking Brake Valve Maintenance ................................................................................... 13-21

Pillow Block Bearing Replacement .................................................................................. 10-5
Pintle Replacement ........................................................................................................... 16-6
Pitman Arm Maintenance ................................................................................................. 15-9
Placard Replacement......................................................................................................... 20-27
Power Cable Replacement (M K1 5A1 and MK17A1) .................................................... 21-13
Pressure Protection Valve Replacement ........................................................................... 13-19
Priming Pump Replacement ............................................................................................. 4-5
Propeller Shaft and Universal Joint Maintenance............................................................. 10-3
Proximity Switch Replacement......................................................................................... 20-5
Quick Build-Up Reservoir Replacement .......................................................................... 13-32

Quick Disconnect Fitting Replacement ............................................................................ 13-31
Quick Release Valve Replacement................................................................................... 13-17
Quick Release Valve Replacement (LVSA1 Series Vehicles Only) ................................ 13-18
Quick Release Valve Replacement (ABS Only) .............................................................. 13-44
Radiator Service................................................................................................................ 6-3

Rear Axle Breather Service .............................................................................................. 12-7
Relay Replacement ........................................................................................................... 20-9
Relay Valve (MK14, 15, 16 and 17)................................................................................. 13-16
Relay Valve Replacement (MK48)................................................................................... 13-15
Remote Control Box Repair (MK15A1 and MK17A1) ................................................... 21-18
Remote Control Harness Replacement (MK15A1 and MK17A1) ................................... 21-14
INDEX-7
TM 08780B-20
Subject Para
R (Continue)
Repair Parts and Special Tool List........................................................................ Appendix C

Resistor Replacement........................................................................................................ 7-51
Right Outrigger Cylinder Replacement ............................................................................ 20-14
Remove Control Stowage Box Replacement (MK17A1)................................................. 21-4
Rocker Cover and Gasket Replacement ........................................................................... 3-4
Roof Vent Replacement ................................................................................................... 18-16
Schematic and Wiring Diagram........................................................................... Appendix G

Seat and Frame Assembly Replacement........................................................................... 18-12
Seat Belt Replacement ...................................................................................................... 18-13
Seat Belt Replacement (LVSA1 Series Vehicles Only) ................................................... 18-14
Seat Cushion Replacement ............................................................................................... 18-11
Secondary Fuel Filter and Adapter Replacement ............................................................. 4-21
Selector Valve Replacement ............................................................................................. 23-4
Sending Unit Replacement ............................................................................................... 7-39
Shift Cable Maintenance................................................................................................... 8-7
Shift Control Repair.......................................................................................................... 8-5
Shift Control Replacement................................................................................................ 8-4
Shift Lever Replacement................................................................................................... 9-5
Shift Tower Lamp Replacement ....................................................................................... 8-6
Shock Absorber and Bushing Replacement...................................................................... 17-3
Shutdown Solenoid Replacement ..................................................................................... 4-13
Shutdown Solenoid Replacement (LVSA1 Series Vehicles Only) .................................. 4-14
Skid Plate and Skid Plate Frame Replacement ................................................................. 18-18
Skid Plate Grille Replacement .......................................................................................... 18-17
Slack Adjuster Replacement ............................................................................................. 13-10
Slave Connector Replacement .......................................................................................... 7-47
Solenoid Dump Valve Wiring Replacement..................................................................... 20-6
Speedometer/Tachometer Replacement............................................................................ 7-19
Spring Brake Control Valve Replacement........................................................................ 13-20
Stabilizer Cylinder Replacement ...................................................................................... 20-15
INDEX-8
TM 08780B-20
Subject Para
S (Continued)
Stabilizer Pad Maintenance............................................................................................... 20-28

Stabilizer Selector/Locking Valve Replacement .............................................................. 20-22
Standard Troubleshooting................................................................................................. 2-7
Starter Relay Replacement................................................................................................ 7-8
Starter Replacement .......................................................................................................... 7-7
Starter Solenoid Replacement........................................................................................... 7-6
Steering Adjustments ........................................................................................................ 15-17
Steering Column Repair.................................................................................................... 15-5
Steering Column Replacement ......................................................................................... 15-4
Steering Linkage and Universal Joint Maintenance ......................................................... 15-6
Steering Selector Switch Replacement ............................................................................. 7-16
Steering Shaft Assembly Maintenance ............................................................................. 15-14
Steering System Hose and Fitting Replacement............................................................... 15-16
Steering Wheel Replacement............................................................................................ 15-3
STE/ICE Card ...................................................................................................... Appendix H
STE/ICE Troubleshooting ................................................................................................ 2-6
Step Replacement.............................................................................................................. 18-6
Stop Light Switch Replacement........................................................................................ 7-25
Stowage Box Maintenance (MK15) ................................................................................. 20-25
Stowage Compartment Replacement (MK16).................................................................. 18-22
Stowage Box Maintenance (MK17) ................................................................................. 20-26
Stowing Cable Maintenance ............................................................................................. 20-29
Testing Main Crane Relief Pressure ................................................................................. 20-33

Thermostat and Housing Replacement ............................................................................. 6-6
Throttle Control Cylinder Repair...................................................................................... 4-16
Throttle Control Solenoid Replacement ........................................................................... 4-15
Throttle Cylinder Replacement......................................................................................... 4-16
Throttle Treadle Valve Replacement ................................................................................ 4-23
Tie Rod Maintenance........................................................................................................ 15-8
Tilt Sensor and Alarm Replacement (MK15A1 and MK17A1)....................................... ... 21-5
Tilt Sensor Harness Replacement (MK15A1 and MK17A1) ........................................... 21-17
Tire Maintenance (Non Run Flat)..................................................................................... 14-6
Tire Maintenance (Run Flat)............................................................................................. 14-7
Tire Winch Cable Replacement ........................................................................................ 22-22
Tire Winch Repair............................................................................................................. 22-23
Toggle Switch Replacement ............................................................................................. 7-15
Tool Box and Stowage Compartment Replacement......................................................... 18-20
INDEX-9
TM 08780B-20
Subject Para
T (Continued)
Tool Box and Stowage Compartment Replacement (LVSA1 Series Vehicles Only) ...... 18-21
Torque Limits....................................................................................................... Appendix F
Torque Rod Maintenance (MK48).................................................................................... 17-4
Torque Rod Maintenance (MK14, 15, 16 and 17)............................................................ 17-5
Tractor Control Valve Replacement ................................................................................. 13-41
Traction Protection Valve Replacement ........................................................................... 13-22
Trailer Air Supply Valve Replacement............................................................................. 13-40
Transfer Case Breather Replacement................................................................................ 9-8
Transfer Case Lubrication Pump Replacement ................................................................ 9-7
Transfer Case Oil Change................................................................................................. 9-3
Transmission Breather Replacement ................................................................................ 8-16
Transmission Cooler Replacement ................................................................................... 8-15
Transmission Lockup Solenoid Valve Replacement ........................................................ 8-9
Transmission Lockup Switch Replacement...................................................................... 8-8
Transmission Oil Change and Spin On Filter Replacement ............................................. 8-3
Travel Lock Pin Maintenance........................................................................................... 20-32
Troubleshooting (Standard) .............................................................................................. 2-7
Troubleshooting (STE/ICE).............................................................................................. 2-6
Turn Signal Switch and Flasher Replacement .................................................................. 7-17
Turn Signal Switch and Flasher Replacement (LVSA1 Series Vehicles Only) ............... 7-18
Vehicle Step Replacement ................................................................................................ 18-7

Voltage Regulator Maintenance ....................................................................................... 7-5
Warranty Information ....................................................................................................... 1-8

Washer Reservoir Hose and Nozzle Replacement............................................................ 22-8
Washer Reservoir Hose and Nozzle Replacement (LVSA1 Series Vehicles Only)......... 22-9
Wedge Brake Maintenance ............................................................................................... 13-8
Wheel and Tire Replacement............................................................................................ 14-5
Winch Cable Maintenance................................................................................................ 19-3
Winch Control Handle Repair (MK16) ............................................................................ 19-4
Window Glass, Door Vent Window Glass and Peep Glass Replacement........................ 18-9
Windshield Wiper Arm and Blade Replacement.............................................................. 22-5
Windshield Glass Replacement ........................................................................................ 18-8
Windshield Wiper Control Valve Replacement ............................................................... 22-7
INDEX-10
TM 08780B-20
Subject Para
W (Continued)
Windshield Wiper Motor Replacement (LVSA1 Series Vehicles Only) ......................... 22-4
Wiper Control Valve Replacement................................................................................... 22-6
Windshield Wiper Motor Replacement ............................................................................ 22-3
Wiring Harness and Connector Repair ............................................................................. 7-48
Worklight Replacement .................................................................................................... 7-37
Yaw Control Valve Replacement ..................................................................................... 23-5

Yaw Cylinder Replacement .............................................................................................. 23-8
Yaw Feedback Linkage Maintenance............................................................................... 15-13
INDEX-11/(INDEX-12 blank)
TM 08780B-20
THE METRIC SYSTEM AND EQUIVALENTS
Linear Measure Liquid Measure
1 centimeter = 10 millimeters = .39 inch 1 centiliter = 10 milliters = .34 fl. ounce

1 decimeter = 10 centimeters = 3.94 inches 1 deciliter = 10 centiliters = 3.38 fl. ounces
1 meter = 10 decimeters = 39.37 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 dekameter = 10 meters = 32.8 feet 1 dekaliter = 10 liters = 2.64 gallons
1 hectometer = 10 dekameters = 328.08 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 kilometer = 10 hectometers = 3,280.8 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
Weights Square Measure
1 centigram = 10 milligrams = .15 grain 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 decigram = 10 centigrams = 1.54 grains 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 gram = 10 decigram = .035 ounce 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 dekagram = 10 grams = .35 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 hectogram = 10 dekagrams = 3.52 ounces 1 sq. hectometer (hectare) = 100 sq. dekameters = 247 acres
1 kilogram = 10 hectograms = 2.2 pounds 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch

1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
APPROXIMATE CONVERSION FACTORS
To change To Multiply by To change To Multiply by
inches centimeters 2.540 ounce-inches newton-meters .007

feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29.573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet newton-meters 1.356 metric tons short tons 1.102
pound-inches newton-meters .11296
TEMPERATURE (EXACT)
o o
F Fahrenheit temperature 5/9 (after subtracting 32) Celsius temperature C

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TM 08780B-20

U.S. MARINE CORPS TECHNICAL MANUAL

POWER UNIT, FRONT,

OSHKOSH TRUCK CORPORATION

FOR OFFICIAL USE ONLY

DEPARTMENT OF THE NAVY

2. Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC

3. TM 2320-20/12A Volume 1 dated 28 May 1999 and TM 2320-20/12A Volume 2 dated 28

BY DIRECTION OF THE COMMANDANT OF THE MARINE CORPS

DISTRIBUTION: PCN 180 002327 00

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

Page No. *Change No. Page No. *Change No.

*ZERO IN THIS COLUMN INDICATES AN ORIGINAL PAGE

How to Use This Manual .................................................................................................. xvii

CHAPTER 1. INTRODUCTION ................................................................................. 1-1

Section I. General Information............................................................................... 1-1

Section II. Equipment Description and Data ........................................................... 1-2

CHAPTER 2. VEHICLE MAINTENANCE ................................................................ 2-1

Section I. Service Upon Request............................................................................ 2-1

Section III. Troubleshooting ..................................................................................... 2-33

Section IV. Maintenance Procedures ........................................................................ 2-607

TABLE OF CONTENTS (Continued)

2-13 General Repair Instructions...................................................... 2-612

CHAPTER 3. ENGINE................................................................................................. 3-1

CHAPTER 4. FUEL SYSTEMS................................................................................... 4-1

CHAPTER 5. EXHAUST SYSTEM ............................................................................ 5-1

TABLE OF CONTENTS (Continued)

5-2 Description and Data ................................................................ 5-1

CHAPTER 6. COOLING SYSTEM............................................................................. 6-1

CHAPTER 7. ELECTRICAL SYSTEM ...................................................................... 7-1

TABLE OF CONTENTS (Continued)

7-26 Neutral Safety Switch Maintenance ......................................... 7-95

TABLE OF CONTENTS (Continued)

CHAPTER 8. TRANSMISSION .................................................................................. 8-1

CHAPTER 9. TRANSFER CASE................................................................................ 9-1

CHAPTER 10. PROPELLER SHAFTS ......................................................................... 10-1

CHAPTER 11. FRONT AXLE....................................................................................... 11-1

TABLE OF CONTENTS (Continued)

11-3 No. 1 Axle Oil Change ............................................................. 11-2

CHAPTER 12. REAR AXLES ....................................................................................... 12-1

CHAPTER 13. TRANSMISSION .................................................................................. 13-1

TABLE OF CONTENTS (Continued)

13-27 Left Instrument Panel Air Manifold Replacement ................... 13-102

CHAPTER 14. WHEELS AND TIRES.......................................................................... 14-1

CHAPTER 15. STEERING SYSTEM ........................................................................... 15-1

TABLE OF CONTENTS (Continued)

15-12 Frame 90 Degree Gear Box Replacement ................................ 15-34

CHAPTER 16. FRAME.................................................................................................. 16-1

CHAPTER 17. SUSPENSION ....................................................................................... 17-1

CHAPTER 18. CAB AND BODY ................................................................................. 18-1

TABLE OF CONTENTS (Continued)

18-19 Engine Access Door Replacement ........................................... 18-52

CHAPTER 19. WINCHES ............................................................................................. 19-1

CHAPTER 20. CRANE .................................................................................................. 20-1

TABLE OF CONTENTS (Continued)

20-28 Stabilizer Pad Maintenance ...................................................... 20-172

CHAPTER 21. CRANE (LVSA1 SERIES VEHICLES ONLY) ................................... 21-1

CHAPTER 22. BODY ACCESSORY ITEMS............................................................... 22-1

TABLE OF CONTENTS (Continued)

22-10 Mirror Replacement ................................................................. 22-24

CHAPTER 23. HYDRAULIC SYSTEM ....................................................................... 23-1

TABLE OF CONTENTS (Continued)

Page No. Change No. Page No. Change No.