CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
GENERAL INFORMATION
CORROSION PREVENTION AND CONTROL (CPC)
LIST OF ABBREVIATIONS/ACRONYMS
LIST OF ABBREVIATIONS/ACRONYMS - Continued
EQUIPMENT DESCRIPTION AND DATA
Figure 2. M917A1 with MCS and M917A2 with MCS.
Figure 3. Driver's Side Front of Dump Truck.
Figure 4. Passenger's Side Rear of Dump Truck.
DIFFERENCES BETWEEN MODELS
Table 3. Equipment Data.
Table 3. Equipment Data - Continued.
Table 3. Equipment Data - Continued.
THEORY OF OPERATION
Figure 1. Tailgate Components: M917A1 and M917A2.
Figure 2. Tailgate Components: M917A1 and M917A2 with MCS.
HYDRAULIC SYSTEM
Figure 3. Hydraulic System.
CHAPTER 2 OPERATOR INSTRUCTIONS
Figure 1. Console.
Figure 2. Dashboard and Instrument Cluster.
Figure 3. Hydraulics.
Figure 4. Cargo Cover and Transport Lock.
Figure 5. Material Control System.
OPERATION UNDER USUAL CONDITIONS
LOADING DUMP BODY
DUMPING LOAD
Figure 1. Securing Mud Flaps.
DUMPING LOAD - Continued
Figure 2. Dashboard Controls and Indicators.
DUMPING LOAD - Continued
DUMPING LOAD - Continued
Figure 3. Hydraulic Control Lever and Body Up Indicator Light.
Figure 4. Hydraulic Control Lever and Dashboard Controls and Indicators.
Figure 5. Releasing Mud Flaps.
Figure 6. Tailgate Opening Adjustment.
ADJUSTING MCS GATE OPENINGS (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 7. MCS Gate Opening Adjustment.
CONTROLLED SPREADING (M917A1 WITH MCS AND M917A2 WITH MCS)
CONTROLLED SPREADING (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 8. Controlled Spreading.
OPERATING CARGO COVER
Figure 9. Uncovering Load.
Figure 10. Crank and Cargo Cover Components.
Figure 11. Covering Load.
OPERATING BODY PROPS
OPERATING BODY PROPS - Continued
Figure 12. Body Prop Operation.
OPERATION UNDER UNUSUAL CONDITIONS
OPERATION IN COLD WEATHER
DECALS, INSTRUCTION PLATES, AND STENCILS
Figure 1. Driver's Side Decals.
Figure 3. Top Driver's Side Cab Corner Decals.
Figure 4. Hydraulic Oil Tank Decal.
Figure 6. Reverse Alarm Decal.
Figure 7. Dashboard Decals.
CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INDEX
TROUBLESHOOTING INDEX - Continued
DUMP BODY TROUBLESHOOTING PROCEDURES
DUMP BODY
MATERIAL CONTROL SYSTEM (MCS) GATE TROUBLESHOOTING PROCEDURES
MCS GATE
MCS GATE - Continued
MCS GATE - Continued
MCS GATE - Continued
MCS GATE - Continued
MCS GATE - Continued
TAILGATE TROUBLESHOOTING PROCEDURES
CHAPTER 4 FIELD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INDEX
TROUBLESHOOTING INDEX - Continued
DUMP BODY TROUBLESHOOTING PROCEDURES
DUMP BODY
MATERIAL CONTROL SYSTEM (MCS) GATE TROUBLESHOOTING PROCEDURES
MCS GATE
MCS GATE - Continued
MCS GATE - Continued
TAILGATE TROUBLESHOOTING PROCEDURES
CHAPTER 5 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS INTRODUCTION
GENERAL PMCS PROCEDURES
LUBRICATION INSTRUCTIONS
CORROSION PREVENTION AND CONTROL (CPC)
Leakage Definitions for PMCS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS INTSRUCTIONS
Table 1. Operator Preventive Maintenance Checks and Services (PMCS)
Figure 1. Dump Body Controls and Indicators.
Figure 2. Dashboard and Instrument Cluster Controls and Indicators.
Figure 3. Front and Driver's Side.
Figure 5. Cargo Cover.
Figure 6. Rear and Passenger's Side.
Figure 8. Hydraulic Reservoir.
Figure 9. Filter Service Indicator Gauge.
Figure 10. MCS Tailgate.
Figure 11. MCS Control Unit.
Figure 12. MCS Tailgate Components.
Figure 13. Tailgate Cable Pull.
Figure 14. Hydraulic System.
Figure 15. Body Props.
Figure 17. Transport Lock.
Figure 19. Tailgate Hinge Pins.
Mandatory Replacement Parts
CHAPTER 6 FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INSTRUCTIONS
FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION, INCLUDING LUBRICATION INSTRUCTIONS
GENERAL LUBRICATION INSTRUCTIONS
GENERAL PMCS PROCEDURES
GENERAL PMCS PROCEDURES - Continued
CORROSION PREVENTION AND CONTROL (CPC)
CORROSION PREVENTION AND CONTROL (CPC) - Continued
FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS), INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Figure 1. Cargo Cover Roller Shaft Bearings and Brackets.
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Figure 2. Hydraulic Oil Reservoir.
CHAPTER 7 OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR MAINTENANCE - LUBRICATION
OPERATOR MAINTENANCE - CLEANING
CHAPTER 8 FIELD MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
SERVICING INSTRUCTIONS
MATERIAL CONTROL SYSTEM (MCS) REMOTE CONTROL REPAIR (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 2. MCS Control Box Cover Disassembly.
Figure 4. MCS Control Box Cable Disassembly.
Figure 5. MCS Control Box Cable Assembly.
Figure 7. MCS Control Box Cover Assembly.
Figure 8. MCS Remote Control Plug Assembly.
MATERIAL CONTROL SYSTEM (MCS) CONTROL UNIT MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. MCS Control Unit Removal.
Figure 2. MCS Control Unit.
Figure 3. MCS Control Unit Installation.
Figure 1. MCS Rear Panel Removal.
Figure 2. MCS Switch Removal.
Figure 3. MCS Switch Installation.
Figure 4. MCS Rear Panel Installation.
TAILLIGHT REPLACEMENT
Figure 1. Taillight Replacement.
MARKER CLEARANCE LIGHT REPLACEMENT
Figure 1. Marker Clearance Light Replacement.
REFLECTOR REPLACEMENT
BODY UP SWITCH REPLACEMENT
Figure 1. Body Up Switch Replacement.
BODY UP SWITCH REPLACEMENT - Continued
TRANSPORT LOCK SWITCH REPLACEMENT
Figure 1. Transport Lock Switch Removal.
Figure 2. Transport Lock Switch Installation.
BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE
Figure 1. Beacon Warning Light Hardware Removal.
Figure 2. Beacon Warning Light Wiring Harness Removal.
Figure 3. Beacon Warning Light Wiring Harness Installation.
Figure 4. Beacon Warning Light Hardware Installation.
LIGHTS WIRING HARNESS MAINTENANCE
LIGHTS WIRING HARNESS MAINTENANCE - Continued
Figure 1. Lights Wiring Harness.
TRUCKTOMATERIAL CONTROL SYSTEM (MCS) TAILGATE WIRING HARNESS MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. TrucktoMCS Tailgate Wiring Harness Removal.
Figure 3. Wiring Harness Removal.
Figure 4. Wiring Harness Installation.
Figure 6. TrucktoMCS Tailgate Wiring Harness Installation.
TRUCKTOMATERIAL CONTROL SYSTEM (MCS) TAILGATE WIRING HARNESS MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE WIRING HARNESS MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 2. Wiring Harness Removal from Solenoid.
Figure 3. Tailgate Hardware Removal.
Figure 4. Tailgate Hardware Installation.
Figure 5. Connections at Solenoid.
Figure 6. Wiring Harness Installation.
BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTENANCE
BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTENANCE - Continued
Figure 1. Transport Lock Switch Connector and Wiring Harness.
CYLINDER SUPPORT FRAME REPLACEMENT
Figure 1. Cylinder Support Frame Removal.
Figure 2. Cylinder Support Frame Installation.
CYLINDER SUPPORT FRAME REPLACEMENT - Continued
DUMP BODY AND STABILIZER REPLACEMENT
Figure 1. Angle Bracket Hardware Removal.
Figure 2. Securing Stabilizer.
Figure 3. Mounting Bracket Removal.
Figure 4. Hinge Pin Removal.
DUMP BODY AND STABILIZER REPLACEMENT
DUMP BODY AND STABILIZER REPLACEMENT - Continued
Figure 5. Stabilizer Up.
Figure 6. Hinge Pin Installation.
Figure 7. Stabilizer Down.
Figure 9. Mounting Bracket Installation.
DUMP BODY AND STABILIZER REPLACEMENT - Continued
BODY PROP REPLACEMENT
Figure 1. Body Prop Replacement.
CAB SHIELD REPLACEMENT
Figure 1. Cab Shield Removal.
Figure 2. Cab Shield Installation.
CAB SHIELD REPLACEMENT - Continued
MUD FLAP REPLACEMENT
Figure 2. Mud Flap Hardware Removal.
Figure 3. Mud Flap Hardware Installation.
Figure 4. Mud Flap Installation.
TAILGATE REPLACEMENT (M917A1 AND M917A2)
TAILGATE REPLACEMENT (M917A1 AND M917A2) - Continued
Figure 1. Tailgate Replacement.
TAILGATE REPLACEMENT (M917A1 AND M917A2) - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 1. MCS Tailgate Removal.
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 2. MCS Tailgate Installation.
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE COVER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
MATERIAL CONTROL SYSTEM (MCS) TAILGATE COVER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 1. MCS Tailgate Cover Replacement.
MATERIAL CONTROL SYSTEM (MCS) GATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. MCS Gate Removal.
Figure 2. MCS Gate Installation.
MATERIAL CONTROL SYSTEM (MCS) ADJUSTMENT TUBE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. Adjustment Tube Removal.
Figure 2. Adjustment Tube Installation.
MATERIAL CONTROL SYSTEM (MCS) AIR RESERVOIR REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
MATERIAL CONTROL SYSTEM (MCS) AIR RESERVOIR REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 1. MCS Air Reservoir Replacement.
MATERIAL CONTROL SYSTEM (MCS) AIR RESERVOIR REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
TAILGATE RELEASE MATERIAL CONTROL SYSTEM (MCS) AIR LINES AND FITTINGS REPLACEMENT
Figure 1. Tailgate Air Fittings Replacement.
TAILGATE RELEASE MATERIAL CONTROL SYSTEM (MCS) AIR LINES AND FITTINGS REPLACEMENT - Continued
TAILGATE RELEASE AIR CYLINDER REPLACEMENT
TAILGATE RELEASE AIR CYLINDER REPLACEMENT - Continued
Figure 1. Tailgate Release Air Cylinder Replacement.
TAILGATE RELEASE AIR CYLINDER REPLACEMENT - Continued
MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. Solenoid Connection Removal.
Figure 2. Air Cylinder Replacement.
Figure 3. Solenoid Connection Installation.
MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. Solenoid Removal.
Figure 2. Valve Body Elbow and Filters Disassembly.
Figure 3. Valve Body Fittings and Solenoid Disassembly.
Figure 4. Valve Body Filter and Components Disassembly.
Figure 5. Valve Body End Cap and Valve Disassembly.
Figure 6. Valve Body End Cap and Valve Assembly.
Figure 7. Valve Body Filter and Components Assembly.
Figure 8. Valve Body Fittings and Solenoid Assembly.
Figure 9. Valve Body Elbow and Filters Assembly.
Figure 10. Solenoid Installation.
TAILGATE RELEASE/MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER REPAIR
Figure 1. MCS Air Cylinder.
Figure 2. Cylinder Components.
Figure 3. Cylinder Piston.
Figure 4. Cylinder Piston Assembly.
Figure 5. Cylinder Component Assembly.
Figure 6. MCS Air Cylinder Assembly.
CARGO COVER REPLACEMENT
Figure 2. Cargo Cover.
Figure 3. Cargo Cover Installation.
CARGO COVER REPAIR
CARGO COVER CRANK ASSEMBLY MAINTENANCE
CARGO COVER CRANK ASSEMBLY MAINTENANCE - Continued
Figure 1. Cargo Cover Crank.
CARGO COVER CRANK ASSEMBLY MAINTENANCE - Continued
CARGO COVER CHAIN AND SPROCKETS REPLACEMENT
Figure 1. Cover Removal.
Figure 2. Crank Hardware Removal.
Figure 3. Chain and Sprocket Removal.
Figure 4. Chain and Sprocket Installation.
Figure 5. Crank Hardware Installation.
Figure 6. Cover Installation.
CARGO COVER SUPPORT FRAME AND ROLL-UP BAR REPLACEMENT
Figure 1. Roll-Up Bar Spring Removal.
Figure 2. Roll-Up Bar Removal.
Figure 3. Roll-Up Bar Installation.
Figure 4. Roll-Up Bar Spring Installation.
CARGO COVER SUPPORT FRAME AND ROLL-UP BAR REPLACEMENT - Continued
SHOVEL BRACKET REPLACEMENT
DATA PLATE REPLACEMENT
HYDRAULIC PUMP REPLACEMENT
HYDRAULIC PUMP REPLACEMENT - Continued
Figure 1. Hydraulic Pump Removal.
HYDRAULIC PUMP REPLACEMENT - Continued
Figure 2. Hydraulic Pump Installation.
HYDRAULIC PUMP REPAIR
Figure 1. Drive Shaft Retaining Ring Removal.
Figure 4. Check Assemblies and Roller Bearings Removal.
Figure 6. Hydraulic Pump Disassembly.
Figure 7. Check Assemblies and Roller Bearings Installation.
Figure 9. Gear Housing and Drive Shaft Installation.
Figure 11. Drive Shaft Retaining Ring Installation.
HYDRAULIC CONTROL LEVER REPLACEMENT
Figure 1. Rear Access Panel Removal.
Figure 2. Connector Removal.
Figure 3. Transmission Shift Cable and Components Removal.
Figure 4. Transfer Case Shift Cable and Components Removal.
Figure 5. Hydraulic Control Cable and Components Removal.
Figure 6. Handle Assemblies Removal.
Figure 7. Hydraulic Control Lever Removal.
Figure 8. Hydraulic Control Lever Installation.
Figure 9. Handle Assemblies Installation.
Figure 10. Hydraulic Control Cable and Components Installation.
Figure 11. Transfer Case Shift Cable and Components Installation.
Figure 12. Transmission Shift Cable and Components Installation.
Figure 13. Connector Installation.
Figure 14. Rear Access Panel Installation.
HYDRAULIC CONTROL LEVER CABLE REPLACEMENT
Figure 1. Shift Tower Cover Removal.
Figure 2. Transmission Shift Cable Disconnection.
Figure 3. Transfer Case Shift Cable Disconnection.
Figure 4. Hydraulic Control Lever Cable Disconnection.
Figure 5. Shift Tower Removal.
Figure 6. Hardware Removal.
Figure 7. Hardware Installation.
Figure 8. Shift Tower Installation.
Figure 9. Hydraulic Control Lever Cable Connection.
Figure 10. Transfer Case Shift Cable Connection.
Figure 11. Transmission Shift Cable Connection.
Figure 12. Shift Tower Cover Installation.
HYDRAULIC OIL FILTER ELEMENT REPLACEMENT
HYDRAULIC OIL FILTER ELEMENT REPLACEMENT - Continued
Figure 1. Hydraulic Oil Filter Element Replacement.
HYDRAULIC HOSES AND FITTINGS REPLACEMENT
HYDRAULIC HOSES AND FITTINGS REPLACEMENT - Continued
Figure 1. Hydraulic Hoses and Fittings Removal.
HYDRAULIC HOSES AND FITTINGS REPLACEMENT - Continued
Figure 2. Hydraulic Hoses and Fittings Installation.
HYDRAULIC CYLINDER REPLACEMENT
HYDRAULIC CYLINDER REPLACEMENT - Continued
HYDRAULIC CYLINDER REPLACEMENT - Continued
Figure 1. Hydraulic Cylinder Removal.
HYDRAULIC CYLINDER REPLACEMENT - Continued
Figure 2. Hydraulic Cylinder Installation.
HYDRAULIC CYLINDER REPAIR
Figure 1. Retaining Ring Removal.
Figure 3. Spiral Retaining Ring Removal.
Figure 4. Guide Ring Removal.
Figure 5. Bottom Retaining Ring Removal.
Figure 8. Wiper Component Removal.
Figure 10. Bottom Guide Ring Removal.
Figure 12. Wear Ring and Piston Ring Removal From Sleeve.
Figure 14. Wiper, Wiper Retainer, and Seal Removal.
Figure 15. Spiral Retaining Ring Removal.
Figure 18. Wear Ring and Piston Ring Removal.
Figure 19. Bushing Removal.
Figure 20. Bushing Installation.
Figure 23. Ring, Seal, and Wiper Installation.
Figure 24. Wear Ring and Piston Ring Installation.
Figure 26. Ring, Seal, and Wiper Installation.
Figure 27. Piston Ring and Wear Ring Installation.
Figure 29. Ring, Seal, and Wiper Installation.
HYDRAULIC RESERVOIR REPLACEMENT
HYDRAULIC RESERVOIR REPLACEMENT - Continued
Figure 1. Hydraulic Reservoir Removal.
HYDRAULIC RESERVOIR REPLACEMENT - Continued
Figure 2. Hydraulic Reservoir Installation.
HYDRAULIC RESERVOIR REPAIR
HYDRAULIC RESERVOIR REPAIR - Continued
Figure 1. Hydraulic Reservoir Disassembly.
HYDRAULIC RESERVOIR REPAIR - Continued
Figure 2. Hydraulic Reservoir Assembly.
HYDRAULIC OIL SERVICE INDICATOR GAUGE REPLACEMENT
Figure 1. Hydraulic Oil Filter Service Indicator Gauge Removal.
Figure 2. Hydraulic Oil Filter Service Indicator Gauge Installation.
SPILL SHIELD REPLACEMENT
Figure 1. Spill Shield Replacement.
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE
CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE
PROCEDURES FOR COMMON COMPONENTS AND MISCELLANEOUS ITEMS
PREPARATION OF EQUIPMENT FOR SHIPMENT
GENERAL MAINTENANCE INSTRUCTIONS
CLEANING INSTRUCTIONS
CLEANING INSTRUCTIONS - Continued
INSPECTION INSTRUCTIONS
APPLICATION OF ADHESIVES
STANDARD TOOL REQUIREMENTS
ELECTRICAL GROUND POINTS
ANTISEIZING TAPE
Figure 1. Antiseizing Tape.
Figure 3. Tubes and Compression Fittings.
ELECTRICAL REPAIR
LUBRICATION INSTRUCTIONS
SPECIFIC LUBRICATION INSTRUCTIONS
LUBRICATION CHART
LUBRICATION CHART - Continued
Figure 1. View A: Transport Lock Linkage.
Figure 4. View D: Cargo Cover.
Figure 6. View F: Tailgate Locking Linkage.
Figure 7. View G: Body Props.
SPECIFIC LUBRICATION INSTRUCTIONS - Continued
ILLUSTRATED LIST OF MANUFACTURED ITEMS INTRODUCTION
Table 1. Manufactured Items Part Number Cross-Reference Index
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure 1. Hydraulic Cylinder Disassembly Tool.
TORQUE LIMITS
Figure 3. Measuring Screw.
Figure 4. Torque Limits for Dry Fasteners.
Figure 5. Torque Limits for Wet Fasteners.
Figure 6. Torque Limits for Dry Metric Fasteners.
Figure 7. Torque Limits for Wet Metric Fasteners.
Figure 8. Measurement of Torque Wrench.
WIRING DIAGRAMS
Figure 1. Power Take Off (PTO) Lockout Diagram.
Figure 2. Material Control System (MCS) Diagram.
Figure 4. Beacon Warning Light Diagram.
Figure 5. Dump Body Taillights and Marker Clearance Lights Diagram.
CHAPTER 9 PARTS INFORMATION
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) INTRODUCTION
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES
Maintenance Code.
Recoverability Code.
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
SPECIAL INFORMATION
HOW TO LOCATE REPAIR PARTS
REMOTE CONTROL, MATERIAL CONTROL SYSTEM (MCS)
Figure 1. Remote Control, Material Control System (MCS).
Figure 1. Remote Control, Material Control System (MCS). - Continued
CONTROL UNIT, MATERIAL CONTROL SYSTEM (MCS)
Figure 2. Control Unit, Material Control System (MCS).
Figure 2. Control Unit, Material Control System (MCS). - Continued
TAILLIGHTS, MARKER CLEARANCE LIGHTS, AND REFLECTORS
Figure 3. Taillights, Marker Clearance Lights, and Reflectors.
Figure 3. Taillights, Marker Clearance Lights, and Reflectors. - Continued
BODY UP AND TRANSPORT LOCK SWITCHES
Figure 4. Body Up and Transport Lock Switches.
Figure 4. Body Up and Transport Lock Switches. - Continued
Figure 4. Body Up and Transport Lock Switches.
Figure 5. Wiring Harness, Beacon Light.
Figure 5. Wiring Harness, Beacon Light. - Continued
WIRING HARNESS, DUMP BODY LIGHTS
Figure 6. Wiring Harness, Dump Body Lights.
Figure 6. Wiring Harness, Dump Body Lights. - Continued
MATERIAL CONTROL SYSTEM (MCS) GATE WIRING HARNESS AND MCS POWER WIRING HARNESS
Figure 7. Material Control System (MCS) Gate Wiring Harness and MCS Power Wiring Harness.
Figure 7. Material Control System (MCS) Gate Wiring Harness and MCS Power Wiring Harness. - Continued
Figure 7. Material Control System (MCS) Gate Wiring Harness and MCS Power Wiring Harness. - Continued
BODY UP/TRANSPORT LOCK SWITCH WIRING HARNESS AND MATERIAL CONTROL SYSTEM (MCS) CHASSIS WIRING HARNESS
Figure 8. Body Up/Transport Lock Switch Wiring Harness and Material Control System (MCS) Chassis Wiring Harness.
Figure 8. Body Up/Transport Lock Switch Wiring Harness and Material Control System (MCS) Chassis Wiring Harness. - Continued
CYLINDER SUPPORT FRAME AND BRACKETS
Figure 9. Cylinder Support Frame and Brackets.
Figure 9. Cylinder Support Frame and Brackets. - Continued
STABILIZER AND REAR HINGE
Figure 10. Stabilizer and Rear Hinge.
Figure 10. Stabilizer and Rear Hinge. - Continued
DUMP BODY ASSEMBLY
Figure 11. Dump Body Assembly.
Figure 11. Dump Body Assembly. - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE ASSEMBLY
Figure 12. Material Control System (MCS) Tailgate Assembly.
Figure 12. Material Control System (MCS) Tailgate Assembly. - Continued
AIR TANK, LINES, AND FITTINGS
Figure 13. Air Tank, Lines, and Fittings.
Figure 13. Air Tank, Lines, and Fittings. - Continued
Figure 13. Air Tank, Lines, and Fittings. - Continued
Figure 13. Air Tank, Lines, and Fittings. - Continued
AIR CYLINDER ASSEMBLY
Figure 14. Air Cylinder Assembly.
Figure 14. Air Cylinder Assembly. - Continued
Figure 14. Air Cylinder Assembly. - Continued
Figure 15. Cargo Cover and Component Parts (Sheet 1 of 2).
Figure 15. Cargo Cover and Component Parts (Sheet 2 of 2).
Figure 15. Cargo Cover and Component Parts - Continued
Figure 15. Cargo Cover and Component Parts - Continued
SHOVEL MOUNTING
Figure 16. Shovel Mounting.
Figure 16. Shovel Mounting. - Continued
DECALS, INSTRUCTION PLATES, AND STENCILS
Figure 17. Decals, Instruction Plates, and Stencils.
Figure 17. Decals, Instruction Plates, and Stencils. - Continued
HYDRAULIC PUMP ASSEMBLY
Figure 18. Hydraulic Pump Assembly.
Figure 18. Hydraulic Pump Assembly. - Continued
DUMP CONTROL AND CABLE
Figure 19. Dump Control and Cable.
Figure 19. Dump Control and Cable. - Continued
FILTER ELEMENT, HYDRAULIC
Figure 20. Filter Element, Hydraulic.
Figure 20. Filter Element, Hydraulic. - Continued
HYDRAULIC HOSES AND FITTINGS
Figure 21. Hydraulic Hoses and Fittings.
Figure 21. Hydraulic Hoses and Fittings. - Continued
CYLINDER ASSEMBLY, HOIST
Figure 22. Cylinder Assembly, Hoist.
Figure 22. Cylinder Assembly, Hoist. - Continued
HYDRAULIC RESERVOIR ASSEMBLY
Figure 23. Hydraulic Reservoir Assembly.
Figure 23. Hydraulic Reservoir Assembly. - Continued
Figure 23. Hydraulic Reservoir Assembly. - Continued
SPILL SHIELD
Figure 24. Spill Shield.
Figure 24. Spill Shield. - Continued
BULK MATERIAL
Figure BULK. Bulk Material.
Figure BULK. Bulk Material. - Continued
REPAIR PART KITS
Figure KITS. Repair Part Kits.
Figure KITS. Repair Part Kits. - Continued
NATIONAL STOCK NUMBER (NSN) INDEX
NATIONAL STOCK NUMBER (NSN) INDEX - Continued
NATIONAL STOCK NUMBER (NSN) INDEX - Continued
NATIONAL STOCK NUMBER (NSN) INDEX - Continued
PART NUMBER (P/N) INDEX
PART NUMBER (P/N) INDEX - Continued
PART NUMBER (P/N) INDEX - Continued
PART NUMBER (P/N) INDEX - Continued
CHAPTER 10 SUPPORTING INFORMATION
REFERENCES
TECHNICAL MANUALS
OTHER PUBLICATIONS
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Maintenance Functions
Explanation of Columns in the MAC
Explanation of Columns in the Tools and Test Equipment Requirements
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. Maintenance Allocation Chart (MAC) for Dump Body
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 2. Tools and Test Equipment Requirements for Dump Body.
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Table 1. Basic Issue Items (BII).
Table 1. Basic Issue Items (BII) - Continued
ADDITIONAL AUTHORIZATION LIST (AAL)
EXPENDABLE AND DURABLE ITEMS LIST (EDIL)
Table 1. Expendable and Durable Items List.
Table 1. Expendable and Durable Items List - Continued
Table 1. Expendable and Durable Items List - Continued
TOOL IDENTIFICATION LIST
Table 1. Tool Identification List
MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List.
GENERAL INFORMATION
CORROSION PREVENTION AND CONTROL (CPC)
LIST OF ABBREVIATIONS/ACRONYMS
LIST OF ABBREVIATIONS/ACRONYMS - Continued
EQUIPMENT DESCRIPTION AND DATA
Figure 2. M917A1 with MCS and M917A2 with MCS.
Figure 3. Driver's Side Front of Dump Truck.
Figure 4. Passenger's Side Rear of Dump Truck.
DIFFERENCES BETWEEN MODELS
Table 3. Equipment Data.
Table 3. Equipment Data - Continued.
Table 3. Equipment Data - Continued.
THEORY OF OPERATION
Figure 1. Tailgate Components: M917A1 and M917A2.
Figure 2. Tailgate Components: M917A1 and M917A2 with MCS.
HYDRAULIC SYSTEM
Figure 3. Hydraulic System.
CHAPTER 2 OPERATOR INSTRUCTIONS
Figure 1. Console.
Figure 2. Dashboard and Instrument Cluster.
Figure 3. Hydraulics.
Figure 4. Cargo Cover and Transport Lock.
Figure 5. Material Control System.
OPERATION UNDER USUAL CONDITIONS
LOADING DUMP BODY
DUMPING LOAD
Figure 1. Securing Mud Flaps.
DUMPING LOAD - Continued
Figure 2. Dashboard Controls and Indicators.
DUMPING LOAD - Continued
DUMPING LOAD - Continued
Figure 3. Hydraulic Control Lever and Body Up Indicator Light.
Figure 4. Hydraulic Control Lever and Dashboard Controls and Indicators.
Figure 5. Releasing Mud Flaps.
Figure 6. Tailgate Opening Adjustment.
ADJUSTING MCS GATE OPENINGS (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 7. MCS Gate Opening Adjustment.
CONTROLLED SPREADING (M917A1 WITH MCS AND M917A2 WITH MCS)
CONTROLLED SPREADING (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 8. Controlled Spreading.
OPERATING CARGO COVER
Figure 9. Uncovering Load.
Figure 10. Crank and Cargo Cover Components.
Figure 11. Covering Load.
OPERATING BODY PROPS
OPERATING BODY PROPS - Continued
Figure 12. Body Prop Operation.
OPERATION UNDER UNUSUAL CONDITIONS
OPERATION IN COLD WEATHER
DECALS, INSTRUCTION PLATES, AND STENCILS
Figure 1. Driver's Side Decals.
Figure 3. Top Driver's Side Cab Corner Decals.
Figure 4. Hydraulic Oil Tank Decal.
Figure 6. Reverse Alarm Decal.
Figure 7. Dashboard Decals.
CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INDEX
TROUBLESHOOTING INDEX - Continued
DUMP BODY TROUBLESHOOTING PROCEDURES
DUMP BODY
MATERIAL CONTROL SYSTEM (MCS) GATE TROUBLESHOOTING PROCEDURES
MCS GATE
MCS GATE - Continued
MCS GATE - Continued
MCS GATE - Continued
MCS GATE - Continued
MCS GATE - Continued
TAILGATE TROUBLESHOOTING PROCEDURES
CHAPTER 4 FIELD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INDEX
TROUBLESHOOTING INDEX - Continued
DUMP BODY TROUBLESHOOTING PROCEDURES
DUMP BODY
MATERIAL CONTROL SYSTEM (MCS) GATE TROUBLESHOOTING PROCEDURES
MCS GATE
MCS GATE - Continued
MCS GATE - Continued
TAILGATE TROUBLESHOOTING PROCEDURES
CHAPTER 5 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS INTRODUCTION
GENERAL PMCS PROCEDURES
LUBRICATION INSTRUCTIONS
CORROSION PREVENTION AND CONTROL (CPC)
Leakage Definitions for PMCS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS INTSRUCTIONS
Table 1. Operator Preventive Maintenance Checks and Services (PMCS)
Figure 1. Dump Body Controls and Indicators.
Figure 2. Dashboard and Instrument Cluster Controls and Indicators.
Figure 3. Front and Driver's Side.
Figure 5. Cargo Cover.
Figure 6. Rear and Passenger's Side.
Figure 8. Hydraulic Reservoir.
Figure 9. Filter Service Indicator Gauge.
Figure 10. MCS Tailgate.
Figure 11. MCS Control Unit.
Figure 12. MCS Tailgate Components.
Figure 13. Tailgate Cable Pull.
Figure 14. Hydraulic System.
Figure 15. Body Props.
Figure 17. Transport Lock.
Figure 19. Tailgate Hinge Pins.
Mandatory Replacement Parts
CHAPTER 6 FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INSTRUCTIONS
FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION, INCLUDING LUBRICATION INSTRUCTIONS
GENERAL LUBRICATION INSTRUCTIONS
GENERAL PMCS PROCEDURES
GENERAL PMCS PROCEDURES - Continued
CORROSION PREVENTION AND CONTROL (CPC)
CORROSION PREVENTION AND CONTROL (CPC) - Continued
FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS), INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Figure 1. Cargo Cover Roller Shaft Bearings and Brackets.
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for M917A1, M917A1 with Material Control System (MCS), M917A2, and M917A2 with MCS - Continued
Figure 2. Hydraulic Oil Reservoir.
CHAPTER 7 OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR MAINTENANCE - LUBRICATION
OPERATOR MAINTENANCE - CLEANING
CHAPTER 8 FIELD MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
SERVICING INSTRUCTIONS
MATERIAL CONTROL SYSTEM (MCS) REMOTE CONTROL REPAIR (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 2. MCS Control Box Cover Disassembly.
Figure 4. MCS Control Box Cable Disassembly.
Figure 5. MCS Control Box Cable Assembly.
Figure 7. MCS Control Box Cover Assembly.
Figure 8. MCS Remote Control Plug Assembly.
MATERIAL CONTROL SYSTEM (MCS) CONTROL UNIT MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. MCS Control Unit Removal.
Figure 2. MCS Control Unit.
Figure 3. MCS Control Unit Installation.
Figure 1. MCS Rear Panel Removal.
Figure 2. MCS Switch Removal.
Figure 3. MCS Switch Installation.
Figure 4. MCS Rear Panel Installation.
TAILLIGHT REPLACEMENT
Figure 1. Taillight Replacement.
MARKER CLEARANCE LIGHT REPLACEMENT
Figure 1. Marker Clearance Light Replacement.
REFLECTOR REPLACEMENT
BODY UP SWITCH REPLACEMENT
Figure 1. Body Up Switch Replacement.
BODY UP SWITCH REPLACEMENT - Continued
TRANSPORT LOCK SWITCH REPLACEMENT
Figure 1. Transport Lock Switch Removal.
Figure 2. Transport Lock Switch Installation.
BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE
Figure 1. Beacon Warning Light Hardware Removal.
Figure 2. Beacon Warning Light Wiring Harness Removal.
Figure 3. Beacon Warning Light Wiring Harness Installation.
Figure 4. Beacon Warning Light Hardware Installation.
LIGHTS WIRING HARNESS MAINTENANCE
LIGHTS WIRING HARNESS MAINTENANCE - Continued
Figure 1. Lights Wiring Harness.
TRUCKTOMATERIAL CONTROL SYSTEM (MCS) TAILGATE WIRING HARNESS MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. TrucktoMCS Tailgate Wiring Harness Removal.
Figure 3. Wiring Harness Removal.
Figure 4. Wiring Harness Installation.
Figure 6. TrucktoMCS Tailgate Wiring Harness Installation.
TRUCKTOMATERIAL CONTROL SYSTEM (MCS) TAILGATE WIRING HARNESS MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE WIRING HARNESS MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 2. Wiring Harness Removal from Solenoid.
Figure 3. Tailgate Hardware Removal.
Figure 4. Tailgate Hardware Installation.
Figure 5. Connections at Solenoid.
Figure 6. Wiring Harness Installation.
BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTENANCE
BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTENANCE - Continued
Figure 1. Transport Lock Switch Connector and Wiring Harness.
CYLINDER SUPPORT FRAME REPLACEMENT
Figure 1. Cylinder Support Frame Removal.
Figure 2. Cylinder Support Frame Installation.
CYLINDER SUPPORT FRAME REPLACEMENT - Continued
DUMP BODY AND STABILIZER REPLACEMENT
Figure 1. Angle Bracket Hardware Removal.
Figure 2. Securing Stabilizer.
Figure 3. Mounting Bracket Removal.
Figure 4. Hinge Pin Removal.
DUMP BODY AND STABILIZER REPLACEMENT
DUMP BODY AND STABILIZER REPLACEMENT - Continued
Figure 5. Stabilizer Up.
Figure 6. Hinge Pin Installation.
Figure 7. Stabilizer Down.
Figure 9. Mounting Bracket Installation.
DUMP BODY AND STABILIZER REPLACEMENT - Continued
BODY PROP REPLACEMENT
Figure 1. Body Prop Replacement.
CAB SHIELD REPLACEMENT
Figure 1. Cab Shield Removal.
Figure 2. Cab Shield Installation.
CAB SHIELD REPLACEMENT - Continued
MUD FLAP REPLACEMENT
Figure 2. Mud Flap Hardware Removal.
Figure 3. Mud Flap Hardware Installation.
Figure 4. Mud Flap Installation.
TAILGATE REPLACEMENT (M917A1 AND M917A2)
TAILGATE REPLACEMENT (M917A1 AND M917A2) - Continued
Figure 1. Tailgate Replacement.
TAILGATE REPLACEMENT (M917A1 AND M917A2) - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 1. MCS Tailgate Removal.
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 2. MCS Tailgate Installation.
MATERIAL CONTROL SYSTEM (MCS) TAILGATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE COVER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
MATERIAL CONTROL SYSTEM (MCS) TAILGATE COVER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 1. MCS Tailgate Cover Replacement.
MATERIAL CONTROL SYSTEM (MCS) GATE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. MCS Gate Removal.
Figure 2. MCS Gate Installation.
MATERIAL CONTROL SYSTEM (MCS) ADJUSTMENT TUBE REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. Adjustment Tube Removal.
Figure 2. Adjustment Tube Installation.
MATERIAL CONTROL SYSTEM (MCS) AIR RESERVOIR REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
MATERIAL CONTROL SYSTEM (MCS) AIR RESERVOIR REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
Figure 1. MCS Air Reservoir Replacement.
MATERIAL CONTROL SYSTEM (MCS) AIR RESERVOIR REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
TAILGATE RELEASE MATERIAL CONTROL SYSTEM (MCS) AIR LINES AND FITTINGS REPLACEMENT
Figure 1. Tailgate Air Fittings Replacement.
TAILGATE RELEASE MATERIAL CONTROL SYSTEM (MCS) AIR LINES AND FITTINGS REPLACEMENT - Continued
TAILGATE RELEASE AIR CYLINDER REPLACEMENT
TAILGATE RELEASE AIR CYLINDER REPLACEMENT - Continued
Figure 1. Tailgate Release Air Cylinder Replacement.
TAILGATE RELEASE AIR CYLINDER REPLACEMENT - Continued
MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. Solenoid Connection Removal.
Figure 2. Air Cylinder Replacement.
Figure 3. Solenoid Connection Installation.
MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER REPLACEMENT (M917A1 WITH MCS AND M917A2 WITH MCS) - Continued
MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE (M917A1 WITH MCS AND M917A2 WITH MCS)
Figure 1. Solenoid Removal.
Figure 2. Valve Body Elbow and Filters Disassembly.
Figure 3. Valve Body Fittings and Solenoid Disassembly.
Figure 4. Valve Body Filter and Components Disassembly.
Figure 5. Valve Body End Cap and Valve Disassembly.
Figure 6. Valve Body End Cap and Valve Assembly.
Figure 7. Valve Body Filter and Components Assembly.
Figure 8. Valve Body Fittings and Solenoid Assembly.
Figure 9. Valve Body Elbow and Filters Assembly.
Figure 10. Solenoid Installation.
TAILGATE RELEASE/MATERIAL CONTROL SYSTEM (MCS) AIR CYLINDER REPAIR
Figure 1. MCS Air Cylinder.
Figure 2. Cylinder Components.
Figure 3. Cylinder Piston.
Figure 4. Cylinder Piston Assembly.
Figure 5. Cylinder Component Assembly.
Figure 6. MCS Air Cylinder Assembly.
CARGO COVER REPLACEMENT
Figure 2. Cargo Cover.
Figure 3. Cargo Cover Installation.
CARGO COVER REPAIR
CARGO COVER CRANK ASSEMBLY MAINTENANCE
CARGO COVER CRANK ASSEMBLY MAINTENANCE - Continued
Figure 1. Cargo Cover Crank.
CARGO COVER CRANK ASSEMBLY MAINTENANCE - Continued
CARGO COVER CHAIN AND SPROCKETS REPLACEMENT
Figure 1. Cover Removal.
Figure 2. Crank Hardware Removal.
Figure 3. Chain and Sprocket Removal.
Figure 4. Chain and Sprocket Installation.
Figure 5. Crank Hardware Installation.
Figure 6. Cover Installation.
CARGO COVER SUPPORT FRAME AND ROLL-UP BAR REPLACEMENT
Figure 1. Roll-Up Bar Spring Removal.
Figure 2. Roll-Up Bar Removal.
Figure 3. Roll-Up Bar Installation.
Figure 4. Roll-Up Bar Spring Installation.
CARGO COVER SUPPORT FRAME AND ROLL-UP BAR REPLACEMENT - Continued
SHOVEL BRACKET REPLACEMENT
DATA PLATE REPLACEMENT
HYDRAULIC PUMP REPLACEMENT
HYDRAULIC PUMP REPLACEMENT - Continued
Figure 1. Hydraulic Pump Removal.
HYDRAULIC PUMP REPLACEMENT - Continued
Figure 2. Hydraulic Pump Installation.
HYDRAULIC PUMP REPAIR
Figure 1. Drive Shaft Retaining Ring Removal.
Figure 4. Check Assemblies and Roller Bearings Removal.
Figure 6. Hydraulic Pump Disassembly.
Figure 7. Check Assemblies and Roller Bearings Installation.
Figure 9. Gear Housing and Drive Shaft Installation.
Figure 11. Drive Shaft Retaining Ring Installation.
HYDRAULIC CONTROL LEVER REPLACEMENT
Figure 1. Rear Access Panel Removal.
Figure 2. Connector Removal.
Figure 3. Transmission Shift Cable and Components Removal.
Figure 4. Transfer Case Shift Cable and Components Removal.
Figure 5. Hydraulic Control Cable and Components Removal.
Figure 6. Handle Assemblies Removal.
Figure 7. Hydraulic Control Lever Removal.
Figure 8. Hydraulic Control Lever Installation.
Figure 9. Handle Assemblies Installation.
Figure 10. Hydraulic Control Cable and Components Installation.
Figure 11. Transfer Case Shift Cable and Components Installation.
Figure 12. Transmission Shift Cable and Components Installation.
Figure 13. Connector Installation.
Figure 14. Rear Access Panel Installation.
HYDRAULIC CONTROL LEVER CABLE REPLACEMENT
Figure 1. Shift Tower Cover Removal.
Figure 2. Transmission Shift Cable Disconnection.
Figure 3. Transfer Case Shift Cable Disconnection.
Figure 4. Hydraulic Control Lever Cable Disconnection.
Figure 5. Shift Tower Removal.
Figure 6. Hardware Removal.
Figure 7. Hardware Installation.
Figure 8. Shift Tower Installation.
Figure 9. Hydraulic Control Lever Cable Connection.
Figure 10. Transfer Case Shift Cable Connection.
Figure 11. Transmission Shift Cable Connection.
Figure 12. Shift Tower Cover Installation.
HYDRAULIC OIL FILTER ELEMENT REPLACEMENT
HYDRAULIC OIL FILTER ELEMENT REPLACEMENT - Continued
Figure 1. Hydraulic Oil Filter Element Replacement.
HYDRAULIC HOSES AND FITTINGS REPLACEMENT
HYDRAULIC HOSES AND FITTINGS REPLACEMENT - Continued
Figure 1. Hydraulic Hoses and Fittings Removal.
HYDRAULIC HOSES AND FITTINGS REPLACEMENT - Continued
Figure 2. Hydraulic Hoses and Fittings Installation.
HYDRAULIC CYLINDER REPLACEMENT
HYDRAULIC CYLINDER REPLACEMENT - Continued
HYDRAULIC CYLINDER REPLACEMENT - Continued
Figure 1. Hydraulic Cylinder Removal.
HYDRAULIC CYLINDER REPLACEMENT - Continued
Figure 2. Hydraulic Cylinder Installation.
HYDRAULIC CYLINDER REPAIR
Figure 1. Retaining Ring Removal.
Figure 3. Spiral Retaining Ring Removal.
Figure 4. Guide Ring Removal.
Figure 5. Bottom Retaining Ring Removal.
Figure 8. Wiper Component Removal.
Figure 10. Bottom Guide Ring Removal.
Figure 12. Wear Ring and Piston Ring Removal From Sleeve.
Figure 14. Wiper, Wiper Retainer, and Seal Removal.
Figure 15. Spiral Retaining Ring Removal.
Figure 18. Wear Ring and Piston Ring Removal.
Figure 19. Bushing Removal.
Figure 20. Bushing Installation.
Figure 23. Ring, Seal, and Wiper Installation.
Figure 24. Wear Ring and Piston Ring Installation.
Figure 26. Ring, Seal, and Wiper Installation.
Figure 27. Piston Ring and Wear Ring Installation.
Figure 29. Ring, Seal, and Wiper Installation.
HYDRAULIC RESERVOIR REPLACEMENT
HYDRAULIC RESERVOIR REPLACEMENT - Continued
Figure 1. Hydraulic Reservoir Removal.
HYDRAULIC RESERVOIR REPLACEMENT - Continued
Figure 2. Hydraulic Reservoir Installation.
HYDRAULIC RESERVOIR REPAIR
HYDRAULIC RESERVOIR REPAIR - Continued
Figure 1. Hydraulic Reservoir Disassembly.
HYDRAULIC RESERVOIR REPAIR - Continued
Figure 2. Hydraulic Reservoir Assembly.
HYDRAULIC OIL SERVICE INDICATOR GAUGE REPLACEMENT
Figure 1. Hydraulic Oil Filter Service Indicator Gauge Removal.
Figure 2. Hydraulic Oil Filter Service Indicator Gauge Installation.
SPILL SHIELD REPLACEMENT
Figure 1. Spill Shield Replacement.
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE
CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE
PROCEDURES FOR COMMON COMPONENTS AND MISCELLANEOUS ITEMS
PREPARATION OF EQUIPMENT FOR SHIPMENT
GENERAL MAINTENANCE INSTRUCTIONS
CLEANING INSTRUCTIONS
CLEANING INSTRUCTIONS - Continued
INSPECTION INSTRUCTIONS
APPLICATION OF ADHESIVES
STANDARD TOOL REQUIREMENTS
ELECTRICAL GROUND POINTS
ANTISEIZING TAPE
Figure 1. Antiseizing Tape.
Figure 3. Tubes and Compression Fittings.
ELECTRICAL REPAIR
LUBRICATION INSTRUCTIONS
SPECIFIC LUBRICATION INSTRUCTIONS
LUBRICATION CHART
LUBRICATION CHART - Continued
Figure 1. View A: Transport Lock Linkage.
Figure 4. View D: Cargo Cover.
Figure 6. View F: Tailgate Locking Linkage.
Figure 7. View G: Body Props.
SPECIFIC LUBRICATION INSTRUCTIONS - Continued
ILLUSTRATED LIST OF MANUFACTURED ITEMS INTRODUCTION
Table 1. Manufactured Items Part Number Cross-Reference Index
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure 1. Hydraulic Cylinder Disassembly Tool.
TORQUE LIMITS
Figure 3. Measuring Screw.
Figure 4. Torque Limits for Dry Fasteners.
Figure 5. Torque Limits for Wet Fasteners.
Figure 6. Torque Limits for Dry Metric Fasteners.
Figure 7. Torque Limits for Wet Metric Fasteners.
Figure 8. Measurement of Torque Wrench.
WIRING DIAGRAMS
Figure 1. Power Take Off (PTO) Lockout Diagram.
Figure 2. Material Control System (MCS) Diagram.
Figure 4. Beacon Warning Light Diagram.
Figure 5. Dump Body Taillights and Marker Clearance Lights Diagram.
CHAPTER 9 PARTS INFORMATION
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) INTRODUCTION
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES
Maintenance Code.
Recoverability Code.
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
SPECIAL INFORMATION
HOW TO LOCATE REPAIR PARTS
REMOTE CONTROL, MATERIAL CONTROL SYSTEM (MCS)
Figure 1. Remote Control, Material Control System (MCS).
Figure 1. Remote Control, Material Control System (MCS). - Continued
CONTROL UNIT, MATERIAL CONTROL SYSTEM (MCS)
Figure 2. Control Unit, Material Control System (MCS).
Figure 2. Control Unit, Material Control System (MCS). - Continued
TAILLIGHTS, MARKER CLEARANCE LIGHTS, AND REFLECTORS
Figure 3. Taillights, Marker Clearance Lights, and Reflectors.
Figure 3. Taillights, Marker Clearance Lights, and Reflectors. - Continued
BODY UP AND TRANSPORT LOCK SWITCHES
Figure 4. Body Up and Transport Lock Switches.
Figure 4. Body Up and Transport Lock Switches. - Continued
Figure 4. Body Up and Transport Lock Switches.
Figure 5. Wiring Harness, Beacon Light.
Figure 5. Wiring Harness, Beacon Light. - Continued
WIRING HARNESS, DUMP BODY LIGHTS
Figure 6. Wiring Harness, Dump Body Lights.
Figure 6. Wiring Harness, Dump Body Lights. - Continued
MATERIAL CONTROL SYSTEM (MCS) GATE WIRING HARNESS AND MCS POWER WIRING HARNESS
Figure 7. Material Control System (MCS) Gate Wiring Harness and MCS Power Wiring Harness.
Figure 7. Material Control System (MCS) Gate Wiring Harness and MCS Power Wiring Harness. - Continued
Figure 7. Material Control System (MCS) Gate Wiring Harness and MCS Power Wiring Harness. - Continued
BODY UP/TRANSPORT LOCK SWITCH WIRING HARNESS AND MATERIAL CONTROL SYSTEM (MCS) CHASSIS WIRING HARNESS
Figure 8. Body Up/Transport Lock Switch Wiring Harness and Material Control System (MCS) Chassis Wiring Harness.
Figure 8. Body Up/Transport Lock Switch Wiring Harness and Material Control System (MCS) Chassis Wiring Harness. - Continued
CYLINDER SUPPORT FRAME AND BRACKETS
Figure 9. Cylinder Support Frame and Brackets.
Figure 9. Cylinder Support Frame and Brackets. - Continued
STABILIZER AND REAR HINGE
Figure 10. Stabilizer and Rear Hinge.
Figure 10. Stabilizer and Rear Hinge. - Continued
DUMP BODY ASSEMBLY
Figure 11. Dump Body Assembly.
Figure 11. Dump Body Assembly. - Continued
MATERIAL CONTROL SYSTEM (MCS) TAILGATE ASSEMBLY
Figure 12. Material Control System (MCS) Tailgate Assembly.
Figure 12. Material Control System (MCS) Tailgate Assembly. - Continued
AIR TANK, LINES, AND FITTINGS
Figure 13. Air Tank, Lines, and Fittings.
Figure 13. Air Tank, Lines, and Fittings. - Continued
Figure 13. Air Tank, Lines, and Fittings. - Continued
Figure 13. Air Tank, Lines, and Fittings. - Continued
AIR CYLINDER ASSEMBLY
Figure 14. Air Cylinder Assembly.
Figure 14. Air Cylinder Assembly. - Continued
Figure 14. Air Cylinder Assembly. - Continued
Figure 15. Cargo Cover and Component Parts (Sheet 1 of 2).
Figure 15. Cargo Cover and Component Parts (Sheet 2 of 2).
Figure 15. Cargo Cover and Component Parts - Continued
Figure 15. Cargo Cover and Component Parts - Continued
SHOVEL MOUNTING
Figure 16. Shovel Mounting.
Figure 16. Shovel Mounting. - Continued
DECALS, INSTRUCTION PLATES, AND STENCILS
Figure 17. Decals, Instruction Plates, and Stencils.
Figure 17. Decals, Instruction Plates, and Stencils. - Continued
HYDRAULIC PUMP ASSEMBLY
Figure 18. Hydraulic Pump Assembly.
Figure 18. Hydraulic Pump Assembly. - Continued
DUMP CONTROL AND CABLE
Figure 19. Dump Control and Cable.
Figure 19. Dump Control and Cable. - Continued
FILTER ELEMENT, HYDRAULIC
Figure 20. Filter Element, Hydraulic.
Figure 20. Filter Element, Hydraulic. - Continued
HYDRAULIC HOSES AND FITTINGS
Figure 21. Hydraulic Hoses and Fittings.
Figure 21. Hydraulic Hoses and Fittings. - Continued
CYLINDER ASSEMBLY, HOIST
Figure 22. Cylinder Assembly, Hoist.
Figure 22. Cylinder Assembly, Hoist. - Continued
HYDRAULIC RESERVOIR ASSEMBLY
Figure 23. Hydraulic Reservoir Assembly.
Figure 23. Hydraulic Reservoir Assembly. - Continued
Figure 23. Hydraulic Reservoir Assembly. - Continued
SPILL SHIELD
Figure 24. Spill Shield.
Figure 24. Spill Shield. - Continued
BULK MATERIAL
Figure BULK. Bulk Material.
Figure BULK. Bulk Material. - Continued
REPAIR PART KITS
Figure KITS. Repair Part Kits.
Figure KITS. Repair Part Kits. - Continued
NATIONAL STOCK NUMBER (NSN) INDEX
NATIONAL STOCK NUMBER (NSN) INDEX - Continued
NATIONAL STOCK NUMBER (NSN) INDEX - Continued
NATIONAL STOCK NUMBER (NSN) INDEX - Continued
PART NUMBER (P/N) INDEX
PART NUMBER (P/N) INDEX - Continued
PART NUMBER (P/N) INDEX - Continued
PART NUMBER (P/N) INDEX - Continued
CHAPTER 10 SUPPORTING INFORMATION
REFERENCES
TECHNICAL MANUALS
OTHER PUBLICATIONS
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Maintenance Functions
Explanation of Columns in the MAC
Explanation of Columns in the Tools and Test Equipment Requirements
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. Maintenance Allocation Chart (MAC) for Dump Body
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 1. Maintenance Allocation Chart (MAC) for Dump Body - Continued
Table 2. Tools and Test Equipment Requirements for Dump Body.
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Table 1. Basic Issue Items (BII).
Table 1. Basic Issue Items (BII) - Continued
ADDITIONAL AUTHORIZATION LIST (AAL)
EXPENDABLE AND DURABLE ITEMS LIST (EDIL)
Table 1. Expendable and Durable Items List.
Table 1. Expendable and Durable Items List - Continued
Table 1. Expendable and Durable Items List - Continued
TOOL IDENTIFICATION LIST
Table 1. Tool Identification List
MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List.