tm 08780b-20

TM 08780B-20U.S. MARINE CORPS TECHNICAL MANUALORGANIZATIONAL MAINTENANCEFOR

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 [email protected], 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 TM 2320-20/12A Volume 1 dated 28 May 1999 and TM 2320-20/12A Volume 2 dated 28 May 1999 are hereby superseded for Marine Corps use.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

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TM 08780B-20

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TM 08780B-20 TABLE OF CONTENTS Page How to Use This Manual .................................................................................................. CHAPTER 1. INTRODUCTION ................................................................................. 1-1 Overview .................................................................................. General Information............................................................................... 1-2 Scope ........................................................................................ 1-3 Maintenance Forms, Records and Reports............................... 1-4 Destruction of Materiel to Prevent Enemy Use........................ 1-5 Preparation for Storage or Shipment ........................................ 1-6 Repair of Parts, Special Tools and Support Equipment ........... 1-7 Reporting Equipment Improvement Recommendations .......... 1-8 Warranty Information............................................................... Equipment Description and Data ........................................................... 1-9 Equipment Characteristics........................................................ 1-10 Principles of Operation............................................................. 1-11 Location and Description of Major Components ..................... VEHICLE MAINTENANCE ................................................................ 2-1 Overview .................................................................................. Service Upon Request............................................................................ 2-2 General ..................................................................................... 2-3 Service Upon Request .............................................................. Preventive Maintenance Checks and Services (PMCS) ........................ 2-4 General ..................................................................................... 2-5 PMCS Tables............................................................................ Troubleshooting ..................................................................................... 2-6 STE/ICE Troubleshooting........................................................ 2-7 Standard Troubleshooting ........................................................ Maintenance Procedures ........................................................................ 2-8 Introduction .............................................................................. 2-9 General Removal Instructions .................................................. 2-10 General Disassembly Instructions ............................................ 2-11 General Cleaning Instructions .................................................. 2-12 General Inspection Instructions................................................ xvii 1-1 1-1 1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-2 1-2 2-1 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-33 2-33 2-91 2-607 2-607 2-607 2-607 2-608 2-610

Section I.

Section II.

CHAPTER 2.

Section I.

Section II.

Section III.

Section IV.

i

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 2-13 2-14 CHAPTER 3. General Repair Instructions...................................................... General Assembly Instructions ................................................ 2-612 2-613 3-1 3-1 3-1 3-4 3-8 3-11 3-13 3-16 3-19 3-21 4-1 4-1 4-1 4-4 4-7 4-14 4-17 4-24 4-27 4-29 4-34 4-42 4-53 4-56 4-61 4-69 4-72 4-75 4-79 4-82 4-89 4-95 4-98 4-101 5-1 5-1

ENGINE................................................................................................. 3-1 Overview .................................................................................. 3-2 Description and Data ................................................................ 3-3 Engine Oil Service.................................................................... 3-4 Rocker Cover and Gasket Replacement ................................... 3-5 Oil Filter Adapter Replacement ............................................... 3-6 Oil Pan and Gasket Replacement ............................................. 3-7 Exhaust Manifold and Gasket Replacement ............................ 3-8 Engine Oil Sampling Valve (LVSA1 Series Vehicles Only)... 3-9 New Replacement Dipstick Installation ................................... FUEL SYSTEMS................................................................................... 4-1 Overview .................................................................................. 4-2 Fuel System Principles of Operation........................................ 4-3 Fuel Supply Pump Replacement .............................................. 4-4 Fuel Supply Pump Repair......................................................... 4-5 Hand Priming Pump Replacement ........................................... 4-6 Air Cleaner Assembly Replacement ........................................ 4-7 Air Cleaner Element Replacement ........................................... 4-8 Air Restriction Indicator Replacement..................................... 4-9 Intake Ducting Replacement .................................................... 4-10 Left Fuel Tank Replacement .................................................... 4-11 Right Fuel Tank Replacement .................................................. 4-12 Fuel Line, Vent and Fitting Replacement ................................ 4-13 Shutdown Solenoid Replacement............................................. 4-14 Shutdown Solenoid Replacement (LVSA1 Series Vehicles Only) ................................................ 4-15 Throttle Control Solenoid Replacement................................... 4-16 Throttle Cylinder Replacement ................................................ 4-17 Throttle Cylinder Repair .......................................................... 4-18 Fuel/Water Separator Service................................................... 4-19 Fuel/Water Separator Replacement.......................................... 4-20 Fuel/Water Separator Repair .................................................... 4-21 Secondary Fuel Filter and Adapter Replacement..................... 4-22 Ether Starting Aid Replacement............................................... 4-23 Throttle Treadle Valve Replacement ....................................... EXHAUST SYSTEM ............................................................................ 5-1 Overview ..................................................................................

CHAPTER 4.

CHAPTER 5.

ii

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 5-2 5-3 5-4 CHAPTER 6. Description and Data ................................................................ Muffler/Pipe Replacement ....................................................... Exhaust Crossover Tube Maintenance ..................................... 5-1 5-2 5-8 6-1 6-1 6-1 6-3 6-5 6-8 6-11 6-19 6-26 7-1 7-1 7-1 7-6 7-9 7-15 7-18 7-21 7-26 7-29 7-32 7-34 7-36 7-50 7-65 7-68 7-70 7-72 7-75 7-78 7-81 7-84 7-86 7-88 7-90 7-92

COOLING SYSTEM............................................................................. 6-1 Overview .................................................................................. 6-2 Cooling System Description..................................................... 6-3 Radiator Service ....................................................................... 6-4 Radiator Grille and Grate Replacement ................................... 6-5 Coolant Filter and Adapter Replacement ................................. 6-6 Thermostat and Housing Replacement..................................... 6-7 Cooling System Hose and Tube Replacement ......................... 6-8 Radiator Testing ....................................................................... ELECTRICAL SYSTEM ...................................................................... 7-1 Overview .................................................................................. 7-2 Principles of Operation............................................................. 7-3 Alternator Circuit Breaker and Diode Replacement ................ 7-4 Alternator Replacement............................................................ 7-5 Voltage Regulator Maintenance ............................................... 7-6 Starter Solenoid Replacement .................................................. 7-7 Starter Replacement ................................................................. 7-8 Starter Relay Replacement ....................................................... 7-9 Cooling System Switch Replacement ...................................... 7-10 Oil Pressure Switch Replacement ............................................ 7-11 Instrument Panel Assembly Replacement ................................ 7-12 Instrument Panel Harness Replacement ................................... 7-13 Instrument Panel Harness Replacement (LVSA1 Series Vehicles Only) ................................................ 7-14 Circuit Breaker Replacement ................................................... 7-15 Toggle Switch Replacement..................................................... 7-16 Steering Selector Switch Replacement..................................... 7-17 Turn Signal Switch and Flasher Replacement ......................... 7-18 Turn Signal Switch and Flasher Replacement (LVSA1 Series Vehicles Only) ................................................ 7-19 Speedometer/Tachometer Replacement ................................... 7-20 Electrical Gauge Replacement ................................................. 7-21 Magnetic Switch Replacement ................................................. 7-22 Ether Start Switch Replacement............................................... 7-23 Ignition Switch Replacement ................................................... 7-24 Master Light Switch Replacement ........................................... 7-25 Stop Light Switch Replacement ...............................................

CHAPTER 7.

iii

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42 7-43 7-44 7-45 7-46 7-47 7-48 7-49 7-50 7-51 7-52 7-53 7-54 7-55 7-56 Neutral Safety Switch Maintenance ......................................... Hi Idle Neutral Switch Replacement........................................ Relay Replacement................................................................... Dashboard Warning and/or Indicator Light Replacement........ Headlight Maintenance............................................................. Clearance Light Replacement .................................................. Clearance Light Mounting Bracket Replacement .................... Dome Light Replacement......................................................... Front Composite Light Replacement ....................................... Map Light Replacement ........................................................... Rear Composite Light Replacement......................................... Worklight Replacement............................................................ Beacon Light Replacement ...................................................... Sending Unit Replacement....................................................... Fuel Level Sending Unit Replacement..................................... Buzzer Warning System Replacement ..................................... Alarm Replacement .................................................................. Low Air Pressure Switch Replacement.................................... Fuel Restriction Sensor Replacement....................................... Battery and Battery Box Replacement ..................................... Battery and Battery Box Replacement (LVSA1Series Vehicles Only) ................................................. Slave Connector Replacement.................................................. Wiring Harness Maintenance ................................................... Optic Ribbon Light Source Replacement................................. Optic Ribbon Replacement ...................................................... Resistor Replacement ............................................................... Dimmer Switch Replacement................................................... Electrical Control Unit (ECU) Power Cable Replacement, FPU, (ABS Modified Vehicles Only) ...................................... Electrical Control Unit (ECU) Power Cable Replacement, RBU, (ABS Modified Vehicles Only) ..................................... Electrical Control Unit (ECU) Relay Assembly Replacement (ABS Modified Vehicles Only).......................... Antilocking Brake System (ABS Warning Light Replacement (ABS Modified Vehicles Only).......................... 7-95 7-99 7-101 7-103 7-105 7-110 7-113 7-115 7-117 7-121 7-124 7-127 7-129 7-132 7-135 7-138 7-141 7-143 7-145 7-147 7-155 7-166 7-169 7-184 7-186 7-188 7-190 7-192 7-197 7-203 7-206

iv

TM 08780B-20 TABLE OF CONTENTS (Continued) Page CHAPTER 8. TRANSMISSION .................................................................................. 8-1 Overview .................................................................................. 8-2 Description and Data ................................................................ 8-3 Transmission Oil Change and Spin-on Filter Replacement ..... 8-4 Shift Control Replacement ....................................................... 8-5 Shift Control Repair ................................................................. 8-6 Shift Tower Lamp Replacement............................................... 8-7 Shift Cable Maintenance .......................................................... 8-8 Transmission Lockup Switch Replacement ............................. 8-9 Transmission Lockup Solenoid Valve Replacement................ 8-10 Governor Replacement............................................................. 8-11 Modulator Valve Replacement................................................. 8-12 Oil Filter Bracket Replacement ................................................ 8-13 Oil Filter Bracket Replacement (LVSA1 Series Vehicles Only) ................................................ 8-14 Oil Pan, Gasket and Internal Filter Replacement ..................... 8-15 Transmission Cooler Replacement........................................... 8-16 Transmission Breather Replacement........................................ TRANSFER CASE................................................................................ 9-1 Overview .................................................................................. 9-2 Principles of Operation............................................................. 9-3 Transfer Case Oil Change ........................................................ 9-4 2-Speed Shift Linkage Maintenance ........................................ 9-5 Shift Lever Replacement .......................................................... 9-6 Lubrication Lines and Fitting Replacement ............................. 9-7 Transfer Case Lubrication Pump Replacement........................ 9-8 Transfer Case Breather Replacement ....................................... 9-9 Lockup Air Chamber Replacement .......................................... 8-1 8-1 8-1 8-4 8-8 8-11 8-13 8-15 8-22 8-24 8-27 8-29 8-31 8-34 8-37 8-41 8-43 9-1 9-1 9-1 9-3 9-5 9-12 9-14 9-19 9-21 9-23 10-1 10-1 10-1 10-2 10-12 10-15 11-1 11-1 11-1

CHAPTER 9.

CHAPTER 10. PROPELLER SHAFTS ......................................................................... 10-1 Overview .................................................................................. 10-2 Principles of Operation............................................................. 10-3 Propeller Shafts and Universal Joint Maintenance................... 10-4 Cardan Joint Repair .................................................................. 10-5 Pillow Block Bearing Replacement ......................................... CHAPTER 11. FRONT AXLE....................................................................................... 11-1 Overview .................................................................................. 11-2 No. 1 Axle Principles of Operation ..........................................

v

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 11-3 11-4 11-5 11-6 No. 1 Axle Oil Change ............................................................. Front Axle Breather Service..................................................... Nose Box Breather Maintenance.............................................. No. 1 Axle Shaft Maintenance ................................................. 11-2 11-5 11-7 11-9 12-1 12-1 12-1 12-2 12-4 12-7 13-1 13-1 13-1 13-6 13-8 13-10 13-14 13-17 13-20 13-25 13-28 13-34 13-37 13-42 13-45 13-52 13-58 13-63 13-66 13-69 13-72 13-75 13-80 13-83 13-88 13-92 13-95

CHAPTER 12. REAR AXLES ....................................................................................... 12-1 Overview .................................................................................. 12-2 Principles of Operation............................................................. 12-3 No. 2, 3 and 4 Axle Oil Change ............................................... 12-4 Axle Shaft Replacement (No. 2, 3 and 4 Axles) ...................... 12-5 Rear Axle Breather Service...................................................... CHAPTER 13. TRANSMISSION .................................................................................. 13-1 Overview .................................................................................. 13-2 Principles of Operation............................................................. 13-3 Antilocking Brake System........................................................ 13-4 Brake Inspection and Adjustment (No. 1 Axle) ....................... 13-5 Brake Inspection and Adjustment (No. 2, 3 and 4 Axles)........ 13-6 Brake Shoe Replacement (No. 1 Axle) .................................... 13-7 Brake Shoe Replacement (No. 2, 3 and 4 Axles) ..................... 13-8 Wedge Brake Maintenance (No. 1 Axle) ................................. 13-9 Brake Spider and Skein Replacement (No. 1 Axle) ................. 13-10 Camshaft and Slack Adjuster Replacement (No. 2, 3 and 4 Axles) .............................................................. 13-11 Brake Spider and Bracket Replacement (No. 2, 3 and 4 Axles) .............................................................. 13-12 Brake Chamber Replacement (No. 2, 3 and 4 Axles) .............. 13-13 Brake Chamber Replacement (No. 1 Axle).............................. 13-14 Brake Treadle Valve Replacement........................................... 13-15 Relay Valve Replacement (MK48) .......................................... 13-16 Relay Valve Replacement (MK14, 15, 16, 17) ........................ 13-17 Quick Release Valve Replacement .......................................... 13-18 Quick Release Valve Replacement (LVSA1 Series Vehicles Only) ................................................ 13-19 Pressure Protection Valve Replacement................................... 13-20 Spring Brake Control Valve Replacement ............................... 13-21 Parking Brake Valve Maintenance........................................... 13-22 Tractor Protection Valve Replacement .................................... 13-23 Air Line and Fitting Replacement ............................................ 13-24 Front Air Manifold Replacement ............................................. 13-25 Rear Air Manifold Replacement .............................................. 13-26 Main Air Manifold Replacement .............................................

vi

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 13-27 13-28 13-29 13-30 13-31 13-32 13-33 13-34 13-35 13-36 13-37 13-38 13-39 13-40 13-41 13-42 13-43 13-44 13-45 Left Instrument Panel Air Manifold Replacement ................... One-Way Check Valve Replacement....................................... Ball Valve Replacement ........................................................... Right Instrument Panel Air Manifold Replacement................. Quick Disconnect Fitting Replacement.................................... Quick Build-up Air Reservoir Replacement ............................ Right Air Reservoir Replacement ............................................ Left Air Reservoir Replacement............................................... Rear Unit Air Reservoir Replacement...................................... Glad Hand Replacement........................................................... Air Governor Maintenance....................................................... Air Dryer Maintenance............................................................. Hand Control Valve Replacement............................................ Trailer Air Supply Valve Replacement .................................... Traction Control Valve Replacement....................................... Electronic Control Unit/Air control Valve Replacement ......... Antilocking Brake System Sensor Replacement...................... Quick Release Valve Replacement (ABS only)....................... R14 Valve Replacement (ABS only) ....................................... 13-102 13-106 13-109 13-112 13-116 13-118 13-124 13-133 13-140 13-146 13-150 13-158 13-170 13-175 13-178 13-182 13-188 13-193 13-197 14-1 14-1 14-1 14-2 14-9 14-15 14-19 14-28 15-1 15-1 15-1 15-3 15-6 15-9 15-12 15-15 15-19 15-22 15-25 15-30

CHAPTER 14. WHEELS AND TIRES.......................................................................... 14-1 Overview .................................................................................. 14-2 Description and Data ................................................................ 14-3 Hub, Drum, Toner Ring and Wheel Bearing Replacement (No. 2, 3 and 4 Axles) .............................................................. 14-4 Hub, Drum and Wheel Bearing Replacement (No. 1 Axle)..... 14-5 Wheel and Tire Replacement ................................................... 14-6 Tire Maintenance (Non Run Flat) ............................................ 14-7 Tire Maintenance (Run Flat) .................................................... CHAPTER 15. STEERING SYSTEM ........................................................................... 15-1 Overview .................................................................................. 15-2 Principles of Operation............................................................. 15-3 Steering Wheel Replacement ................................................... 15-4 Steering Column Replacement ................................................. 15-5 Steering Column Repair ........................................................... 15-6 Steering Linkage and Universal Joint Maintenance................. 15-7 Drag Link Maintenance............................................................ 15-8 Tie Rod Maintenance ............................................................... 15-9 Pitman Arm Maintenance......................................................... 15-10 Bell Crank Maintenance ........................................................... 15-11 Cab 90 Degree Gear Box Replacement....................................

vii

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 15-12 15-13 15-14 15-15 15-16 15-17 Frame 90 Degree Gear Box Replacement ................................ Yaw Feedback Linkage Maintenance ...................................... Steering Shaft Assembly Maintenance..................................... Fuse Link Maintenance ............................................................ Steering System Hose and Fitting Replacement ...................... Steering Adjustment ................................................................. 15-34 15-37 15-43 15-47 15-54 15-56 16-1 16-1 16-1 16-2 16-5 16-11 16-15 17-1 17-1 17-1 17-2 17-4 17-10 18-1 18-1 18-1 18-2 18-4 18-12 18-14 18-17 18-19 18-22 18-25 18-27 18-29 18-33 18-35 18-38 18-43 18-45 18-47

CHAPTER 16. FRAME.................................................................................................. 16-1 Overview .................................................................................. 16-2 Description and Data ................................................................ 16-3 Fifth Wheel Ramp Replacement .............................................. 16-4 Landing Leg Assembly Replacement....................................... 16-5 Landing Leg Assembly Repair................................................. 16-6 Pintle Replacement................................................................... CHAPTER 17. SUSPENSION ....................................................................................... 17-1 Overview .................................................................................. 17-2 Description and Data ................................................................ 17-3 Shock Absorber and Bushing Replacement ............................. 17-4 Torque Rod Replacement (MK48)........................................... 17-5 Torque Rod Replacement (MK14, 15, 16 and 17) ................... CHAPTER 18. CAB AND BODY ................................................................................. 18-1 Overview .................................................................................. 18-2 Cab and Body ........................................................................... 18-3 Door Replacement .................................................................... 18-4 Door Repair .............................................................................. 18-5 Mud Flap Replacement ............................................................ 18-6 Cab Step Replacement.............................................................. 18-7 Vehicle Step Replacement........................................................ 18-8 Windshield Glass Replacement................................................ 18-9 Rear Window Glass, Door Vent Window Glass and Peep Glass Replacement .......................................................... 18-10 Door Glass and Regulator Replacement .................................. 18-11 Seat Cushion Replacement....................................................... 18-12 Seat and Frame Assembly Replacement .................................. 18-13 Seat Belt Replacement.............................................................. 18-14 Seat Belt Replacement (LVSA1 Series Vehicles Only)........... 18-15 Access Cover and Panel Replacement ..................................... 18-16 Roof Vent Replacement ........................................................... 18-17 Skid Plate Grille Replacement ................................................. 18-18 Skid Plate and Skid Plate Frame Replacement ........................

viii

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 18-19 18-20 18-21 18-22 18-23 Engine Access Door Replacement ........................................... Tool Box and Stowage Compartment Replacement (MK14, 15, 17)......................................................................... Tools Box and Stowage Compartment Replacement (LVSA1 Series Vehicles Only) ................................................ Stowage Compartment Replacement (MK16) ......................... Grab Handle Replacement (LVSA1 Series Vehicles Only)..... 18-52 18-54 18-57 18-63 18-70 19-1 19-1 19-1 19-2 19-4 20-1 20-1 20-1 20-11 20-25 20-39 20-45 20-50 20-55 20-57 20-60 20-63 20-70 20-77 20-83 20-89 20-95 20-112 20-119 20-124 20-131 20-139 20-149 20-153 20-157 20-161 20-164 20-166

CHAPTER 19. WINCHES ............................................................................................. 19-1 Overview .................................................................................. 19-2 Principles of Operation............................................................. 19-3 Winch Cable Maintenance ....................................................... 19-4 Winch Control Handle Repair (MK16).................................... CHAPTER 20. CRANE .................................................................................................. 20-1 Overview .................................................................................. 20-2 Description and Data ................................................................ 20-3 Junction Box Maintenance (MK15) ......................................... 20-4 Junction Box Maintenance (MK17) ......................................... 20-5 Proximity Switch Replacement ................................................ 20-6 Solenoid Dump Valve Wiring Replacement ............................ 20-7 Main Power Wiring Replacement ............................................ 20-8 Neutral Switch Replacement .................................................... 20-9 Relay Replacement................................................................... 20-10 Circuit Breaker Replacement (Junction Box) .......................... 20-11 Extension Cylinder No. 1 Replacement ................................... 20-12 Extension Cylinder No. 2 Replacement ................................... 20-13 Left Outrigger Cylinder Replacement ...................................... 20-14 Right Outrigger Cylinder Replacement.................................... 20-15 Stabilizer Cylinder Replacement.............................................. 20-16 A-Frame Maintenance.............................................................. 20-17 Hose Breakage Valve Replacement ......................................... 20-18 Manifold Replacement (MK17) ............................................... 20-19 Manifold Replacement (MK15) ............................................... 20-20 Basic Solenoid Valve Maintenance.......................................... 20-21 Electrical Failure Valve Replacement ...................................... 20-22 Stabilizer Selector/Locking Valve Replacement...................... 20-23 Outrigger Selector/Locking Valve Replacement (MK15) ....... 20-24 Outrigger Selector/Locking Valve Replacement (MK17) ....... 20-25 Stowage Box Maintenance (MK15)......................................... 20-26 Stowage Box Maintenance (MK17)......................................... 20-27 Placard Replacement ................................................................

ix

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 20-28 20-29 20-30 20-31 20-32 20-33 20-34 20-35 Stabilizer Pad Maintenance ...................................................... Stowing Cable Replacement .................................................... Main Control Lever Maintenance ............................................ Auxiliary Control Lever Maintenance ..................................... Travel Lock Pin Maintenance .................................................. Testing Main Crane Relief Pressure......................................... Holding Valve(s) Adjustment .................................................. Outrigger Beam Adjustment .................................................... 20-172 20-177 20-179 20-184 20-186 20-189 20-191 20-202 21-1 21-1 21-1 21-9 21-29 21-32 21-35 21-39 21-42 21-54 21-66 21-69 21-77 21-81 21-84 21-87 21-90 21-95 21-98 21-108 22-1 22-1 22-1 22-2 22-5 22-8 22-11 22-14 22-17 22-20

CHAPTER 21. CRANE (LVSA1 SERIES VEHICLES ONLY) ................................... 21-1 Overview .................................................................................. 21-2 Description and Data ................................................................ 21-3 Junction Box Maintenance ....................................................... 21-4 Remote Control Stowage Box Replacement (MK17A1) ......... 21-5 Tilt Sensor and Alarm Replacement ........................................ 21-6 Crane Tubing Replacement (MK15A1) ................................... 21-7 Crane Tubing Replacement (MK17A1) ................................... 21-8 Crane Hoses Replacement (MK15A1)..................................... 21-9 Crane Hoses Replacement (MK17A1)..................................... 21-10 Hoist Cable Replacement ......................................................... 21-11 Hook Block Assembly Maintenance ........................................ 21-12 Boom Sheave Replacement...................................................... 21-13 Power Cable Replacement........................................................ 21-14 Remote Control Harness Replacement..................................... 21-15 Overload Shutdown Cable Replacement.................................. 21-16 Control Solenoid Cable Replacement ...................................... 21-17 Tilt Sensor Harness Replacement............................................. 21-18 Remote Control Box Repair ..................................................... 21-19 Holding Valve Replacement .................................................... CHAPTER 22. BODY ACCESSORY ITEMS............................................................... 22-1 Overview .................................................................................. 22-2 Description and Data ................................................................ 22-3 Windshield Wiper Motor Replacement.................................... 22-4 Windshield Wiper Motor Replacement (LVSA1 Series Vehicles Only) ................................................ 22-5 Windshield Wiper Arm and Blade Replacement ..................... 22-6 Wiper Control Valve Replacement .......................................... 22-7 Windshield Wiper Control Valve Replacement ....................... 22-8 Washer Reservoir Hose and Nozzle Replacement ................... 22-9 Washer Reservoir Hose and Nozzle Replacement (LVSA1 Series Vehicles Only) ................................................

x

TM 08780B-20 TABLE OF CONTENTS (Continued) Page 22-10 22-11 22-12 22-13 22-14 22-15 22-16 22-17 22-18 22-19 22-20 22-21 22-22 22-23 Mirror Replacement ................................................................. Air Horn Replacement.............................................................. Air Horn Repair........................................................................ Air Horn Valve Replacement ................................................... Electric Horn Replacement ...................................................... Heater Replacement ................................................................. Heater Blower Replacement..................................................... Heater Blower Repair ............................................................... Heater Core Replacement......................................................... Heater Hose and Fitting Replacement...................................... Defroster Hose, Plenums and Control Cable Replacement...... Heater Control Cable Replacement .......................................... Tire Winch Cable Replacement ............................................... Tire Winch Repair .................................................................... 22-24 22-26 22-29 22-31 22-34 22-36 22-39 22-41 22-43 22-45 22-49 22-54 22-56 22-58 23-1 23-1 23-1 23-6 23-14 23-17 23-20 23-24 23-28 23-31 23-36 23-39 23-42 23-48 23-54 23-66 23-67 23-70 23-73 23-76 23-78 23-83

CHAPTER 23. HYDRAULIC SYSTEM ....................................................................... 23-1 Overview .................................................................................. 23-2 Principles of Operation............................................................. 23-3 Hydraulic System Service ........................................................ 23-4 Selector Valve .......................................................................... 23-5 Yaw Control Valve Replacement............................................. 23-6 Hydraulic Filter Replacement .................................................. 23-7 Hydraulic Filter Replacement (LVSA1 Series Vehicles Only) ................................................ 23-8 Yaw Cylinder Replacement...................................................... 23-9 Hydraulic Reservoir Replacement............................................ 23-10 Hydraulic Oil Level Gauge Replacement ................................ 23-11 Hydraulic Oil Cooler Replacement .......................................... 23-12 Hydraulic Oil Filter Housing Maintenance .............................. 23-13 Hydraulic Filter Housing Maintenance (LVSA1 Series Vehicles Only) ................................................ 23-14 Hydraulic Hose and Fitting Replacement ................................ 23-15 Hydraulic Hose Reel Replacement........................................... 23-16 Auxiliary Hydraulic Hose Replacement................................... 23-17 Auxiliary Hydraulic Hose Reel Roller Replacement ............... 23-18 Auxiliary Hydraulic Hose Reel Roller Replacement (LVSA1 Series Vehicles Only) ................................................ 23-19 Directional Relief Valve Filter Screen Replacement ............... 23-20 Hi-Pressure Hydraulic Filter and Head Replacement (MK15A1/MK17A1-LVSA1 Series Vehicles Only) ............... 23-21 Hi-Pressure Hydraulic Filter and Head Replacement (MK48A1-LVSA1 Series Vehicles Only) ...............................

xi

TM 08780B-20 TABLE OF CONTENTS (Continued) Page CHAPTER 24. SPECIAL PURPOSE KITS 24-1 Overview .................................................................................. 24-2 Description and Data ................................................................ 24-3 Machine Gun Mount Replacement........................................... 24-4 Machine Gun Platform Replacement ....................................... 24-5 Machine Gun Hatch Replacement............................................ CHAPTER 25. NON-ELECTRICAL GAUGES 25-1 Overview .................................................................................. 25-2 Description and Data ................................................................ 25-3 Air Pressure Gauge Replacement.............................................

24-1 24-1 24-2 24-5 24-7

25-1 25-1 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 2-1 2-2 Organizational Preventive Maintenance Checks and Services................. Antilocking Brake System Diagnosis Code.............................................. Page 2-3 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 manufacturers 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) 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. What is the quickest way to find the solution to the problem? Turn to

Here you will find the most likely causes of the problem. After following each step, in the order listed and finding the problem (lets say a defective engine oil-pressure gage) go to the referenced paragraph. (4) Replacement. How do you fix the problem? Turn to paragraph 7-18, Electrical Gauge

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 dont like about your equipment. Let us know why you dont 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. Section II. Section III. Section IV. Service Upon Receipt Preventive Maintenance Checks and Services (PMCS) Troubleshooting 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 Interval Item To Be Inspected S A B 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. While starting vehicle, listen for unusual noises and difficult cranking at starter. Listen for unusual engine noises, hesitations and varying speed. Be alert for excessive vibration and smell of fuel, oil or exhaust. Observe gauges for any low or abnormal readings. Test for engine response to throttle treadle feed. Check for sticking or binding of throttle treadle. 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). 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. A - Annually B - Biennially Procedures PRIOR TO ROAD TEST 1.

Item No.

b.

c.

d. e.

f.

g.

2-3

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B BRAKES a. Reach a desired speed and apply brakes with steady force. Vehicle should stop smoothly without side-pull or vibrations. After stopping vehicle and with transmission in gear, release brake treadle. The wheel brakes should release immediately. 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. A - Annually B - Biennially Procedures ROAD TEST 2.

Item No.

b.

c.

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. With the vehicle moving on straight and level ground, lightly hold steering wheel to detect pull, wander or shimmy.

b.

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

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B A - Annually B - Biennially Procedures ROAD TEST 4. TRANSFER CASE a. b. Check transfer case shift lever for proper operation. Operate vehicle in both DIRECT and LOW range. Transfer should shift smoothly with no unusual noise.

Item No.

ENGINE 5. CAUTION WHEN CHECKING ENGINE LOAD SPEED, MAKE SURE THE ENGINE DOES NOT EXCEED GOVERNED SPEED OF 2250 RPM. 6. 7. a. b. Check engine operation at all permissible load speeds. Check engines Jacobs Brake for proper operation in both HIGH and LOW positions.

TRANSMISSION a. Check transmission temperature gauge for proper operation and correct temperature. Check transmission for smooth shifting and proper response in all speed ranges. Listen for unusual noises corning from transmission when shifting.

b.

c.

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

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Item To Be Interval Inspected S A B 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. 9. a. b. Inspect battery cables for frays, splits or looseness. Check the specific gravity of each battery cell and record readings. A - Annually B - Biennially Procedures AFTER ROAD TEST 8.

Item No.

FUEL SYSTEM a. b. Check fuel lines and fittings for leaks. Change fuel-water separator element (1). Refer to paragraph 4-18.

2-6

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B A - Annually B - Biennially Procedures

Item No. 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 650750 foot-pounds (881-1,017 N*m).

2-7

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Item To Be Interval Inspected S A B A - Annually B - Biennially Procedures

Item No. 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 oclock, 4 oclock and 8 oclock 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

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B STEERING a. Check steering system U-joints (1) and shafts (2) for looseness, breaks, cracks, rust or wear. Check steering gear (3) mounting bolts for looseness. Inspect gear (3) for leaks. A - Annually B - Biennially Procedures

Item No. 11.

b.

c. d.

Inspect pitman arm (4) for cracks, breaks or loose mounting. 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). Inspect bellcrank (6) for looseness, breaks or cracks. Inspect fuse link assembly (7) for looseness, breaks or cracks. Inspect yaw cylinder feedback linkage (8) for looseness, breaks, cracks or bends. Inspect both yaw cylinders (9) for scoring, bends or leakage.

e. f. g.

h.

2-9

TM 08780B-20


Item No. 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

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B SUSPENSION a. Check spring leaves (1) for cracks or breaks. Report damaged spring leaves to Direct Support/Intermediate Maintenance (3rd Echelon). 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). A - Annually B - Biennially Procedures

Item No. 12.

b.

c. d.

Inspect Spring U-bolts (3) for cracks, breaks or looseness. Inspect spring seat (4) for cracks, breaks or looseness. Inspect spring pressure plate (5) for cracks, breaks or looseness. Inspect front and rear shock absorbers (6) for oil leaks or damage. Inspect front and rear shock absorber rubber bushings (7 and 8) for cracks, dry rotting, damage or looseness.

e. f. g.

2-11

TM 08780B-20


Item No. 12.

SUSPENSION (Continued) h. i. Inspect lockout strut (1) for cracks, breaks or obvious damage. 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. 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. Check the mounting brackets of torque rods (9 and 10) for cracks, breaks or loose mounting on frame. Torque mounting bolts to 440580 foot-pounds (596-786 N*m). Refer to paragraph 17-5.

l.

m.

2-12

TM 08780B-20


Item No. 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


Item No. 13.

PROPELLER SHAFTS a. b. Inspect all propeller shafts (1) for bends or cracks. 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. Inspect pillow blocks (b) for cracks, breaks or looseness. Inspect center bearing (8) for cracks, breaks or looseness. Inspect Cardan joint (7) for cracks, breaks or looseness.

d. e. f.

2-14

TM 08780B-20


Item No.

14.

BRAKES a. b. Inspect brake adjustment. Refer to paragraphs 13-4 and 13-5. 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. 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.

c.

2-15

TM 08780B-20


Item No. 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. c. d.

Inspect oil seals (2) for damage or leaks. Inspect transfer case (3) for leaks, cracks, damage and loose bolts. Inspect transfer case shift cable (4) for kinks, excessive play, wear or damage.

2-16

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B TRANSMISSION a. b. Inspect transmission for cracks, leaks or obvious damage. Inspect transmission shift cable (1) for kinks, excessive play, wear or damage. A - Annually B - Biennially Procedures

Item No. 16.

c.

Check transmission drain plug (2) for looseness. Torque to 15-20 foot-pounds (22-27 N*m). Inspect transmission oil pan bolts (3) for looseness. Tighten pan bolts (3) to 10-13 foot-pounds (13-17 N*m). Inspect output shaft seal (4) for damage or leaks. If there are signs of oil leaks, notify Direct Support/Intermediate Maintenance (3rd Echelon). Remove breather (5) from transmission. Refer to paragraph 8-16. Wash breather in solvent (item 53, Appendix D) and allow to air dry.

d.

e.

f.

2-17

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Item To Be Interval Inspected S A B 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. A - Annually B - Biennially Procedures

Item No. 17.

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). 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). Inspect wheel bearings (5) for looseness, damage or wear. Refer to paragraph 14-3 and 14-4. Check trunnion bearing cover (6) for damage or wear. Inspect axle shaft and cage ring assembly. Clean and repack,

c.

d.

e. f.

2-18

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B 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. A - Annually B - Biennially Procedures

Item No. 18.

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). Inspect wheel bearings (4) for scoring, pitting or discoloration. Replace seals. Refer to paragraphs 14-3 and 14-4.

c.

2-19

TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Interval Item To Be Inspected S A B FRAME a. Inspect for broken crossmembers (1), broken welds and loose, broken or missing bolts. A - Annually B - Biennially Procedures

Item No. 19.

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. Replace all coupling nuts and bolts (3). Lubricate and torque to 375 foot-pounds (508.5 N*m).

d.

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TM 08780B-20


Item No. 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. Remove and clean directional relief valve filter screen (4). Refer to paragraph 23-19.

c.

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TM 08780B-20


Item No. 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. Change both primary and secondary air filter elements. Refer to paragraph 4-7.

b.

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TM 08780B-20


Item No. 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. Test coolant. Refer to TB 750-651. Service cooling system if necessary. Refer to paragraph 6-3. Drain, flush and refill coolant. Refer to paragraph 6-3. Replace coolant water filter. Refer to paragraph 6-5.

b.

c. d.

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TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued) S - Semiannually Item To Be Interval Inspected S A B ENGINE a. Inspect oil filter housing (1) for oil leaks and looseness. Tighten bolts to 30-35 foot-pounds (40-47 N*m). Inspect all oil lines (2) for cracks, frays or wear that could cause leaks. 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). A - Annually B - Biennially Procedures

Item No. 23.

b.

c.

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TM 08780B-20


Item No. 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). Inspect rocker cover gaskets (2) for oil leaks. Replace rocker cover gaskets if oil leaks exist. Refer to paragraph 3-4. Inspect all engine compartment wiring for frays, splits, missing insulation or poor connections. Repair or replace any worn wiring. Inspect alternator wiring (3) for frays, splits, missing insulation or loose terminal connections. Repair or replace any worn wiring. Check that alternator mounting bolts (4) are tightened to 35 footpounds (47 N*m). Check engine mount bolts (5) for correct torque 170 foot-pounds (230 N*m) wet.

e.

f.

g.

h.

i.

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TM 08780B-20


Item No. 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.

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TM 08780B-20


Item No. 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). Inspect all air reservoirs and their attaching valves, lines and connections for looseness, bends, dents and cracks that could cause leaks. Replace air dryer desiccant (2). Refer to paragraph 13-38. Check air governor (3) for leaks. Make sure governor mounting bolts are tight. Check air governor for proper operation. Adjust governor as required. Refer to paragraph 13-37.

b.

c. d.

e.

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TM 08780B-20


Item No. 26.

PINTLE HOOK AND LANDING LEGS a. b. Inspect pintle hook for damage. Check pintle for proper operation. 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. 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. With boom raised and extended, inspect crane hydraulic cylinders for bends or scoring. Check for loose crane mounting bolts. 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 2035.

b.

c.

d. e.

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TM 08780B-20


Item No. 28.

A-FRAME (MK15/15A1) a. Inspect A-Frame for cracks, bends, broken welds or loose mounting. Inspect A-Frame cylinder for leaks, bends or scoring. Inspect A-frame snatch block for proper operation. Inspect towing cable for kinks, broken strands or wear.

b. c. d.

29.

WINCH (MK15/15A1 AND 16/16A1) a. b. Check winch for loose mounting bolts. 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.

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TM 08780B-20


Item No. 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.

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TM 08780B-20


Item No. 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. Refer to TM 08686A-13&P for Preventive Maintenance Checks and Services.

b.

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TM 08780B-20


Item No. 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. b. Check tow unit for cracks or broken welds. Check tow unit for damaged air lines and hoses. Inspect glad hands for missing or rotted seals.

35.

LIFT SLINGS a. b. Inspect for tears or rips. Check clevis and pin for bends or breaks. 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 a. b. c. d. e. f. Introduction STE/ICE Maintenance STE/ICE Description Vehicle Test Meter (VTM) Transducer Kit (TK) Transport Case g. h. i. j. k. l. Cable Assemblies Vehicle Test Cards (VTC) Types of Readouts Operating Modes Testing STE/ICE Tests

This task covers:

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 94910-571-12&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) tests: a. b. c. d. e. f. g. Voltage (AC and DC) Current (High and Low) Resistance Pressure and Vacuum Temperature Compression Balance Starter System The STE/ICE system includes multimeter functions and the following

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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.

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TM 08780B-20

Vehicle Test Meter (VTM) (5) test procedures. The FLIP CARDS list the two digit test numbers and a summary of the

(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) electrical system. CURRENT PROBE. This probe is used to measure amperage draw in the

(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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Hose and Fitting Assembly (TK Item 10) Current Probe (TK Item 11) Reducer 314 (TK Item 12) Reducer 112 (TK Item 13) Reducer 318 (TK Item 14) Pipe Plug 1/4 (TK Item 15) Pipe Plug 1/8 (TK Item 16) Pressure Transducer Blue Stripe (TK Item 17) Male Connector 1/4 (TK Item 18) Pipe Reducer Coupling (TK Item 19) Adapter (TK Item 20) Snubber (TK Item 21) Pressure Transducer Red Stripe (TK Item 22)

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Street Tee 112 (TK I

tm 08780b-20

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