CHAPTER 1 INTRODUCTIONPREPARATION FOR STORAGE OR SHIPMENTCORROSION PREVENTION AND CONTROL (CPC)Section II. EQUIPMENT DESCRIPTION AND DATALOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-5-3805-264-14P_19LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Cont)PIates.Decals.LOCATION AND CONTENTS OF PLATES, DECALS, AND STENCILS (Con't)StencilsDIFFERENCES BETWEEN MODELSModelsSection III. PRINCIPLES OF OPERATIONDUMP BODY (Cont) - TM-5-3805-264-14P_28DUMP BODY (Cont) - TM-5-3805-264-14P_29HYDRAULIC SYSTEMHYDRAULIC SYSTEM (Cont).CHAPTER 2 OPERATING INSTRUCTIONSCAB-MOUNTED CONTROLS AND INDICATORS (Cont)EXTERNAL CONTROLS AND INDICATORSEXTERNAL CONTROLS AND INDICATORS (Cont) - TM-5-3805-264-14P_36EXTERNAL CONTROLS AND INDICATORS (Cont) - TM-5-3805-264-14P_37Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)GENERAL PMCS PROCEDURESGENERAL PMCS PROCEDURES (Cont)Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS BodyTable 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_42Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_43Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_44Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_45Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_46Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_47Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_48Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con?) - TM-5-3805-264-14P_49Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con?) - TM-5-3805-264-14P_50Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont) - TM-5-3805-264-14P_51Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MS Body (Cont)Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con't) - TM-5-3805-264-14P_53Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con't) - TM-5-3805-264-14P_54Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con't) - TM-5-3805-264-14P_55Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con't) - TM-5-3805-264-14P_56Section III. OPERATION UNDER USUAL CONDITIONSSection III. OPERATION UNDER USUAL CONDITIONSLOADING DUMP BODYDUMPING LOADDUMPING LOAD (Cont).DUMPING LOAD (Con't)Lowering Dump BodyAfter DumpingADJUSTING TAILGATE OPENING (Cont)ADJUSTING MCS GATE OPENINGS (M917A1 W/MCS) (Cont)CONTROLLED SPREADING (M917A1 W/MCS).CONTROLLED SPREADING (M917A1 W/MCS) (Cont)OPERATING CARGO COVERCovering Load.OPERATING BODY PROPSSection IV. OPERATION UNDER UNUSUAL CONDITIONSCHAPTER 3 OPERATOR MAINTENANCESection II. OPERATOR TROUBLESHOOTING PROCEDURESTROUBLESHOOTING SYMPTOM INDEX - TM-5-3805-264-14P_75Table 3-1. Operator Troubleshooting.Table 3-1. Operator Troubleshooting (Cont) - TM-5-3805-264-14P_77Table 3-1. Operator Troubleshooting (Cont) - TM-5-3805-264-14P_78Section III. OPERATOR MAINTENANCECHAPTER 4 UNIT MAINTENANCESection II. SERVICE UPON RECEIPTSection Ill. GENERAL MAINTENANCE INSTRUCTIONSWORK SAFETYCLEANING INSTRUCTIONS (Con't).INSPECTION INSTRUCTIONSAPPLICATION OF ADHESIVESTAGGING WIRES AND HOSESELECTRICAL GROUND POINTSANTISEIZE TAPETUBES AND COMPRESSION FITTINGS.WELDINGSection IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)GENERAL LUBRICATION PROCEDURESTM-5-3805-264-14P_95PMCS INITIAL SETUPLUBRICATION DATAMANDATORY REPLACEMENT PARTSTable 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS BodyTable 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Con't)Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont). - TM-5-3805-264-14P_101Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont). - TM-5-3805-264-14P_102Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont). - TM-5-3805-264-14P_103Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont). - TM-5-3805-264-14P_104Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont). - TM-5-3805-264-14P_105Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) for M917A1 and M917A1 w/MCS Body (Cont). - TM-5-3805-264-14P_106Section V. UNIT TROUBLESHOOTING PROCEDURESDUMP BODY TROUBLESHOOTINGTable 4-3. Unit Troubleshooting.Table 4-3. Unit Troubleshooting (Cont). - TM-5-3805-264-14P_110Table 4-3. Unit Troubleshooting (Cont). - TM-5-3805-264-14P_111Table 4-3. Unit Troubleshooting (Cont). - TM-5-3805-264-14P_112Section VI. ELECTRICAL SYSTEM MAINTENANCEREMOVAL - TM-5-3805-264-14P_114TRANSPORT LOCK SWITCH REPLACEMENT.INSTALLATION TAILLIGHT REPLACEMENTMARKER CLEARANCE LIGHT REPLACEMENTMCS CONTROL UNIT MAINTENANCE (M917A1 W/MCS)DISASSEMBLY FOLLOW-ON TASKSMCS REMOTE CONTROL REPAIR (M917A1 W/MCS).MCS REMOTE CONTROL REPAIR (M917A1 W/MCS) (Cont)CLEANING AND INSPECTIONMCS REMOTE CONTROL REPAIR (M917A1 W/MCS) (Con't)MCS REMOTE CONTROL REPAIR (M917A1 W/MCS) (Cont).BODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTENANCEBODY UP AND TRANSPORT LOCK SWITCHES WIRING HARNESS MAINTE- NANCE (Cont)BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE.BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE (Cont) - TM-5-3805-264-14P_130BEACON WARNING LIGHT WIRING HARNESS MAINTENANCE (Cont) - TM-5-3805-264-14P_131LIGHTS WIRING HARNESS MAINTENANCEINSTALLATION - TM-5-3805-264-14P_133TRUCK-TO-MCS TAILGATE WIRING HARNESS MAINTENANCE (M917A1 W/ MCS)TRUCK-TO-MCS TAILGATE WIRING HARNESS MAINTENANCE (M917A1 W/MCS) (Con't)MCS TAILGATE WIRING HARNESS MAINTENANCE (M917A1 W/MCS)MCS TAILGATE WIRING HARNESS MAINTENANCE (M917A1 W/MCS) (Cont) - TM-5-3805-264-14P_137MCS TAILGATE WIRING HARNESS MAINTENANCE (M917A1 W/MCS) (Cont) - TM-5-3805-264-14P_138MCS TAILGATE WIRING HARNESS MAINTENANCE (M917A1 W/MCS) (Cont).travel lock switchMCS (M917A1 W/MCS)BEACON WARNING LIGHTDUMP BODY TAILLIGHTS AND MARKER CLEARANCE LIGHTSSection VII. DUMP BODY MAINTENANCETAILGATE REPLACEMENT (M917A1) (Cont)TAILGATE RELEASE AIR CYLINDER REPLACEMENTINSTALLATION - TM-5-3805-264-14P_147MCS TAILGATE REPLACEMENT (M917A1 W/MCS)MCS TAILGATE REPLACEMENT (M917A1 W/MCS) (Con't)MCS TAILGATE REPLACEMENT (M917A1 W/MCS) (Cont)MCS TAILGATE COVER REPLACEMENT (M917A1 W/MCS)INSTALLATION - TM-5-3805-264-14P_152MCS GATE REPLACEMENT (M917A1 W/MCS)FOLLOW-ON TASKS:MCS AIR RESERVOIR REPLACEMENT (M917A1 W/MCS)MCS AIR RESERVOIR REPLACEMENT (M917A1 W/MCS) (Con't)MCS AIR CYLINDER REPLACEMENT (M917A1 W/MCS)CLEANING AND INSPECTION - TM-5-3805-264-14P_158MCS AIR CYLINDER REPLACEMENT (M917A1 W/MCS (Cont).MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE (M917A1 W/MCS)DISASSEMBLY - TM-5-3805-264-14P_161MCS AIR CYLINDER SOLENOID ASSEMBLY MAINTENANCE (M917A1 W/MCS) (Cont)FOLLOW-ON TASKS - TM-5-3805-264-14P_163TAILGATE RELEASE/MCS AIR CYLINDER REPAIRassembly - TM-5-3805-264-14P_165TAILGATE RELEASE/MCS AIR CYLINDER REPAIR (Con't)TAILGATE RELEASE/MCS AIR LINES AND FITTINGS REPLACEMENTinstallation - TM-5-3805-264-14P_168MCS ADJUSTMENT TUBE REPLACEMENT (M917A1 W/MCS)INSTALLATION - TM-5-3805-264-14P_170BODY PROP REPLACEMENTCAB SHIELD REPLACEMENT.CAB SHIELD REPLACEMENT (Con't)CAB SHIELD REPLACEMENT (Cont).MUD FLAP REPLACEMENTINSTALLATION - TM-5-3805-264-14P_176Section VIII. DUMP BODY ACCESSORY ITEMS MAINTENANCEinstallation - TM-5-3805-264-14P_178CARGO COVER CRANK ASSEMBLY MAINTENANCECLEANING AND INSPECTION - TM-5-3805-264-14P_180CARGO COVER CRANK ASSEMBLY MAINTENANCE (Cont).CARGO COVER CHAIN AND SPROCKETS REPLACEMENTCARGO COVER CHAIN AND SPROCKETS REPLACEMENT (Con't)installation - TM-5-3805-264-14P_184FOLLOW-ON TASKS - TM-5-3805-264-14P_185CARGO COVER SUPPORT FRAME AND ROLL-UP BAR REPLACEMENTCARGO COVER SUPPORT FRAME AND ROLL-UP BAR REPLACEMENT (Cont)FOLLOW - ON TASKSREFLECTOR REPLACEMENTDATA PLATE REPLACEMENTSection IX. HYDRAULIC SYSTEM MAINTENANCEHYDRAULIC CONTROL LEVER REPLACEMENT (Cont) - TM-5-3805-264-14P_192HYDRAULIC CONTROL LEVER REPLACEMENT (Cont) - TM-5-3805-264-14P_193HYDRAULIC CONTROL LEVER REPLACEMENT (Con't) - TM-5-3805-264-14P_194HYDRAULIC CONTROL LEVER REPLACEMENT (Con't) - TM-5-3805-264-14P_195HYDRAULIC CONTROL LEVER REPLACEMENT (Cont) - TM-5-3805-264-14P_196INSTALLATION - TM-5-3805-264-14P_197INSTALLATION-cont. - TM-5-3805-264-14P_198HYDRAULIC CONTROL LEVER REPLACEMENT (Cont) - TM-5-3805-264-14P_199FOLLOW-ON TASKS - TM-5-3805-264-14P_200HYDRAULIC CONTROL LEVER CABLE REPLACEMENTremoval - TM-5-3805-264-14P_202removal-cont. - TM-5-3805-264-14P_203removal-cont. - TM-5-3805-264-14P_204removal-cont. - TM-5-3805-264-14P_205installation - TM-5-3805-264-14P_206removal-cont. - TM-5-3805-264-14P_207removal-cont. - TM-5-3805-264-14P_208removal-cont. - TM-5-3805-264-14P_209HYDRAULIC HOSES AND FITTINGS REPLACEMENTremoval - TM-5-3805-264-14P_211HYDRAULIC HOSES AND FITTINGS REPLACEMENT (Cont)FOLLOW-ON TASKS - TM-5-3805-264-14P_213HYDRAULIC RESERVOIR REPLACEMENTcleaning and inspection - TM-5-3805-264-14P_215installation - TM-5-3805-264-14P_216HYDRAULIC RESERVOIR REPAIR.assembly - TM-5-3805-264-14P_218HYDRAULIC OIL FILTER ELEMENT REPLACEMENTinstallation - TM-5-3805-264-14P_220HYDRAULIC OIL FILTER SERVICE INDICATOR GAGE REPLACEMENT.installation - TM-5-3805-264-14P_222Section X. PREPARATION FOR STORAGE OR SHIPMENTPREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE (Cont)CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGEPROCEDURES FOR COMMON COMPONENTS AND MISCELLANEOUS ITEMS.CHAPTER 5 DIRECT SUPPORT MAINTENANCEDUMP BODY AND STABILIZER REPLACEMENT (Cont). - TM-5-3805-264-14P_228DUMP BODY AND STABILIZER REPLACEMENT (Cont). - TM-5-3805-264-14P_229installation - TM-5-3805-264-14P_230DUMP BODY AND STABILIZER REPLACEMENT (Con't)FOLLOW-ON TASKS - TM-5-3805-264-14P_232CYLINDER SUPPORT FRAME REPLACEMENTinstallation - TM-5-3805-264-14P_234Section II. DUMP BODY ACCESSORY ITEMS MAINTENANCESection III. HYDRAULIC SYSTEM MAINTENANCEremoval-cont. - TM-5-3805-264-14P_237installation - TM-5-3805-264-14P_238FOLLOW-ON TASKS - TM-5-3805-264-14P_239HYDRAULIC PUMP REPAIRdisassembly-cont. - TM-5-3805-264-14P_241HYDRAULIC PUMP REPAIR (Cont).assembly - TM-5-3805-264-14P_243assembly-cont. - TM-5-3805-264-14P_244FOLLOW-ON TASKS - TM-5-3805-264-14P_245HYDRAULIC CYLINDER REPLACEMENT.removal - TM-5-3805-264-14P_247installation - TM-5-3805-264-14P_248HYDRAULIC CYLINDER REPAIRdisassembly - TM-5-3805-264-14P_250disassembly-cont. - TM-5-3805-264-14P_251disassembly-cont. - TM-5-3805-264-14P_252disassembly-cont. - TM-5-3805-264-14P_253disassembly-cont. - TM-5-3805-264-14P_254disassembly-cont. - TM-5-3805-264-14P_255disassembly-cont. - TM-5-3805-264-14P_256assembly - TM-5-3805-264-14P_257assembly-cont. - TM-5-3805-264-14P_258assembly-cont. - TM-5-3805-264-14P_259HYDRAULIC CYLINDER REPAIR (Cont).FOLLOW-ON TASKS - TM-5-3805-264-14P_261CHAPTER 6 GENERAL SUPPORT MAINTENANCEAPPENDIX A REFERENCES - TM-5-3805-264-14P_265APPENDIX A REFERENCES - TM-5-3805-264-14P_266APPENDIX B MAINTENANCE ALLOCATION CHART - TM-5-3805-264-14P_267APPENDIX B MAINTENANCE ALLOCATION CHART - TM-5-3805-264-14P_268APPENDIX B MAINTENANCE ALLOCATION CHART - TM-5-3805-264-14P_269Section II. MAINTENANCE ALLOCATION CHARTSection II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-3805-264-14P_271Section II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-3805-264-14P_272Section Ill. TOOLS AND TEST EQUIPMENT REQUIREMENTSAPPENDIX C REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL)EXPLANATION OF COLUMNS (SECTIONS II AND Ill) (Cont) - TM-5-3805-264-14P_276EXPLANATION OF COLUMNS (SECTIONS II AND Ill) (Cont) - TM-5-3805-264-14P_277EXPLANATION OF COLUMNS (SECTIONS II AND Ill) (Cont) - TM-5-3805-264-14P_278EXPLANATION OF COLUMNS (SECTIONS II AND Ill) (Cont) - TM-5-3805-264-14P_279SPECIAL INFORMATIONABBREVIATIONSFigure 1. Control Unit Assembly, MCSDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_283Figure 2. Control Switches, MCS.DESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_285Figure 3. Taillights, Marker Lights and Reflectors.DESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_287Figure 4. Wiring Harness, Beacon LightDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_289Figure 5. Bodyup and Transport Lock SwitchesDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_291Figure 6. Wiring Harness, Dump Body LightsDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_293Figure 7. MCS Gate Harness and MCS Power HarnessDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_295Figure 8. Bodyup/Transport Lock HarnessDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_297Figure 9. Cylinder Support Frame and Brackets.DESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_299Figure 10. Stabilizer and Rear HingeDESCRIPTION AND USABLE ON CODES (UOC) - TM-5-3805-264-14P_301Figure 11. Dump Body AssemblyDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_303Figure 12. MCS Tailgate AssemblyDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_305Figure 13. Air Cylinder AssemblyDESCRIPTION AND USABLE ON CODE (UOC)Figure 14. Air Tank, Lines and Fittings.DESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_309DESCRIPTION AND USABLE ON CODES (UOC)Figure 15. Cargo Cover and Component Parts (Sheet 1 of 2).Figure 15. Cargo Cover and Component Parts (Sheet 2 of 2).DESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_315DESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_316Figure 16. DecalsDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_319Figure 17. Hydraulic Pump AssemblyDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_321Figure 18. Dump Control and CableDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_323Figure 19. Filter Element, HydraulicDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_325Figure 20. Hydraulic Hoses and FittingsDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_327Figure 21. Cylinder Assembly, HoistDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_329Figure 22. Hydraulic Reservoir AssemblyDESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_331DESCRIPTION AND USABLE ON CODES(UOC) - TM-5-3805-264-14P_333CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_335CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_336CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_337CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_338CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_339CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_340CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_341CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_342CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_343CROSS-REFERENCE INDEXES - TM-5-3805-264-14P_344APPENDIX D COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTSSection II. COMPONENTS OF END ITEMSection III. BASIC ISSUE ITEMSAPPENDIX E ADDITIONAL AUTHORIZATION LISTAPPENDIX F EXPENDABLE AND DURABLE ITEMS LISTSection II. EXPENDABLE AND DURABLE ITEMS LISTSection II. EXPENDABLE AND DURABLE ITEMS LIST (Cont) - TM-5-3805-264-14P_353Section II. EXPENDABLE AND DURABLE ITEMS LIST (Cont) - TM-5-3805-264-14P_354APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMSSection II. MANUFACTURING INSTRUCTIONSHYDRAULIC CYLINDER DISASSEMBLY TOOL.APPENDIX H TORQUE LIMITSTable H-1. Torque Limits.APPENDIX I TOOL IDENTIFICATION LISTSection II. TOOL IDENTIFICATION LIST (Cont)APPENDIX J LUBRICATION INSTRUCTIONSLUBRICATION CHART - TM-5-3805-264-14P_364LUBRICATION CHART - TM-5-3805-264-14P_365Lubricant/ ComponentTRANSPORT LOCK LINKAGETAILGATE HINGE PINSBODY PROPSNOTES - TM-5-3805-264-14P_370