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TM 08780B-20

U.S. MARINE CORPS TECHNICAL MANUAL

ORGANIZATIONAL MAINTENANCE
FOR

TRUCKS, 8 X 8
LOGISTICS VEHICLE SYSTEM
(DIESEL)
CONSISTING OF

POWER UNIT, FRONT,


4 X 4, MK48 (NSN 2320-01-177-5167)
4 X 4, MK48A1 (NSN 2320-01-417-3180)

TRAILER, POWERED
CONTAINER HAULER,
4 X 4, MK14 (NSN 2320-01-176-0469)
4 X 4, MK14A1 (NSN 2320-01-417-5294)

TRAILER, POWERED,
WRECKER/RECOVERY
4 X 4, MK15 (NSN 2320-01-176-6928)
4 X 4, MK15A1 (NSN 2320-01-417-8144)

TRAILER, POWERED,
FIFTH WHEEL, SEMI-TRAILER ADAPTER,
4 X 4, MK16 (NSN 2320-01-176-0467)
4 X 4, MK16A1 (NSN 2320-01-417-5293)

TRAILER, POWERED,
DROPSIDE, CARGO W/CRANE,
4 X 4, MK17 (NSN 2320-01-176-0468)
4 X 4, MK17A1 (NSN 2320-01-417-5296)

OSHKOSH TRUCK CORPORATION


DAAE07-83-C-H418
DAAE07-95-C-X057

THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR OPERATIONAL PURPOSES.
DISTRIBUTION IS LIMITED TO U S GOVERNMENT AGENCIES ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE
REFERRED TO COMMANDANT OF THE MARINE CORPS (ARD), WASHINGTON, D C 20380-0001

FOR OFFICIAL USE ONLY

JUNE 2004
PCN 180 002327 00
TM 08780B-20

DEPARTMENT OF THE NAVY


Headquarters, U. S. Marine Corps
Washington, DC 20380-0001

30 June 2004

1. This Technical Manual (TM 08780B-20), authenticated for Marine Corps use and effective
upon receipt, provides organization maintenance instructions for the Logistics Vehicle System
(LVS) series of vehicles, consisting of the Front Power Unit MK48/48A1, Trailer, Powered,
Container Hauler MK14/14A1, Trailer, Powered, Wrecker/Recovery MK15/15A1, Trailer,
Powered, Fifth Wheel, Semi-Trailer Adapter MK16/16A1 and Trailer, Powered, Dropside,
Cargo with Crane MK17/17A1.

2. Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC


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

3. TM 2320-20/12A Volume 1 dated 28 May 1999 and TM 2320-20/12A Volume 2 dated 28


May 1999 are hereby superseded for Marine Corps use.

BY DIRECTION OF THE COMMANDANT OF THE MARINE CORPS

OFFICIAL

S. I. SCHULER
Colonel, USMC
Program Manager, Motor Transport (PMM151)
Marine Corps Systems Command

DISTRIBUTION: PCN 180 002327 00

1/(2 blank)
TM 08780B-20

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES


NOTE: The portion of the text affected by the changes is
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TABLE OF CONTENTS

Page

How to Use This Manual .................................................................................................. xvii

CHAPTER 1. INTRODUCTION ................................................................................. 1-1


1-1 Overview .................................................................................. 1-1

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


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

Section II. Equipment Description and Data ........................................................... 1-2


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

CHAPTER 2. VEHICLE MAINTENANCE ................................................................ 2-1


2-1 Overview .................................................................................. 2-1

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


2-2 General ..................................................................................... 2-1
2-3 Service Upon Request .............................................................. 2-1

Section II. Preventive Maintenance Checks and Services (PMCS) ........................ 2-2
2-4 General ..................................................................................... 2-2
2-5 PMCS Tables............................................................................ 2-2

Section III. Troubleshooting ..................................................................................... 2-33


2-6 STE/ICE Troubleshooting........................................................ 2-33
2-7 Standard Troubleshooting ........................................................ 2-91

Section IV. Maintenance Procedures ........................................................................ 2-607


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

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TABLE OF CONTENTS (Continued)

Page

2-13 General Repair Instructions...................................................... 2-612


2-14 General Assembly Instructions ................................................ 2-613

CHAPTER 3. ENGINE................................................................................................. 3-1


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

CHAPTER 4. FUEL SYSTEMS................................................................................... 4-1


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

CHAPTER 5. EXHAUST SYSTEM ............................................................................ 5-1


5-1 Overview .................................................................................. 5-1

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TABLE OF CONTENTS (Continued)

Page

5-2 Description and Data ................................................................ 5-1


5-3 Muffler/Pipe Replacement ....................................................... 5-2
5-4 Exhaust Crossover Tube Maintenance ..................................... 5-8

CHAPTER 6. COOLING SYSTEM............................................................................. 6-1


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

CHAPTER 7. ELECTRICAL SYSTEM ...................................................................... 7-1


7-1 Overview .................................................................................. 7-1
7-2 Principles of Operation............................................................. 7-1
7-3 Alternator Circuit Breaker and Diode Replacement ................ 7-6
7-4 Alternator Replacement............................................................ 7-9
7-5 Voltage Regulator Maintenance ............................................... 7-15
7-6 Starter Solenoid Replacement .................................................. 7-18
7-7 Starter Replacement ................................................................. 7-21
7-8 Starter Relay Replacement ....................................................... 7-26
7-9 Cooling System Switch Replacement ...................................... 7-29
7-10 Oil Pressure Switch Replacement ............................................ 7-32
7-11 Instrument Panel Assembly Replacement ................................ 7-34
7-12 Instrument Panel Harness Replacement ................................... 7-36
7-13 Instrument Panel Harness Replacement
(LVSA1 Series Vehicles Only) ................................................ 7-50
7-14 Circuit Breaker Replacement ................................................... 7-65
7-15 Toggle Switch Replacement..................................................... 7-68
7-16 Steering Selector Switch Replacement..................................... 7-70
7-17 Turn Signal Switch and Flasher Replacement ......................... 7-72
7-18 Turn Signal Switch and Flasher Replacement
(LVSA1 Series Vehicles Only) ................................................ 7-75
7-19 Speedometer/Tachometer Replacement ................................... 7-78
7-20 Electrical Gauge Replacement ................................................. 7-81
7-21 Magnetic Switch Replacement ................................................. 7-84
7-22 Ether Start Switch Replacement............................................... 7-86
7-23 Ignition Switch Replacement ................................................... 7-88
7-24 Master Light Switch Replacement ........................................... 7-90
7-25 Stop Light Switch Replacement ............................................... 7-92

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TABLE OF CONTENTS (Continued)

Page

7-26 Neutral Safety Switch Maintenance ......................................... 7-95


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

iv
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TABLE OF CONTENTS (Continued)

Page

CHAPTER 8. TRANSMISSION .................................................................................. 8-1


8-1 Overview .................................................................................. 8-1
8-2 Description and Data ................................................................ 8-1
8-3 Transmission Oil Change and Spin-on Filter Replacement ..... 8-4
8-4 Shift Control Replacement ....................................................... 8-8
8-5 Shift Control Repair ................................................................. 8-11
8-6 Shift Tower Lamp Replacement............................................... 8-13
8-7 Shift Cable Maintenance .......................................................... 8-15
8-8 Transmission Lockup Switch Replacement ............................. 8-22
8-9 Transmission Lockup Solenoid Valve Replacement................ 8-24
8-10 Governor Replacement............................................................. 8-27
8-11 Modulator Valve Replacement................................................. 8-29
8-12 Oil Filter Bracket Replacement ................................................ 8-31
8-13 Oil Filter Bracket Replacement
(LVSA1 Series Vehicles Only) ................................................ 8-34
8-14 Oil Pan, Gasket and Internal Filter Replacement ..................... 8-37
8-15 Transmission Cooler Replacement........................................... 8-41
8-16 Transmission Breather Replacement........................................ 8-43

CHAPTER 9. TRANSFER CASE................................................................................ 9-1


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

CHAPTER 10. PROPELLER SHAFTS ......................................................................... 10-1


10-1 Overview .................................................................................. 10-1
10-2 Principles of Operation............................................................. 10-1
10-3 Propeller Shafts and Universal Joint Maintenance................... 10-2
10-4 Cardan Joint Repair .................................................................. 10-12
10-5 Pillow Block Bearing Replacement ......................................... 10-15

CHAPTER 11. FRONT AXLE....................................................................................... 11-1


11-1 Overview .................................................................................. 11-1
11-2 No. 1 Axle Principles of Operation .......................................... 11-1

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TM 08780B-20

TABLE OF CONTENTS (Continued)

Page

11-3 No. 1 Axle Oil Change ............................................................. 11-2


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

CHAPTER 12. REAR AXLES ....................................................................................... 12-1


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

CHAPTER 13. TRANSMISSION .................................................................................. 13-1


13-1 Overview .................................................................................. 13-1
13-2 Principles of Operation............................................................. 13-1
13-3 Antilocking Brake System........................................................ 13-6
13-4 Brake Inspection and Adjustment (No. 1 Axle) ....................... 13-8
13-5 Brake Inspection and Adjustment (No. 2, 3 and 4 Axles)........ 13-10
13-6 Brake Shoe Replacement (No. 1 Axle) .................................... 13-14
13-7 Brake Shoe Replacement (No. 2, 3 and 4 Axles) ..................... 13-17
13-8 Wedge Brake Maintenance (No. 1 Axle) ................................. 13-20
13-9 Brake Spider and Skein Replacement (No. 1 Axle) ................. 13-25
13-10 Camshaft and Slack Adjuster Replacement
(No. 2, 3 and 4 Axles) .............................................................. 13-28
13-11 Brake Spider and Bracket Replacement
(No. 2, 3 and 4 Axles) .............................................................. 13-34
13-12 Brake Chamber Replacement (No. 2, 3 and 4 Axles) .............. 13-37
13-13 Brake Chamber Replacement (No. 1 Axle).............................. 13-42
13-14 Brake Treadle Valve Replacement........................................... 13-45
13-15 Relay Valve Replacement (MK48) .......................................... 13-52
13-16 Relay Valve Replacement (MK14, 15, 16, 17) ........................ 13-58
13-17 Quick Release Valve Replacement .......................................... 13-63
13-18 Quick Release Valve Replacement
(LVSA1 Series Vehicles Only) ................................................ 13-66
13-19 Pressure Protection Valve Replacement................................... 13-69
13-20 Spring Brake Control Valve Replacement ............................... 13-72
13-21 Parking Brake Valve Maintenance........................................... 13-75
13-22 Tractor Protection Valve Replacement .................................... 13-80
13-23 Air Line and Fitting Replacement ............................................ 13-83
13-24 Front Air Manifold Replacement ............................................. 13-88
13-25 Rear Air Manifold Replacement .............................................. 13-92
13-26 Main Air Manifold Replacement ............................................. 13-95

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TABLE OF CONTENTS (Continued)

Page

13-27 Left Instrument Panel Air Manifold Replacement ................... 13-102


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

CHAPTER 14. WHEELS AND TIRES.......................................................................... 14-1


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

CHAPTER 15. STEERING SYSTEM ........................................................................... 15-1


15-1 Overview .................................................................................. 15-1
15-2 Principles of Operation............................................................. 15-1
15-3 Steering Wheel Replacement ................................................... 15-3
15-4 Steering Column Replacement ................................................. 15-6
15-5 Steering Column Repair ........................................................... 15-9
15-6 Steering Linkage and Universal Joint Maintenance................. 15-12
15-7 Drag Link Maintenance............................................................ 15-15
15-8 Tie Rod Maintenance ............................................................... 15-19
15-9 Pitman Arm Maintenance......................................................... 15-22
15-10 Bell Crank Maintenance ........................................................... 15-25
15-11 Cab 90 Degree Gear Box Replacement.................................... 15-30

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15-12 Frame 90 Degree Gear Box Replacement ................................ 15-34


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

CHAPTER 16. FRAME.................................................................................................. 16-1


16-1 Overview .................................................................................. 16-1
16-2 Description and Data ................................................................ 16-1
16-3 Fifth Wheel Ramp Replacement .............................................. 16-2
16-4 Landing Leg Assembly Replacement....................................... 16-5
16-5 Landing Leg Assembly Repair................................................. 16-11
16-6 Pintle Replacement................................................................... 16-15

CHAPTER 17. SUSPENSION ....................................................................................... 17-1


17-1 Overview .................................................................................. 17-1
17-2 Description and Data ................................................................ 17-1
17-3 Shock Absorber and Bushing Replacement ............................. 17-2
17-4 Torque Rod Replacement (MK48)........................................... 17-4
17-5 Torque Rod Replacement (MK14, 15, 16 and 17) ................... 17-10

CHAPTER 18. CAB AND BODY ................................................................................. 18-1


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

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Page

18-19 Engine Access Door Replacement ........................................... 18-52


18-20 Tool Box and Stowage Compartment Replacement
(MK14, 15, 17)......................................................................... 18-54
18-21 Tools Box and Stowage Compartment Replacement
(LVSA1 Series Vehicles Only) ................................................ 18-57
18-22 Stowage Compartment Replacement (MK16) ......................... 18-63
18-23 Grab Handle Replacement (LVSA1 Series Vehicles Only)..... 18-70

CHAPTER 19. WINCHES ............................................................................................. 19-1


19-1 Overview .................................................................................. 19-1
19-2 Principles of Operation............................................................. 19-1
19-3 Winch Cable Maintenance ....................................................... 19-2
19-4 Winch Control Handle Repair (MK16).................................... 19-4

CHAPTER 20. CRANE .................................................................................................. 20-1


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

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TABLE OF CONTENTS (Continued)

Page

20-28 Stabilizer Pad Maintenance ...................................................... 20-172


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

CHAPTER 21. CRANE (LVSA1 SERIES VEHICLES ONLY) ................................... 21-1


21-1 Overview .................................................................................. 21-1
21-2 Description and Data ................................................................ 21-1
21-3 Junction Box Maintenance ....................................................... 21-9
21-4 Remote Control Stowage Box Replacement (MK17A1) ......... 21-29
21-5 Tilt Sensor and Alarm Replacement ........................................ 21-32
21-6 Crane Tubing Replacement (MK15A1) ................................... 21-35
21-7 Crane Tubing Replacement (MK17A1) ................................... 21-39
21-8 Crane Hoses Replacement (MK15A1)..................................... 21-42
21-9 Crane Hoses Replacement (MK17A1)..................................... 21-54
21-10 Hoist Cable Replacement ......................................................... 21-66
21-11 Hook Block Assembly Maintenance ........................................ 21-69
21-12 Boom Sheave Replacement...................................................... 21-77
21-13 Power Cable Replacement........................................................ 21-81
21-14 Remote Control Harness Replacement..................................... 21-84
21-15 Overload Shutdown Cable Replacement.................................. 21-87
21-16 Control Solenoid Cable Replacement ...................................... 21-90
21-17 Tilt Sensor Harness Replacement............................................. 21-95
21-18 Remote Control Box Repair ..................................................... 21-98
21-19 Holding Valve Replacement .................................................... 21-108

CHAPTER 22. BODY ACCESSORY ITEMS............................................................... 22-1


22-1 Overview .................................................................................. 22-1
22-2 Description and Data ................................................................ 22-1
22-3 Windshield Wiper Motor Replacement.................................... 22-2
22-4 Windshield Wiper Motor Replacement
(LVSA1 Series Vehicles Only) ................................................ 22-5
22-5 Windshield Wiper Arm and Blade Replacement ..................... 22-8
22-6 Wiper Control Valve Replacement .......................................... 22-11
22-7 Windshield Wiper Control Valve Replacement ....................... 22-14
22-8 Washer Reservoir Hose and Nozzle Replacement ................... 22-17
22-9 Washer Reservoir Hose and Nozzle Replacement
(LVSA1 Series Vehicles Only) ................................................ 22-20

x
TM 08780B-20

TABLE OF CONTENTS (Continued)

Page

22-10 Mirror Replacement ................................................................. 22-24


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

CHAPTER 23. HYDRAULIC SYSTEM ....................................................................... 23-1


23-1 Overview .................................................................................. 23-1
23-2 Principles of Operation............................................................. 23-1
23-3 Hydraulic System Service ........................................................ 23-6
23-4 Selector Valve .......................................................................... 23-14
23-5 Yaw Control Valve Replacement............................................. 23-17
23-6 Hydraulic Filter Replacement .................................................. 23-20
23-7 Hydraulic Filter Replacement
(LVSA1 Series Vehicles Only) ................................................ 23-24
23-8 Yaw Cylinder Replacement...................................................... 23-28
23-9 Hydraulic Reservoir Replacement............................................ 23-31
23-10 Hydraulic Oil Level Gauge Replacement ................................ 23-36
23-11 Hydraulic Oil Cooler Replacement .......................................... 23-39
23-12 Hydraulic Oil Filter Housing Maintenance .............................. 23-42
23-13 Hydraulic Filter Housing Maintenance
(LVSA1 Series Vehicles Only) ................................................ 23-48
23-14 Hydraulic Hose and Fitting Replacement ................................ 23-54
23-15 Hydraulic Hose Reel Replacement........................................... 23-66
23-16 Auxiliary Hydraulic Hose Replacement................................... 23-67
23-17 Auxiliary Hydraulic Hose Reel Roller Replacement ............... 23-70
23-18 Auxiliary Hydraulic Hose Reel Roller Replacement
(LVSA1 Series Vehicles Only) ................................................ 23-73
23-19 Directional Relief Valve Filter Screen Replacement ............... 23-76
23-20 Hi-Pressure Hydraulic Filter and Head Replacement
(MK15A1/MK17A1-LVSA1 Series Vehicles Only) ............... 23-78
23-21 Hi-Pressure Hydraulic Filter and Head Replacement
(MK48A1-LVSA1 Series Vehicles Only) ............................... 23-83

xi
TM 08780B-20

TABLE OF CONTENTS (Continued)

Page

CHAPTER 24. SPECIAL PURPOSE KITS


24-1 Overview .................................................................................. 24-1
24-2 Description and Data ................................................................ 24-1
24-3 Machine Gun Mount Replacement........................................... 24-2
24-4 Machine Gun Platform Replacement ....................................... 24-5
24-5 Machine Gun Hatch Replacement............................................ 24-7

CHAPTER 25. NON-ELECTRICAL GAUGES


25-1 Overview .................................................................................. 25-1
25-2 Description and Data ................................................................ 25-1
25-3 Air Pressure Gauge Replacement............................................. 25-2

Appendix A References.............................................................................................. A-1


Appendix B Maintenance Allocation Chart ............................................................... B-1
Appendix C Repair Parts, Special Tools and Equipment........................................... C-1
Appendix D Expendable Supplies and Materials List................................................ D-1
Appendix E Illustrated List of Manufactured Items .................................................. E-1
Appendix F Torque Limits ........................................................................................ F-1
Appendix G Schematic and Wiring Diagrams ........................................................... G-1
Appendix H STE/ICE Card ........................................................................................ H-1
Appendix I LVS Extended Storage Maintenance Procedures .................................. I-1
Glossary .................................................................................................................. Glossary-1
Alphabetical Index ................................................................................................. INDEX-1

xii
TM 08780B-20

LIST OF TABLES

Table Number Page

2-1 Organizational Preventive Maintenance Checks and Services................. 2-3


2-2 Antilocking Brake System Diagnosis Code.............................................. 2-602

xiii
TM 08780B-20

WARNING SUMMARY

The following is a list of warnings that appear in this manual. LVS mechanics must become
familiar with all warnings. Severe injury or death can be avoided by mechanics who understand
the vehicle and are alert to possible dangers.

• Remove rings, bracelets, wristwatches and neck chains before working around the
vehicle or other vehicles. Jewelry can catch on equipment and cause injury or may short across
an electrical circuit and cause severe burns or electrical shock.

• Adhesives and solvents burn easily and give off harmful vapors. To avoid injury, use in a
well ventilated area and keep away from flame.

• Compressed air used for cleaning purposes will not exceed 30 psi. Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

• Improper cleaning methods and use of unauthorized cleaning solvents will injure
personnel and damage equipment.

• To prevent personal injury when working under the truck always block the wheels.

• Snaprings are spring steel and may pop off when being removed. Wear eye protection
when removing snaprings to prevent personal injury.

• To prevent personal injury when working with fuel do not smoke or use open flame.
Fuel is flammable and may explode. Keep fire extinguisher within reach.

• During vehicle operation the exhaust pipe and muffler can become very hot. Be careful
not to touch these parts with your bare hands or allow your body to come in contact with the pipe
of muffler. Exhaust system parts can become hot enough to cause serious burns.

• Do not reach into radiator fan area with engine running. The fan is thermostatically
controlled and may engage without warning, causing serious personal injury.

• Cooling system components become hot during operation. To avoid personal injury, do
not service cooling system components until they have cooled down.

• Let radiator cool before removing cap. Remove radiator cap in two steps. First, place a
thick cloth over the cap and slowly rotate cap counterclockwise to its first stop. Pause, then let
pressure escape from cooling system. Rotate cap further counterclockwise until you can remove
it. Failure to follow this procedure can result in serious burns.

• Always remove negative battery ground cables first or install them last to avoid sparks
that can cause an explosion. Failure to follow this precaution may result in serious injury to you
and other personnel.

xiv
TM 08780B-20

• To prevent personal injury, drain all air pressure from the air system before removing air
lines or components.

• The brake linings contain asbestos. Asbestos dust can cause cancer. Avoid breathing
dust from brake linings or creating dust while servicing.

• Do NOT mix hose assembly components from different manufacturers. During assembly
repair make sure all components (hose and fittings) are from the same manufacturer. Never
reuse existing hose. Always replace with new hose. If you can not positively identify the
manufacturer of ALL components or you cannot obtain replacement parts from the same
manufacturer, REPLACE THE ENTIRE ASSEMBLY. Hose assemblies made up of different
manufacturer’s parts can fail. Failure to comply could result in death or serious injury to
personnel.

WARNING

CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU. CARBON MONOXIDE IS


WITHOUT COLOR OR SMELL, BUT CAN KILL YOU. BREATHING AIR WITH
CARBON MONOXIDE PRODUCES SYMPTOMS OF HEADACHE, DIZZINESS, LOSS OF
MUSCULAR CONTROL, A SLEEPY FEELING AND COMA. BRAIN DAMAGE OR
DEATH CAN RESULT FROM HEAVY EXPOSURE. CARBON MONOXIDE IS IN THE
EXHAUST FUMES OF FUEL-BURNING HEATERS AND INTERNAL COMBUSTION
ENGINES. CARBON MONOXIDE CAN BECOME DANGEROUSLY CONCENTRATED
UNDER CONDITIONS OF NO VENTILATION. PRECAUTIONS MUST BE FOLLOWED
TO INSURE CREW SAFETY WHEN THE PERSONNEL HEATER OR ENGINE OF ANY
VEHICLE IS OPERATED FOR ANY PURPOSE.

(1) DO NOT DRIVE ANY VEHICLE WITH INSPECTION PLATES, COVER


PLATES OR ENGINE COMPARTMENT COVERS REMOVED UNLESS NECESSARY
FOR MAINTENANCE PURPOSES.

(2) BE ALERT AT ALL TIMES DURING VEHICLE OPERATION FOR


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

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD


VENTILATION.

WARNING

FRONT AND REAR FRAMES PIVOT. STAY CLEAR OF TIRES AND ARTICULATION
JOINT AREA WHILE ENGINE IS RUNNING.

xv
TM 08780B-20

HOW TO USE THIS MANUAL

a. Overview. This manual covers all components and systems in individual


chapters. Each chapter is divided into the following sections as needed:

(1) General Information. This section provides necessary information and


makes the chapter more useful.

(2) Description and Data. This section provides descriptions of components,


theories of operation and data tables the user needs in order to understand the equipment. This
information is limited to the maintenance level of this manual.

(3) General Maintenance. This section provides replacement, repair and


maintenance instructions for the components and systems. These instructions are presented in a
logical order, grouping similar tasks near each other.

b. Manual Use. As a maintenance technician, you are responsible for maintaining


the equipment covered in this manual. The best way to do this is with the aid of your
maintenance manual. Below is a sample problem:

PROBLEM. The operator reports low oil pressure.

(1) How do you start?

Turn to the Cover of this manual.

On the right-hand side, you will find a listing for TROUBLESHOOTING.


Along with the listing is a page number and a black marker. Follow either the page number
reference or the black marker to the first page in the TROUBLESHOOTING section.

(2) What is the quickest way to find the solution to the problem? Turn to
paragraph 2-7.

This paragraph begins with the Troubleshooting Symptom Index. Follow


the Index until you find the problem (Low Oil Pressure, in this case). Now go to the page cited
directly to the right of the malfunction.

(3) What caused the problem? Use paragraph 2-7, Troubleshooting.

Here you will find the most likely causes of the problem. After following
each step, in the order listed and finding the problem (let’s say a defective engine oil-pressure
gage) go to the referenced paragraph.

(4) How do you fix the problem? Turn to paragraph 7-18, Electrical Gauge
Replacement.

xvi
TM 08780B-20

This is the maintenance procedure for electrical gages. It is arranged in


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

Your maintenance manual is easy to use. Plus, it eliminates mistakes you


might make by warning you of possible problems before they occur. To protect personnel and
equipment, you must read and follow all WARNINGS and CAUTIONS.

c. Repair Parts and Special Tools. For repair parts and special tools used on this
vehicle, refer to TM 08780B-24P.

xvii/(xviii blank)
TM 08780B-20

CHAPTER 1

INTRODUCTION

1-1. OVERVIEW

This chapter familiarizes the technician with standard forms, record data, and the equipment for
use at the Second Echelon Maintenance Level. This information is covered in the following
sections:

Section I. General Information


Section II. Equipment Description and Data

Section I. General Information

1-2. SCOPE

a. Type of Manual. This technical manual contains instructions for Organizational


(Second Echelon) Maintenance for the Logistics Vehicle System (LVS).

b. Equipment Name and Model Numbers. The components of the LVS covered in
this manual include:

MK48/48A1-Power Unit, front, 4 x 4

MK14/14A1-Trailer, powered, Container Hauler, 4 x 4

MK15/15A1-Trailer, powered, Wrecker/ Recovery, 4 x 4

MK16/16A1-Trailer, powered, Fifth Wheel, Semitrailer Adapter, 4 x 4

MK17/17A1-Trailer, powered, Dropside Cargo w/Crane, 4 x 4

1-3. MAINTENANCE FORMS, RECORDS, AND REPORTS

Equipment record procedures refer to TM 4700-15.

1-4. DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of materiel to prevent enemy use can be found in TM 750-244-2.

1-5. PREPARATION FOR STORAGE OR SHIPMENT

Information about storage or shipment of the LVS can be found in Appendix I of this manual.

1-1
TM 08780B-20

1-6. REPAIR PARTS, SPECIAL TOOLS AND SUPPORT EQUIPMENT

All repair parts, special tools and support equipment are listed in TM 08780B-24P.

1-7. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS

If the Logistics Vehicle System needs improvement, let us know. Send us an EIR. You, the
user, are the only one who can tell us what you don’t like about your equipment. Let us know
why you don’t like the design. Put it on an SF 368 (Quality Deficiency Report). Submit to:

Commanding General
Marine Corps Logistics Base
Code 808
Albany, Georgia 31704-5000

1-8. WARRANTY INFORMATION

The LVS Series vehicles are warranted by Oshkosh Truck Corporation for 15 months or 15,000
miles (24,135 km), whichever comes first. The warranty starts on the date found in block 23,
DA Form 2408-9, in the logbook. Report all defects in material or workmanship to your
NCOIC, who will take appropriate action.

Section II. Equipment Description and Data

1-9. EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES

For a complete description of characteristics, capabilities, and features of the Logistics Vehicle
System, refer to TM 08780B-10.

1-10. PRINCIPLES OF OPERATION

The principles of operation for the vehicle can be found in TM 08780B-10. The principles of
operation for individual components can be found in the applicable maintenance chapters within
this manual.

1-11. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Refer to TM 08780B-10 for the location and description of the major components of the
Logistics Vehicle System.

1-2
TM 08780B-20

CHAPTER 2

VEHICLE MAINTENANCE

2-1. OVERVIEW

This chapter provides information authorized for Second Echelon Maintenance level mechanics.
The following sections cover maintenance procedures for the LVS.

Section I. Service Upon Receipt


Section II. Preventive Maintenance Checks and Services (PMCS)
Section III. Troubleshooting
Section IV. Maintenance Procedures

Section I. Service Upon Receipt

2-2. GENERAL

Upon receipt of a new, used or reconditioned vehicle, you must determine if the vehicle has been
properly prepared for service. The following paragraph provides the service requirements to
prepare the vehicle for use.

2-3. SERVICE UPON RECEIPT

a. Visually inspect the entire vehicle for shipping damage, signs of vandalism or
missing parts.

b. Perform Semi-annual PMCS checks at the Organizational Level.

c. Check the level of lubricant in all components. Refer to LI 2320-12/9, LO


9-2320-297-12.

d. Install ether starting aid canister. Refer to paragraph 4-22 in this manual.

NOTE
Perform these checks or have the operator perform them.

e. Perform all PMCS checks at the Operators Level.

f. Check all Basic Issue Items. Refer to TM 08780B-10 to be sure every item is
present, is in good condition and is properly mounted or stowed.

2-1
TM 08780B-20

Section II. Preventive Maintenance Checks and Services (PMCS)

2-4. GENERAL

This section contains Preventive Maintenance Checks and Services (PMCS) requirements for the
MK48/48A1/14/14A1 through MK48/48A1/17/17A1 LVS vehicles.

2-5. PMCS TABLES

The PMCS tables contain checks and services necessary to find and correct defects before they
result in serious damage to the vehicle. Use table 2-1 to perform your PMCS at the specified
intervals. Explanations of the columns used in these tables are as follows:

a. Item Number Column. This column lists the numbers of all necessary checks and
services in logical order of performance regardless of interval. This column may be used as a
source of item numbers for maintenance forms required to record the results of the PMCS.

b. Interval Columns. There are three interval column heads: ‘S’, ‘A’ and ‘B’. Each
column stands for a specific time interval at which a maintenance check is to be made. The
following is an explanation of these columns:

(1) If a check is performed every 6 months (semi-annually), a dot will be


found within the ‘S’ column.

(2) If a check is performed every 12 months (annually), a dot will be found


within the ‘A’ column.

(3) If a check is performed every 24 months (biennially), a dot will be found


within the ‘B’ column.

c. Items to be Inspected Column. This column is divided into groups such as road
test, cab interior, transmission and brakes. Each group identifies a general location on the
vehicle in which specific items are to be inspected. Items are listed in order regardless of
interval.

d. Procedures Columns. This column contains a brief description of the inspections,


checks and services to be performed on each item listed.

2-2
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected
PRIOR TO ROAD TEST
1. CAB INTERIOR

NOTE

Prior to road test, perform all operator PMCS checks listed in TM


08780B-10.

• a. Check operator and crew seats and seat belts for loose mountings
and damage.

• b. While starting vehicle, listen for unusual noises and difficult


cranking at starter.

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


alert for excessive vibration and smell of fuel, oil or exhaust.

• d. Observe gauges for any low or abnormal readings.

• e. Test for engine response to throttle treadle feed. Check for sticking
or binding of throttle treadle.

• f. Check brake treadle valve for slow or no response, air leaks or


blocked exhaust. Check brake treadle for proper adjustment. Refer
to Direct Support/Intermediate Maintenance (3rd Echelon).

• g. Check for operator and crew seats and seat belts for loose
mountings and damage. Replace operator or crew seat or seat belt
mountings if damaged or missing. Tighten loose parts. Refer to
paras 18-13 and 18-14.

2-3
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected
ROAD TEST
2. BRAKES

• a. Reach a desired speed and apply brakes with steady force. Vehicle
should stop smoothly without side-pull or vibrations.

• b. After stopping vehicle and with transmission in gear, release brake


treadle. The wheel brakes should release immediately.

• c. On a level surface, set parking brake, shift transfer to direct range


and shift transmission to drive (D). Run engine at 1,000 rpm.
Vehicle should not move.

3. STEERING

• a. Check vehicle response to steering wheel action. Vehicle should


respond instantly. Check steering wheel free play. With vehicle
moving forward, free play should not exceed approximately 1-1/2
inches in either direction.

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

CAUTION

DO NOT HOLD STEERING WHEEL IN THE EXTREME LEFT OR


RIGHT POSITION FOR LONGER THAN 10 SECONDS. OIL
OVERHEATING AND PUMP FAILURE CAN RESULT.

• c. With the vehicle stopped, turn steering wheel and check for hard or
erratic steering and backlash. Check for proper response of yaw
cylinders to steering wheel movement in both directions. Steering
should operate smoothly with no backlash.

2-4
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected
ROAD TEST
4. TRANSFER CASE

• a. Check transfer case shift lever for proper operation.

• b. Operate vehicle in both DIRECT and LOW range. Transfer should


shift smoothly with no unusual noise.

ENGINE

5.
CAUTION

WHEN CHECKING ENGINE LOAD SPEED, MAKE SURE THE


ENGINE DOES NOT EXCEED GOVERNED SPEED OF 2250 RPM.

• a. Check engine operation at all permissible load speeds.

• b. Check engine’s Jacobs Brake for proper operation in both HIGH


and LOW positions.

6. TRANSMISSION

• a. Check transmission temperature gauge for proper operation and


correct temperature.

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


speed ranges.

• c. Listen for unusual noises corning from transmission when shifting.

7. SUSPENSION

• Observe how the vehicle responds to road shocks. If the vehicle sways or
is constantly bouncing this indicates suspension problems.

2-5
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected
AFTER ROAD TEST
8. BATTERIES

WARNING

DO NOT WEAR WATCHES, RINGS OR OTHER JEWELRY WHEN


SERVICING BATTERIES. THEY CAN SHORT OUT BATTERY
TERMINALS. DO NOT SMOKE OR USE OPEN FLAME AROUND
BATTERIES. BATTERIES MAY EXPLODE FROM A SPARK.
BATTERY ACID IS HARMFUL TO SKIN AND EYES.

• a. Inspect battery cables for frays, splits or looseness.

• b. Check the specific gravity of each battery cell and record readings.

9. FUEL SYSTEM

• a. Check fuel lines and fittings for leaks.

• b. Change fuel-water separator element (1). Refer to paragraph 4-18.

2-6
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

10. WHEELS AND TIRES

• a. Inspect wheel side rings (1) and clamp plate (2) for damage, dents
or breaks. Check clamp plate (2) for loose mounting bolts. Tighten
bolts to 80 foot-pounds (108 N*m).

• b. Make sure all wheel stud nuts (3) are present and tightened to 650-
750 foot-pounds (881-1,017 N*m).

2-7
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

10. WHEELS AND TIRES (Continued)

• c. Check each tire for wear using tire depth gauge. Three separate sets
of measurements must be taken to determine overall tread wear.
Measure tread depth at outside edge (1), center (2) and inside edge
(3) at approximately 12 o’clock, 4 o’clock and 8 o’clock positions
around outside of tire. Tread depth should be no less than 3/32 inch
(2.38 mm).

NOTE
Tires should be rotated only on the same side and within the same
tandem.

• d. Rotate tires. Switch tires on No. 1 and 2 axles on right side. Switch
tires on No. 3 and 4 axles on right side. Switch tires on No. 1 and 2
axles on left side. Switch tires on No. 3 and 4 axles on left side.

2-8
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

11. STEERING

• a. Check steering system U-joints (1) and shafts (2) for looseness,
breaks, cracks, rust or wear.

• b. Check steering gear (3) mounting bolts for looseness. Inspect gear
(3) for leaks.

• c. Inspect pitman arm (4) for cracks, breaks or loose mounting.

• d. Inspect upper and lower drag links (5) for looseness, breaks or
cracks. Tighten nuts on both drag links at bellcrank and at steering
arm to 185-200 foot-pounds (250-271 N*m).

• e. Inspect bellcrank (6) for looseness, breaks or cracks.

• f. Inspect fuse link assembly (7) for looseness, breaks or cracks.

• g. Inspect yaw cylinder feedback linkage (8) for looseness, breaks,


cracks or bends.

• h. Inspect both yaw cylinders (9) for scoring, bends or leakage.

2-9
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

11. STEERING (Continued)

• i. Inspect tie rods (1) for breaks or looseness.

• j. Follow routing of all hydraulic steering lines, hoses and tubes to


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

2-10
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

12. SUSPENSION

• a. Check spring leaves (1) for cracks or breaks. Report damaged


spring leaves to Direct Support/Intermediate Maintenance (3rd
Echelon).

• b. Inspect spring leave ends (2) for alignment. Spring leave ends (2)
must be within 1/4 inch (6.35 mm) of each other. Report
misalignment exceeding 1/4 inch (6.35 mm) to Direct Support/
Intermediate Maintenance (3rd Echelon).

• c. Inspect Spring U-bolts (3) for cracks, breaks or looseness.

d. Inspect spring seat (4) for cracks, breaks or looseness.

• e. Inspect spring pressure plate (5) for cracks, breaks or looseness.

• f. Inspect front and rear shock absorbers (6) for oil leaks or damage.

• g. Inspect front and rear shock absorber rubber bushings (7 and 8) for
cracks, dry rotting, damage or looseness.

2-11
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

12. SUSPENSION (Continued)

• h. Inspect lockout strut (1) for cracks, breaks or obvious damage.

• i. Check lockout strut sensor (2) cap and chain (3) for damage.

NOTE
Perform step (j) for LVSA1 series vehicles only.

• j. Check articulation joint lockout strut sensor (2.1) cap and chain
(3.1) for damage.

• k. Check front torque rods (1 thru 6) for damage and for looseness
where they attach to frame and axles. Tighten all mounting bolts to
225 foot-pounds (305 N*m). Refer to paragraph 17-4.

• l. Check rear torque rods (7 thru 12) for damage and for looseness
where they attach to axles and frame. Tighten all mounting bolts to
440-580 foot-pounds (596-786 N*m). Refer to paragraph 17-5.

• m. Check the mounting brackets of torque rods (9 and 10) for cracks,
breaks or loose mounting on frame. Torque mounting bolts to 440-
580 foot-pounds (596-786 N*m). Refer to paragraph 17-5.

2-12
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

12. SUSPENSION (Continued)

• n. Check for metal to metal contact between spring seat (13) and
spring seat cap (14) or between spring seat (13) and inner retainer
(15) on rear suspension. Alert Direct Support Maintenance to
replace trunnion bushings if metal to metal contact occurs.

2-13
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

13. PROPELLER SHAFTS

• a. Inspect all propeller shafts (1) for bends or cracks.

• b. Make sure all flange mounting screws (2) and U-joint mounting
screws (3) are tight.

• c. Inspect U-joints (4) and slip spline (5) for wear and play and for
broken or missing lubrication fittings. There should be no play at
U-joints.

• d. Inspect pillow blocks (b) for cracks, breaks or looseness.

• e. Inspect center bearing (8) for cracks, breaks or looseness.

• f. Inspect Cardan joint (7) for cracks, breaks or looseness.

2-14
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

14. BRAKES

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

• b. Inspect brake shoe linings. If linings are less than 1/4 inch (6.35
mm) thick, linings should be replaced. Refer to paragraphs 13-6
and 13-7.

• c. Inspect inside the spring brake chambers for mud, water or other
debris. If any is found, remove the spring chamber and send to
Direct Support/Intermediate Maintenance (Third Echelon). Refer to
paragraphs 13-8 and 13-13 in this manual.

2-15
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

15. TRANSFER CASE

• a. Remove breather (1) from transfer case. Refer to paragraph 9-8.


Wash breather in solvent (item 53, Appendix D) and allow to air
dry.

• b. Inspect oil seals (2) for damage or leaks.

• c. Inspect transfer case (3) for leaks, cracks, damage and loose bolts.

• d. Inspect transfer case shift cable (4) for kinks, excessive play, wear
or damage.

2-16
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

16. TRANSMISSION

• a. Inspect transmission for cracks, leaks or obvious damage.

• b. Inspect transmission shift cable (1) for kinks, excessive play, wear
or damage.

• c. Check transmission drain plug (2) for looseness. Torque to 15-20


foot-pounds (22-27 N*m).

• d. Inspect transmission oil pan bolts (3) for looseness. Tighten pan
bolts (3) to 10-13 foot-pounds (13-17 N*m).

• e. Inspect output shaft seal (4) for damage or leaks. If there are signs
of oil leaks, notify Direct Support/Intermediate Maintenance (3rd
Echelon).

• f. Remove breather (5) from transmission. Refer to paragraph 8-16.


Wash breather in solvent (item 53, Appendix D) and allow to air
dry.

2-17
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

17. FRONT AXLES

• a. Remove breathers (1 and 2) from each axle housing. Refer to


paragraph 11-4 and 12-5. Wash breathers in solvent (item 53,
Appendix D) and allow to air dry. Install breathers in each axle
housing.

• b. Check each input and output shaft seal (3) for damage and leaks. If
there are signs of oil leaks, notify Direct Support/Intermediate
Maintenance (3rd Echelon).

• c. Inspect each front axle ball (4) for excessive grease. If there are
signs of excessive grease, this indicates worn or damaged wiper
seal. Notify Direct Support/Intermediate Maintenance (3rd
Echelon).

• d. Inspect wheel bearings (5) for looseness, damage or wear. Refer to


paragraph 14-3 and 14-4.

• e. Check trunnion bearing cover (6) for damage or wear.

• f. Inspect axle shaft and cage ring assembly. Clean and repack,

2-18
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

18. REAR AXLES

• a. Remove breathers (1 and 2) from each axle housing. Refer to


paragraph 12-5. Wash breathers in solvent (item 53, Appendix D)
and allow to air dry. Install breathers in each axle housing.

• b. Check each input and output shaft seal (3) for damage and leaks. If
there are signs of oil leaks, notify Direct Support/intermediate
Maintenance (3rd Echelon).

• c. Inspect wheel bearings (4) for scoring, pitting or discoloration.


Replace seals. Refer to paragraphs 14-3 and 14-4.

2-19
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

19. FRAME

• a. Inspect for broken crossmembers (1), broken welds and loose,


broken or missing bolts.

• b. Inspect articulation joint (2) for breaks or cracks.

• c. Check for loose coupling bolts (3). Lubricate and torque to 375
foot-pounds (508.5 N*m) if needed.

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

2-20
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

20. HYDRAULIC SYSTEM

• a. Replace hydraulic fluid filter (1). Refer to paragraph 23-6 (or 23-7
for LVSA1 series vehicles only).

NOTE
Perform steps a.1 and a.2 for LVSA1 series vehicles only.

• a.1. Replace high pressure filter (1.1) on MK48A1. Refer to paragraph


23-21.

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


to paragraph 23-20.

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


2320-297-12. Remove and clean screen (3). Refer to paragraph
23-3.

• c. Remove and clean directional relief valve filter screen (4). Refer to
paragraph 23-19.

2-21
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

21. AIR INTAKE SYSTEM

a. Inspect air cleaner (1), hoses (2) and tubing (3) for cracks, breaks or
loose connections that could permit unfiltered air to enter system.
Replace as required. Refer to paragraph 4-9.

b. Change both primary and secondary air filter elements. Refer to


paragraph 4-7.

2-22
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

22. COOLING SYSTEM

• a. Inspect all hoses (1) for looseness, splits, wear or cracks that could
cause leaks. Inspect hose clamps (2) for wear. Replace as required.
Refer to paragraph 6-7.

• b. Test coolant. Refer to TB 750-651. Service cooling system if


necessary. Refer to paragraph 6-3.

• c. Drain, flush and refill coolant. Refer to paragraph 6-3.

• d. Replace coolant water filter. Refer to paragraph 6-5.

2-23
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

23. ENGINE

• a. Inspect oil filter housing (1) for oil leaks and looseness. Tighten
bolts to 30-35 foot-pounds (40-47 N*m).

• b. Inspect all oil lines (2) for cracks, frays or wear that could cause
leaks.

• c. Check oil pan bolts (3) and oil pan drain plug (4) looseness.
Tighten pan bolts to 10-20 foot-pounds (13-27 N*m). Tighten oil
drain plug to 33-37 foot-pounds (44-50 N*m).

2-24
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

23. ENGINE (Continued)

• d. Check starter (1) for loose wire connections and missing bolts or
hardware. Tighten starter bolts to 137-147 foot-pounds (185-200
N*m).

• e. Inspect rocker cover gaskets (2) for oil leaks. Replace rocker cover
gaskets if oil leaks exist. Refer to paragraph 3-4.

• f. Inspect all engine compartment wiring for frays, splits, missing


insulation or poor connections. Repair or replace any worn wiring.

• g. Inspect alternator wiring (3) for frays, splits, missing insulation or


loose terminal connections. Repair or replace any worn wiring.

• h. Check that alternator mounting bolts (4) are tightened to 35 foot-


pounds (47 N*m).

• i. Check engine mount bolts (5) for correct torque 170 foot-pounds
(230 N*m) wet.

2-25
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

24. EXHAUST SYSTEM

WARNING

DO NOT TOUCH HOT EXHAUST PIPES WITH BARE HAND.


SEVERE BURNS WILL RESULT.

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

2-26
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

25. COMPRESSED AIR SYSTEM

• a. Drain air reservoirs (1). If any moisture is expelled, inspect air


dryer and replace desiccant filter if necessary. Refer to paragraph
13-38. If moisture is milky, blue or green, serious internal engine
or compressor malfunctions are indicated. Notify Direct
Support/intermediate Maintenance (3rd Echelon).

• b. Inspect all air reservoirs and their attaching valves, lines and
connections for looseness, bends, dents and cracks that could cause
leaks.

• c. Replace air dryer desiccant (2). Refer to paragraph 13-38.

• d. Check air governor (3) for leaks. Make sure governor mounting
bolts are tight.

• e. Check air governor for proper operation. Adjust governor as


required. Refer to paragraph 13-37.

2-27
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

26. PINTLE HOOK AND LANDING LEGS

• a. Inspect pintle hook for damage. Check pintle for proper operation.

• b. Inspect landing legs for breaks or bends and loose mounting bolts.
Check for proper operation.

27. CRANE (MK15/15A1 AND 17/17A1)

• a. Check all hydraulic lines and hoses for splits, cracks or signs of
wear. Make sure all lines are secure and properly routed.

• b. Perform operational check using all crane controls. Check for


smooth operation of crane and outrigger controls. Crane and
outrigger controls should not bind or stick.

• c. With boom raised and extended, inspect crane hydraulic cylinders


for bends or scoring.

• d. Check for loose crane mounting bolts.

• e. Load test crane. Refer to TB 43-0142.

NOTE
Step (f) is not required on LVSA1 series vehicles.

• f. Check adjustment of both outrigger beams. Refer to paragraph 20-


35.

2-28
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

28. A-FRAME (MK15/15A1)

• a. Inspect A-Frame for cracks, bends, broken welds or loose


mounting.

• b. Inspect A-Frame cylinder for leaks, bends or scoring.

• c. Inspect A-frame snatch block for proper operation.

• d. Inspect towing cable for kinks, broken strands or wear.

29. WINCH (MK15/15A1 AND 16/16A1)

• a. Check winch for loose mounting bolts.

• b. Operate winch. Make sure engine governor maintains 2,200 ± 50


RPM. If engine surges, notify Direct Support/Intermediate
Maintenance (Third Echelon). Refer to TM 08780B-10 for winch
operation.

30. FIFTH WHEEL (MK16/16A1)

• Check fifth wheel and ramps for loose mounting bolts.

2-29
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

31. BODY AND FRAME

• Inspect sheet metal, frame rails, crossmembers and mounting brackets for
rusting or rust through condition. Look for bubbling or discolored paint
which indicates rusting from the inside. Pay particular attention to areas
where dirt may collect. Remove panels or parts if necessary for
inspection.

• Apply corrosion control products to the following areas:

a. Inside cab

NOTE
Application of corrosion control materials will require the removal of
panels and covers to gain access to the electrical components in the
cab.

Apply Cortec VCI 238 electrical spray (item 15.1, Appendix D) to ALL
electrical terminations, switches and all other electrical components
found in the cab, especially the following:
• All relays and circuit breakers located in the electrical control box.
• Low air pressure and stop light switches on the brake treadle valve.
• All electrical connections to gauges and switches located on the
dash and side panels.
• All connections to the ignition switch panel.
• Fan switch and connections at the heater panel.

b. Outside cab

NOTE
Apply corrosion control products, only to areas that have surface
damage that could allow rust and corrosion to form, if left untreated.

Apply Cortec VCI 386 (Item 60.1, Appendix D) and a final topcoat of
CARC paint, as required to:
• Auxiliary hydraulics selector valve on right fender.
• Hydraulic return filter housing on hydraulic reservoir.
• Motion control valve.

2-30
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

31. BODY AND FRAME (Continued)

NOTE
Brass connectors for air and hydraulics do not require use of corrosion
control products. However, all steel connections do require corrosion
control products.
• All quick disconnect hose ends and other fittings at the
articulation joint.
• All steel air line bulkhead connections at the articulation joint.

c. Rear modules MK14/14A1, 15/15A1, 16/16A1, 17/17A1:

NOTE
Apply corrosion control products only to areas that have surface
damage that could allow rust and corrosion to form, if left untreated.

Brass connectors do not require use of corrosion control products.


However, all steel connections do require corrosion control products.

Apply Cortec VCI 386 (Item 60.1, Appendix D) and a final topcoat of
CARC paint, as required; to all quick disconnect hose ends and other
fittings for air and hydraulic line connections at rear module.

NOTE
If your vehicle has a special purpose kit installed, continue with items
32-35. If your vehicle does not have a special purpose kit, go to item
36, Final Road Test.

32. MACHINE GUN MOUNT

• a. Check gun mount for loose or missing hardware and bolts. Tighten
bolts as required.

• b. Refer to TM 08686A-13&P for Preventive Maintenance Checks


and Services.

2-31
TM 08780B-20

Table 2-1. Organizational Preventive Maintenance Checks and Services (Continued)

S - Semiannually A - Annually B - Biennially


Item Interval Item To Be
Procedures
No. S A B Inspected

33. EXTENDED PINTLE

Check extended pintle for cracks or broken welds. Make sure hook is
secure and locking mechanism operates properly.

34. REAR BODY TOW UNIT

a. Check tow unit for cracks or broken welds.

b. Check tow unit for damaged air lines and hoses. Inspect glad hands
for missing or rotted seals.

35. LIFT SLINGS

a. Inspect for tears or rips. Check clevis and pin for bends or breaks.

b. Load test lift slings. Refer to TB 43-0142.

36. FINAL ROAD TEST

After all services and inspections have been completed, take vehicle on a
road test to make sure all corrections have been accomplished. Correct or
report any defects or malfunctions that occur during this test.

2-32
TM 08780B-20

Section III. Troubleshooting

2-6. STE/ICE TROUBLESHOOTING

This task covers: a. Introduction g. Cable Assemblies


b. STE/ICE Maintenance h. Vehicle Test Cards (VTC)
c. STE/ICE Description i. Types of Readouts
d. Vehicle Test Meter (VTM) j. Operating Modes
e. Transducer Kit (TK) k. Testing
f. Transport Case l. STE/ICE Tests

Initial Setup:

References: TM 9-4910-571-12&P
Applicable Configurations: MK48/48A1

a. Introduction. This portion of the troubleshooting section covers the use of


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

b. STE/ICE Maintenance. Maintenance of the STE/ICE system is covered in TM 9-


4910-571-12&P.

c. STE/ICE Description

(1) STE/ICE is portable and can be operated on either 12 or 24 volts. Power


can be drawn from the MK48/48A1 electrical system or from a separate source.

(2) The STE/ICE system includes multimeter functions and the following
tests:

a. Voltage (AC and DC)


b. Current (High and Low)
c. Resistance
d. Pressure and Vacuum
e. Temperature
f. Compression Balance
g. Starter System

2-33
TM 08780B-20

d. Vehicle Test Meter (VTM). The VTM is a tool used by the mechanic to test
electrical and mechanical parts. Readings are either PASS/FAIL or digital displays in units
familiar to the mechanic (psi, rpm, volts, etc). The VTM is connected to the MK48/48A1
through either the permanent Diagnostic Connector Assembly (DCA) or the transducers from the
TK. The DCA provides power for the VTM and connections to the most commonly used test
points, without the need for additional connections. This is called the DCA mode of operation.
Additional tests may be performed by installing transducers from the TK. This is called the TK
mode of operation. The main features of the VTM are as follows:

(1) The POWER SWITCH is a push ON/ pull OFF type switch that controls
power to the VTM. The switch contains a four amp circuit breaker that pops out if the VTM
draws more than four amps. If this happens, check all connections carefully before resetting or
sending the VTM to be repaired.

(2) The two TEST SELECT SWITCHES are used to select the test to be
performed. There are ten positions on each switch, numbered 0 thru 9. The numbers dialed in
are read by the VTM when the TEST BUTTON is pressed.

(3) The TEST BUTTON, when pressed and released, starts the selected test.
The TEST BUTTON must be released quickly. Holding it down will cause an offset test to be
done.

(4) The READOUT DISPLAY shows different information during testing.


Readouts of up to four characters may be displayed, for example (.8.8.8.8). There are three types
of readouts. STATUS READOUT keeps the mechanic informed of what is happening with
regard to power application, test passage, etc. NUMERICAL READOUT displays measured
value in units of the measurement being taken. For example, if you are measuring 0-45 volts, the
number 24 on the display indicates 24 volts. ERROR READOUT indicates a problem, such as,
wrong test selected, VTM faulty, etc.

2-34
TM 08780B-20

Vehicle Test Meter (VTM)

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

(6) The POWER/DCA CONNECTOR, J1, connects the VTM to the DCA
using cable W1 or it connects directly to a power source using cable W5.

(7) The TRANSDUCER CABLE CONNECTORS, J2 AND J3, connect the


VfM to any transducer in the TK using cables W4. These cables pass power to and signals from
the transducer. Connectors J2 and J3 are the same and may be used one at a time or in
combination.

(8) The TEST PROBE CONNECTOR J4 is used to connect cable W2 to the


VTM when doing manual voltage and resistance tests.

e. Transducer Kit (TK). The TK contains transducers, adapters and fittings in a


molded storage tray. Make sure that the TK items are kept clean and the MK48 mounting
surface is clean before installing any TK item. Dirt entering the engine may cause damage.

(1) PRESSURE TRANSDUCERS. There are two pressure transducers in the


TK. The transducer with a red stripe measures from minus 30 inches HG to plus 25 PSIG. The
transducer with the blue stripe measures from 0 to 1,000 PSIG, both positive and negative. Each
transducer has a small breather hole on the side that must not be plugged. Never use high
pressure air to clean the breather holes. Air pressure of 20 psi or less may be used.

(2) PULSE TACHOMETER. Make sure that the slotted hole in the engine
tachometer drive shaft is clear before installing.

2-35
TM 08780B-20

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

(4) THREADED ADAPTORS. Be careful not to attempt to install pipe


threaded adapters into straight threaded adapters or vice versa.

Each transducer has a built-in identification resister that the VTM uses to
determine if the correct transducer is connected for the test being made. If it does not match,
error code E002 will be displayed.

1. Hose and Fitting Assembly (TK Item 10) 14. Street Tee 112 (TK Item 23)
2. Current Probe (TK Item 11) 15. Street Tee 114 (TK Item 24)
3. Reducer 314 (TK Item 12) 16. Street Tee 118 (TK Item 25)
4. Reducer 112 (TK Item 13) 17. Street Elbow 1/4 (TK Item 26)
5. Reducer 318 (TK Item 14) 18. Street Elbow 1/8 (TK Item 27)
6. Pipe Plug 1/4 (TK Item 15) 19. Inverted Flare Tee (TK Item 28)
7. Pipe Plug 1/8 (TK Item 16) 20. Connector Adapter (TK Item 29)
8. Pressure Transducer Blue Stripe 21. Ignition Adapter (TK Item 30)
(TK Item 17) 22. Adapter, Tachometer Drive
9. Male Connector 1/4 (TK Item 18) (TK Item 31)
10. Pipe Reducer Coupling (TK Item 19) 23. Fuel Line Adapter (TK Item 32)
11. Adapter (TK Item 20) 24. Air Chuck (TK Item 33)
12. Snubber (TK Item 21) 25. Pulse Tachometer (TK Item 34)
13. Pressure Transducer Red Stripe 26. Flexible Hose Assembly (TK Item 35)
(TK Item 22) 27. Long Hex Pipe Nipple (TK Item 36)

2-36
TM 08780B-20

f. Transport Case. The transport case is designed to store and protect all of the
components of the STE/ICE system during transportation.

g. Cable Assemblies. The cable assemblies are referred to by the cable numbers and
a name that describes how each is used.

(1) CABLE W1 is the DCA CABLE.


(2) CABLE W2 is the TEST PROBE CABLE.
(3) CABLE W3 is the IGNITION ADAPTER CABLE.
(4) CABLE W4 is the TRANSDUCER CABLE.
(5) CABLE W5 is the POWER CABLE.

Two W4 cables may be joined, using an adapter, to form one long cable. If you suspect that a
cable is bad, refer to TM 9-4910-571-12&P for testing the cable.

h. Vehicle Test Cards (VTC). A set of VTC is included to provide testing


information for each type of vehicle that STE/ICE can be used on.

i. Types of Readouts

(1) STATUS READOUT. This readout keeps you informed about the status
of the test equipment. There are four status readouts.

(a) Readout .8.8.8.8 appears each time the VTM is turned ON. It
means that there is power to the VTM and that all elements of the display are working.

2-37
TM 08780B-20

(b) When ._._._._ readout is displayed, it means one of two things.


First, after power is turned ON, it means the VTM is ready for testing. Second, during a
compression imbalance test, it means testing is in progress.

(c) Readout .9.9.9.9 indicates that the VTM is reading a test value
beyond the range of its measurement capability. Either the wrong test has been selected for what
is being measured or there is a problem in the vehicle.

(d) PASS/FAIL. This is the result of a test on a component. Either the


component passes or fails the test.

(2) PROMPTING MESSAGE. This readout tells the mechanic to do


something. After the proper action is taken, the test will automatically continue. There are
seven prompting messages.

(a) UEH signals the mechanic to enter the vehicle identification


number (VID). VID numbers are found under TEST DATA on the flip cards, on the VTC and in
the G01 test chain in this manual. The LVS MK48 VID is 18.

(b) CYL signals the mechanic to enter the number of cylinders on the
TEST SELECT switches.

(c) GO signals the mechanic to crank the engine in compression


balance or first peak tests.

(d) CIP signals the mechanic to apply full throttle in a CI power test.

(e) OFF signals the mechanic to stop cranking in compression balance


test or to release the accelerator in the CI power test.

(f) CAL signals the mechanic to release the TEST button during an
offset test.

(g) 66 signals the mechanic to dial in 99 during the confidence test.

(3) NUMERICAL READOUT. This readout is a measured valve in the units


of the test being made. The numbers are always positive, unless a minus sign shows.

(4) ERROR READOUT. There are 17 different readouts and they all start
with E. They warn you that something is wrong. You must correct the problem to continue
testing. A list showing what each message number means is shown on the flip cards. If the error
message will not go away, refer to TM 9-4910-571-12&P.

(5) CONFIDENCE ERROR READOUT. There are 44 different confidence


error readouts and they all start with C. They are used when repairing the VTM.

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TM 08780B-20

j. Operating Modes. STE/ICE can be operated in three modes.

(1) DCA MODE. In the DCA mode, the VTM is connected to the MK48 at
the DCA plug permanently mounted in the cab. The DCA plug is connected to a wiring harness
that is routed to test points on the MK48/48A1.

(2) TK MODE. In the TK mode, the VTM is connected to the MK48/48A1


using the adapters, transducers and cable assemblies. The transducers are installed to make the
tests. They are removed when the tests are completed. One or more cables are needed to
connect required points and to supply power to the VTM.

(3) COMBINED MODE. The DCA and TK modes can be used at the same
time to perform certain tests.

k. Testing.

(1) DATA ENTRY TESTS. At the beginning of testing, you are usually
required to enter the VID into the VTM. The VTC will show what data is needed. This tells the
VTM what vehicle it is connected to.

(a) TEST 58. The number of cylinders must be entered separately.


When test 58 is selected, the VTM will respond with CYL. At this point, dial in the number of
cylinders on the test select switches and press TEST. The VTM will not perform a test, but will
remember the number of cylinders. If the wrong number is entered, one of the following error
messages will be displayed: E007, E010, E014 or E015.

(b) TEST 60. When test 60 is selected, the VTM will respond with
UEH. At this point, dial the VID into the VTM and press test. The VTM will not perform a test,
but will remember the VID. If the wrong number is entered, one of the following error messages
will be displayed: E007 or E010.

(2) DATA DISPLAY TESTS. Tests 59, 61, 62, 63 and 64 are used to display
data already stored in the VTM.

(a) Test 59 displays stored cylinder information when the test button is
pressed.

(b) Test 61 displays the VID when the test button is pressed.

(c) Test 62 displays the DCA ID number when the test button is
pressed.

(d) Test 63 displays the ID number of the transducer attached to


connector J2.

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TM 08780B-20

(e) Test 64 displays the ID number of the transducer- attached to


connector J3.

Transducer ID Numbers

TRANSDUCER ATTACHED ID NUMBER DISPLAYED


TO 12 OR 13 BY TEST 63 OR 64
Pressure transducer -15 to +25 4
PSIG (red stripe)
Pressure transducer 0-1,000 PSIG 7
(blue stripe)
Pulse tachometer 10
Current probe 13

(3) OFFSET TESTS. The STE/ICE VTM will perform an offset test when
the test number is entered and the test button is pressed and held down until the VTM displays
CAL. The offset test allows for differences in the VTM, test leads and transducers. Once the
offset is performed the VTM automatically corrects for the offset before displaying measured
values. An offset value will be displayed and must be checked against limits from the VTC. If
this value is outside these limits, either the transducer or cable are faulty and must be replaced.
Offset tests are done in both the DCA and TK modes. All tests requiring offset are identified by
a star (*) on the flip cards and by OFFSET LIMITS on the VTC. All offset tests are performed
with the DCA or TK connected, test probe leads should be shorted together. Make sure no
stimulus is being applied to the transducer.

(4) CONTROL TESTS. These tests are used to change the way a test is
displayed or the way it is run. There are five control tests.

(a) Test 01 (interleave). This test measures engine speed and


alternately makes a second measurement, such as fuel pressure or alternator voltage. To start
this test, dial 01 into the test select switches and press the test button. When PASS is displayed,
dial in the second test number and again press the test button.

(b) Test 02 (minimum value). This test displays the minimum value
measured during a test. To start this test, dial 02 into the test select switches and press the test
button. When PASS is displayed, dial in the second test number and again press the test button.
The minimum value will now be displayed and is updated when a lower value is measured.

(c) Test 03 (maximum value). This test is done exactly as test 02


except that the maximum measured value is displayed.

(d) Test 04 (peak-to-peak value). This test will display the peak-to-
peak value of battery volts (test 67), alternator output volts (test 82), 45 volts DC (test 89) and
1500 amps DC (test 90). To start test, dial 04 into test select switches and press test. When
PASS is displayed, dial in test numbers 82, 89, 90 or 67 and again press test button.

2-40
TM 08780B-20

(e) Test 05 (Initiate SI full power simulation) is not used on LVS


MK48.

l. STE/ICE Tests

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

Go Page Test Title


Test Number
Number
GO1 2-44 VTM Connections and Checkout
GO2 2-50 First Peak Test - Starter Current
GO3 2-52 Engine Start - Lubrication Check
GO4 2-55 Charging Circuit and Battery Voltage Test
GO5 2-57 Engine Warmup/Coolant Check/Oil
Pressure Test/Fuel Filter Restriction Test
GO6 2-60 Governor Check/Power Test
GO7 2-62 Idle Speed/Governor Check
GO8 2-63 Compression Unbalance Test

No-Go Page Test Title


Test Number
Number
NG05 2-66 Low Oil Pressure Check
NG20 2-68 No Crank - No Start
NG30 2-69 Engine Crank - No Start
NG31 2-73 Gage Test
NG50 2-75 Charging Circuit Tests
NG80 2-76 Starter Circuit Tests
NG81 2-82 Battery Tests
NG90 2-87 Governor/Power Test Fault Isolation
NG130 2-90 Engine Tightness Test

(2) To use the test chains, the condition of the MK48/48A1 need not be
known. The passing of all tests, in order, will quickly show that an MK48 has no problem. The
failing of one or more tests will lead to fault isolation and corrective action. The only problems
needed to indicate the need for STE/ICE testing are, engine will not start or engine will not run
properly.

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TM 08780B-20

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(3) Unneeded tests can be avoided by going directly to the proper test when
the actual problem is known.

NOTE
The GO1 test must be performed before any other tests.

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TM 08780B-10

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TM 08780B-10

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TM 08780B-10

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GAUGE TEST

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END OF TASK

2-90
TM 08780B-20

2-7. STANDARD TROUBLESHOOTING

a. General. The troubleshooting charts in this paragraph are presented in the same
order as the chapters in this manual. Engine first, fuel systems second, exhaust systems third,
etc. They provide information needed to correctly isolate, diagnose and correct malfunctions
within the systems. Each malfunction symptom given for an individual component or system is
followed by step(s) leading to the cause of the malfunction and the actions needed to correct it.

Before taking any action to correct a possible malfunction, follow these rules:

(1) Obtain as much information from the operator as possible about the
malfunction.

(2) Never overlook the possibility that the problem may be of simple origin
and may be repairable with a simple adjustment.

(3) Use all of your senses to observe and locate troubles.

(4) Use all available test equipment to help find and isolate problems.

(5) Whenever possible, isolate the system first and then the component
causing the malfunction.

(6) Remember, for every failed part there is a cause. Whenever possible,
determine the cause of the failure before assuming the malfunction is fully repaired.

(7) Use standard automotive theories and principles when troubleshooting the
vehicle.

To quickly find the troubleshooting procedure you need, use the Symptom Index.
Symptoms are listed by components or system headings.

2-91
TM 08780B-20

Troubleshooting Symptom Index

Page

Engine

1. Engine Fails to Crank............................................................................... 2-99


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

Fuel System

1. Engine Will Not Start or Stalls ................................................................ 2-116


2. Engine Does Not Start When Ether Starting Aid is Used in
Cold Weather ........................................................................................... 2-123

Exhaust System

Exhaust Noisy .......................................................................................... 2-125

Cooling System

Engine Overheats ..................................................................................... 2-126

Electrical System

1. Batteries Fail to Maintain Charge or


Discharge Rapidly.................................................................................... 2-130
2. Charging System Does Not Operate ........................................................ 2-134
3. Electrical Systems Do Not Work............................................................. 2-140
4. Electric Gauges Do Not Work ................................................................. 2-144
5. Ether Starting Aid Does Not Work.......................................................... 2-150
6. Engine Brake Does Not Operate.............................................................. 2-155
7. Engine HI Idle Does Not Work ............................................................... 2-163
8. Air Pressure Warning Light and/or Buzzer Do Not Work ...................... 2-174

2-92
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Troubleshooting Symptom Index (Continued)

Page

Electrical System (Continued)

9. Air Pressure Warning Light and/or Buzzer Do Not


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

Transmission

1. Transmission Oil Temperature Gauge Stays Over 250 Degrees F


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

2-93
TM 08780B-20

Troubleshooting Symptom Index (Continued)

Page

Transmission (Continued)

11. Vehicle Moves in Neutral ........................................................................ 2-309


12. Transmission Slips in All Gears .............................................................. 2-311

Transfer Case

1. Constant Noise When in Low Range and/or Direct Range .................... 2-312
2. Lubricant Leaks at Drive Yokes .............................................................. 2-314
3. Transfer Case Overheats .......................................................................... 2-315
4. Differential Lockup Will Not Engage or Disengage ............................... 2-316

Propeller Shafts

Driveline Vibration or Noise ................................................................... 2-317

Nose Box

1. Nose Box Overheats ................................................................................ 2-319


2. Lubricant Leaks at Drive Yoke................................................................ 2-320
3. Nose Box Noisy ....................................................................................... 2-321

Axles

1. Differential(s) Noisy ................................................................................ 2-322


2. Lubricant Leaks at Pinion or Axle Shafts ................................................ 2-323
3. Controlled Traction Differential Will Not Engage or Disengage............ 2-325
4. Vehicle Will Not Move............................................................................ 2-327

Air System

1. No Air Pressure or Slow Buildup ............................................................ 2-329


2. Throttle Air Cylinder Does Not Work ..................................................... 2-335
3. Compressor Cycles Constantly or Safety Valve Opens Before
Compressor Unloads................................................................................ 2-337
4. Compressor Noisy.................................................................................... 2-338
5. Coolant and/or Lubricant Leaks from Compressor ................................. 2-339
6. Air Pressure Above 150 PSI (1,034 kPa), Safety Valve
Does Not Release..................................................................................... 2-340
7. Left and/or Right Windshield Wiper Does Not Work ............................. 2-342
8. Windshield Washers Do Not Work ......................................................... 2-347
9. Air Horn Does Not Work......................................................................... 2-350

2-94
TM 08780B-20

Troubleshooting Symptom Index (Continued)

Page

Air System (Continued)

10. Axle Differentials Will Not Lock or Unlock ........................................... 2-352


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

Hydraulic Steering System

1. Vehicle Steers Hard in One or Both Directions....................................... 2-413


2. Front Wheels Turn, Yaw Cylinders Do Not Move.................................. 2-419
3. Front Wheels Will Not Turn in Either Direction ..................................... 2-424
4. Steering is Oversensitive.......................................................................... 2-427
5. Vehicle Wanders...................................................................................... 2-429

Winch MK15/15A1

Winch Will Not Operate in One or Both Directions................................ 2-435

Winch MK16/16A1

Winch Will Not Operate in One or Both Directions................................ 2-438

Suspension

1. Vehicle Wanders or Shimmies................................................................. 2-448


2. Vehicle Leans to One Side....................................................................... 2-451

Crane Electric- MK15A1 and MK17A1

1. Crane Does Not Operate .......................................................................... 2-452


2. Remote Control Does Not Operate .......................................................... 2-460
3. Hoist Does Not Lower with Remote Control .......................................... 2-466

2-95
TM 08780B-20

Troubleshooting Symptom Index (Continued)

Page

Crane Electric- MK15A1 and MK17A1 (Continued)

4. Hoist Does Not Raise with Remote Control ............................................ 2-471


5. Boom Does Not Lower with Remote Control ......................................... 2-479
6. Boom Does Not Raise with Remote Control........................................... 2-487
7. Boom Does Not Telescope in with Remote Control ............................... 2-495
8. Boom Does Not Telescope Out With Remote Control............................ 2-502
9. Crane Will Not Swing Clockwise Using Remote Control....................... 2-504
10. Crane Will Not Swing Counterclockwise Using Remote Control........... 2-517
11. Tilt Alarm Does Not Operate................................................................... 2-525

Crane Hydraulics - MK15A1 And MK17A1

1. Outrigger Beams/Jack Cylinders Do Not Operate................................... 2-534


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

Crane Electric

1. Crane Inoperative..................................................................................... 2-545


2. Remote Control Does Not Work.............................................................. 2-556
3. Capacity Alert System Does Not Work
(Crane Overload Protection) .................................................................... 2-558

Crane Hydraulics - MK15 and MK17

1. Crane Functions are Slow ........................................................................ 2-563


2. Outrigger Beams Will Not Extend or Retract or Operates Slowly.......... 2-566
3. Stabilizer Leg Will Not Extend or Retract or Operates Slowly............... 2-572
4. Stabilizer Legs Will Not Hold Load ........................................................ 2-578
5. Crane Will Not Rotate, Rotates Slowly or Rotates in Only One
Direction .................................................................................................. 2-580
6. Main Boom Will Not Operate.................................................................. 2-583
7. Folding Boom Will Not Operate.............................................................. 2-587
8. Extension Boom Will Not Operate .......................................................... 2-592
9. Crane Will Not Lift Load......................................................................... 2-596

2-96
TM 08780B-20

Troubleshooting Symptom Index (Continued)

Page

MK15 A-Frame Hydraulics

1. A-Frame Cylinder Will Not Operate Or Operates Slowly....................... 2-598

Antilocking Brake System

1. One or Both ABS Warning Lights Come on and Remain on .................. 2-600

End Of Troubleshooting Symptom Index

2-97
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

ENGINE

1. Engine Fails To Crank

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

• ENGINE MAY CRANK AND START DURING TROUBLESHOOTING TESTS. TO


PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR
BEFORE TURNING IGNITION SWITCH TO START POSITION.

NOTE
• Ignition switch must be in the ON position for all voltage tests.

• Electrical system voltage (22 to 30 volts) will be written as 24 volts in this section of the
manual.

Test 1. Make sure transmission shift selector is in the neutral (N) position. Move selector in
and out of neutral (N) several times.
• If engine now cranks, go to Test 6.
• If engine does not crank, go to Test 2.

Test 2. Check for 22 volts minimum reading on dash voltmeter gauge.


• If gauge reads 22 volts minimum, go to Test 4.
• If gauge does not read 22 volts minimum, go to Test 3.

2-98
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for 24 volts on battery terminals (wires 138 and 139).
• If 24 volts are present, go to Test 4.
• If 24 volts are not present, refer to ELECTRICAL SYSTEMS troubleshooting,
Malfunction No. 1, in this section.

2-99
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Slide rubber boot back and inspect neutral safety switch for visible damage.
• If no damage is visible, go to Test 5.
• If switch is damaged, replace switch. Refer to paragraph 7-26 in this manual.

NOTE
If ignition switch is turned to START position and released to ON position, it must be reset by
turning to OFF position before turning to START position again.

Test 5. With ignition switch held in START position, check for 24 volts on wire 021 of
neutral safety switch.
• If 24 volts are present, go to Test 10.
• If 24 volts are not present, go to Test 6.

Test 6. With ignition switch held in START position, check for 24 volts on wire 436 of
neutral safety switch.
• If 24 volts are present, adjust or replace switch as needed. Refer to paragraph
7-26 in this manual.
• If 24 volts are not present, go to Test 7.

Test 7. With ignition switch held in START position, check for 24 volts on wire 436 terminal
of ignition switch.
• If 24 volts are present, repair or replace wire 436 between ignition switch and
neutral safety switch. Refer to paragraph 7-48 in-this manual.
• If 24 volts are not present, go to Test 8.

Test 8. Check for 24 volts on wire 431 terminal of ignition switch.


• If 24 volts are present, replace ignition switch. Refer to paragraph 7-23 in this
manual.
• If 24 volts are not present, go to Test 9.

2-100
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-101
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check for 24 volts on wire 431 terminal of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 431 between ignition switch and
circuit breaker.
• If 24 volts are not present, go to Test 12.

2-102
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. With ignition switch held in START position, check for 24 volts on wire 021 terminal
of starter relay.
• If 24 volts are present, go to Test 11.
• If 24 volts are not present, repair or replace wire 021 between neutral safety
switch and starter relay. Refer to paragraph 7-48 in this manual.

Test 11. Check for continuity between wire 196 terminal of starter relay and ground.
• If ground is good, go to Test 14.
• If ground is bad, repair or replace wire 196 between starter relay and ground.
Refer to paragraph 7-48 in this manual.

Test 12. Check for 24 volts on wire 046 terminal of starter relay.
• If 24 volts are present, repair or replace wire 430 between starter relay and circuit
breaker No. 5. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 13.

2-103
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 13. Check for 24 volts on wire 046 terminal of starter solenoid.
• If 24 volts are present, repair or replace wire 046 between starter and starter relay.
Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 139 between starter and batteries.
Refer to paragraph 7-48 in this manual.

Test 14. With ignition switch held in START position, check for 24 volts on wire 045 terminal
of starter relay.
• If 24 volts are present, go to Test 15.
• If 24 volts are not present, replace relay. Refer to paragraph 7-8 in this manual.

Test 15. With ignition switch held in START position, check for 24 volts in wire 045 terminal
of starter solenoid.
• If 24 volts are present, go to Test 16.
• If 24 volts are not present,- repair or replace wire 045 between starter relay and
starter solenoid. Refer to paragraph 7-48 in this manual.

Test 16. With ignition switch held in START position, check for 24 volts on jumper plate
terminal of starter solenoid.
• If 24 volts are present, to Test 18.
• If 24 volts are not present, go to Test 17.

Test 17. Remove negative battery cable (wire 138) and check for continuity between battery
end of cable 138 and cable 138 at starter end plate.
• If continuity is found, go to Test 18.
• If no continuity is found, repair or replace cable (wire 138). Refer to paragraph
7-48 in this manual.

Test 18. Check for continuity of jumper wire between terminal on starter end plate and starter
solenoid.
• If continuity is found, go to Test 19.
• If no continuity is found, replace jumper. Refer to paragraph 7-6 in this manual.

Test 19. Check for continuity between wire 148 at starter end plate and chassis ground.
• If continuity is found, replace starter solenoid. Refer to paragraph 7-6.
• If continuity is not found, repair or replace wire 148.
• If engine fails to crank, go to Test 20.

2-104
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 20. Check for 24 volts between wire 938 terminal on starter and wire 139 terminal on
starter solenoid.
• If 24 volts are present, replace starter. Refer to paragraph 7-7 in this manual.

END OF TEST

2-105
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Engine Cranks, but Will Not Start

Test 1. Check fuel tanks for fuel.


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

Test 2. Check engine cranking speed.


• If cranking speed is normal, refer to FUEL SYSTEMS troubleshooting,
Malfunction 1, in this manual.
• If cranking speed is slow, refer to ELECTRICAL SYSTEMS and perform
troubleshooting tests as needed.

NOTE
Slow cranking speed can be caused by internal seizure of engine. If this is found to be the
cause of slow speed, refer problem to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

3. Hard To Start, Runs Rough, Lacks Power

Test 1. Check air restriction indicator on dash.


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

Test 2. Check fuel system for leaks, damage or contamination.


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

Test 3. Check throttle treadle valve for proper operation.


• Refer to AIR SYSTEM troubleshooting, Malfunction 2, in this manual.

NOTE
If malfunction still exists, refer problem to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

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TEST OR INSPECTION
CORRECTIVE ACTION

4. Engine Does Not Develop Full Power

Test 1. Check fuel system for leaks, damage or contamination.


• Refer to FUEL SYSTEM troubleshooting tests.
• If no problem is found, go to Test 2.

Test 2. Check air filter and intake tubing for damage or restrictions.
• If not damaged or restricted, go to Test 3.
• If damaged or restricted, repair or replace as needed. Refer to paragraphs 4-6 thru
4-9 in this manual.

Test 3. Check for brakes dragging.


• If brakes are not dragging, refer problem to Direct Support/Intermediate
Maintenance (Third Echelon).
• If brakes are dragging, refer to chapter 13 of this manual.

END OF TEST

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TEST OR INSPECTION
CORRECTIVE ACTION

5. Low Engine Oil Pressure

Test 1. Check engine oil level on dipstick.


• If level is correct, go to Test 3.
• If level is not correct, drain or add oil as needed to correct level. Refer to LI
2320-12/9, LO 9-2320-297-12. Then go to Test 2.

Test 2. Check oil filter, oil lines and engine for leaks.
• If no leaks are found, go to Test 3.
• If leaks are found, repair or replace parts as needed.
• If beyond capabilities, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).

Test 3. Check oil pressure gauge and warning light circuits.


• Refer to ELECTRICAL SYSTEM troubleshooting in this manual.

NOTE
If malfunction is still present, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

6. High Oil Consumption

Test 1. Check engine for oil leaks.


• If no leaks are found, go to Test 2.
• If leaks are found, repair or replace parts as needed.
• If beyond capabilities, refer problem to Direct Support, Third Echelon,
Maintenance.

Test 2. Check dipstick and tube for correct length and marking. Compare with known good
parts, if needed.
• If correct, go to Test 3.
• If not correct, repair or replace as needed. Refer to paragraph 3-6 in this manual.

Test 3. Check for engine overheating.


• If overheating, refer to COOLING SYSTEM troubleshooting in this manual.

NOTE
If malfunction still exists, refer problem to Direct Support, Third Echelon Maintenance.

2-108
TM 08780B-20

END OF TEST

GAUGE

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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. Engine Will Not Stop Running

WARNING

• DURING ENGINE OPERATION THE ENGINE AND RELATED PARTS CAN


BECOME VERY HOT. BE CAREFUL NOT TO TOUCH THESE PARTS WITH
YOUR BARE HANDS OR ALLOW YOUR BODY TO COME IN CONTACT WITH
THEM. ENGINE PARTS CAN BECOME HOT ENOUGH TO CAUSE SERIOUS
BURNS.

• TO PREVENT PERSONAL INJURY, ENGINE MUST BE SHUT DOWN BEFORE


STARTING TROUBLESHOOTING TESTS.

CAUTION
IF ENGINE IS RUNNING ABOVE ITS GOVERNED SPEED (2,250 RPM) AND
CLIMBING UNCONTROLLABLY, BLOCK THE AIR PASSAGES AT THE AIR CLEANER
INLET WITH MATERIAL THAT WILL SEAL OFF THE AIR PASSAGES. ALERT
DIRECT SUPPORT/INTERMEDIATE MAINTENANCE (THIRD ECHELON) THAT THE
ENGINE HAS BEEN SHUT DOWN IN THIS MANNER AND MAY REQUIRE REPAIR.

NOTE
If the engine is running at idle or within governed speed (2,250 rpm) perform the following
steps in order to shut down engine.

(1) Open engine access door and manually pull shut down solenoid linkage toward
solenoid as far as it will go.

(2) Tighten governor shaft nut and inspect shut down solenoid linkage for binding.
Pull shut down solenoid linkage toward solenoid as far as it will go.

(3) Back off nut on solenoid push rod closest to solenoid all the way and manually
pull shut down solenoid linkage toward solenoid.

(4) Disconnect fuel line at fuel/water separator’s primary fuel filter. This will cut
off the engine’s fuel supply and cause air to enter the system. Once the shut down problem
has been repaired the fuel system must be primed. If engine had to be shut down by removing
fuel line, send to Direct Support/Intermediate Maintenance (Third Echelon).

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TEST OR INSPECTION
CORRECTIVE ACTION

2-111
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 1. DO NOT START ENGINE. With the aid of an assistant, place engine stop switch in
the STOP position and watch for movement of shut down linkage.
• If movement of shut down linkage is noticed, adjust or repair shut down linkage.
Refer to paragraph 4-13 of this manual.
• If no movement is noticed, go to Test 2.

Test 2. With engine stop switch held down, check for 24 volts on wire 019 terminal of shut
down solenoid.
• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

Test 3. Check shut down solenoid ground wire for good connection.
• If connection is good, replace solenoid. Refer to paragraph 4-13 in this manual.
• If connection is bad, repair or replace ground wire, as needed. Refer to paragraph
7-48 in this manual.

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. With engine stop switch held down, check for 24 volts on wire 019 terminal of engine
stop switch.
• If 24 volts are present, repair or replace wire 019 between switch and solenoid.
• If 24 volts are not present, go to Test 5.

Test 5. Check for 24 volts on wire 096 terminal of engine stop switch.
• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts on wire 096 terminal of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 096 between circuit breaker and
switch.
• If 24 volts are not present, go to Test 7.

Test 7. Check for 24 volts on wire 430 terminal of circuit breaker No. 5.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, refer to ELECTRICAL SYSTEM troubleshooting,
Malfunction 3, in this manual.

END OF TEST

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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

8. Excessive Black Or Gray Exhaust (Engine Temperature 160 Degrees F Or Above)

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, PULL OUT


AUXILIARY/STEERING SELECTOR VALVE BEFORE PERFORMING ANY
TROUBLESHOOTING TESTS.

Test 1. Check air restriction indicator on dash.


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

Test 2. Check for correct fuel in tanks.


• If fuel is correct, go to Test 3.
• If fuel is not correct, drain and refill tanks. Refer to paragraphs 4-10 and 4-11 in
this manual and TM 08780B-10.

Test 3. Check exhaust pipe and muffler for damage or obstructions.


• If no damage or obstructions are found, refer problem to Direct Support, Third
Echelon, Maintenance.
• If damage or obstructions are found, repair or replace parts as needed. Refer to
paragraph 5-3 in this manual.

END OF TEST

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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. Blue Exhaust Smoke (Engine Temperature 160 Degrees F or Above)

• Refer problem to Direct Support, Third Echelon, Maintenance.

10. White Exhaust Smoke (Engine Temperature 160 Degrees F or Above)

Check for correct fuel in tanks.


• If fuel is correct, refer problem to Direct Support, Third Echelon, Maintenance.
• If fuel is not correct, drain and refill tanks. Refer to paragraphs 4-10 and 4-11 in
this manual and TM 08780B-10.

END OF TEST

11. Oil Leakage from Exhaust Pipe or Breathers (Excessive Crankcase Pressure)

Test 1. Check for a restriction in the breathers.


• If a restriction is found, clean or replace. Refer to paragraph 3-4 in this manual.
• If no restriction is found, go to Test 2.

Test 2. Check for restricted or damaged exhaust pipe or muffler.


• If restriction or damage is found, repair or replace parts as needed. Refer to
paragraph 5-3 in this manual.
• If no restriction or damage is found, refer problem to Direct Support, Third
Echelon, Maintenance.

END OF TEST

2-115
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

FUEL SYSTEM

1. Engine Will Not Start Or Stalls

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


EXPLODE. KEEP FIRE - EXTINGUISHER WITHIN REACH.

Test 1. Check fuel level in both the right fuel tank and the left fuel tank.
• If both fuel tanks have three inches (7.6 cm) or more of fuel, go to Test 6.
• If left fuel tank has fuel and right fuel tank does not, go to Test 3.
• If both fuel tanks are empty, go to Test 2.

Test 2. Inspect both fuel tanks for damage and/or leaks.


• If damage or leaks are found, repair or replace fuel tank(s) as needed. Refer to
paragraph 4-10 and 4-11 in this manual.
• If no damage or leaks are found, fill both fuel tanks and prime fuel system. Refer
to paragraph 2-13 (TM 08780B-10).

Test 3. Check fuel shutoff valve on crossover fuel line from left fuel tank.
• If shutoff valve is closed, open it and check for fuel flow to right fuel tank.
• If shutoff valve is open and fuel does not flow to right fuel tank, go to Test 4.
• If fuel flows, add fuel and prime fuel system. Refer to paragraph 2-13 (TM
08780B-10).

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Close both fuel shutoff valves and disconnect crossover fuel line from right fuel tank.
• If fuel flows through fuel line when left shutoff valve is opened, repair or replace
right fuel tank as needed. Refer to paragraph 4-10 and 4-11 in this manual.
• If fuel does not flow through fuel line when left shutoff valve is opened, go to
Test 5.

Test 5. Make sure that both fuel shutoff valves are closed and disconnect crossover fuel line
from left fuel tank.
• If fuel flows when left shut off valve is opened, repair or replace crossover fuel
line.
• If fuel does not flow, repair or replace left fuel shutoff valve and left fuel tank as
needed. Refer to paragraph 4-10 or 4-11 in this manual.

2-117
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TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check T-handle on top of fuel/water separator for fuel/air leaks.


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

Test 7. Check fuel/water separator bowl for contamination, leaks or damage.


• If contamination or damage is found, service, repair or replace fuel/water
separator as needed. Refer to paragraph 4-18 in this manual.
• If contamination or damage is not found, go to Test 8.

Test 8. Check fuel lines for loose connections, leaks and damage.
• If lines are loose, leaking or damaged, repair or replace as needed. Refer to
paragraph 4-12 in this manual.
• If lines are not loose, leaking or damaged, go to Test 9.

Test 9. Check secondary fuel filter for leaks or damage.


• If leaking or damaged, tighten or replace secondary fuel filter as needed. Refer to
paragraph 4-22 in this manual.
• If no leaks or damage are found, go to Test 10.

NOTE
Hand priming pump must be locked in closed position when not priming fuel system.

Test 10. Check hand priming pump for leaks and damage.
• If leaking or damaged, repair or replace as needed. Refer to paragraph 4-5 in this
manual.
• If no leaks or damage are found, go to Test 11.

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TEST OR INSPECTION
CORRECTIVE ACTION

2-119
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for a fuel/air leak between primary filter inlet and fuel tank.
• If a fuel/air leak is found, tighten, repair or replace fuel line or fittings as needed.
Refer to paragraph 4-12 in this manual.
• If no fuel/air leak is found, go to Test 12.

Test 12. Check primary filter seal ring for leaks or damage.
• If seal ring is leaking or damaged, replace it. Refer to paragraph 4-18 in this
manual.
• If seal ring is not leaking or damaged, go to Test 13.

Test 13. Check for cracked fuel standpipe in right fuel tank.
• If cracked, replace fuel standpipe. Refer to paragraphs 4-10 and 4-11 in this
manual.
• If not cracked, go to Test 14.

Test 14. Check drain valve for looseness and/or damaged seal ring.
• If drain valve is loose or seal ring is damaged, tighten valve or replace seal ring as
needed. Refer to paragraph 4-18 in this manual.
• If no leaks or damage are found, go to Test 15.

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TEST OR INSPECTION
CORRECTIVE ACTION

2-121
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15. Check operation of fuel check valve on right fuel tank.
• If not operating properly, replace it. Refer to paragraph 4-12 in this manual.
• If operating properly, go to ENGINE troubleshooting in this chapter.

END OF TEST

2-122
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Engine Does Not Start When Ether Starting Aid Is Used In Cold Weather

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


EXPLODE. KEEP FIRE EXTINGUISHER WITHIN REACH.

NOTE
Coolant temperature must be below 70 degrees F ± 10 degrees F (21 degrees C ± 5 degrees C)
before ether starting aid will work.

Test 1. Check ether supply cylinder.


• If cylinder is loose or empty, tighten or replace as needed. Refer to paragraph
4-22 in this manual.
• If not loose or empty, go to Test 2.

2-123
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check tubing between ether supply cylinder and engine for damage.
• If damaged, replace. Refer to paragraph 4-22 in this manual.
• If not damaged, go to Test 3.

Test 3. Check ether injector valve for damage.


• If damaged, replace. Refer to paragraph 4-22 in this manual.
• If not damaged and problem still exists, go to ELECTRICAL troubleshooting in
this chapter.

END OF TEST

2-124
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

EXHAUST SYSTEM

Exhaust Noisy

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check muffler and exhaust pipes for damage and loose connections.
• If damaged or loose, repair or replace as needed. Refer to paragraph 5-3 in this
manual.
• If not damaged or loose, go to Test 2.

Test 2. Check exhaust manifolds for damage or leaks.


• If damaged or leaking, repair or replace as needed. Refer to paragraph 3-7 in this
manual.

END OF TEST

2-125
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

COOLING SYSTEM

Engine Overheats

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


TEMPERATURE BEFORE OPENING COOLING SYSTEM.

Test 1. Remove radiator cap and check coolant level.


• Add coolant if needed. Refer to paragraph 6-3 in this manual.
• If no coolant is needed, go to Test 2.

Test 2. Check inside of radiator for scale or other deposits.


• If needed, flush and refill cooling system. Refer to paragraph 6-3 in this manual.
• If flushing is not needed, go to Test 3.

Test 3. Check coolant hoses and water pump for damage and/or leaks.
• If damaged or leaking, repair or replace as needed. Refer to paragraph 6-7 in this
manual for hoses. If leakage is detected at water pump, notify Direct
Support/Intermediate Maintenance (Third Echelon).
• If no damage or leaks are found, go to Test 4.

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TEST OR INSPECTION
CORRECTIVE ACTION

2-127
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check radiator for leaks or damage.


• If damaged or leaking, notify Direct Support, Third Echelon, Maintenance.
• If no leak or damage is found, go to Test 5.

Test 5. Check cooling fan blades and shroud for damage.


• If damaged, notify Direct Support, Third Echelon, Maintenance.
• If no damage is found, go to Test 6.

Test 6. Check that fan motor is coming on when coolant temperature exceeds 180 degrees F
(83 degrees C).
• If fan does not come on, refer to HYDRAULIC and ELECTRICAL
troubleshooting as needed.
• If fan does come on, go to Test 7.

Test 7. Remove thermostats (left and right) from engine. Refer to paragraph 6-6 in this
manual. Test thermostats as follows:

a. Suspend thermostats in a container of water so that they do not touch the sides
or bottom of the container.
b. Heat water. Thermostats should begin to open at 160 degrees F (79 degrees C)
and should be fully open at 180 degrees F (83 degrees C).
• If thermostats test good, reinstall them. If problem still exists, refer to the
HYDRAULIC and ELECTRICAL troubleshooting sections.

END OF TEST

2-128
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-129
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

ELECTRICAL SYSTEM

NOTE
• System voltage (22 to 30 volts) will be written as 24 volts in this section of the manual.

• If available, perform STE/ICE tests first.

1. Batteries Fail to Maintain Charge or Discharge Rapidly

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for loose connections and/or corroded battery terminals.

• If needed, service batteries. Refer to paragraph 7-45.

• If no service is needed, go to Test 2.

Test 2. Disconnect battery cables to isolate batteries. Refer to paragraph 7-45. Test each
battery separately.

NOTE
Batteries must be fully charged prior to testing. If batteries are not charged, they will indicate
a failure.

Fixed Load Test

a. Attach tester clamps to battery terminals -negative clamp to negative terminal,


positive clamp to positive terminal.

b. Apply a load of 312 ampheres to battery for 15 seconds.

c. Read voltage indicator at the end of 15 seconds.

d. Use chart to determine battery condition.

2-130
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

VOLTAGE CHART
ESTIMATED MINIMUM REQUIRED VOLTAGE
TEMPERATURE UNDER 15 SEC. LOAD
70°F (21°C) & ABOVE 9.6
60°F (16°C) 9.5
50°F (10°C) 9.4
40°F (4°C) 9.3
30°F (-1°C) 9.1
20°F (-7°C) 8.9
10°F (-12°C) 8.7
0°F (-18°C) 8.5

• If voltage reading is equal to or more than minimum from chart, return the battery
to service, then go to Test 3.
• If voltage reading is less than minimum from chart, go to OPEN CIRCUIT
VOLTAGE TEST.

Open Circuit Voltage Test

a. Allow 10 minutes for battery voltage to stabilize after load test.

b Read voltage.

• If reading is 12.4 volts or above, but did not pass load test, replace battery.
• If reading is below 12.4 volts, charge battery and repeat load test. If battery
fails load test after charging, replace battery.

Reconnect batteries. Refer to paragraph 7-45 or paragraph 7-46 (MK48A1 series


vehicles only).

2-131
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Start engine. Refer to paragraph 2-13 (TM 08780B-10). Check charging system
voltage at battery terminal posts (wires 138 and 139).
• If reading is 27.8 to 29.1 volts, go to Test 4.
• If reading is not 27.8 to 29.1 volts, go to Malfunction 2 in this section.

Test 4. Check for electrical draw. Turn off ALL electrical accessories. Disconnect negative
battery cable (wire 138) and STE/ICE wires (813 and 821). Leave wire (137) on
negative terminal and install nut. Connect a DC ampmeter (capable of reading 0.1
ampheres) between wires (138, 813 and 821) and negative battery terminal,
• If current draw is less than 0.1 ampere, no leakage is present.
• If current draw is 0.1 ampere or more, go to Test 5.

2-132
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. With DC ampmeter still connected (Test 4), disconnect wires from circuit breakers
one at a time. When current draw drops to less than 0.1 ampheres, repair affected
circuit(s) as needed.

Connect negative battery cable (wire 138) and STE/ICE wires (813 and 821).
Tighten nut to 15 foot-pounds (20.3 N*m).

END OF TEST

2-133
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Charging System Does Not Operate

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


TEMPERATURE) BEFORE STARTING THIS PROCEDURE. RUN ENGINE
ONLY LONG ENOUGH TO TAKE VOLTAGE READINGS. EXHAUST PARTS
CAN BECOME HOT ENOUGH TO CAUSE SERIOUS BURNS.

NOTE
Batteries must be fully charged before beginning testing.

Test 1. With ignition switch OFF, check for 24 volts (battery voltage) on the positive wire
278/820 and negative wire 128/815 output terminals on the back of the alternator.
• If 24 volts are not present, go to Test 2.
• If 24 volts are present, record reading and go to Test 6.

CAUTION

TO PREVENT EQUIPMENT DAMAGE, DISCONNECT NEGATIVE BATTERY CABLE


NO. 138 BEFORE GOING TO TEST 2.

2-134
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TEST OR INSPECTION
CORRECTIVE ACTION

2-135
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Connect positive lead of voltmeter to positive wire 278 on output terminal on
alternator. Connect negative lead to ground. Check for 24 volts.
• If 24 volts are present, go to Test 5.
• If 24 volts are not present, go to Test 3.

Test 3. Check for 24 volts on wire 278 at output side of circuit breaker number 14.
• If 24 volts are present, repair wire 278 from circuit breaker number 14 to
alternator.
• If 24 volts are not present, go to Test 4.

NOTE
If circuit breaker number 14 shorts upon installation, replace diode at circuit breaker number
14.

Test 4. Check for 24 volts on wire 833 of input side of circuit breaker number 14.
• If 24 volts are present, replace circuit breaker number 14.
• If 24 volts are not present, repair or replace wire 833 from circuit breaker number
14 to batteries.

Test 5. Check for continuity between negative terminal wire 128 on alternator to ground.
• If continuity is found, go to Test 6.
• If continuity is not found, repair or replace wire 128 between alternator and
starter.

2-136
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-137
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. By-pass voltage regulator as follows:

a. Remove four capscrews and rear cover plate from alternator.

b. Insert a paper clip or small wire into brush access hole.

c. Connect a jumper lead from the paper clip to the negative output terminal.

d. Connect multimeter to positive and negative output terminals.

e. Reconnect negative battery cable No. 138.

f. Make sure all electrical accessories are OFF.

g. Start engine and run at 1,200-1,500 rpm. Refer to paragraph 2-13 (TM 08780B-
10).

h. Record multimeter reading and shut down engine.

• If voltage reading is lower or the same as in Test 1, replace alternator. Refer


to paragraph 7-4 in this manual.

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


in this manual.

Test 7. Remove jumper lead, start engine and run at 1,200-1,500 rpm. Check output voltage.
• If voltage reading is lower than 27.8 volts or higher than 29.1 volts, replace
voltage regulator. Refer to paragraph 7-5 in this manual.

END OF TEST

2-138
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-139
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Electrical Systems Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check battery cable (wires 138 and 139) for loose connections and/or corrosion.
• If connections are good, go to Test 2.
• If connections are not good, clean and tighten as needed. Torque nuts to 15 foot-
pounds (20.3 N*m).

Test 2. Take a voltage reading across battery cables (wires 138 and 139).
• If voltage is 22 volts or above, go to Test 3.
• If voltage is below 22 volts, go to Malfunction 1.

2-140
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for 24 volts on cable (wire 139) at starter solenoid.


• If 24 volts are present, go to Test 4.
• If 24 volts are not present, repair or replace cable (wire 139) or connectors as
needed. Refer to paragraph 7-48 in this manual.

2-141
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check for 24 volts on wire 046 of starter relay.


• If 24 volts are present, go to Test 5.
• If 24 volts are not present, repair or replace wire 046. Refer to paragraph 7-48 in
this manual.

2-142
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for 24 volts on input terminal (wire 430) of circuit breaker No. 5.
• If 24 volts are not present, repair or replace wire 430. Refer to paragraph 7-48 in
this manual. Check quick disconnects in engine compartment.

END OF TEST

2-143
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Electrical Gauges Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be in ON position for all voltage tests.

• If only one gauge does not work and vehicle is an LVSA1 series vehicle, go to Test 12.

• If only one gauge does not work and vehicle is a non-A1 series vehicle, go to Test 11.

• If all gauges do not work, go to Test 1.

Test 1. Check for 24 volts on wire 076 at circuit breaker No. 8.


• If 24 volts are present, go to Test 8.
• If 24 volts are not present, go to Test 2.

Test 2. Check for 24 volts on input terminal wire 735 of circuit breaker No. 8.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Test 3.

Test 3. Check for 24 volts on wire 735 at ignition switch relay.


• If 24 volts are present, repair or replace wire 735 between relay and circuit
breaker. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 4.

Test 4. Check for 24 volts on wire 075 of ignition switch relay.


• If 24 volts are present, go to Test 6.
• If 24 volts are not present, go to Test 5.

2-144
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-145
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

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


• If 24 volts are present, repair or replace wire 075 from ignition switch to relay
No.2.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts at wire 431 on ignition switch.


• If 24 volts are present, replace ignition switch.
• If 24 volts are not present, go to Test 7.

Test 7. Check for 24 volts on wire 431 of circuit breaker number 5.


• If 24 volts are present, repair or replace wire 431 from circuit breaker number 5 to
ignition switch.
• If 24 volts are not present, go to ELECTRIC SYSTEM; Malfunction No. 3.

2-146
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for 24 volts on wire 736 at relay No. 2.


• If 24 volts are present, go to Test 9.
• If 24 volts are not present, go to Test 10.

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


• If continuity is found, replace relay No. 2.
• If continuity is not found, repair or replace wire 435 from relay No. 2 to ground.

Test 10. Check for 24 volts on wire 736 at circuit breaker No. 6.
• If 24 volts are present repair or replace wire 736 from circuit breaker No. 6 and
relay No. 2.
• If 24 volts are not present, go to Malfunction No. 3.

2-147
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for 24 volts on any wire 076 of terminal board. (All wires at terminal board
are marked 076).
• If 24 volts are present, go to Test 12.
• If 24 volts are not present, repair or replace wire 076 between terminal board and
circuit breaker No. 8. Refer to paragraph 7-48 in this manual.

Test 12. Disconnect wire from sending unit of the non-working gauge. Connect that wire to
ground.
• If gauge reads full scale, replace sending unit. Refer to paragraph 7-39 in this
manual.
• If gauge does not read full scale, go to Test 13.

Test 13. Using a jumper, connect sending unit terminal of gauge to a ground.
• If gauge reads full scale, repair or replace sending unit wire between gauge and
sending unit. Refer to paragraph 7-48 in this manual.
• If gauge does not read full scale, go to Test 14.

Test 14. Check for 24 volts on wire 076 at rear of gauge.


• If 24 volts are present, replace gauge. Refer to paragraph 7-20 in this manual.
• If 24 volts are not present and vehicle is an LVSA1 series vehicle, repair or
replace wire 076 between circuit breaker No. 8 and gauge. Refer to paragraph 7-
48 in this manual.
• If 24 volts are not present and vehicle is a non-A1 series vehicle, go to Test 15.

Test 15. Check for 24 volts on wire 076 of the non-working gauge at the terminal board.
• If 24 volts are present, repair or replace wire 076 between terminal board and
gauge.

END OF TEST

2-148
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-149
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

5. Ether Starting Aid Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Engine coolant temperature must be below 70 degrees F ± 10 degrees F (21 degrees C
± 5 degrees C) for system to work.

• Ignition switch must be in ON position for all voltage tests.

Test-1. Check ether supply bottle.


• If empty, replace supply bottle. Refer to paragraph 4-22 in this manual.
• If not empty, go to Test 2.

Test 2. Disconnect wire 036 plug at ether solenoid. Check for 24 volts on wire 036 (male pin
No. 2 at harness) while ether switch is ON.
• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 8.

2-150
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for continuity between pin one of wire 036 at ether start solenoid harness plug
and wire 036 at temperature sending unit.
• If continuity is found, go to Test 5.
• If continuity is not found, go to Test 4.

Test 4. Check for continuity between pin one on wire 036 at ether start solenoid harness plug
and pin one at plug connector from main harness.
• If continuity is found, replace wire 036 from temperature sending unit to plug
connector.
• If continuity is not found, replace wire 036 from plug connector to connector at
ether start solenoid.

Test 5. Check ether temperature sending unit for continuity. Reading should be 0 ohms
below 70 degrees F ± 10 degrees F (21 degrees C ± 5 degrees C).
• If reading is 0 ohms, go to Test 6.
• If reading is not 0 ohms, replace sending unit. Refer to paragraph 7-39 in this
manual.

Test 6. Check for 0 ohms reading between ground and ground wire 036 at sending unit.
• If reading is 0 ohms, replace solenoid. Refer to paragraph 421 in this manual.
• If reading is not 0 ohms, repair or replace wire 036. Refer to paragraph 7-48 in
this manual.

2-151
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
Input and output terminals are not marked on switch. Wire 036 is connected to both
terminals. Voltage will only be found on input terminal when the button is not pressed on.

Test 7. With ether switch ON, check for 24 volts on wire 036 at output terminal of ether
switch.
• If 24 volts are present, repair or replace wire 036 between switch and plug at
solenoid. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 8.

Test 8. Check for 24 volts on input terminal of ether switch wire 036.
• If 24 volts are present, replace switch. Refer to paragraph 7-22 in this manual.
• If 24 volts are not present, go to Test 9.

2-152
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check for 24 volts on wire 036 at circuit breaker No. 11.
• If 24 volts are present, repair or replace wire 036 between switch and circuit
breaker. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 10.

Test 10. Check for 24 volts on wire 640 at input terminal of circuit breaker No. 11.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Test 11.

2-153
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for 24 volts on wire 640 at ignition switch.


• If 24 volts are present, repair or replace wire 640 between ignition switch and
circuit breaker. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 12.

Test 12. Check for 24 volts on wire 431 at ignition switch.


• If 24 volts are present, replace ignition switch.
• If 24 volts are not present, go to Test 13.

Test 13. Check for 24 volts on wire 431 on input side of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 431 from circuit breaker No. 5 to
ignition switch.
• If 24 volts are not present go to ELECTRICAL SYSTEM, Malfunction No. 3.

END OF TEST

2-154
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

6. Engine Brake Does Not Operate

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

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


• If damaged wires are found, repair as needed. Refer to paragraph 7-48 in this
manual.
• If no damage is found, go to Test 2.

NOTE
Ignition switch must be in ON position for all voltage tests.

Test 2. Turn ignition switch and engine brake switch ON. Check engine brake indicator
light.
• If light is on, go to Test 4.
• If light is not on, go to Test 3.

Test 3. Remove indicator light bulb, refer to paragraph 7-29 in this manual. Check for 24
volts on center terminal of bulb socket.
• If 24 volts are present, replace bulb and go to Test 5.
• If 24 volts are not present, go to Test 4.

Test 4. Turn engine brake switch on. Check for 24 volts on wire 713 at ON/OFF switch.
• If 24 volts are present, repair or replace wire 713 from ON/OFF switch to engine
brake indicator light.
• If 24 volts are not present go to Test 9.

2-155
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Start engine. Refer to paragraph 2-13 (TM 08780B-10). Turn engine brake switch
ON. Open engine cover and check for 24 volts on wire 713 of buffer switch when
engine rpm is above 1,800.
• If 24 volts are present, go to Test 12.
• If 24 volts are not present, go to Test 6. Shut down engine.

2-156
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Turn engine brake switch ON. Check for 24 volts on input side of transmission
lockup switch, wire 713.
• If 24 volts are present, go to Test 7.
• If 24 volts are not present, go to Test 8.

Test 7. Turn engine brake switch ON. By-pass the transmission lockup switch with a jumper
lead. Check for 24 volts on wire 713 of buffer switch.
• If 24 volts are present, replace transmission lockup switch. Refer to paragraph
8-8 in this manual.
• If 24 volts are not present, repair or replace wire 713 between lockup switch and
buffer switch. Refer to paragraph 7-48 in this manual.

2-157
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Turn engine brake switch ON. Check for 24 volts on wire 713 terminal of ON/OFF
switch.
• If 24 volts are present, repair or replace wire 713 between lockup switch and
ON/OFF switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 9.

Test 9. Check for 24 volts on wire 712 terminal of ON/OFF switch.


• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are not present, go to Test 10.

2-158
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Check for 24 volts on wire 712 terminal of circuit breaker No. 9.
• If 24 volts are present, repair or replace wire 712 between circuit breaker and
ON/OFF switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 11.

Test 11. Check for 24 volts on input side of circuit breaker No. 9.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Malfunction 4, Test 2. Follow the
troubleshooting test in Malfunction 4 until problem is solved.

2-159
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 12. Start engine. Refer to paragraph 2-13 (TM 08780B-10). Turn engine brake switch
ON. Accelerate engine to full rpm and release throttle quickly. Check for 24 volts on
wire 714 terminal of buffer switch during deceleration. Voltage will be present only
during deceleration.
• If 24 volts are present, go to Test 13.
• If 24 volts are not present, notify Direct Support/Intermediate Maintenance (Third
Echelon).

Test 13. With engine running and brake switch ON, manually engage buffer switch. Check
for 24 volts on wire 839 of governor lockup solenoid valve.
• If 24 volts are present, check solenoid valve coil for opens, shorts or grounds.
Check valve movement. Replace if needed. Refer to paragraph 8-9 in this
manual. Go to Test 14.
• If 24 volts are not present, repair or replace wire 839 between buffer switch and
solenoid valve. Refer to paragraph 7-48 in this manual.

2-160
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 14. With engine running and brake switch ON, accelerate engine to full rpm and release
throttle quickly. Check for 24 volts on wire 714 terminal of engine brake HI/LOW
switch. Voltage will be present only during deceleration.
• If 24 volts are present, go to Test 15.
• If 24 volts are not present, repair or replace wire 714 between buffer switch and
HI/LOW switch. Refer to paragraph 7-48 in this manual.

2-161
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15. With engine running and brake switch ON, accelerate engine to full rpm and release
throttle quickly. Check for 24 volts on wire 716 at connector for right cylinder bank,
voltage will be present only during deceleration.
• If 24 volts are present, go to step 16.
• If 24 volts are not present, repair or replace wire 716 between connector and
HI/LOW switch. Refer to paragraph 7-48 in this manual.

Test 16. With engine running, brake switch ON and HI/LOW switch in HI position, accelerate
engine to full rpm and release throttle quickly. Check for 24 volts on wire 715 at
connector for left cylinder bank. Voltage will be present only during deceleration.
• If 24 volts are present, refer problem to Direct Support, Third Echelon,
Maintenance.
• If 24 volts are not present, repair or replace wire 715 between connector and
HI/LOW switch. Refer to paragraph 7-48 in this manual.

END OF TEST

2-162
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. Engine HI Idle Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be in ON position for all voltage tests.

• Make sure auxiliary/steering valve is in the auxiliary position. Make sure winch
control switch is depressed and held in either in or out position.

• Do NOT disconnect plugs unless told to do so in the test.

• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

2-163
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 1. Using a sharp probe, check for 24 volts on wire 592 at HI idle solenoid on
transmission.
• If 24 volts are present, go to Test 2.
• If 24 volts are not present, go to Test 3.

Test 2. Check ground wire from HI idle solenoid for good connection to ground.
• If ground is bad, clean contact point or repair ground wire.
• If ground is good, replace HI idle solenoid. Refer to paragraph 7-27 in this
manual.

2-164
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check both sides of connector MC13 for 24 volts on wire 592 (pin x).
• If 24 volts are present on both sides of connector MC13, repair or replace wire
592 between connector MC13 and Hi idle solenoid. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of connector MC13 and not on the other side,
clean, repair or replace connector MC13 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 4.

2-165
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check both sides of connector MC6 for 24 volts on wire 592 (pin 18).
• If 24 volts are present on both sides of connector MC6, repair or replace wire 592
between connectors MC13 and MC6. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of connector MC6 and not on the other side,
clean, repair or replace connector MC6 as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present, go to Test 5.

2-166
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for 24 volts on wire 592 terminal at relay No. 5.


• If 24 volts are present, repair or replace wire No. 592 between relay No. 5 and
connector MC6. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts on wire 516 terminal at relay No. 5.


• If 24 volts are not present, go to Test 9.
• If 24 volts are present, go to Test 7.

Test 7. Check for 24 volts on wire 838 at relay No. 5.


• If 24 volts are present, go to Test 8.
• If 24 volts are not present, repair wire 838 between relay No. 5 and relay No. 8.

Test 8. Connect a jumper wire to wire 843 terminal on relay No. 5 to ground. Check for 24
volts at wire 592 at relay No. 5.
• If 24 volts are present, go to Malfunction 25, Test 5.
• If 24 volts are not present, replace relay No. 5. Refer to paragraph 7-28 in this
manual.

2-167
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check both sides of connector MC6 for 24 volts on wire 516 (pin 17).
• If 24 volts are present on both sides of connector MC6, repair or replace wire 516
between connector MC6 and relay No. 5. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of connector MC6 and not on other side, clean,
repair or replace connector MC6 as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present, go to Test 10.

2-168
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Check both sides of connector MC18 for 24 volts on wire 516 (pin F).
• If 24 volts are present on both sides of connector MC18, repair or replace wire
516 between connector MC6 and connector MC18. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of connector MC18 and not on the other side,
clean, repair or replace connector MC18 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 11.

NOTE
For MK15, go to Test 13. For MK16, continue with Test 11.

Test 11. Check both sides of connector MC19 for 24 volts on wire 516 (pin D).
• If 24 volts are present on both sides of connector MC19, repair or replace wire
516 between connectors MC18 and MC19. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present on one side of connector MC19 and not on the other side,
clean, repair or replace connector MC19 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 12.

2-169
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 12. Check for 24 volts on wire 516 at diodes.


• If 24 volts are present, repair or replace wire 516 between diodes and connector
MC19. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, replace diodes. Refer to paragraph 19-4 in this manual.

2-170
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 13. Check for 24 volts on both sides of connector MC20 at wire 516 (pin C).
• If 24 volts are present, repair or replace wire 516 between connector MC20 and
connector MC18.
• If 24 volts are not present, go to Test 14.

Test 14. Open cover on junction box and check for 24 volts at terminal No. 3 on terminal
board No. 1.
• If 24 volts are present, repair or replace green wire between crane connector
MC20 (pin C) and terminal No. 3 on terminal board No. 1. Refer to paragraph 7-
48 in this manual.
• If 24 volts are not present, go to Test 15.

2-171
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15. Unplug connector at high idle wire harness leading from the solenoid dump valve.
Check for 24 volts on the male connector leading to the solenoid dump valve. Plug
connectors together.
• If 24 volts are present, go to Test 16.
• If 24 volts are not present, repair or replace wire between male connector and
solenoid dump valve. Refer to paragraph 7-48 in this manual.

Test 16. Open junction box cover and check for 24 volts on terminal No. 2 of terminal board
No. 1.
• If 24 volts are present, go to Test 17.
• If 24 volts are not present, repair or replace green wire between female connector
and terminal No. 2. Refer to paragraph 7-48 in this manual.

Test 17. Pull boot back at neutral switch on winch main control valve. Check for 24 volts on
white wire.
• If 24 volts are present, go to Test 18.
• If 24 volts are not present, repair or replace white wire between terminal No. 2
and neutral switch. Refer to paragraph 7-48 in this manual.

Test 18. Check for 24 volts on black wire at neutral switch in winch main control valve.
• If 24 volts are present, install boot and go to Test 19.
• If 24 volts are not present, replace neutral switch. Refer to paragraph 20-8 in this
manual.

2-172
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 19. Check for 24 volts at terminal No. 3 on terminal board No. 1.
• If 24 volts are present, go to Test 20.
• If 24 volts are not present, repair or replace black wire between neutral switch and
terminal No. 3 on terminal board No. 1.

Test 20. Unplug connector MC20 at crane wire harness. Check for 24 volts on pin C on crane
harness.
• If 24 volts are not available, repair or replace green wire between terminal No. 3
and pin C of crane connector.

END OF TEST

2-173
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

8. Air Pressure Warning Light and/or Buzzer Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be in ON position for all voltage tests.

• Air system pressure must be below 65 psi.

Test 1. Remove bulb and check for 24 volts on center terminal of light socket.
• If 24 volts are present, replace bulb. Refer to paragraph 7-29 in this manual, then
go to Test 2.
• If 24 volts are not present, go to Test 6.

2-174
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check wires 120 on low pressure switches for looseness.


• If wires 120 are tight, go to Test 3.
• If wires 120 are loose, tighten them.

NOTE
Disconnect wire 032 from terminal No. 4 on buzzer. This will remove low oil/high
temperature circuit from buzzer.

Test 3. Turn ignition switch to ON, remove wire 120 from top low pressure switch and touch
it to ground.
• If light and/or buzzer work, replace both low pressure switches. Refer to
paragraph 7-43 in this manual.
• If light and/or buzzer do not work, go to Test 4.
Test 4. Turn ignition switch to ON and, using a jumper, connect terminal No. 5 of buzzer to
ground.
• If light and/or buzzer work, repair or replace wire 120 between buzzer and low
pressure switches. Refer to paragraph 7-48 in this manual.
• If light and/or buzzer do not work, go to Test 5.
Test 5. Check for 24 volts on terminal No. 7 of buzzer.
• If 24 volts are present, go to Test 9.
• If 24 volts are not present, go to Test 6.

2-175
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for 24 volts on circuit breaker No. 8 terminal for wire 079.
• If 24 volts are present, repair or replace wire 079 between buzzer and circuit
breaker. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 7.
Test 7. Check for 24 volts on input terminal of circuit breaker No. 8.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Test 8.
Test 8. Check for 24 volts on wire 735 of ignition switch relay.
• If 24 volts are present, repair or replace wire 735 between relay and circuit
breaker. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, refer to Malfunction No. 4, Test 2 of ELECTRICAL
troubleshooting.

2-176
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check for 24 volts on terminal No. 2 of buzzer.


• If 24 volts are present, replace buzzer. Refer to paragraph 7-39 in this manual.
• If 24 volts are not present, repair or replace wires 076 or 120 between buzzer and
warning light. Refer to paragraph 7-48 in this manual.

END OF TEST

2-177
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. Air Pressure Warning Light and/or Buzzer Do Not Work When Only One System Drops
Below 65 Psi

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be in the ON position for all voltage tests.

• Air system pressure must be below 65 psi (448 kPa) in both systems.

Test 1. Remove wires No. 120 from sending unit. Touch wire one at a time to ground.
• If buzzer and/or light works with both wires were grounded, go to Test 2.
• If buzzer and/or light does not work when both wires were grounded, repair or
replace defective wire between low air pressure switch and terminal 120 on
buzzer and/or light that did not work.
Test 2. Connect either wire 120 to each sending unit one at a time.
• If buzzer and/or light work, sending unit is good.
• If buzzer and/or light does not work, replace sending unit. Refer to paragraph 13-
14 in this manual.

END OF TEST

2-178
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-179
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

10. Turn Signal Indicator or One or More Turn Signals Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• If turn signal indicators do not work but turn signals do work, go to Test 16.

• Master light switch must be in either the STOPLIGHT position or the SERVICE
DRIVE position. Turn signal switch must be in left or right turn position, as needed.

Test 1. Check all affected turn signal bulb filaments.


• If filaments are broken, replace bulb(s) as needed. Refer to paragraphs 7-34 and
7-36 in this manual.
• If filaments are not broken, go to Test 2.

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CORRECTIVE ACTION

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CORRECTIVE ACTION

Test 2. Check for flashing 24 volts reading on center contact of affected turn signal bulb
sockets.
• If 24 volts are present, try a new bulb in the socket and check ground for that
socket. If still not working, replace composite light assembly. Refer to paragraph
7-34 or 7-36 in this manual as needed.
• If 24 volts are not present, go to Test 3.

Test 3. Unplug affected composite light turn signal wire (front, 001/460, 002/461), (rear,
003/22, 004/22).
• If 24 volts are present, repair or replace composite light plug. Refer to paragraph
7-48 in this manual. Or replace composite light. Refer to paragraph 7-34 or 7-36
in this manual as needed.
• If 24 volts are not present for rear turn signals, go to Test 4.
• If 24 volts are not present for front turn signals, go to Test 6.

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. For rear turn signals, check for flashing 24 volts on wires 003/22 (pin C) and 004/22
(pin A) on both sides of connector MC18.
• If 24 volts are present on one side and not on the other, clean, repair or replace
connector MC18 as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC18, repair or replace wire
003/22 or 004/22 as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 5.

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. For rear turn signals, check for flashing 24 volts on wires 003/22 (pin 6) and 004/22
(pin 4) on both sides of connector MC4.
• If 24 volts are present on one side and not on the other, clean, repair or replace
connector MC4 as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC4, repair or replace wire
003/22 or 004/22 between connector MC4 and connector MC18 as needed. Refer
to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

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CORRECTIVE ACTION

NOTE
LVSA1 series vehicles have a new style turn signal switch and flasher module. It will be
necessary to remove turn signal switch from steering wheel post to gain access to pierce wire
insulation at the back of MC28.

Test 6. For front turn signals, check for flashing 24 volts at turn signal switch on wires 001
and 002.
• If 24 volts are present, repair or replace wires as needed. Refer to paragraph 7-48
in this manual.
• If 24 volts are not present, go to Test 7.

2-185
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for 24 volts on wire 430 terminal of circuit breaker No. 5.
• If 24 volts are not present, go to Malfunction 3, Tests 1 thru 5.
• If 24 volts are present, go to Test 8.

Test 8. Remove connector from rear of Master light switch. Check for 24 volts on pin F of
wiring harness plug.
• If 24 volts are not present, repair or replace wire 674 between circuit breaker No.
6 and Master light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 9.

2-186
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Make sure Master light switch is in SERVICE DRIVE or STOPLIGHT position.
Using an ohmmeter, check for continuity between pin F and pin J on blackout light
switch.
• If no continuity is found, replace Master light switch. Refer to paragraph 7-24 in
this manual.
• If continuity is found, go to test 10.

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Reconnect connector to Master light switch. Check for 24 volts on wire 080 terminal
of circuit breaker No. 1.
• If 24 volts are not present, repair or replace wire 080 between Master light switch
and circuit breaker No. 1. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 11.

Test 11. Check for 24 volts on wire 837/080 terminal of circuit breaker No. 1.
• If 24 volts are not present, replace circuit breaker No. 1. Refer to paragraph 7-14
in this manual.
• If 24 volts are present, go to Test 12.

2-188
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
When working on LVSA1 series vehicles, skip Tests 12 through 15. Perform Tests 15.1
through 15.5 for LVSA1 series vehicles only.

Test 12. Remove instrument panel screws and tilt panel outward against steering wheel.
Check for 24 volts on wire 080 at turn signal flasher.
• If 24 volts are not present, repair or replace wire 080 between turn signal flasher
and circuit breaker No. 1. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 13.

Test 13. Check for flashing 24 volts on output side of turn signal flasher.
• If 24 volts are not present and flasher is an old style, replace turn signal flasher.
Refer to paragraph 7-17 in this manual.
• If 24 volts are not present and flasher is a new style, check ground wire for
continuity and proper ground connection. If OK, replace signal flasher. Refer to
paragraph 7-17 in this manual.
• If 24 volts are present, go to Test 14.

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 14. Check for flashing 24 volts on wires 001, 002, 003 and/or 004 where they come out
of the turn signal switch.
• If 24 volts are not present, replace turn signal switch. Refer to paragraph 7-17 in
this manual.
• If 24 volts are present, go to Test 15.

Test 15. Check for flashing 24 volts at plugs where turn signal switch wires plug into wiring
harness.
• If 24 volts are not present on both sides of plug, repair or replace wires as needed.
Refer to paragraph 7-48 in this manual.

2-190
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15.1. Remove clamp and turn signal switch and disconnect connector MC28. Check for 24
volts on wire 080 (terminal G) on both sides of harness connector MC28.
• If 24 volts are present on one side of connector and not on other, clean, repair or
replace connector MC28, as required. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC28, reconnect connector
MC28 and go to Test 15.2.
• If 24 volts are not present, repair or replace wire 080 between MC28 and blackout
light switch. Refer to paragraph 7-48 in this manual.

2-191
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15.2. Remove harness connector MC29 at turn signal flasher unit. Position turn signal
switch to activate four way flashers. Check for 24 volts at wire 080 (terminal B) on
both sides of harness connector MC29.
• If 24 volts are present on one side of connector and not on other, clean, repair or
replace connector MC29, as required. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC29, go to Test 15.4.
• If 24 volts are not present, go to Test 15.3.

2-192
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15.3. Check for continuity of wire 080 between MC28 and MC29, terminals F and B.
• If no continuity is found, repair or replace wire 080 or connectors. Refer to
paragraph 7-48 in this manual.
• If continuity is found, replace turn signal switch. Refer to paragraph 7-18 in this
manual.

2-193
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15.4. Check for continuity of flasher wire between MC28 and MC29, terminals H and A.
• If no continuity is found, repair or replace flasher wire or connectors. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 15.5.

Test 15.5. Check for flashing 24 volts on flasher wire.


If 24 volts are not present, check flasher ground wire for continuity and proper
ground connection. If OK, replace turn signal flasher. Refer to paragraph 7-18 in
this manual.

2-194
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TEST OR INSPECTION
CORRECTIVE ACTION

Test 16. Check affected indicator bulb filaments.


• If filaments are broken, replace bulb(s) as needed. Refer to paragraph 7-35 in this
manual.
• If filaments are not broken, go to Test 17.

Test 17. Check for flashing 24 volts on center contact of affected indicator bulb sockets.
• If 24 volts are present, try a new bulb in the socket and check ground for that
socket. If still not working, replace indicator light socket.
• If 24 volts are not present, go to Test 18.

Test 18. Check for 24 volts on both sides of instrument harness plug, wires 001 and 002 (pin
A and pin B).
• If 24 volts are present on both sides of plug, repair or replace wires as needed
between plug and bulb sockets. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of the plug and not on the other, repair or
replace plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wires as needed between instrument
panel plug and turn signal switch. Refer to paragraph 7-48 in this manual.

END OF TEST

2-195
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

11. Brakelights Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Master light switch must be in STOPLIGHT or SERVICE DRIVE position.

• Air system pressure must be between 60 and 120 psi.

• Brake treadle valve must be applied.

• Hand trailer brake valve in OFF position unless stated in test procedure.

Test 1. Check brake light bulb filaments.


• If filaments are broken, replace bulb(s) as needed. Refer to paragraph 7-36 in this
manual.
• If filaments are not broken, go to Test 2.

Test 2. With bulbs removed, check for 24 volts on center contacts of brake light bulb sockets.
• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

Test 3. Check for proper grounding of light socket.


• If ground is bad, clean, repair or replace as needed. Refer to paragraph 7-36 in
this manual.
• If ground is good, replace composite light assembly. Refer to paragraph 7-36 in
this manual.

2-196
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-197
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 4. Check for 24 volts on both sides of plug at rear composite light wires 003 and 004.
• If 24 volts are present on one side of plug and not on the other, clean, repair or
replace plug as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of plug, replace composite light. Refer to
paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 5.

Test 5. Check for 24 volts on both sides of connector MC18, wire 003 (pin C) and 004 (pin
A).
• If 24 volts are present on one side of connector MC18 and not on the other side,
clean, repair or replace connector MC18 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present both sides of connector MC18, repair or replace wires 003
and/or 004 between connector MC18 and plug at rear of composite lights. Refer
to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts on both sides of connector MC4, wires 003 (pin 6 and 004 (pin 4).
• If 24 volts are present on one side of connector MC4 and not on the other side,
clean, repair or replace connector MC4 as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present on both sides of connector MC4, repair or replace wires
003 and/or 004 between connector MC4 and connector MC18. Refer to
paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 7.

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CORRECTIVE ACTION

2-199
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for 24 volts on wire 009 terminal of brake light switches, on left side of brake
treadle valve.
• If 24 volts are not present, go to Test 8.
• If 24 volts are present, go to Test 11.

2-200
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for 24 volts on wire 009 on output terminal of circuit breaker No. 10.
• If 24 volts are present, repair or replace wire 009 between circuit breaker No. 10
and stop light switches. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 9.

Test 9. Check for 24 volts on wire 009 on input terminal of circuit breaker No. 10.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Test 10.

Test 10. Check for 24 volts on wire 009 terminal of circuit breaker No. 4.
• If 24 volts are present, repair or replace wire 009 between circuit breakers No. 4
and No. 10. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to ELECTRICAL SYSTEMS troubleshooting,
Malfunction 3, Tests 1 thru 5.

2-201
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TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for 24 volts on wire 005 terminal of brake light switches on treadle valve.
• If 24 volts are not present, replace brake light switches. Refer to paragraph 7-25
in this manual.
• If 24 volts are present, go to Test 12.

2-202
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 12. Disconnect plug at rear of Master light switch. Check for 24 volts on pin K of plug to
harness.
• If 24 volts are not present, repair or replace wire 005 between Master light switch
and stoplight switches. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 13.

Test 13. Using ohmmeter, check for continuity between terminals C and K on the Master light
switch.
• If no continuity is found, replace Master light switch. Refer to paragraph 7-24 in
this manual.
• If continuity is found, go to Test 14.

2-203
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 14. Reconnect plug to Master light switch. Remove screws and tilt instrument panel out
toward steering wheel. Check for 24 volts on wire 294 where it plugs into turn signal
switch wiring.
• If 24 volts are not present, repair or replace wire 294 between plug and Master
light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 15.

Test 15. Check for 24 volts at plugs for turn signal switch wires 003 and 004.
• If 24 volts are not present, replace turn signal switch. Refer to paragraph 7-17.
• If 24 volts are present, go to Test 16.

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TEST OR INSPECTION
CORRECTIVE ACTION

Test 16. Check for 24 volts on wires 003 (pin 6) and 004 (pin 4) at connector MC4.
• If 24 volts are not present, repair or replace wires 003 and 004 between connector
MC4 and turn signal switch plugs. Refer to paragraph 7-48 in this manual.

END OF TEST

2-205
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

12. Marker Lights Do Not Work


WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
For all voltage tests, the ignition switch must be in the ON position, the clearance light switch
must be in the ON position and the blackout light switch must be in either the STOPLIGHT
position or the SERVICE DRIVE position.

Test 1. Check for 24 volts on wire 090 terminal of circuit breaker No. 3.
• If 24 volts are not present, go to Test 2.
• If 24 volts are present, go to Test 9.

Test 2. Check for 24 volts on input side of circuit breaker No. 3.


• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Test 3.

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


• If 24 volts are present, repair or replace wire 835 between magnetic switch and
circuit breaker No. 2. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 4.

Test 4. Check for 24 volts on wire 836 terminal of magnetic switch.


• If 24 volts are present, go to Test 5.
• If 24 volts are not present, go to Test 8.

Test 5. Check for 24 volts on wire 837 terminal of magnetic switch.


• If 24 volts are present, go to Test 6.
• If 24 volts are not present, go to Test 7.

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


• If ground wire is bad, repair or replace ground wire 196. Refer to paragraph 7-48
in this manual.
• If ground wire is good, replace magnetic switch. Refer to paragraph 7-21 in this
manual.

2-206
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for 24 volts on wire 837 of circuit breaker No. 1.


• If 24 volts are present, repair or replace wire 837 between magnetic switch and
circuit breaker No. 1. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Malfunction 10, Tests 8 thru 11.

Test 8. Check for 24 volts on wire 836 terminal of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 836 between circuit breaker No. 5
and relay No. 1. Refer paragraph 7-48 in this manual.
• If 24 volts are not present, go to Malfunction 3, Tests 1 thru 5.

2-207
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check for 24 volts on wire 090 terminal of clearance light switch.
• If 24 volts are not present, repair or replace wire 090 between clearance light
switch and circuit breaker No. 3. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 10.

Test 10. Check for 24 volts on wire 012 terminal of clearance light switch.
• If 24 volts are not present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are present, go to Test 11.

2-208
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• For MK48 only, follow Tests 11 thru 13. For rear trailer units only, follow Tests 14
thru 18.

• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 11. For clearance marker lights on MK48, check for 24 volts on both sides of clearance
light plugs.
• If 24 volts are present on one side of plug and not the other, repair or replace plug.
Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 012 between clearance light
switch and clearance light plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of plug, go to Test 12.

2-209
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 12. For MK48 clearance marker lights, check for 24 volts on center contact of bulb
socket.
• If 24 volts are not present, replace socket assembly. Refer to paragraph 7-31 in
this manual.
• If 24 volts are present, go to Test 13.

Test 13. For MK48 clearance marker lights, check for good ground at bulb socket.
• If ground is good, replace bulb. Refer to paragraph 7-31 in this manual.
• If ground is bad, clean, repair or replace socket as needed. Refer to paragraph
7-31 in this manual.

2-210
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 14. For rear trailer units, check for 24 volts on both sides of connector MC4, wire 012.
• If 24 volts are present on one side of connector MC4 and not on the other side,
repair or replace connector MC4. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 012 between clearance light
switch and connector MC4. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC4, go to Test 15.

Test 15. For rear trailer units, check for 24 volts on both sides of connector MC18, wire 012
(pin K).
• If 24 volts are present on one side of connector MC18 and not on the other side,
repair or replace connector MC18. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 012 between connector MC4 and
connector MC18. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of connector MC18, go to Test 17.

2-211
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 16. For rear trailer units, check for 24 volts on both sides of plugs at clearance lights.
• If 24 volts are present on one side of plug and not on the other side, repair or
replace plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 012 between clearance light plug
and intervehicular connector. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of plug, go to Test 17.

Test 17. For rear trailer units, check for 24 volts on center contact of bulb sockets.
• If 24 volts are not present, replace bulb socket assembly. Refer to paragraph 7-36
in this manual.
• If 24 volts are present, go to Test 18.

Test 18. For rear trailer units, check for good ground at bulb socket.
• If ground is good, replace bulb. Refer to paragraph 7-36 in this manual.
• If ground is bad, clean, repair or replace socket as needed. Refer to paragraph
7-36 in this manual.

END OF TEST

2-212
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

13. One or More Parking Lights Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Master light switch must be in the SERVICE DRIVE position and the auxiliary
lighting switch must be in the PARK position for all voltage tests.

• For front park lights, go to Tests 1 thru 7. For rear park lights, go to Tests 9 thru 15.

Test 1. Check filaments of park light bulbs in front composite lights.


• If filaments are broken, replace bulbs. Refer to paragraph 7-34 in this manual.
• If filaments are not broken, go to Test 2.

2-213
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for 24 volts on center contact of bulb socket(s).


• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

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


• If ground is good, replace composite light. Refer to paragraph 7-34 in this
manual.
• If ground is bad, clean or repair as needed. Refer to paragraph 7-48 in this
manual.

2-214
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Unplug wire 491 at composite light(s) and check for 24 volts on wire harness plug.
• If 24 volts are present, replace front composite light. Refer to paragraph 7-34 in
this manual.
• If 24 volts are not present, go to Test 5.

Test 5. Using a sharp probe, check for 24 volts on wire 491 (pin L) at rear of Master light
switch plug.
• If 24 volts are present, repair or replace wire 491 between composite light plug
and master light switch plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Using a sharp probe, check for 24 volts on wire 674 (pin F) at rear of Master light
switch plug.
• If 24 volts are not present, go to Test 7.
• If 24 volts are present, go to Test 8.

Test 7. Check for 24 volts on wire 674 at circuit breaker No. 6


• If 24 volts are present, repair or replace wire 674 between master light switch and
circuit breaker No. 6.
• If 24 volts are not present, go to Malfunction 3.

2-215
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MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Unplug Master light switch and check for continuity between pin F and pin L on
Master light switch.
• If no continuity is found, replace Master light switch. Refer to paragraph 7-24 in
this manual.

2-216
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check filaments of park light bulbs in rear composite lights.


• If filaments are broken, replace bulbs. Refer to paragraph 7-36.
• If filaments are not broken, go to Test 10.

Test 10. Check for 24 volts on center contacts of bulb socket(s).


• If 24 volts are present, go to Test 11.
• If 24 volts are not present, go to Test 12.

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


• If ground is good, replace composite light. Refer to paragraph 7-36 in this
manual.
• If ground is bad, clean or repair as needed. Refer to paragraph in this manual.

Test 12. Unplug wire 008 at composite light(s) and check for 24 volts on wire harness plug.
• If 24 volts are present, replace rear composite light. Refer to paragraph 7-36 in
this manual.
• If 24 volts are not present, go to Test 13.

2-217
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 13. Check for 24 volts on both sides of connector MC18, wire 008 (pin B).
• If 24 volts are present on both sides of connector MC18, repair or replace wire
008 between connector MC18 and composite light plug. Refer to paragraph 7-48
in this manual.
• If 24 volts are present on one side of connector MC18 and not on the other side,
clean, repair or replace connector MC18 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 14.

Test 14. Check for 24 volts on both sides of connector MC4, wire 008 (pin 5).
• If 24 volts are present on both sides of connector MC4, repair or replace wire 008
between connector MC4 and connector MC18. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present on one side of connector MC4 and not on the other side,
clean, repair or replace connector MC4 as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present, go to Test 15.

2-218
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-219
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15. Using a sharp probe, check for 24 volts on wire 008 (pin H) at rear of Master light
switch plug.
• If 24 volts are present, repair or replace wire 008 between Master light switch and
plug H. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, refer to Test 7.

END OF TEST

2-220
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

14. Headlights Do Not Work, Low and/or Hi Beam and Indicator

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Master light switch must be in SERVICE DRIVE position before any troubleshooting
tests are done.

• Make sure auxiliary lighting lever (on Master light switch) is in the OFF position.

• If hi beam headlights do not work but low beam headlights work properly, go to Tests
12 thru 14.

• If hi beam indicator does not work go to Tests 15 thru 17.

Test 1. Place dimmer switch in LOW beam position. Using a sharp probe to pierce the
insulation, check for 24 volts on wire 006 behind headlight plug (under dash).
• If 24 volts are present, go to Test 2.
• If 24 volts are not present, go to Test 4.

2-221
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Remove headlight sealed beam from mounting. Refer to paragraph 7-30 in this
manual. Check for 24 volts at plug for wire 018 on headlight bucket.
• If 24 volts are not present, repair or replace headlight bucket. Refer to paragraph
7-30 in this manual.
• If 24 volts are present, go to Test 3.

Test 3. Check for good ground on wire 091.


• If ground is good, replace sealed beam. Refer to paragraph 7-30 in this manual.
• If ground is bad, repair as needed. Refer to paragraph 7-48 in this manual.

2-222
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check for 24 volts on wire 006 terminal of dimmer switch.


• If 24 volts are present, repair or replace wire(s) 006 between dimmer switch and
headlight plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 5.

Test 5. Check for 24 volts on wire 017 terminal of dimmer switch.


• If 24 volts are present, replace dimmer switch. Refer to paragraph 7-52 in this
manual.
• If 24 volts are not present, go to Test 6.

2-223
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for 24 volts on wire 017 terminal of circuit breaker No. 7.
• If 24 volts are present, repair or replace wire 017 between circuit breaker No. 7
and dimmer switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 7.

Test 7. Check for 24 volts on wire 084 terminal of circuit breaker No. 7.
• If 24 volts are present, replace circuit breaker No. 7. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, go to Test 8.

2-224
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Using a sharp probe, check for 24 volts at rear of Master light switch plug wire 084
(pin M).
• If 24 volts are present, repair or replace wire 084 between Master light switch and
circuit breaker No. 7. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 9.

Test 9. Using a sharp probe, check for 24 volts at rear of Master light switch wire 674 (pin
F).
• If 24 volts are not present, go to Test 10.
• If 24 volts are present go to Test 11.

Test 10. Check for 24 volts at wire 674 at circuit breaker No. 6.
• If 24 volts are present, repair or replace wire 674 between circuit breaker No. 6
and Master light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present go to Malfunction 3.

2-225
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Disconnect plug from rear of Master light switch and check for continuity between
pin F and pin M.
• If continuity is not found, replace Master light switch. Refer to paragraph 7-24 in
this manual.

Test 12. If high beam headlights do not work, make sure Master light switch is in SERVICE
DRIVE position and dimmer switch is in HI beam position. Check for 24 volts at
wire 007 terminal of dimmer switch.
• If 24 volts are not present, replace dimmer switch. Refer to paragraph 7-52 in this
manual.
• If 24 volts are present, go to Test 13.

2-226
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 13. Disconnect plug for wire 007 at rear of headlight bucket. Check for 24 volts at plug.
• If 24 volts are not present, repair or replace wire 007 between headlight bucket
and dimmer switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 14.

2-227
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 14. Reinstall plug for wire 007 and with headlight sealed beam removed, check for 24
volts on headlight bucket connector for wire 017.
• If 24 volts are not present, replace headlight bucket. Refer to paragraph 7-30 in
this manual.
• If 24 volts are present, replace sealed beam. Refer to paragraph 7-30 in this
manual.

2-228
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15. Check hi beam indicator bulb filament.


• If filament is broken, replace bulb as needed. Refer to paragraph 7-35 in this
manual.
• If filament is not broken go to Test 16.

Test 16. Check for 24 volts on center contact of high beam indicator bulb socket.
• If 24 volts are present, try a new bulb in the socket and check ground for that
socket. If still not working, replace hi beam indicator light socket.
• If 24 volts are not present, go to Test 17.

Test 17. Check for 24 volts on both sides of instrument harness plug wire 018 (pin M).
• If 24 volts are present on both sides of the plug, repair or replace wire as needed
between plug and bulb socket. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on one side of the plug and -not the other, repair or replace
plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 018 as needed between
instrument harness plug and dimmer switch. Refer to paragraph 7-48 of this
manual.

END OF TEST

2-229
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

15. Worklight(S) Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
Before performing any troubleshooting tests, turn the worklight(s) switch to the ON position,
worklight switch in cab to the ON position and the Master light switch to the STOPLIGHT or
SERVICE DRIVE position.

Test 1. Disconnect plug at worklight handle and check for 24 volts on wire 040 (pin B) of
wire harness plug.
• If 24 volts are present, go to Test 2.
• If 24 volts are not present, go to Test 7.

Test 2. Check for continuity between pin A of the harness plug and ground.
• If continuity is not found, repair or replace ground wire between pin A of harness
plug and ground. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 3.

Test 3. Make sure switch on worklight is in the ON position and check for continuity
between pin A and pin B of receptacle on worklight.
• If continuity is not found, go to Test 4.

2-230
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-231
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Disassemble worklight. Refer to paragraph 7-37 in this manual. Check for continuity
between the two terminals of the sealed beam.
• If continuity is not found, replace sealed beam. Refer to paragraph 7-37 in this
manual.
• If continuity is found, go to Test 5.

Test 5. With worklight switch in ON position, check for continuity between input and output
terminals of switch.
• If continuity is not found, replace switch. Refer to paragraph 7-37 in this manual.
• If continuity is found, go to Test 6.

Test 6. Check each wire within the worklight for continuity.


• If continuity is not found, repair or replace wiring as needed. Refer to paragraph
7-48 in this manual.
• If continuity is found, reassemble worklight and reinstall.

2-232
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 7. Using a sharp probe, check for 24 volts on both sides of connector MC5 wire 040 (pin
S).
• If 24 volts are present on one side of the connector MC5 and not on the other side,
repair or replace connector MC5, as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present on both sides of the connector MC5, repair or replace wire
040 between connector MC5 and the plug at the worklight. Refer to paragraph 7-
48 in this manual.
• If 24 volts are not present on both sides of the connector MC5, go to Test 8.

2-233
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for 24 volts on wire 040 at output terminal of worklight switch in cab.
• If 24 volts are present, repair or replace wire 040 between worklight switch and
plug C. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 9.

Test 9. Check for 24 volts on wire 040 at input terminal of worklight switch in cab.
• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are not present, go to Test 10.

2-234
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Check for 24 volts on wire 040 terminal of circuit breaker No. 2.
• If 24 volts are present, repair or replace wire 040 between circuit breaker and
switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 11.

Test 11. Check for 24 volts on wire 835 terminal of circuit breaker No. 2.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section,

END OF TEST

2-235
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

16. Dome Light Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
Master light switch must be in the STOPLIGHT or SERVICE DRIVE position and dome light
switch must be in the ON position before doing any troubleshooting tests.

Test 1. Check dome light bulb for broken filament.


• If broken, replace bulb. Refer to paragraph 7-33 in this manual.
• If not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of dome light bulb socket.
• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

Test 3. Check for good ground for dome light socket.


• If ground is bad, repair or replace dome light socket as needed. Refer to
paragraph 7-33 in this manual.
• If ground is good, replace bulb. Refer to paragraph 7-33 in this manual.

2-236
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check for 24 volts on wire 153 terminal of dome light switch.
• If 24 volts are present, repair or replace wire 153 between dome light and dome
light, switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 5.

Test 5. Check for 24 volts on wire 027 terminal of dome light switch.
• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are not present, go to Test 6.

2-237
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for 24 volts on wire 027 terminal of circuit breaker No. 3.
• If 24 volts are present, repair or replace wire 027 between dome light switch and
circuit breaker No. 3.
• If 24 volts are not present, go to Test 7.

Test 7. Check for 24 volts on input terminal of circuit breaker No. 3.


• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Malfunction 12, Test 3 in this section.

END OF TEST

2-238
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

17. Map Light Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
Master light switch must be in the SERVICE DRIVE or STOPLIGHT position and map light
switch must be in the ON position before performing any troubleshooting tests.

Test 1. Check map light bulb for broken filament. Refer to paragraph 7-35 in this manual.
• If broken, replace bulb. Refer to paragraph 7-35 in this manual.
• If not broken, go to Test 2.

2-239
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for 24 volts on center contact of map light bulb socket.
• If 24 volts are present, go to Test 3.
• if 24 volts are not present, go to Test 4.

Test 3. Check for a good ground for map light bulb socket.
• If ground is good, replace bulb. Refer to paragraph 7-35 in this manual.
• If ground is bad, repair or replace map light as needed. Refer to paragraph 7-35 in
this manual.

Test 4. With switch on, check for 24 volts on output terminal of map light switch.
• If 24 volts are present, repair or replace wire between map light and switch.
• If 24 volts are not present, go to Test 5.

Test 5. Check for 24 volts on wire 413 terminal of map light switch.
• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are not present, go to Test 6.

2-240
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for 24 volts on wire 413 terminal of circuit breaker No. 2.
• If 24 volts are present, repair or replace wire 413 between circuit breaker No. 2
and map light switch. Refer to paragraph 7-48 in this manual.
• If volts 24 are not present, go to Test 7.

Test 7. Check for 24 volts on wire 835 terminal of circuit breaker No. 2.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section of the
manual.

END OF TEST

2-241
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

18. Beacon Light Does Not Work

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

• BEACON LIGHT POWER SUPPLY CONTAINS PARTS THAT HOLD


DANGEROUS VOLTAGES (UP TO 500 VOLTS) EVEN WHEN OFF. TO
PREVENT PERSONAL INJURY, MAKE SURE POWER IS OFF AND DO NOT
TOUCH TOP OR BOTTOM OF THE CIRCUIT BOARD. DO NOT TOUCH THE
LEADS TO ANY CAPACITOR OR THE TRANSFORMER. HANDLE CIRCUIT
BOARD BY EDGES ONLY.

NOTE
Master light switch must be in STOPLIGHT or SERVICE DRIVE position and beacon light
switch must be ON for all voltage tests.

Test 1. Using a sharp probe, pierce the insulation on wire 029 above the plug located about
half way down the mounting bracket. Check for 24 volts at this point.
• If 24 volts are not present, go Test 7.
• If 24 volts are present, go to Test 2.

CAUTION

TO PREVENT DAMAGE TO POWER SUPPLY, DO NOT TURN BEACON LIGHT ON


WHEN STROBE LIGHT TUBE IS REMOVED. THIS CAN DAMAGE THE POWER
SUPPLY.

2-242
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Turn beacon light OFF and remove lens. Refer to paragraph 7-38 in this manual.
Perform the following tests:

a. Set multimeter to read at least 450 volts. Connect leads to the large capacitor
under the circuit board. Connect the positive meter lead to the positive capacitor
lead and the negative meter lead to the negative capacitor lead. Make sure that
meter lead clips pierce the insulating coating on the capacitor leads. Turn beacon
light ON and note voltage.

b. Turn beacon light OFF. Set multimeter to read at least 200 volts. Connect
negative meter lead to ground. Using a sharp probe on the positive meter lead,
pierce the insulating coating on the lead from the 22 mfd capacitor. Turn beacon
light ON and note voltage.

c. Turn beacon light OFF. Set multimeter to read at least-3 volts. Connect negative
meter lead to ground. Using a sharp probe on the positive meter lead, pierce the
insulating coating on pin 3 of IC 555. Be careful not to touch any other pin of IC
555. Turn beacon light ON and note voltage.

Voltage readings should be as follows:

a. 350 to 450 volts


b. 200 volts
c. 2.5 to 3.5 volts

• If all three voltages (a, b and c) are present and correct, replace strobe light
tube. Refer to paragraph 7-38 in this manual.
• If one or two of the voltages (a, b or c) are not present or correct, replace
power supply. Refer to paragraph 7-38 in this manual.
• If none of the voltages (a, b or c) are present, go to Test 3.

2-243
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Turn beacon light OFF. Remove strobe light tube. Refer to paragraph 7-38 in this
manual. Check for continuity between ground and pins 6 and 7 of strobe light tube
socket. A small amount of resistance (20-30 ohms) may be found. This is normal.
Reinstall strobe light tube.
• If continuity is not found, go to Test 5.
• If continuity is found, go to Test 4.

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test, do not disconnect plug or connector.

Test 4. Remove the three screws and clip holding the power supply to the base. Carefully
torn power supply over, turn beacon light ON and check for 24 volts on both sides of
power supply plug (white wire on harness side and red wire on power supply side).
• If 24 volts are not present, repair or replace wire 029 between power supply plug
and plug on mounting bracket. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on the white wire and not on the red wire, repair or replace
power supply plug as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are present on both sides of the plug, go to Test 5.

2-244
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for continuity between black and violet wires from power supply to ground.
• If continuity is not found, repair or replace black and/or violet wires between
power supply and ground. Be sure to check plug for continuity from one side to
the other. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 6.

Test 6. Check for 24 volts on power supply circuit board where the red wire connects to the
board.
• If 24 volts are present, replace beacon light assembly. Refer to paragraph 7-38 in
this manual.
• If 24 volts are not present, repair or replace red wire between plug and circuit
board. Refer to paragraph 7-48 in this manual.

2-245
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for 24 volts on output terminal wire 029 of beacon light toggle switch.
• If 24 volts are present, repair or replace wire 029 between switch and plug on
mounting bracket. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 8.

Test 8. Check for 24 volts on input terminal wire 029 of beacon light switch.
• If 24 volts are present, replace beacon light switch. Refer to paragraph 7-15 in
this manual.
• If 24 volts are not present, go to Test 9.

2-246
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check for 24 volts on wire 029 terminal of circuit breaker No. 3.
• If 24 volts are present, repair or replace wire 029 between circuit breaker No. 3
and beacon light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 10.

Test 10. Check for 24 volts on input terminal of circuit breaker No. 3.
• If 24 volts are present, replace circuit breaker No. 3. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, go to Malfunction 12, Test 3 in this section.

END OF TEST

2-247
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

19. One Or More Blackout Marker Light(S) Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
Master light switch must be in BLACKOUT MARKER or BLACKOUT DRIVE position before
doing any troubleshooting tests.

Test 1. Remove lens from composite light, remove bulb and check for broken filament(s).
• If filaments) are broken, replace bulb. Refer to paragraphs 7-34 and 7-36 in this
manual as needed.
• If filament(s) are not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of bulb socket(s).


• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

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


• If ground is good, replace bulb. Refer to paragraphs 7-34 and 7-36 in this manual.
• If ground is bad, repair or replace light as needed. Refer to paragraphs 7-34 and
7-36 in this manual.

Test 4. Unplug composite light(s) at wire 680/20, for front lights or 680/24 for rear lights.
Check for 24 volts on harness plug (wire 680/20 or 680/24).
• If 24 volts are present, replace composite light. Refer to paragraphs 7-34 or 7-36
in this manual.
• If 24 volts are not present, go to Test 5.

2-248
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-249
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• For the rear composite lights, go to Test 5. For the front composite lights, go to Test 7.

• When told to check both sides of a plug or connector, probe the male and female parts.
Probe from the rear of the plug or connector, at the wire or pin called for in the test.
This will check the continuity of the plug or connector and let you know if it is usable
or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 5. Check for 24 volts on both sides of the connector MC18 wire 024 (pin S).
• If 24 volts are present on both sides of the connector, repair or replace wire 024
between composite light plug and connector MC18. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of the connector and not on the other, repair or
replace connector MC18 as needed. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts on both sides of connector MC4 wire 024 (pin 18).
• If 24 volts are present on both sides of the connector MC4, repair or replace wire
024 between connector MC4 and connector MC18. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of the connector MC4 and not on the other,
repair or replace connector MC4. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 7.

2-250
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-251
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Disconnect plug on rear of Master light switch. Check for 24 volts on pin F of plug.
• If 24 volts are present, go to Test 8.
• If 24 volts are not present, go to Test 9.

Test 8. With plug still disconnected, check for continuity between pin F and pin E on the
back of the Master light switch.
• If continuity is not found, replace blackout light switch. Refer to paragraph 7-24
in this manual.
• If continuity is found, go to Test 9.

Test 9. Check for 24 volts on wire 674 terminal of circuit breaker No. 6.
• If 24 volts are present, repair or replace wire 674 between circuit breaker No. 6
and Master light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section of the
manual.

END OF TEST

2-252
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-253
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

20. Blackout Brake Lights Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Before doing any troubleshooting tests, check operation of service drive stop lights. If
they do not work, refer to Malfunction 11, BRAKE LIGHTS DO NOT WORK first. If
they are working, go on to Test 1.

• Master light switch must be in BLACKOUT MARKER or BLACKOUT DRIVE


position, air system pressure must be between 60 and 120 psi (413.7 to 827.4 kPa) and
brake treadle valve must be applied before performing any troubleshooting test.

Test 1. Remove lens from rear composite lights and check for broken filaments in blackout
brake light bulbs. Refer to paragraph 7-36 in this manual.
• If filaments are broken, replace bulb. Refer to paragraph 7-36 in this manual.
• If filaments are not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of bulb sockets.


• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

2-254
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

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


• If ground is good, replace bulb. Refer to paragraph 7-36 in this manual.
• If ground is bad, repair or replace composite lights as needed. Refer to paragraph
7-36 in this manual.

Test 4. Disconnect wire 678/23 plug at rear of composite light and check for 24 volts on plug
from harness.
• If 24 volts are present, repair or replace composite light as needed. Refer to
paragraph 7-36 in this manual.
• If 24 volts are not present, go to Test 5.

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 5. Check for 24 volts on both sides of connector MC18 wire 678 (pin H).
• If 24 volts are present on both sides of the connector, repair or replace wire 678
between connector and plug at composite light. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present, go to Test 6.

2-255
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for 24 volts on both sides of connector MC4 wire 678 (pin 9).
• If 24 volts are present on both sides of the connector MC4, repair or replace wire
678 between connector MC4 and connector MC18. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of the connector MC4 and not on the other,
repair or replace connector MC4. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 7.

2-256
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Using a sharp probe, check for 24 volts or wire 678 (pin N) at rear of Master light
switch plug.
• If 24 volts are present, repair or replace wire 678 between composite light plug
and Master light switch plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, replace Master light switch. Refer to paragraph 7-24 in
this manual.

END OF TEST

2-257
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

21. Suspension Lockup Warning Light Does Not Come On When Caps Are Off

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be ON for all voltage tests.

• Do not unplug any parts unless told to do so in the test.

Test 1. Remove warning light bulb and check for a broken filament. Refer to paragraph 7-29
in this manual.
• If filament is broken, replace bulb.
• If filament is not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of bulb socket.


• If 24 volts are present, go to Test 5.
• If 24 volts are not present, go to Test 3.

2-258
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for 24 volts on wire 805 terminal of circuit breaker No. 8.
• If 24 volts are present, repair or replace wire 805 between circuit breaker No. 8
and warning light socket. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 4.

Test 4. Check for 24 volts on wire 735 terminal of circuit breaker No. 8.
• If 24 volts are present, replace circuit breaker No. 8. Refer to paragraph 7-16 in
this manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section of the
manual.

2-259
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test, do not disconnect plug or connector.

Test 5. Check for continuity between wire 852 at warning light bulb socket and wire 852 A at
relay No. 6.
• If continuity is present, go to Test 6.
• If continuity is not present, repair or replace wires between warning light socket
and relay No. 6.

Test 6. Check for continuity between wire 435 at relay No. 6 and ground.
• If no continuity is found, repair or replace wire 435 between relay No. 6 and
ground. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 7.

Test 7. Unplug connector at relay No. 6 and check for continuity between 852 A terminal and
435 Terminal at relay No. 6.
• If continuity is not found, replace relay. Refer to paragraph 7-28 in this manual.
• If continuity is found, go to Malfunction 22 in this section.

END OF TEST

2-260
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-261
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

22. Suspension Lockup Warning Light Does Not Go Out When Caps Are On

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be ON for all voltage tests.

• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 1. Check for 24 volts on wire 805 terminal of relay No. 6.


• If 24 volts are not found, repair or replace wire 805, between relay No. 6 and
circuit breaker No. 8. Refer to paragraph 7-48 in this manual.

Test 2. Remove wire 852 from relay No. 6. Using a jumper wire, connect relay No. 6
terminal 852 to ground.
• If suspension lockup warning light goes out, go to Test 3.
• If suspension lockup warning light stays on, replace relay No. 6. Refer to
paragraph 7-48 in this manual.

2-262
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove wire 852 from relay No. 6. Check for continuity between wire 852 at relay
No. 6 and both sides of connector MC4 (pin 1).
• If continuity is found on both sides of connector MC4, go to Test 4.
• If continuity is found on one side of connector MC4 and not on the other side,
repair or replace connector MC4. Refer to paragraph 7-48 in this manual.
• If no continuity is found on either side of connector MC4, repair or replace wire
852 between connector and relay No. 6.

Test 4. Check continuity of wire 852 from rear of connector MC4 (pin 1) to pin A on driver’s
side sensor plug.
• If no continuity is found, repair or replace wire 852 between connector MC4 and
driver’s side sensor plug.
• If continuity is found, go to Test 5.

Test 5. Make sure sensor caps are properly installed on both sides of the MK48. Probing
from the rear of the plug, check for continuity between pins A and B and ground on
the driver’s side plug.
• If continuity is found on pin B and not on pin A, repair or replace plug and/or cap
as needed. Refer to paragraph 7-48 in this manual.
• If continuity is not found, go to Test 6.

2-263
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for continuity between pin B on driver’s side plug and pin A on passenger’s
side plug.
• If continuity is not found, repair or replace wire 852 between the two plugs.
Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 7.

Test 7. Probing from rear of plug, check for continuity between pins A and B and ground on
passenger’s side plug.
• If continuity is found on pin B and not pin A, repair or replace plug and/or cap as
needed. Refer to paragraph 7-48 in this manual.
• If continuity is not found on pin A or pin B, repair or replace wire 435 between
plug and ground. Refer to paragraph 7-48 in this manual.

END OF TEST

2-264
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

23. Air Dryer and/or Fuel/Water Separator Heater Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
Ignition switch must be in the ON position for all voltage tests.

Test 1. Check for 24 volts on wire 538 of fuel/water separator and/or air dryer.
• If 24 volts are not present, go to Test 3.
• If 24 volts are present, go to Test 2.
• If 24 volts are present at air dryer, but not fuel/water separator, repair or replace
wire 538 between air dryer and fuel/water separator. Refer to paragraph 7-48 in
this manual.

Test 2. Check for good ground at fuel/water separator and/or air dryer.
• If ground is good, repair or replace defective heater. Refer to paragraph 13-38 in
this manual for air dryer or paragraph 4-20 in this manual for fuel/water separator.
• If ground is bad, repair as needed. Refer to paragraph 7-48 in this manual.

2-265
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for 24 volts on wire 538 terminal of circuit breaker No. 12.
• If 24 volts are present, repair or replace wire 538 between circuit breaker No. 12
and air dryer or fuel/ water separator.
• If 24 volts are not present, go Test 4.

Test 4. Check for 24 volts on input terminal of circuit breaker No. 12.
• If 24 volts are present, replace circuit breaker No. 12. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 5.

2-266
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for 24 volts at wire 640 terminal of ignition switch.


• If 24 volts are present, repair or replace wire 640 between ignition switch and
circuit breaker No. 11. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, replace ignition switch. Refer to paragraph 7-23 in this
manual.

Test 6. Check for 24 volts at wire 431 at ignition switch.


• If 24 volts are present, replace ignition switch. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present go to Step 7.

Test 7. Check for 24 volts at wire 431 terminal on circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 431 between circuit breaker No. 5
and ignition switch.
• If 24 volts are not present, refer to Malfunction 3 in this section.

END OF TEST

2-267
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

24. One or Both Horns Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. With horn button depressed, check for 24 volts on wire 168 terminal of non-working
horn.
• If 24 volts are not present, go to Test 3.
• If 24 volts are present, go to Test 2.

Test 2. Check for good ground at non-working horn.


• If ground is good, replace horn as needed. Refer to paragraph 22-14 in this
manual.
• If ground is bad, repair as needed. Refer to paragraph 22-14 in this manual.

2-268
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. With horn button depressed, check for 24 volts on wire 168 at relay No. 3.
• If 24 volts are present, repair or replace wire 168 between relay No. 3 and horns.
Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 4.

Test 4. Check for volts on wire 031/279 at relay No. 3.


• If 24 volts are present, go to Test 7.
• If 24 volts are not present, go to Test 5.

Test 5. Check for 24 volts on wire 031 terminal of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 031 between relay No. 3 and circuit
breaker No. 5. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

2-269
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for 24 volts on wire 430 terminal of circuit breaker No. 5.
• If 24 volts are present, replace circuit breaker. Refer to paragraph 7-14 in this
manual.
• If 24 volts are not present go to Malfunction 3 in this section.

Test 7. Check for 24 volts on wire 279 at relay No. 3.


• If 24 volts are not present, repair or replace wire 279. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present, go to Test 8.

Test 8. With horn button depressed, check for good ground on wire 016 at relay No. 3.
• If ground is bad, repair or replace horn switch and/or wire 016. Refer to
paragraph 15-3 in this manual.
• If ground is good, replace relay No. 3. Refer to paragraph 7-48 in this manual.

END OF TEST

2-270
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

25. Hydraulic Steering Disengage Light Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be in ON position for all voltage tests.

• Selector valve must be in the auxiliary hydraulics (out) position for all tests.

• This test is not applicable to MK48/14 configuration.

Test 1. Remove bulb and check for broken filament.


• If filament is broken, replace bulb. Refer to paragraph 7-29 of this manual.
• If filament is not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of bulb socket.


• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Malfunction 21, Tests 3 thru 9.

Test 3. Check for continuity between wire 843 terminal of light bulb socket and ground.
• If continuity is found, replace bulb.
• If continuity is not found, go to Test 4.

2-271
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Probing from the rear with a sharp probe, check both sides of warning light connector
MC2, wire 843 (pin 1) for continuity to ground.
• If continuity is found on both sides of connector MC2, repair or replace wire 843
between bulb socket and connector MC2. Refer to paragraph 7-48 in this manual.
• If continuity is found on one side of the connector MC2 and not on the other side,
repair or replace connector MC2. Refer to paragraph 7-48 in this manual.
• If continuity is not found, go to Test 5.

Test 5. Check continuity to ground on wire 843 at relay No. 5.


• If continuity is not found, go to Test 6.
• If continuity is found, repair or replace wire 843 between connector MC2 and
relay No. 5. Refer to paragraph 7-48 in this manual.

2-272
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check both sides of connector MC6 wire 843 (pin 13) for continuity to ground.
• If continuity is found on both sides of connector MC6, repair or replace wire 843
between relay No. 5 and connector MC6. Refer to paragraph 7-48 in this manual.
• If continuity is found on one side of connector MC6 and not on the other side,
repair or replace connector MC6. Refer to paragraph 7-48 in this manual.
• If continuity is not found, go to Test 7.

2-273
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for continuity to ground on wire 843 terminal of steering disengage switch.
• If continuity is found, repair or replace wire 843 between switch and connector
MC6. Refer to paragraph 7-48 in this manual.
• If continuity is not found, go to Test 8.

Test 8. Check for continuity to ground on ground terminal of steering disengage switch.
• If continuity is not found, repair or replace ground wire between switch and
ground. Refer to paragraph 7-48 in this manual.
• If continuity is found, replace steering disengage switch. Refer to paragraph 7-16
in this manual.

END OF TEST

2-274
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

26. Traction Control Valve Indicator Light(S) Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Air pressure must be between 60 and 120 psi (413-826 kPa).

• Ignition switch must be in ON position for all voltage tests.

• Do Tests 1 thru 6 if either or both lights are not working. Then go to Tests 7 and 8 if
transfer case lockup light is not working or Tests 9 thru 11 if axle lockup light is not
working.

Test 1. Remove bulb(s) and check for broken filaments(s).


• If filament(s) are broken, replace bulb. Refer to paragraph 7-29 in this manual.
• If filament is not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of bulb socket.


• If 24 volts are not present, go to Test 4.
• If 24 volts are present, go to Test 3.

Test 3. Check bulb socket for good ground.


• If ground is bad, repair or replace ground wire. Refer to paragraph 7-48 in this
manual.
• If ground is good, replace bulb. Refer to paragraph 7-48 in this manual.

2-275
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check for 24 volts on wire 279/092 terminal of transfer case lockup light switch.
• If 24 volts are not present, go to Test 5.
• If 24 volts are present, go to Test 7.

Test 5. Check for 24 volts on wire 092 terminal of circuit breaker No. 8.
• If 24 volts are present, replace circuit breaker No. 8. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts on wire 735 terminal of circuit breaker No. 8.
• If 24 volts are present, replace circuit breaker No. 8. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, go to Malfunction 4, Test 2 in this section.

Test 7. Engage transfer case lockup switch and check for 24 volts on wire 092 terminal of
transfer case lockup light switch.
• If 24 volts are not present, replace switch. Refer to paragraph 13-41 in this
manual.
• If 24 volts are present, go to Test 8.

Test 8. Check for 24 volts on center contact of bulb socket.


• If 24 volts are not present, repair or replace wire 092 between bulb socket and
light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, check bulb socket for ground or replace bulb socket. Refer
to paragraph 7-48 in this manual.

Test 9. Check for 24 volts on wire 279 terminal of axle lockup switch.
• If 24 volts are not present, repair or replace wire 279 between transfer case lockup
switch and axle lockup switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 10.

Test 10. Engage axle lockup switch and check for 24 volts on output terminal of axle lockup
switch.
• If 24 volts are not present, replace axle lockup switch. Refer to paragraph 13-41
in this manual.
• If 24 volts are present, go to Test 11.

2-276
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for 24 volts on center contact of bulb socket.


• If 24 volts are not present, repair or replace wire 092 between bulb socket and
light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, check bulb socket for good ground or replace bulb socket.
Refer to paragraph 7-48 in this manual.

END OF TEST

2-277
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

27. Instrument Panel (Gauge) Lights Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Master light switch must be in STOPLIGHT or SERVICE DRIVE position.

• Auxiliary lighting switch on Master light switch must be in HI panel light position.

• Do Tests 1 thru 8 if instrument panel lights do not work in the HIGH position. Do
Tests 9-13 if instrument panel lights do not work in the LOW position.

Test 1. Remove light bulb(s), as needed and check for broken filaments. Refer to paragraph
7-29 in this manual.
• If filament(s) are broken, replace bulb(s). Refer to paragraph 7-29 in this manual.
• If filaments are not broken, go to Test 2.

Test 2. Check for 24 volts on center contact of bulb socket.


• If 24 volts are present, go to Test 3.
• If 24 volts are not present, go to Test 4.

Test 3. Check for good connection between bulb socket and ground.
• If ground is bad, clean or repair as needed. Refer to paragraph 7-48 in this
manual.
• If ground is good, replace bulb. Refer to paragraph 7-48 in this manual.

2-278
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 4. Check for 24 volts on both sides of instrument panel plug, wire 052 (pin U).
• If 24 volts are present on both sides of plug, repair or replace wire 052 between
plug and bulb socket(s). Refer to paragraph 7-48- in this manual.
• If 24 volts are present on one side of the plug and not on the other, repair or
replace plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 5.

2-279
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Using a sharp probe, check for 24 volts at rear of Master light switch plug, wire 052
(pin B).
• If 24 volts are present, repair or replace wire 052 between Master light switch
plug and instrument panel plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Unplug Master light switch and check for 24 volts on wire 674 (pin F) of harness
plug.
• If 24 volts are not present, go to Test 7.
• If 24 volts are present, go to test 8.

Test 7. Check for 24 volts on wire 674 terminal of circuit breaker No. 6.
• If 24 volts are present, repair or replace wire 674 between circuit breaker No. 6
and Master light plug. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, refer to Malfunction 3 in this section.

Test 8. With plug removed, check for continuity between pin F and pin B of Master light
switch.
• If continuity is not found, replace Master light switch. Refer to paragraph 7-24 in
this manual.
• If low panel lights remain inoperative go to Test 9.

Test 9. Place auxiliary lighting switch in LO panel light position. Check for continuity
between pin F and pin A of Master light switch.
• If continuity is not found, replace Master light switch. Refer to paragraph 7-24 in
this manual.
• If continuity is found, go to Test 10.

Test 10. Install plug onto rear of Master light switch. Using a sharp probe, check for 24 volts
on wire 677 (pin A) at rear of Master light switch plug.
• If 24 volts are not present, repair or replace Master light switch plug. Refer to
paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 11.

2-280
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-281
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for 24 volts on wire 677 input terminal of resistor.
• If 24 volts are not present, repair or replace wire 677 between resistor and Master
light switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 12.

Test 12. Check for four to six volts on output terminal of resistor.
• If four to six volts are not present, replace resistor. Refer to paragraph 7-51 in this
manual.
• If four to six volts are present, go to Test 13.

Test 13. Check for four to six volts at center contact of bulb socket.
• If four to six volts are not present, repair or replace wire 677 between resistor and
wire 052.

END OF TEST

2-282
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

28. One or Both Speeds On Heater Blower Do Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must in ON position for all voltage tests.

• Make sure heater blower switch is in HI position.

• If only low speed is inoperative, do Tests 8 thru 10.

Test 1. Check for 24 volts on wire 070 terminal of blower motor.


• If 24 volts are present, go to Test 2.
• If 24 volts are not present, go to Test 3.

2-283
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for good ground on ground terminal of blower motor.


• If ground is bad, clean or repair as needed. Refer to paragraph 7-48 in this
manual.
• If ground is good, replace blower motor. Refer to paragraph 22-16 in this manual.

Test 3. Check for 24 volts on wire 070 terminal of blower motor switch.
• If 24 volts are present, repair or replace wire 070 between switch and blower
motor plug.
• If 24 volts are not present, go to Test 4.

Test 4. Check for 24 volts on wire 082 terminal of blower motor switch.
• If 24 volts are present, replace switch. Refer to paragraph 7-15 in this manual.
• If 24 volts are not present, go to Test 5.

2-284
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for 24 volts on wire 082 terminal of circuit breaker No. 11.
• If 24 volts are present, repair or replace wire 082 between switch and circuit
breaker. Refer to paragraph 7-48 of this manual.
• If 24 volts are not present, go to Test 6.

Test 6. Check for 24 volts on wire 640 terminal of circuit breaker No. 11.
• If 24 volts are present, replace circuit breaker No. 11. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, go to Test 7.

2-285
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for 24 volts on wire 640 terminal of ignition switch.


• If 24 volts are present, repair or replace wire 640 between circuit breaker No. 11
and ignition switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 8.

Test 8. Check for 24 volts at wire 431 on ignition switch.


• If 24 volts are present, replace ignition switch.
• If 24 volts are not present, go to Test 9.

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


• If 24 volts are present, repair or replace wire 431 from circuit breaker No. 5 to
ignition switch.
• If 24 volts are not present, go to ELECTRICAL system troubleshooting
Malfunction 3.

2-286
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Place blower motor switch in LO position. Check for 24 volts on wire 071 terminal
of resistor.
• If 24 volts are not present, go to Test 11.
• If 24 volts are present, go to Test 12.

Test 11. Check for 24 volts on wire 071 terminal of blower motor switch.
• If 24 volts are present, repair or replace wire 071 between resistor and plug.
Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, replace switch. Refer to paragraph 7-15 in this manual.

Test 12. Check for 16 volts on output terminal of resistor.


• If 16 volts are not present, replace resistor. Refer to paragraph 22-17 in this
manual.

END OF TEST

2-287
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

29. Hydraulic Low Oil Level Alarm and/or Light Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
• Ignition switch must be in ON position for all voltage tests.

• Steering selector switch must be IN.

• The sending unit has a test circuit built into it and will activate alarm and light for a
short time when ignition is first turned ON.

• Hydraulic oil level must be below oil level sending unit for Tests 2 thru 18.

Test 1. Unplug hydraulic low oil level sender. Using a jumper wire, connect wire 525 (pin 2)
of harness plug to ground.
• If alarm and light work, go to Test 2.
• If alarm works and light does not, go to Test 5.
• If alarm does not work and light does, go to Test 8.
• If both alarm and light do not work, go to test 10.

Test 2. Check for continuity between pin 2 and pin 3 of sending unit plug.
• If continuity is not found, replace sending unit. Refer to paragraph 7-39 in this
manual.
• If continuity is found, go to Test 3.

Test 3. Check for continuity between pin 3 (wire 435) of sending unit harness plug and
ground.
• If continuity is not found, repair or replace plug or wire 435. Refer to paragraph
7-48 in this manual.
• If continuity is found, go to Test 4.

Test 4. Remove jumper wire and reconnect sending unit plug. Check for continuity between
pin 2 on both sides of plug and pin 3 on both sides of plug.
• If continuity is not found on both pins 2 and 3, repair or replace plug. Refer to
paragraph 7-48 in this manual.

2-288
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-289
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Remove warning light bulb and check for broken filament.
• If filament is broken, replace bulb. Refer to paragraph 7-29 in this manual.
• If filament is not broken, go to Test 6.

Test 6. Check for 24 volts on center contact of bulb socket.


• If 24 volts are not present, repair or replace wire 033 between bulb socket and
alarm. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 7.

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

Test 8. Check for 24 volts on wire 033 terminal of alarm.


• If 24 volts are not present, repair or replace wire 033 between alarm and bulb
socket.
• If 24 volts are present, go to Test 9.

Test 9. Check for continuity between wire 525 terminal of alarm and ground.
• If continuity is not found, repair or replace wire 525 between alarm and bulb
socket.
• If continuity is found, replace alarm. Refer to paragraph 7-42 in this manual.

Test 10. Check for 24 volts on wire 033 terminal of alarm and warning light.
• If 24 volts are present, go to Test 25.
• If 24 volts are not present, go to Test 11.

2-290
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-291
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Check for 24 volts at wire 033/778 output terminal at relay No. 9.
• If 24 volts are present, repair or replace wire 033 between relay and alarm.
• If 24 volts are not present, go to Test 12.

Test 12. Check for 24 volts at wire 033A input terminal at relay No. 9.
• If 24 volts are present, go to Test 13.
• If 24 volts are not present, go to Test 18.

Test 13. Check for continuity between wire 435 at relay No. 9 and ground.
• If continuity is found, go to Test 14.
• If continuity is not found, repair or replace wire 435 between relay No. 9 and
ground. Refer to paragraph 7-48 in this manual.

Test 14. Unplug connector at relay No. 9 and check for continuity between 778A terminal and
435 terminal at relay No. 9.
• If continuity is not found, replace relay No. 9. Refer to paragraph 7-48 in this
manual.
• If continuity is found, go to Test 15.

2-292
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 15. Check for 24 volts at terminal 778A of relay No. 9.


• If 24 volts are present, replace relay No. 9. Refer to paragraph 7-28 in this
manual.
• If 24 volts are not present, go to Test 16.

Test 16. Check for 24 volts on wire 778A at circuit breaker No. 8.
• If 24 volts are present, repair or replace wire 778A between relay No. 9 and
circuit breaker No. 8. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 17.

Test 17. Check for 24 volts at wire 735 at circuit breaker No. 8.
• If 24 volts are present, replace circuit breaker No. 8. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, refer to Malfunction 4 in this section.

Test 18. Check for 24 volts at wire 033A at relay No. 4.


• If 24 volts are present, repair or replace wire 033A between relay No. 4 and relay
No. 9. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 19.

Test 19. Check for 24 volts at wire 840A at relay No. 4.


• If 24 volts are not present, go to Test 20.
• If 24 volts are present, go to Test 23.

Test 20. Check for 24 volts at wire 840A on circuit breaker No. 13.
• If 24 volts are present, repair or replace wire 840A between circuit breaker No. 13
and relay No. 4. Refer to paragraph 7-28 in this manual.
• If 24 volts are not present, go to Test 21.

Test 21. Check for 24 volts at wire 736A at circuit breaker No. 13.
• If 24 volts are present, replace circuit breaker No. 13. Refer to paragraph 7-14 in
this manual.
• If 24 volts are not present, go to Test 22.

Test 22. Check for 24 volts at wire 736A at circuit breaker No. 4.
• If 24 volts are present, repair or replace wire 736A between circuit breaker No. 4
and circuit breaker No. 13.
• If 24 volts are not present, refer to Malfunction 3 in this section.

2-293
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 23. Remove wire 843 from relay No. 4 and check for 24 volts at wire 033A at relay
No. 4.
• If 24 volts are present, go to Test 24.
• If 24 volts are not present, replace relay. Refer to paragraph 7-28 in this manual.

Test 24. Disconnect wire 843 from hydraulic steering disengage switch. Check for continuity
between wire 843 and ground.
• If continuity is found, repair or replace wire 843 between switch and relay No. 4.
Refer to paragraph 7-48 in this manual.
• If continuity is not found, replace hydraulic steering disengage switch. Refer to
paragraph 7-16 in this manual.

2-294
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 25. Check for continuity between ground and wire 525 terminal of alarm and warning
light socket.
• If continuity is not found, go to Test 26.
• If continuity is found, replace alarm and warning light. Refer to paragraphs 7-42
and 7-29 in this manual.
NOTE
• When told to check both sides of a plug or connector, probe both the male and female
parts. Probe from the rear of the plug or connector, at the wire or pin called for in the
test. This will check the continuity of the plug or connector and let you know if it is
usable or needs repair.

• Unless told to do so in the test being done, do not disconnect plug or connector.

Test 26. Check for continuity between ground and both sides of connector MC5, wire 525
(pin x).
• If continuity is found on both sides of connector MC5, repair or replace wire 525
between connector MC5 and alarm. Refer to paragraph 7-48 in this manual.
• If continuity is found on one side of connector MC5 and not on the other side,
repair or replace connector MC5. Refer to paragraph 7-48 in this manual.
• If no continuity is found, go to Test 27.

2-295
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 27. Check for continuity on both sides of sending unit plug, wire 525 (pin 2).
• If continuity is found on both sides of sending unit plug, repair or replace wire
525 between plug C and sending unit plug. Refer to paragraph 7-48 in this
manual.
• If continuity is found on one side of the plug and not on the other, repair or
replace plug. Refer to paragraph 7-48 in this manual.
• If continuity is not found, go to Test 28.

Test 28. Check for continuity between ground and both sides of sending unit plug, wire 435
(pin 3).
• If continuity is found on both sides of plug, replace sending unit. Refer to
paragraph 7-39 in this manual.
• If continuity is found on one side of the plug and not on the other, repair or
replace plug. Refer to paragraph 7-48 in this manual.
• If continuity is not found, repair or replace wire 435 between plug and ground.
Refer to paragraph 7-48 in this manual.

END OF TEST

2-296
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

TRANSMISSION

1. Transmission Oil Temperature Gauge Stays Over 250 Degrees F (121 Degrees C)

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for clogged transmission oil filter.


• If clogged, replace filter. Refer to paragraph 8-3 in this manual.
• If not clogged, go to Test 2.

Test 2. Check for a restriction in the transmission oil cooler.


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

Test 3. Check fluid level.


• If incorrect, add or remove fluid as needed. Refer to LI 2320-12/9, LO 9-2320-
297-12.
• If fluid level is correct go to ELECTRICAL SYSTEM Troubleshooting
Malfunction 4 to check gauge operation.

END OF TEST

2-297
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Transmission Noisy

Test 1. Check fluid level.


• If incorrect, add or remove fluid as needed. Refer to LI 2320-12/9, LO 9-2320-
297-12.
• If problem still exists, go to Test 2.
Test 2. Check for a restriction in transmission oil cooler.
• If restricted, repair or replace as needed. Refer to paragraph 8-15 in this manual.
• If problem still exists, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

2-298
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Transmission Will Not Shift Into Gear

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

CAUTION

TO PREVENT EQUIPMENT DAMAGE, PERFORM A VISUAL INSPECTION FOR


LEAKS AND MAKE SURE FLUID LEVEL IS CORRECT BEFORE OPERATING
VEHICLE. IF NEEDED, TIGHTEN ANY LOOSE CAPSCREWS, PLUGS OR
CONNECTIONS.

Test 1. Check shift lever and linkage from cab to transmission for proper adjustment and/or
damage.
• If damaged or misadjusted, repair, replace or adjust as needed. Refer to
paragraphs 8-4, 8-5 and 8-7 in this manual.
• If not damaged or misadjusted, go to Test 2.

Test 2. Check for correct fluid level,


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

Test 3. Check for correct lubricant.


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

Test 4. Check for clogged transmission oil filter.


• If clogged, replace filter. Refer to paragraph 8-3 in this manual.
• If not clogged, refer problem to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

2-299
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Transmission Slips Out Of Gear Or Operates Erratically

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

CAUTION

TO PREVENT EQUIPMENT DAMAGE, PERFORM A VISUAL INSPECTION FOR


LEAKS AND MAKE SURE FLUID LEVEL IS CORRECT BEFORE OPERATING
VEHICLE. IF NEEDED, TIGHTEN ANY LOOSE CAPSCREWS, PLUGS OR
CONNECTIONS.

Check shift lever and linkage from cab to transmission for proper adjustment and/or damage.
• If damaged or misadjusted, repair, replace or adjust as needed. Refer to
paragraphs 8-4, 8-5 and 8-7 in this manual.
• If not damaged or misadjusted, send to Direct Support/intermediate Maintenance
(Third Echelon).

END OF TEST

2-300
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

5. Transmission Leaks

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


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

Test 2. Check for loose or damaged oil cooler or lines.


• If loose or damaged, repair or replace. Refer to paragraph 8-15 in this manual.
• If not loose or damaged, go to Test 3.

Test-3. Check for clogged or damaged breather.


• If clogged or damaged, service or replace breather. Refer to paragraph 8-16 in
this manual.
• If not clogged or damaged, go to Test 4.

Test 4. Check housing and seals for damage.


• If damaged, send to Direct Support/Intermediate Maintenance (Third Echelon).
• If not damaged, go to Test 5.

Test 5. Remove cover from top of torque converter housing and check for oil.
• If leaking, send to Direct Support, Third Echelon, Maintenance.
• If not leaking and problem has not been solved, send to Direct
Support/Intermediate Maintenance (Third Echelon).

END OF TEST

2-301
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-302
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

6. Oil Thrown From Filler Tube

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


• If loose, missing or wrong, tighten or replace dipstick. Refer to TM 08780B-10.
• If not loose, missing or wrong, go to Test 2.

Test 2. Check for oil level too high.


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

Test 3. Check for clogged or damaged breather.


• If clogged or damaged, service or replace breather. Refer to paragraph 8-16 in
this manual.
• If not clogged or damaged, go to Test 4.

Test 4. Check for worn or damaged dipstick tube gasket.


• If worn or damaged, replace gasket. Refer to paragraph 8-14 in this manual.
• If problem still exists, send to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

2-303
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-304
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. Excessive Creep In First And Reverse

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

Check for throttle pedal binding (idle too high).


• If binding, repair or replace as needed. Refer to paragraph 4-23 in this manual.
• If not binding, send to Direct Support/Intermediate Maintenance (Third Echelon).

END OF TEST

8. Transmission Oil Dirty

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check that oil changes have been done at proper intervals.
• If not, change oil and filter. Refer to paragraph 8-3 in this manual.
• If oil has been changed at proper interval, go to Test 2.

2-305
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for damaged oil filter.


• If damaged, replace. Refer to paragraph 8-3 in this manual.
• 1f not damaged, go to Test 3.

2-306
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check temperature gauge for overheating.


• If overheating, go to Malfunction 1.
• If not overheating and problem still exists, send to Direct Support/Intermediate
Maintenance (Third Echelon).

END OF TEST

GAUGE

2-307
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. Automatic Shifts Occur at Too High or Low a Speed

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for proper oil level.


• If level is wrong, add or drain oil as needed. Refer to paragraph 8-3 in this
manual.
• If level is correct, go to Test 2.

Test 2. Remove and check for sticking governor. Refer to paragraph 8-9 in this manual.
• If governor is not sticking, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
• If governor is sticking, remove and clean governor or replace.

END OF TEST

2-308
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

10. Transmission Shifts Rough

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.
CAUTION
TO PREVENT EQUIPMENT DAMAGE, PERFORM A VISUAL INSPECTION FOR
LEAKS AND MAKE SURE FLUID LEVEL IS CORRECT BEFORE OPERATING
VEHICLE. IF NEEDED, TIGHTEN ANY LOOSE CAPSCREWS, PLUGS OR
CONNECTIONS.

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


• If loose, damaged or misadjusted, repair, replace or adjust as needed. Refer to
paragraphs 8-4, 8-5 and 8-7 in this manual.
• If not loose, damaged or misadjusted, send to Direct Support/Intermediate
Maintenance (Third Echelon).

END OF TEST

11. Vehicle Moves In Neutral

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.
CAUTION
TO PREVENT EQUIPMENT DAMAGE, PERFORM A VISUAL INSPECTION FOR
LEAKS AND MAKE SURE FLUID LEVEL IS CORRECT BEFORE OPERATING
VEHICLE. IF NEEDED, TIGHTEN ANY LOOSE CAPSCREWS, PLUGS OR
CONNECTIONS.

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


• If loose, damaged or misadjusted, repair, replace or adjust as needed. Refer to
paragraphs 8-4, 8-5 and 8-7 in this manual.
• If not loose, damaged or misadjusted, send to Direct Support/Intermediate
Maintenance (Third Echelon).

END OF TEST

2-309
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-310
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

12. Transmission Slips In All Gears

WARNING

TO PREVENT PERSONAL INJURY, BLOCK WHEELS AND SET PARKING BRAKE


BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

CAUTION

TO PREVENT EQUIPMENT DAMAGE, PERFORM A VISUAL INSPECTION FOR


LEAKS AND MAKE SURE FLUID LEVEL IS CORRECT BEFORE OPERATING
VEHICLE. IF NEEDED, TIGHTEN ANY LOOSE CAPSCREWS, PLUGS OR
CONNECTIONS.

Check for low oil level.


• If low, add oil to proper level. Refer to paragraph 8-3 in this manual.
• If not low, send to Direct Support/Intermediate Maintenance (Third Echelon).

END OF TEST

2-311
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

TRANSFER CASE

1. Constant Noise When In Low Range and/or Direct Range

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for correct lubricant and correct level.


• If wrong level or type of lubricant, change lubricant as needed. Refer to
paragraph 9-3 in this manual.
• If correct, go to Test 2.

Test 2. Check for loose, misadjusted or damaged shifter and/or linkage.


• If loose, misadjusted or damaged, adjust, repair or replace as needed. Refer to
paragraphs 9-4 and 9-5 in this manual.
• If not loose, misadjusted or damaged, go to Test 3.

2-312
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove one of the three oil feed lines from lubrication pump. Have assistant apply
parking brake, place transfer case in neutral, start engine and shift to drive. Allow
vehicle to idle. Watch for lubricant to flow from pump. It may take a moment for the
oil to flow.
• If lubricant does not flow from the pump, go to Test 4.
• If lubricant does flow from pump, send to Direct Support/Intermediate
Maintenance (Third Echelon).

Test 4. Check for clogged lubrication pump pickup strainer, pump pickup line or lubrication
feed lines. Refer to paragraph 9-6.
• If strainer, pump pickup line or lubrication lines are clogged, clean or replace as
required.
• If strainer, pump pickup line or lubrication lines are clear, replace transfer case
lubrication pump. Refer to paragraph 9-7.

END OF TEST

2-313
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Lubricant Leaks At Drive Yokes

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

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


• If incorrect, change lubricant or drain to proper level. Refer to paragraph 9-3 in
this manual.
• If correct, go to Test 2.

Test 2. Check for clogged or damaged breather.


• If clogged or damaged, clean or replace breather. Refer to paragraph 9-8 in this
manual.
• If not clogged or damaged, send to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

2-314
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Transfer Case Overheats

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

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


• If incorrect, change lubricant or drain to proper level. Refer to paragraph 9-3 in
this manual.
• If correct, go to Test 2.

Test 2. Check for clogged or damaged breather.


• If clogged or damaged, clean or replace breather. Refer to paragraph 9-8 in this
manual.
• If not clogged or damaged, go to Test 3.

Test 3. Check for damage or restricted lubricant line.


• If damaged or restricted, replace lubricant line. Refer to paragraph 9-6 in this
manual.
• If not damaged or restricted, send to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

2-315
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Differential Lockup Will Not Engage Or Disengage

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

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


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

Test 2. Check for damaged or leaking air chamber.


• If damaged or leaking, replace air chamber. Refer to paragraph 9-9 in this
manual.
• If not damaged or leaking, send to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

2-316
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

PROPELLER SHAFTS

Driveline Vibration or Noise

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for damaged or worn universal joints.


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

Test 2. Check for worn or damaged pillow block.


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

Test 3. Check for damaged propeller shaft.


• If damaged, replace. Refer to paragraph 10-3 in this manual.
• If not damaged, go to Test 4.

Test 4. Check for damaged or worn cardan joint.


• If damaged or worn, replace. Refer to paragraph 10-4 in this manual.
• If not damaged or worn, send to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

2-317
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-318
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOSE BOX

1. Nose Box Overheats

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for correct type and level of lubricant.


• If wrong type or level, change lubricant or adjust level as needed. Refer to
paragraph 11-3 in this manual.
• If type and level are correct, go to Test 2.

Test 2. Check for clogged or damaged breather.


• If clogged or damaged, replace breather. Refer to paragraph 11-4 in this manual.
• If not clogged or damaged, send to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

2-319
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Lubricant Leaks At Drive Yoke

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for correct type and level of lubricant.


• If wrong type or level, change lubricant or adjust level as needed. Refer to
paragraph 11-3 in this manual.
• If type and level are correct, go to Test 2.

Test 2. Check for clogged or damaged breather.


• If clogged or damaged, replace breather. Refer to paragraph 11-4 in this manual.
• If not clogged or damaged, send to Direct Support/Intermediate Maintenance
(Third Echelon).

END OF TEST

2-320
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Nose Box Noisy

WARNING
TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE
THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for proper type and level of lubricant.


• If wrong type or level, change lubricant or adjust level. Refer to paragraph 11-3
in this manual.
• If type and level are correct, send to Direct Support/Intermediate Maintenance
(Third Echelon)

END OF TEST

2-321
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

AXLES

1. Differential(s) Noisy

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for correct type and level of lubricant.


• If wrong type or level, change lubricant or adjust level as needed. Refer to
paragraphs 11-3 or 12-3 in this manual.
• If type and level are correct, go to Test 2.

Test 2. Check for improperly lubricated, worn or damaged wheel bearings. Refer to
paragraph 14-3 or 14-4 in this manual.
• If wheel bearings are worn or damaged, replace them. Refer to paragraphs 14-3
and 14-4 in this manual.
• If not worn or damaged, send to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

2-322
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Lubricant Leaks At Pinion Or Axle Shafts

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

Test 1. Check for correct type and level of lubricant.


• If lubricant type or level is wrong, change lubricant or adjust level. Refer to
paragraphs 11-3 and 12-3 in this manual.
• If lubricant type and level are correct, go to Test 2.

Test 2. Check for clogged or damaged breather.


• If clogged or damaged, clean or replace breather. Refer to paragraphs 11-4 and
12-5 in this manual.
• If not clogged or damaged, go to Test 3.

Test 3. Check for worn or damaged gaskets at axle shafts.


• If worn or damaged, replace gasket(s). Refer to paragraphs 11-6 and 12-4 in this
manual.
• If not worn or damaged, send to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

2-323
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-324
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Controlled Traction Differential Will Not Engage or Disengage

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

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


• If loose or damaged, repair or replace as needed. Refer to paragraph 13-23 in this
manual.
• If not loose or damaged, send to Direct Support/Intermediate Maintenance (Third
Echelon).

END OF TEST

2-325
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-326
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Vehicle Will Not Move

Test 1. Move driveline lockup control lever to TRANSFER CASE LOCKUP. Shift
transmission range selector to DRIVE.
• If vehicle now moves, go to Test 2.
• If vehicle does not move, go to Malfunction 3, Axle Troubleshooting in this
section of the manual.

2-327
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Move driveline lockup control lever to AXLE LOCKUP. Shift transmission range
selector to DRIVE.
• If vehicle now moves, go to Test 3.
• If vehicle does not move, go to Malfunction 3, Axle Troubleshooting in this
section of the manual.

Test 3. Jack up No. 1 axle at the left side. Ensure that axle lockup is engaged. Try to turn
left wheel by hand.
• If wheel turns, axle shaft is broken. Refer to paragraph 11-6 in this manual to
repair axle shaft.
• If wheel does not turn, repeat Test 3 on right side of axle. If wheel does not turn,
axle is OK. Repeat Test 3 on No. 2, 3 and 4 axles.
• If wheel can be turned, refer to paragraph 12-4 for repair of broken axle shaft on
No. 2, 3 or 4 axles.

2-328
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

AIR SYSTEM

1. No Air Pressure or Slow Build Up

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

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


• If valves are open, close them.
• If valves are leaking, replace them as needed. Refer to-paragraph 13-32 in this
manual.
• If not open or leaking, go to Test 2.

Test 2. Check air lines and air system components for leaks.
• If air lines are leaking, repair or replace as needed. Refer to paragraph 13-23 in
this manual.
• If any components are leaking, repair or replace as needed. Refer to correct
paragraph for that component.
• If no leaks are found, go to Test 3.

Test 3. Check for restriction or damage to air inlet line 600, running to compressor.
• If restricted or damaged, repair or replace as needed. Refer to paragraph 13-23 in
this manual.
• If not restricted or damaged, go to Test 4.

2-329
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-330
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

WARNING
TO PREVENT PERSONAL INJURY, BE VERY CAREFUL WHEN LOOSENING OR
REMOVING AIR LINES. AIR PRESSURE CAN CAUSE A LINE TO WHIP. THIS MAY
RESULT IN PERSONAL INJURY.

Test 4. Carefully loosen and bleed air pressure from governor signal line 114 at governor.
When air pressure is gone, disconnect air line. Start engine. Refer to TM 08780B-
10. Very carefully loosen air line 183 at compressor and listen for air escaping.
• If no air is heard escaping, send to Direct Support, Third Echelon, Maintenance.
• If air is heard escaping, shut down engine, tighten line 183 and go to Test 5.

Test 5. Connect and tighten governor signal line 114 to governor. Drain all air pressure from
air tanks. Close drain valves on air tanks and start engine. Refer to TM 08780B-10.
Allow engine to run long enough to build pressure to 100-120 psi (689-826 kPa) no
more than 10 minutes.
• If 100-120 psi (689-826 kPa) is not present, adjust governor. Refer to paragraph
13-37 in this manual.
• If governor will not adjust, replace it. Refer to paragraph 13-37 in this manual.
• If 100-120 psi (689-826 kPa) is present, go to Test 6.

Test 6. Check for restricted or damaged compressor discharge line 183.


• If restricted or damaged, repair or replace air line. Refer to paragraph 13-23 in
this manual.
• If not restricted or damaged, go to Test 7.

Test 7. Drain air pressure. Remove air dryer outlet line 184. Start engine. Refer to TM
08780B-10. Check for air flow from air dryer discharge port.
• If little or no air comes from air dryer’s discharge port, go to Test 8.
• If a large amount of air comes from discharge port, go to Test 9.

2-331
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Shut down engine and drain air pressure. Remove check valve from air dryer
discharge port. Start engine. Refer to TM 08780B-10. Check for air flow from air
dryer discharge port.
• If little or no air comes from air dryer discharge port, service, repair or replace air
dryer as needed. Refer to paragraph 13-38 in this manual.
• If air flow is greater than in Test 7, replace check valve. Refer to paragraph 13-38
in this manual.

2-332
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Drain air pressure from system. Install a test air gauge at quick disconnect on left air
tank. Start engine. Refer to TM 08780B-10. Watch both gauges during air pressure
build up.
• If test gauge builds quickly and dash gauge builds slowly, remove and inspect
inlet check valves. Replace as needed, refer to paragraph 13-34 in this manual.
• If both gauges build at same rate, go to Test 10.

Test 10. Check for restricted or damaged air line 184 between air dryer and quick build up air
tank.
• If air line is restricted or damaged, repair or replace as needed. Refer to
paragraph 13-23 in this manual.
• If not restricted or damaged, go to Test 11.

2-333
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Drain air pressure from quick build up air tank. Disconnect air line 003 from quick
build up air tank. Remove pressure protection valve. Install a tee into quick build up
air tank and install pressure protection valve into tee. Install an air pressure test
gauge into the tee. Start engine. Refer to TM 08780B-10.
• If air does not discharge from pressure protection valve when gauge reaches about
70 psi (483 kPa) ± 10 psi (69 kPa), replace valve. Refer to paragraph 13-19 in
this manual.
• If air discharges, but test gauge reading climbs above 70 psi (483 kPa) ± 10 psi
(69 kPa), replace valve.
• If air discharges and test gauge pressure stays around 70 psi (483 kPa) ± 10 psi
(69 kPa), shut down engine and remove test gauge and tee. Install pressure
protection valve and air line 003. Start engine and allow pressure to build up. If
problem still exists, send to Direct Support, Third Echelon, Maintenance.

END Of TEST

2-334
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Throttle Air Cylinder Does Not Work

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check dash gauge for proper system air pressure, 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) is not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is present, go to Test 2.

Test 2. Loosen air line 415 running to throttle treadle valve at throttle treadle valve.
• If air escapes, go to Test 3.
• If no air escapes, repair or replace air line 415 between quick build-up air tank
and throttle treadle valve. Refer to paragraph 13-54 in this manual.

GAUGE

2-335
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Disconnect air line 416 at throttle treadle valve. Install test air gauge into throttle
treadle valve. Depress throttle treadle fully.
• If 60-75 psi (414-517 kPa) is present on test air gauge, go to Test 4.
• If 60-75 psi (414-517 kPa) is not present, repair or replace throttle treadle valve.
Refer to paragraph 4-24 in this manual.

Test 4. Loosen air line 416 at tee fitting on throttle cylinder. Depress throttle treadle valve
fully.
• If air escapes, go to Test 5.
• If no air escapes, repair or replace air line 416 between throttle treadle valve and
tee fitting.

Test 5. Remove throttle air cylinder from check valve. Install test air gauge into check valve.
Depress throttle treadle valve fully.
• If 60-75 psi (414-517 kPa) is present on test air gauge, repair or replace throttle
cylinder. Refer to paragraph 4-16 or 4-17 in this manual.
• If 60-75 psi (414-517 kPa) is not present on test air gauge, repair or replace check
valve. Refer to paragraph 4-16 in this manual.

2-336
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Compressor Cycles Constantly or Safety Valve Opens Before Compressor Unloads

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING-ANY AIR LINE OR AIR COMPONENT.

Test 1. Check all air lines and components for leaks.


• If leaking, repair or replace as needed.
• If not leaking, go to Test 2.

Test 2. Check for loose or damaged governor air signal line 114.
• If loose or damaged, repair or replace as needed. Refer to paragraph 13-23 in this
manual.
• If not loose or damaged, go to Test 3.

Test 3. Check safety valve for leaks or releasing at air pressures up to 120 psi (689-826 kPa).
• If leaks or releasing is found replace safety valve. Refer to paragraph 13-32 in
this manual.
• If no leaks or releasing is found go to Test 4.

Test 4. Check governor adjustment. Refer to paragraph 13-37 in this manual.


• If misadjusted, adjust governor.
• If governor will not adjust, replace governor.

END OF TEST

2-337
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Compressor Noisy

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check for loose or damaged compressor.


• If loose, tighten mounting capscrews.
• If damaged, send to Direct Support, Third Echelon, Maintenance.
• If not loose or damaged, go to test 2.

Test 2. Check for restricted or damaged lubricant lines to compressor.


• If lines are restricted or damaged, repair or replace them.
• If not restricted or damaged, go to Test 3.

Test 3. Check for restricted or damaged coolant lines to compressor.


• If lines are restricted or damaged, repair of replace them.
• If not restricted or damaged, send to Direct Support, Third Echelon, Maintenance.

END OF TEST

2-338
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

5. Coolant and/or Lubricant Leaks From Compressor

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

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


• If loose or damaged, repair or replace as needed.
• If not loose or damaged, go to Test 2.

Test 2. Check compressor for leaking gaskets, seals or fittings.


• If leaking, tighten capscrews and fittings.
• If compressor still leaks, send to Direct Support, Third Echelon, Maintenance.

END OF TEST

2-339
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

6. Air Pressure Above 150 PSI (1,034 kPa), Safety Valve Does Not Release

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check for loose or damaged air signal line 114 to governor.
• If loose or damaged, repair or replace signal line 114. Refer to paragraph 13-23
in this manual.
• If not loose, go to Test 2.

2-340
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Adjust governor. Refer to paragraph 13-35 in this manual.


• If governor will not adjust, replace it. Refer to paragraph 13-37 in this manual.
• If governor will adjust, go to Test 3.

Test 3. Check safety valve. Pull valve stem - air should come out. Release valve stem - air
should stop.
• If manual release does not work, replace safety valve and/or repair air dryer as
needed. Refer to paragraph 13-32 in this manual.

END OF TEST

2-341
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. Left and/or Right Windshield Wiper Does Not Work

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check dash gauge for proper system air pressure, 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) is not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is present, go to Test 2.

GAUGE

2-342
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check windshield wiper air lines and components for leaks or damage.
• If leaking or damaged, repair or replace as needed. Refer to Chapter 22 in this
manual.
• If not leaking or damaged, go to Test 3.

Test 3. Operate either the air horn or windshield washers.


• If either the air horn or the windshield washer operates, go to Test 6.
• If neither the air horn nor the windshield washer operates, go to Test 4.

Test 4. Loosen outlet line 073 from pressure protection valve.


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

Test 5. Loosen pressure protection valve from bulkhead fitting.


• If air escapes, replace pressure protection valve. Refer to paragraph 13-19 in this
manual.
• If no air escapes, go to Malfunction 1.

2-343
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-344
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
Wiper motors and wiper control valves on LVSA1 series vehicles differ slightly from wiper
motors and wiper control valves on non-LVSA1 vehicles. Test procedures are, however,
identical for LVSA1 and non-LVSA1 wiper motors and wiper control valves.

Test 6. Loosen air supply lines (032 and 035) running to non-working windshield wiper
control valve.
• If no air escapes, repair or replace air line (032 or 035) between control valve and
air manifold. Refer to paragraph 13-23 in this manual.
• If air escapes, go to Test 7 for windshield wiper(s) that do not work. Go to Test 8
for windshield wiper(s) that do not park.

Test 7. Drain air system. Remove air line running to non-working windshield wiper motor -
033-left or 036-right. Install test air gauge. Start engine and build air pressure to
100-120 psi (689-826 kPa). Refer to TM 08780B-10. Pull out affected wiper control
valve and turn to HIGH.
• If test air gauge reads 100-120 psi (689-826 kPa), replace windshield wiper
motor. Refer to paragraph 22-3 (or 22-4 for LVSA1 series vehicles only) in this
manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 9.

Test 8. Drain air system. Remove air line running to non-working windshield wiper motor -
034-left or 037-right. Install test air gauge. Start engine and build air pressure to
100-120 psi (689-826 kPa). Refer to TM 08780B-10. Push in affected wiper control
valve and hold.
• If test air gauge reads 100-120 psi (689-826 kPa), replace windshield wiper
motor. Refer to paragraph 22-3 (or 22-4 for LVSA1 series vehicles only) in this
manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 9.

2-345
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
Wiper control valves on LVSA1 series vehicles differ slightly from wiper control valves on
non-LVSA1 vehicles. Test procedures are, however, identical for LVSA1 and non-A1 wiper
control valves.

Test 9. Drain air pressure. Remove test gauge and install air line to windshield wiper motor.
Remove other end of air line from wiper control valve. Install test gauge into wiper
control valve. Start engine and build air pressure to 100-120 psi (689-826 kPa).
Refer to TM 08780B-10. Place wiper control valve in the HIGH position or PARK
position as needed.
• If test air gauge does not read 100-120 psi (689-826 kPa), replace wiper control
valve. Refer to paragraph 22-6 in this manual.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line. Refer
to paragraph 13-23 in this manual.

END OF TEST

2-346
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

8. Windshield Washers Do Not Work

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPARTMENT.

NOTE
Washer fluid reservoirs on LVSA1 series vehicles differ from washer fluid reservoirs on non-
A1 vehicles. Test procedures are, however, identical for LVSA1 and non-A1 washer fluid
reservoir.

Test 1. Check washer fluid reservoir for disconnected fluid lines or low fluid level.
• If fluid lines are disconnected, connect them.
• If fluid is low, add fluid.
• If fluid lines are connected and level is correct, go to Test 2.

Test 2. Check dash gauge for 100-120 psi (689-826 kPa) air pressure.
• If not present, go to Malfunction 1.
• If present, go to Test 3.

Test 3. Push in washer control valve.


• If you cannot hear pump running, go to Test 6.
• If you can hear pump running, go to Test 4,

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

Test 5. Check for restricted or damaged washer fluid lines or nozzles.


• If restricted or damaged, repair or replace as needed. Refer to paragraph 22-8 (or
22-9 for LVSA1 series vehicles only) in this manual.
• If not restricted or damaged, go to Test 6.

2-347
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
Washer fluid reservoir and washer control valve on LVSA1 series vehicles differ from washer
fluid reservoir and washer control valve on non-A1 vehicles. Test procedures are, however,
identical for A1 and non-A1 fluid reservoirs and control valves.

Test 6. Remove right air line to washer reservoir cover. Push in washer control valve.
• If air escapes, go to Test 7.
• If no air escapes, go to Test 8.

Test 7. Check air hoses from cover to pump motor for restriction or damage.
• If restricted or damaged, repair or replace hoses. Refer to paragraph 22-8 (or 22-9
for LVSA1 series vehicles only) in this manual.
• If not restricted or damaged, replace pump motor and cover. Refer to paragraph
22-7 in this manual.

Test 8. With system air pressure available, 100-120 psi (689-826 kPa), operate air horn or
windshield wipers.
• If they do not operate, go to Malfunction 7, Tests 4 thru 6.
• If they do operate, go to Test 9.

Test 9. Remove outlet air line from washer control valve and push washer control valve in.
• If air escapes, repair or replace air hose between control valve and washer
reservoir. Refer to paragraph 22-8 (or 22-9 for LVSA1 series vehicles only) in
this manual.
• If no air escapes, go to Test 10.

GAUGE

2-348
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Loosen inlet air line 074 running to washer control valve.

NOTE
Washer control valve on LVSA1 series vehicles differs slightly from washer control valve on
non-A1 vehicles. Test procedures are, however, identical for LVSA1 and non-Al washer
control valves.
• If air escapes, replace washer control valve. Refer to paragraph 22-7 in this
manual.
• If no air escapes, repair or replace inlet air line 074. Refer to paragraph 13-23
in this manual.

END OF TEST

GAUGE

2-349
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. Air Horn Does Not Work

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

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


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

Test 2. Operate windshield wipers or washers.


• If they do not operate, go to Malfunction 7, Tests 4 and 5.
• If they operate, go to Test 3.

GAUGE

2-350
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Loosen air line 038 at air horn control valve.


• If air does not escape, repair or replace air line 038 between control valve and air
manifold. Refer to paragraph 13-23 in this manual.
• If air escapes, go to Test 4.

Test 4. Loosen outlet air line at control valve and engage control valve.
• If air does not escape, replace control valve. Refer to paragraph 22-13 in this
manual.
• If air escapes, go to Test 5.

Test 5. Loosen air line at air horn and engage control valve.
• If air does not escape, repair or replace air line between air horn and control
valve. Refer to paragraph 13-23 in this manual.
• If air does escape, repair or replace air horns as needed. Refer to paragraphs
22-11 and 22-12 in this manual.

END OF TEST

2-351
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

10. Axle Differentials Will Not Lock or Unlock

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

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

Test 2. Operate windshield wipers or air horn.


• If they do not operate, go to Malfunction 7, Tests 4 and 5.
• If they do operate, go to Test 3.

GAUGE

2-352
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Drain air pressure. Remove air line from non-working component.

Air line 069B - Inter-axle lockup No. 1 axle


Air line 069 - Inter-axle lockup No. 3 axle
Air line 069A - CTD lockup No. 1 axle
Air line 069D- CTD lockup No. 2 axle
Air line 069 - CTD lockup No. 3 axle
Air line 069 - CTD lockup No. 4 axle

Install test air gauge into air line. Start engine. Refer to TM 08780B-10. Build air
pressure to 100-120 psi (689-826 kPa). Shift drive line lockup switch to axle lockup
position.
• If 100-120 psi (689-826 kPa) is present, send to Direct Support, Third Echelon,
Maintenance.
• If 100-120 psi (689-826 kPa) is not present, go to Test 4.

Test 4. Loosen air line on the air manifold that supplies the non-working component. Shift
drive line lockup switch to axle lockup position.
• If air escapes, repair or replace air line between air manifold and non-working
component. Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 5 for rear module or Test 6 for front module.

2-353
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-354
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. For rear module, loosen air line 069C at front module air manifold. Shift drive line
lockup switch to axle lockup position.
• If air escapes, repair or replace air line 069C and/or quick couplers to rear module
air manifold. Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 6.

Test 6. Loosen air line 069 at rear of drive line lockup switch. Shift drive line lockup switch
to axle lockup position.
• If air escapes, repair or replace air line 069 between lockup switch and air
manifold. Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 7.

2-355
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Loosen air line 071 from inlet port of axle lockup switch.
• If air escapes, replace drive line lockup switch. Refer to paragraph 13-41 in this
manual.
• If no air escapes, repair or replace air line 071 between air manifold and drive line
lockup switch. Refer to paragraph 13-23 in this manual.

END OF TEST

2-356
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

11. Transfer Case Will Not Lockup or Unlock

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check air pressure gauge for 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) is not available, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is available, go to Test 2.

Test 2. Operate windshield wipers or air horn.


• If they do not operate, go to Malfunction 7, Tests 4 and 5.
• If they do operate, go to Test 3.

GAUGE

2-357
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Loosen air line 706 at lockup air chamber on transfer case. Shift drive line lockup
switch to transfer case lockup position.
• If air does not escape, go to Test 5.
• If air escapes, go to Test 4.

Test 4. Remove pipe plug from top of declutch housing. Watch for movement of shift rod
when drive line lockup switch is shifted to transfer case lockup position.
• If shift rod moves, send to Direct Support, Third Echelon, Maintenance.
• If shift rod does not move, replace air chamber. Refer to paragraph 9-9 in this
manual.

2-358
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Loosen air line 706 at rear of drive line lockup switch. Shift drive line lockup switch
to transfer case lockup position. If air escapes, repair or replace air line 706 between
lockup switch and air chamber. Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 6.

Test 6. Loosen air line 071 at inlet port of drive line lockup switch.
• If air escapes, replace drive line lockup switch. Refer to paragraph 13-41 in this
manual.
• If air does not escape, repair or replace air line 071 between lockup switch and air
manifold. Refer to paragraph 13-23 in this manual.

END OF TEST

GAUGE

2-359
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

12. Braking is Uneven, Slow or Brakes Overheat

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check brake linings and brake adjustment. Refer to paragraph 13-4 in this manual for
axle No. 1 and paragraph 13-5 in this manual for axles No. 2, 3 and 4.
• If brake linings need replacement, refer to paragraph 13-6 for axle No. 1 and
paragraph 13-7 for axles No. 2, 3 and 4.
• If brakes need adjustment, refer to paragraphs 13-4 and 13-5 in this manual.
• If adjustment or replacement is not needed, go to Test 2.

2-360
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check air pressure gauge for 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) are not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) are present, go to Test 3.

Test 3. Check all brake parts for leaks or damage.


• If leaks or damage are found, repair as needed.
• If no leaks or damage are found, go to Test 4.

WARNING

BEFORE RELEASING PARKING BRAKE, BLOCK WHEELS TO PREVENT


MOVEMENT AND PERSONAL INJURY.

Test 4. Release parking brake. Make sure all air chambers on axles No. 2, 3 and 4 are
completely retracted. Clevis locknut should be even with mounting bracket.
• If any air chamber does not retract completely, go to Malfunction 15 in this
section of the manual.
• If all air chambers retract properly, go to Test 5.

Test 5. With parking brake released, apply service brake. Watch brake shoe movement on
No. 1 axle. On axles No. 2, 3 and 4, watch air chamber clevis movement.
• If service brakes apply, disassemble brakes and check for worn, damaged or oil
soaked brake parts. Repair or replace as needed.
• If any service brake does not apply, go to Test 6.

GAUGE

2-361
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-362
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Drain air pressure from system. Remove service brake air line from non-working air
chamber and install test gauge onto air line. Start engine and build air pressure to
100-120 psi (689-826 kPa). Refer to TM 08780B-10. Apply service brake.
• If 40-100 psi (276-689 kPa) is available, replace air chamber. Refer to paragraph
13-12 in this manual.
• If 40-100 psi (276-689 kPa) is not available, go to Test 7.

GAUGE

2-363
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
Air chambers for axle No. 1 do not have a relay valve. Refer to Test 10.

Test 7. Remove air line from discharge port of relay valve controlling non-working air
chamber. Install test air gauge into relay valve discharge port. Apply service brake.
• If 40-100 psi (276-689 kPa) is present, repair or replace air line between air
chamber and relay valve. Refer to paragraph 13-23 in this manual.
• If 40-100 psi (276-689 kPa) is not present, go to Test 8.

2-364
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Remove air line 623 for No. 2 axle or air line 660 from control port of relay valve for
axles No. 3 and 4. Install test air gauge onto air line. Apply service brakes.
• If 40-100 psi (276-689 kPa) is not present, go to Test 10.
• If 40-100 psi (276-689 kPa) is present, go to Test 9.

Test 9. Check air line on supply port of non-working relay valve for restriction or damage
(No. 536 for axle No. 2 and No. 014 for axles No. 3 and 4).
• If restricted or damaged, replace air line. Refer to paragraph 13-23 in this
manual.
• If not restricted or damaged, go to Test 10.

2-365
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Remove stop light switch from left side of brake treadle valve (upper switch for axles
No. 3 and 4, lower switch for axle No. 2). Install test air gauge and apply service
brake. If 40-100 psi (276-689 kPa) are available, replace air line between treadle
valve and relay valve. Refer to paragraph 13-17 or 13-18 for LVSA1 vehicles in this
manual.
• If 40-100 psi (276-689 kPa) are not available, replace brake treadle valve. Refer
to paragraph 13-14 in this manual.

END OF TEST

2-366
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

13. Service Brakes Will Not Release Or Release Slowly

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check air pressure gauge for 100-120 psi (689-826 kPa).
• If 100-120 psi (689-826 kPa) is not present, go to Malfunction 1.
• If only one indicator on dash gauge reads 100-120 psi (689-826 kPa), go to
Malfunction 18.
• If 100-120 psi (689-826 kPa) is present on both indicators of dash gauge, go to
Test 2.

GAUGE

2-367
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check air lines, brake chambers, relay valves and treadle valve for leaks or damage.
• If leaking or damaged, repair or replace as needed.
• If no leaks or damage are found, go to Test 3.

WARNING

BLOCK WHEELS TO PREVENT MOVEMENT AND PERSONAL INJURY WHEN


PARKING BRAKE IS RELEASED.

Test 3. Release parking brake, check that all air chambers retract completely. Clevis locknut
should be even with mounting bracket.
• If any air chamber does not retract completely, go to Malfunction 15.
• If all air chambers retract completely, go to Test 4.

2-368
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check brake adjustment. Refer to paragraph 13-4 for axle No. 1 and paragraph 13-5
for axles No. 2, 3 and 4.
• If brakes are not adjusted properly, adjust them.
• If brakes are adjusted properly, go to Test 6.

Test 5. Apply and release service brake. Remove air line 623 for axle No. 2 or air line 660
for axles No. 3 and No. 4 at the control port of suspect relay valve.
• If air flow is present at suspect line, replace treadle valve. Refer to paragraph
13-14 in this manual.
• If air flow is not present, reconnect air line and go to Test 6.

2-369
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Apply and release service brake. Remove air line from service port of suspect air
chamber.
• If air escapes, replace relay valve. Refer to paragraphs 13-15 and 13-16 in this
manual.
• If no air escapes, go to Test 7.

2-370
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Remove brake drum. Check S-cams or wedges for binding. Check brake shoe return
springs for proper operation. Refer to paragraph 13-6 for axle No. 1. Refer to
paragraphs 13-8 and 13-10 for axles No. 2, 3 and 4.
• If any of the above problems are found, repair as needed.

END OF TASK

2-371
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

14. Pressure Drops More Than 25 Psi (172 KPa) on Air Pressure Gauge When Brakes are
Applied
WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check for 100-120 psi (689-826 kPa) on air pressure gauge.
• If 100-120 psi (689-826 kPa) is not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is present, go to Test 2.

Test 2. Check air chambers, air lines, relay valves and treadle valve for leaks or damage.
• If leaks or damage are found, repair or replace as needed.
• If no leaks or damage are found, go to Test 3.

GAUGE

2-372
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Apply service brakes and note which indicator drops more than 25 psi (172 kPa).
Green - axles No. 1 and 2, red - axles No. 3 and 4.
• If both indicators drop 25 psi (172 kPa) or more, troubleshoot both systems using
Test 4 and Test 6.
• If only one indicator drops 25 psi (172 kPa) or more, troubleshoot the affected
system using Test 4 thru Test 6.

GAUGE

2-373
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Remove air line from control port of affected relay valve. Install test air gauge onto
air line. Apply service brake.
• If air pressure drops over 25 psi (172 kPa) on air pressure gauge, leave air gauge
installed and go to Test 5.
• If air pressure does not drop on air pressure gauge, go to Test 6.

2-374
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Remove stop light switch from brake treadle valve (lower switch - axles No. 1 and 2,
upper switch - axles No. 3 and 4). Install a second test air gauge in stop light switch
port. Apply service brake.
• If air pressure drops 25 psi (172 kPa) at air pressure gauge and both test gauges
read the same, replace brake treadle valve. Refer to paragraph 13-14 in this
manual.
• If air pressure gauge drops 25 psi (172 kPa) and relay valve test gauge reads
lower than the treadle valve test gauge, repair or replace air line between treadle
valve and relay valve. Refer to paragraph 13-23 in this manual.

2-375
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Remove air line from service brake port of suspect brake chamber. Install test air
gauge. Apply service brake.
• If air pressure gauge drops 25 psi (172 kPa), repeat test at each brake chamber
connected to the relay valve. If all brake chambers test the same, replace relay
valve. Refer to paragraphs 13-15 and 13-16 in this manual.
• If air pressure gauge does not drop, replace that brake chamber. Refer to
paragraph 13-12 in this manual.

NOTE
Axle No. 1 brake chambers do not have a relay valve. Test them in the same manner as Test 6,
except if air pressure drops, then repair or replace air line. Refer to paragraph 13-23 in this
manual.

END OF TEST

2-376
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

15. Parking Brakes Will Not Release

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check for 100-120 psi (689-826 kPa) on air pressure gauge.
• If 100-120 psi (689-826 kPa) are not present, go to Malfunction 1.
• If 100-120 psi (689-826 kPa) is present on only one indicator of dash gauge, go to
Malfunction 18.
• If 100-120 psi (689-826 kPa) is present, go to Test 2.

GAUGE

2-377
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check air lines, fittings, valves and brake chambers for leaks or damage.
• If damage or leaks are found, repair or replace as needed.
• If no damage or leaks are found, go to Test 3.

Test 3. Remove spring brake air line from non-working brake chamber. Install test air gauge
onto air line. Release parking brake.
• If 100-120 psi (689-826 kPa) is present, replace brake chamber. Refer to
paragraph 13-12 in this manual.
• If 100-120 psi (689-826 kPa) is not present, go to Test 4.

Test 4. Remove air line from suspect spring brake discharge port of relay valve. Install test
air gauge into discharge port. Release parking brake.
• If 100-120 psi (689-826 kPa) is present, repair or replace air line between brake
chamber and relay valve. Refer to paragraph 13-23 in this manual.
• If 100-120 psi (689-826 kPa) is not present, go to Test 5.

2-378
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Remove air line from control port of suspected relay valve (No. 612 for axle No. 2,
No. 622 for axles No. 3 and 4). Install test air gauge into air line. Release parking
brake.
• If 100-120 psi (689-826 kPa) is present, go to Test 6.
• If 100-120 psi (689-826 kPa) is not present, go to Test 7.

Test 6. Carefully loosen air line on supply port of suspected relay valve (No. 607 for No. 2
axle, No. 620 for axles No. 3 and 4).
• If air escapes, replace relay valve. Refer to paragraphs 13-15 and 13-16 in this
manual.
• If no air escapes, repair or replace air line between relay valve air manifold and
air reservoir. Refer to paragraph 13-23 in this manual.

2-379
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Carefully loosen air line 612 on parking brake control valve. Release parking brake
(push valve in).
• If air escapes, repair or replace air line between control valve and relay valve.
Refer to paragraph 13-23 in this manual.
• If no air escapes, go to Test 8.

Test 8. Carefully loosen air supply line 611 on parking brake control valve.
• If air escapes, replace control valve. Refer to paragraph 13-21 in this manual.
• If no air escapes, go to Test 9.

2-380
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Carefully loosen air line 611 at air manifold (by front glad hands).
• If air escapes, repair or replace air line 611. Refer to paragraph 13-23 in this
manual.
• If no air escapes, go to Test 10.

Test 10. Check air lines 618 and 614 for kinks or damage.
• If kinks or damage is not found, go to Test 11.
• If kinks or damage is found, repair or replace lines as needed.

Test 11. Carefully remove air line 614 at air manifold.


• If air escapes, go to Test 12.
• If no air escapes, repair or replace air line 614 between air reservoir and air
manifold. Refer to paragraph 13-23 in this manual.

Test 12. Carefully remove air line 618 at air manifold.


• If air escapes, replace both check valves. Refer to paragraph 13-24 in this
manual. If problem still exists, replace air manifold. Refer to paragraph 13-24 in
this manual.
• If no air escapes, repair or replace air line 618 between air reservoir and air
manifold. Refer to paragraph 13-23 in this manual.

END OF TEST

2-381
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

16. Parking Brake Will Not Apply

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

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

Test 2. Pull parking brake control knob to apply parking brake.


• If all parking brakes do not apply, go to Test 6.
• If some apply and one or more do not apply, go to Test 3.

2-382
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Loosen air line to the spring chamber that does not apply.
• If brake applies, go to Test 5.
• If brake does not apply, go to Test 4.

Test 4. Apply service brakes and watch actuator linkage.


• If linkage moves and brake applies, replace brake chamber. Refer to paragraph
13-12 in this manual.
• If linkage does not move, remove brake drum and repair or replace brake parts as
needed.

Test 5. Release and apply parking brake. Carefully loosen air line to the control port of the
affected relay valve (air line No. 612 for axle No. 2 or air line No. 622 for axles No. 3
or 4).
• If no air escapes, replace relay valve. Refer to paragraphs 13-15 and 13-16 in this
manual.
• If air escapes, replace parking brake control valve. Refer to paragraph 13-21 in
this manual.

END OF TEST

2-383
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-384
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

17. Air Pressure Gauge Indicators Do Not Read The Same

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check for 100-120 psi (689-826 kPa) on either indicator of the air pressure gauge.
• If 100-120 psi (689-826 kPa) are not present on either indicator, go to
Malfunction 1.
• If 100-120 psi (689-826 kPa) is present on one indicator but not the other, go to
Test 2.

Test 2. Check all air lines, valves, reservoirs and air chambers for leaks or damage.
• If leaks or damage are found, repair or replace as needed.
• If no leaks or damage are found, go to Test 3.

Test 3. Determine which system has low pressure.


• If green indicator is low, go to Test 4 for primary system.
• If red indicator is low, go to Test 12 for secondary system.

2-385
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-386
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Drain air system and disconnect air line 610 at rear of air pressure gauge. Install test
air gauge into air line No. 610. Start engine and build air pressure. Refer to TM
08780B-10.
• If 100-120 psi (689-826 kPa) is present on test air gauge, replace air pressure
gauge. Refer to paragraph 24-3 in this manual.
• If 100-120 psi (689-826 kPa) is not present, go to Test 5.

2-387
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Disconnect and plug air line No. 619 at brake treadle valve. Start engine and build air
pressure. Refer to TM 08780B-10.
• If green indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
brake treadle valve. Refer to paragraph 13-10 in this manual.
• If green indicator does not read 100-120 psi (689-826 kPa), go to Test 6.

2-388
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Disconnect and plug air line No. 614 at air manifold near the front glad hands. Start
engine and build air pressure. Refer to TM 08780B-10.
• If green indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
check valve in manifold. Refer to paragraph 13-28 in this manual.
• If green indicator does not read 100-120 psi (689-826 kPa), go to Test 7.

2-389
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Disconnect air line No. 619 at left air tank of the MK48. Install test air gauge into air
tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line No.
614, 619 or 610 as needed. Refer to paragraph 13-23 in this manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 8.

2-390
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Disconnect and plug air line No. 536 at service brake relay valve. Start engine and
build air pressure. Refer to TM 08780B-10.
• If green indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
relay valve. Refer to paragraph 13-15 in this manual.
• If green indicator does not read 100-120 (689-826 kPa), go to Test 9.

2-391
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Disconnect air line No. 536 from left air tank on MK48. Install test air gauge into air
tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If green indicator on air pressure gauge reads 100-120 psi (689-826 kPa), repair or
replace air line No. 536. Refer to paragraph 13-23 in this manual.
• If green indicator does not read 100-120 psi (689-826 kPa), go to Test 10.

Test 10. Disconnect air line No. 613 from left air tank on MK48. Install test air gauge onto
air line. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace inlet check
valve or air tank. Refer to paragraph 13-34 in this manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 11.

2-392
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 11. Disconnect air line No. 003 from front air tank on MK48. Install test air gauge into
air tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line No.
003 or pressure protection valve as needed. Refer to paragraphs 13-23 and 13-19
in this manual.

2-393
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

WARNING
TO PREVENT PERSONAL INJURY, MAKE SURE ALL AIR PRESSURE IS DRAINED
BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 12. Disconnect air line No. 041 from air pressure gauge. Install test air gauge onto air
line No. 041. Start engine. Refer to TM 08780B-10. Build air pressure.
• If test gauge reads 100-120 psi (689-826 kPa), replace air pressure gauge. Refer
to paragraph 25-3 in this manual.
• If test gauge does not read 100-120 psi (689-826 kPa), go to Test 13.

GAUGE

2-394
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 13. Remove air line No. 006 from bulkhead fitting. Install test air gauge into air line No.
006. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), go to Test 14.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 18.

Test 14. Remove air line No. 041 from bulkhead fitting. Install test air gauge into bulkhead
fitting. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line No.
041 between bulkhead fitting and air gauge. Refer to paragraph 13-23 in this
manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 15.

Test 15. Remove air line No. 027 from bulkhead fitting and install a plug into bulkhead fitting.
Start engine and build air pressure. Refer to TM 08780B-10.
• If red indicator reads 100-120 psi (689-826 kPa), go to Test 16.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 17.

GAUGE

2-395
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-396
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 16. Disconnect and plug air line No. 027 at trailer brake hand control valve. Start engine
and build air pressure. Refer to TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
control valve. Refer to paragraph 13-39 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), repair or replace air line
No. 027 between control valve and bulkhead fitting. Refer to paragraph 13-23 in
this manual.

Test 17. Remove air line No. 073 from bulkhead fitting and install a plug into the bulkhead
fitting. Start engine and build air pressure. Refer to TM 08780B-10.
• if red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), refer to the
specific malfunction for the windshield wipers, windshield washers, air horn or
axle lockup as needed.
• If red indicator does not read 100-120 psi (689-826 kPa) replace bulkhead fitting.
Refer to paragraph 13-27 in this manual.

2-397
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-398
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 18. Disconnect air line No. 005 from right air tank on MK48. Install test air gauge into
air tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If test air gauge reads 100-120 psi (689-826 kPa), repair or replace air line No.
005 and/or No. 006 as needed. Refer to paragraph 13-23 in this manual.
• If test air gauge does not read 100-120 psi (689-826 kPa), go to Test 19.

Test 19. Disconnect air line No. 618 from right air tank on MK48. Install plug into air tank
and test air gauge onto air line No. 618. Start engine and build air pressure. Refer to
TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), repair or
replace air line No. 618 and/or check valve at manifold. Refer to paragraphs
13-23 and 13-28 in this manual.
• If test air gauge reads any pressure, replace check valve at manifold. Refer to
paragraph 13-28 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 20.

WARNING

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


BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 20. Disconnect air line No. 621 from right air tank. Install plug into air tank. Start
engine and build air pressure. Refer to TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), go to Test
21.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 22.

2-399
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-400
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 21. Disconnect air line No. 014 at quick disconnect near articulation joint on trailer. Start
engine and build air pressure. Refer to TM 08780B-10.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 22.
• If red indicator reads 100-120 psi. (689-826 kPa), go to Test 23.

Test 22. Disconnect air line No. 621 from spring brake manifold. Install plug into air line.
Start engine and build air pressure. Refer to TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
spring brake valve. Refer to paragraph 13-20 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), repair or replace air line
621 between spring brake valve and air tank. Refer to paragraph 13-23 in this
manual.

2-401
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 23. Disconnect air line No. 014 at left air tank of trailer. Install plug onto air line. Start
engine and build air pressure. Refer to TM 08780B-10.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 24.
• If red indicator reads 100-120 psi (689-826 kPa), repair or replace air line 014
and/or shut off valve between air tank and quick disconnect. Refer to paragraph
13-23 in this manual.

2-402
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 24. Disconnect air line No. 014 from outlet side of right air tank on trailer. Install plug
into air tank. Start engine and build air pressure. Refer to TM 08780B-10.
• If red indicator does not read 100-120 psi (689-826 kPa), go to Test 25.
• If red indicator reads 100-120 psi (689-826 kPa), repair or replace right or left air
tank and/or inter-connecting air line No. 014 as needed. Refer to paragraph
13-33, 13-34 or 13-23.

2-403
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 25. Disconnect air line No. 014 at service brake relay valve on trailer. Install plug onto
air line. Start engine and build air pressure. Refer to TM 08780B-10.
• If red indicator on air pressure gauge reads 100-120 psi (689-826 kPa), replace
relay valve. Refer to paragraph 13-16 in this manual.
• If red indicator does not read 100-120 psi (689-826 kPa), repair or replace air line.
Refer to paragraph 13-23 in this manual.

END OF TEST

2-404
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

18. Dryer Constantly Cycling or Purging

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check air system for leaking or damaged air lines, fittings, valves, air tanks or air
chambers.
• If leaks or damage are found, repair or replace as needed. Refer to Chapter 13.
• If no leaks or damage are found, go to Test 2.

Test 2. Check system air pressure for too high or too low a reading on air pressure gauge.
• If reading is not 100-120 psi (689-826 kPa), adjust governor. Refer to paragraph
13-37 in this manual.
• If reading is 100-120 psi (689-826 kPa), go to Test 3.

GAUGE

2-405
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for leaking purge valve in air dryer.


• If leaking, repair or replace as needed. Refer to paragraph 13-38 in this manual.

END OF TEST

2-406
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

19. Safety Valve on Air Dryer Releasing Air

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check for plugged or saturated desiccant cartridge. Refer to paragraph 13-38 in this
manual.
• If plugged or saturated, service air dryer. Refer to paragraph 13-38 in this
manual.
• If not plugged or saturated, go to Test 2.

Test 2. Check for damaged or leaking check valve between air dryer and front air reservoir.
• If leaking or damaged, replace check valve. Refer to paragraph 13-38 in this
manual.
• If not leaking or damaged, replace safety valve on air dryer. Refer to paragraph
13-38 in this manual.

END OF TEST

2-407
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-408
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

20. Air Dryer Does Not Purge

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check system air pressure gauge for 100-120 psi (689-826 kPa).
• If gauge reads between 100-120 psi (689-826 kPa), go to Test 2.
• If gauge does not read between 100-120 psi (689-826 kPa), adjust governor.
Refer to paragraph 13-37 in this manual.

GAUGE

2-409
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for damaged or leaking purge control air line No. 126.
• If damaged or leaking, repair or replace air line as needed. Refer to paragraph
13-23 in this manual.
• If not damaged or leaking, replace purge valve. Refer to paragraph 13-38 in this
manual.

END OF TEST

2-410
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

21. Desiccant Material Expelled From Purge Valve

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

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


DRAINED BEFORE REMOVING ANY AIR LINE OR AIR COMPONENT.

Test 1. Check that air dryer is properly mounted.


• If air dryer is loose and vibrating, repair as needed. Refer to paragraph 13-38 in
this manual.
• If air dryer is not loose, go to Test 2.

Test 2. Check desiccant for oil and/or anti-freeze contamination.


• If contaminated with oil or anti-freeze, send to Direct Support/Intermediate (Third
Echelon) Maintenance.
• If not contaminated, go to Test 3.

Test 3. Check heater and thermostat as follows:


1. Cool end cover to below 40 degrees F (4 degrees C).
2. Check for 24 volts on dryer terminal.
• If not present go to Electrical troubleshooting in this section of the manual.
• If 24 volts are present, replace end cover. Refer to paragraph 13-38 in this
manual.

END OF TEST

2-411
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-412
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

HYDRAULIC STEERING SYSTEM

CAUTION

ALWAYS REINSTALL PROTECTIVE CAPS ON HYDRAULIC FITTINGS AFTER


TESTING IS COMPLETE. FAILURE TO DO SO WILL ALLOW DIRT AND MOISTURE
TO ENTER HYDRAULIC FITTINGS.

1. Vehicle Steers Hard in One or Both Directions

WARNING

• TO PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR


OF VEHICLE WHEN YAW STEERING IS BEING USED. SPECIAL CARE MUST
BE TAKEN WHEN PERSONNEL ARE NEAR THE ARTICULATION JOINT.

• TIRE PRESSURE MUST BE CHECKED PROPERLY OR SERIOUS INJURY OR


DEATH MAY OCCUR.

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


• If not correct, service tire.
• If correct, go to Test 2.

Test 2. Make sure selector valve is in the steering position.


• If not in, push valve to the steering position.
• If in the steering position, go to Test 3.

GAUGE

2-413
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check for correct oil level and type. Refer to LI 2320-1219, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 4.

Test 4. Check for hydraulic leaks and damaged lines that may cause oil flow restrictions.
• If lines leak or are damaged, repair as needed.
• If no leak or damage is found, go to Test 5.

Test 5. Disconnect steering linkage from input side of steering gear. Refer to paragraph 15-
14 in this manual. Turn steering wheel in both directions and check for binding in
column or 90° gear boxes.
• If binding is found, repair or replace as needed. Refer to paragraphs 15-5, 15-6,
15-11 or 15-12 as needed.
• If no binding is found, go to Test 6.

2-414
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check for binding or damage to tie rod on front axle.


• If binding or damage is found, repair or replace as needed. Refer to paragraph
15-8 in this manual.
• If no binding or damage is found, go to Test 7.

Test 7. Check front axle ball and socket assemblies for binding or damage.
• If binding or damage is found, send to Direct Support, Intermediate (Third
Echelon) Maintenance.
• If no binding or damage is found, go to Test 8.

2-415
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check bellcranks, pitman arm and drag links for binding or damage.
• If binding or damage is found, repair or replace as needed. Refer to paragraphs
15-7, 15-9 and 15-10 in this manual.
• If no binding or damage is found, go to Test 9.

2-416
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Check power steering gear for looseness or damage.


• If power steering gear is loose or damaged, send to Direct Support, Intermediate
(Third Echelon) Maintenance.
• If power steering gear is not loose or damaged, go to Test 10.

2-417
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Check yaw control valve and yaw cylinders for damage.
• If damaged, repair or replace as needed. Refer to paragraphs 23-6 and 23-8 in this
manual.
• If no damage is found, go to Test 11.

Test 11. Check fuse link and yaw feedback linkage for looseness or damage.
• If loose or damaged, repair or replace as needed. Refer to paragraph 15-13 and
15-15 in this manual.
• If not loose or damaged, go to Test 12.

2-418
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 12. Check articulation joint for damage.


• If damage is found, send to Direct Support, Third Echelon, Maintenance.
• If no damage is found, go to Test 13.

Test 13. Check steering and front alignment.


• If steering and front alignment are correct, refer to Direct Support, Third Echelon,
Maintenance.
• If steering and front alignment are not correct, perform front alignment. Refer to
paragraph 15-17 in this manual.

END OF TEST

2. Front Wheels Turn, Yaw Cylinders Do Not Move

WARNING

TO PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR OF


VEHICLE WHEN YAW STEERING IS BEING USED. SPECIAL CARE MUST BE TAKEN
WHEN PERSONNEL ARE NEAR THE ARTICULATION JOINT.

2-419
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 1. Make sure selector valve is in the STEERING position.


• If not in STEERING position, push valve to STEERING.
• If in STEERING, go to Test 2.

NOTE
Vehicle must either be in gear or have parking brake released to have yaw steering.

GAUGE

2-420
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for correct oil level and type. Refer to LI 2320-1219, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 3.

Test 3. Check for hydraulic leaks and damaged lines that may cause oil flow restrictions.
• If leaks or damage are found, repair as needed.
• If no leaks or damage are found, go to Test 4.

Test 4. Check for damaged bellcrank, pitman arm and drag link.
• If damage is present, repair or replace damaged parts as needed. Refer to
paragraphs 15-10, 15-9 and 15-7 in this manual.
• If no damage is present, go to Test 5.

2-421
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check yaw control valve and yaw cylinders for damage.
• If damaged, repair or replace as needed. Refer to paragraphs 23-5 and 23-8 in this
manual.
• If no damage is found, go to Test 6.

Test 6. Check yaw feedback linkage for damage and proper adjustment.
• If damaged, repair or replace parts as needed. Refer to paragraph 15-13 in this
manual. If not adjusted properly refer to paragraph 15-17 in this manual.
• If no damage or misadjustment is found, go to Test 7.

2-422
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check fuse link for looseness or damage.


• If loose or damaged, repair or replace as needed. Refer to paragraph 15-15 in this
manual.
• If not loose or damaged, go to Test 8.

Test 8. Check articulation joint for damage.


• If damage is found, send to Direct Support, Intermediate (Third Echelon)
Maintenance for yaw steering repairs.
• If no damage is found, send to Direct Support, Intermediate (Third Echelon)
Maintenance.

END OF TEST

2-423
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Front Wheels Will Not Turn In Either Direction

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

Test 2. Check for hydraulic leaks and damaged lines that may cause oil flow restrictions.
• If leaks or damaged lines are present, repair as needed.
• If no leak or damage is found, go to Test 3.

GAUGE

2-424
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Disconnect steering linkage from input side of steering gear. Refer to paragraph
15-14 in this manual. Turn steering wheel in both directions and check for binding in
column or 90° gear boxes.
• If binding is found, repair or replace components as needed. Refer to paragraphs
15-5, 15-6, 15-11 or 15-12 in this manual as needed.
• If no binding is found, go to Test 4.

2-425
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check for binding or damage to tie rod on front axle.


• If binding or damage is found, repair or replace as needed. Refer to paragraph
15-8 in this manual.
• If no binding or damage is found, go to Test 5.

Test 5. Check front axle ball and socket assemblies for binding or damage.
• If binding or damage is found, send to Direct Support, Intermediate (Third
Echelon) Maintenance.
• If no binding or damage is found, go to Test 6.

2-426
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check bellcranks, pitman arm and drag links for binding or damage.
• If binding is found, repair or replace components as needed. Refer to paragraphs
15-7,15-9 and 15-10 in this manual.
• If no binding or damage is found, refer to Direct Support, Intermediate (Third
Echelon) Maintenance.

END OF TEST

4. Steering is Oversensitive

Test 1. Check bellcrank, pitman arm and drag links for binding or damage.
• If binding or damage is found, repair or replace components as needed. Refer to
paragraphs 15-7, 15-9 and 15-10 in this manual.
• If no binding or damage is found, go to Test 2.

2-427
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check yaw control valve for damage.


• If damaged, repair or replace as needed. Refer to paragraph 23-5 in this manual.
• if no damage is found, go to Test 3.

2-428
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check fuse link and yaw feedback linkage for looseness or damage.
• If loose or damaged, repair or replace as needed. Refer to paragraph 15-13 and
15-15 in this manual.
• If not loose or damaged, go to Test 4.

Test 4. Check steering and front alignment.


• If steering and front alignment is correct, refer to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If steering and front alignment is not correct, perform front alignment. Refer to
paragraph 15-17 in this manual.

END OF TEST

5. Vehicle Wanders

WARNING

TO PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR OF


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

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


• If not correct, service tire.
• If correct, go to Test 2.

Test 2. Check bellcrank, pitman arm and drag links for looseness, binding or damage.
• If binding or damage is found, repair or replace components as needed. Refer to
paragraph 15-7, 15-9 and 15-10 in this manual.
• If no binding or damage is found, go to Test 3.

Test 3. Check power steering gear for looseness or damage.


• If power steering gear is loose or damaged, send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If power steering gear is not loose or damaged, go to Test 4.

2-429
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-430
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check yaw control valve and yaw cylinders for damage.
• If damaged, repair or replace components as needed. Refer to paragraphs 23-5
and 23-8 in this manual.
• If no damage is found, go to Test 5.

2-431
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check fuse link and yaw feedback linkage for looseness or damage.
• If loose or damaged, repair or replace as needed. Refer to paragraphs 15-13 and
15-15 in this manual.
• If not loose or damaged, go to Test 6.

Test 6. Check articulation joint for damage.


• If damage is found, send to Direct Support, Intermediate (Third Echelon)
Maintenance.
• If no damage is found, go to Test 7.

2-432
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Disconnect steering linkage from input side of steering gear. Refer to paragraph
15-14 in this manual. Turn, steering wheel in both directions and check for binding
or looseness in column or 90° gear boxes.
• If binding or looseness is found, repair or replace components as needed. Refer to
paragraph 15-5, 15-6, 15-11 or 15-12 as needed.
• If no binding or looseness is found, go to Test 8.

2-433
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for binding, looseness or damage to tie rod on front axle.
• If binding, looseness or damage is found, repair or replace as needed. Refer to
paragraph 15-8 in this manual.
• If no binding, looseness or damage is found, go to Test 9.

Test 9. Check front axle ball and socket assemblies for binding, looseness or damage.
• If binding, looseness or damage is found, send to Direct Support, Intermediate
(Third Echelon) Maintenance.
• If no binding, looseness or damage is found, go to Test 10.

Test 10. Check steering and front alignment.


• If steering and front alignment is correct, refer to Direct Support, Intermediate
(Third Echelon) Maintenance.
• If steering and front alignment is not corrects perform front alignment. Refer to
paragraph 15-17 in this manual.

END OF TEST

2-434
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

WINCH MK15/MK15A1

CAUTION

ALWAYS REINSTALL PROTECTIVE CAPS ON HYDRAULIC FITTINGS AFTER


TESTING IS COMPLETE. FAILURE TO DO SO WILL ALLOW DIRT AND MOISTURE
TO ENTER HYDRAULIC FITTINGS.

Winch Will Not Operate In One or Both Directions

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

• ENGINE MAY CRANK AND START DURING TROUBLESHOOTING TESTS. TO


PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR
BEFORE TURNING IGNITION SWITCH TO START POSITION.

NOTE
• Ignition switch must be in ON position for all voltage tests.

• Electrical system voltage (22 to 30 volts) will be written as 24 volts in this section of the
manual.

• Auxiliary hydraulic selector valve must be in the auxiliary hydraulic position.

Test 1. Check hydraulic oil level.


• Add hydraulic oil as needed. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If hydraulic oil level is correct, go to Test 2.

2-435
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Place manual-off-remote switch in the manual position. Without a load on the winch
line, operate the winch in and out.
• If winch does not operate, go to Test 4.
• If winch does operate properly, go to Test 3.

Test 3. Place manual-off-remote switch in the remote position. Using the remote control
unit, operate the winch in and out.
• If high idle engages and lever moves on the main control panel without operating
the winch, refer to Test 6 above.
• If high idle does not engage or lever on main control panel does not move, send to
Direct Support, Third Echelon, Maintenance.

2-436
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Unplug connector MC20 and check for 24 volts at pin A.


• If 24 volts are not present, refer to MK16 WINCH troubleshooting Malfunction 1,
Test 17.
• If 24 volts are present, refer to CRANE ELECTRIC troubleshooting, Malfunction
1.

END OF TEST

2-437
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

WINCH MK16/MK16A1

CAUTION

ALWAYS REINSTALL PROTECTIVE CAPS ON HYDRAULIC FITTINGS AFTER


TESTING IS COMPLETE. FAILURE TO DO SO WILL ALLOW DIRT AND MOISTURE
TO ENTER HYDRAULIC FITTINGS.

Winch Will Not Operate In One or Both Directions

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TESTS.

• ENGINE MAY CRANK AND START DURING TROUBLESHOOTING TESTS. TO


PREVENT PERSONAL INJURY, MAKE SURE ALL PERSONNEL ARE CLEAR
BEFORE TURNING IGNITION SWITCH TO START POSITION.

NOTE
• Ignition switch must in ON position for all voltage tests.

• Electrical system voltage (22 to 30 volts) will be written as 24 volts in this section of the
manual.

Test 1. Check hydraulic oil level.


• Add hydraulic oil as needed. Refer to LI 2320-1219, LO 9-2320-297-12.
• If hydraulic oil level is correct, go to Test 2.

Test 2. Check all hoses and fittings for leaks or damage.


• If leaks or damage are found, replace hose or fitting. Refer to paragraph 23-14 in
this manual.
• If no leaks or damage are found, go to Test 3.

2-438
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove cap from connector and check for 24 volts at wire 844 (pin B) on both sides
of connector MC19.
• If 24 volts are present, go to Test 4.
• If 24 volts are not present, go to Test 6.

2-439
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Connect remote control unit to vehicle’s connector. Unplug connector MC21 at
control valve. Depress and hold winch OUT button. Check for 24 volts on wire 681
pin No. 3. Depress and hold winch IN button. Check for 24 volts on pin No. 4.
• If 24 volts are present on both pins, go to Test 5.
• If 24 volts are not present on both pins, go to Test 6.

Test 5. Check for continuity at wires 435 (pin 1 and 2) and ground at connector MC21.
• If continuity is found, refer problem to Direct Support/Intermediate Maintenance
(Third Echelon).
• If continuity is not found, repair or replace wire(s) 435 between connector MC21
and ground. Refer to paragraph 7-48 in this manual.

2-440
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Remove remote control’s top cover. Check for 24 volts at wire 844 on terminal
NC. 1 of winch OUT switch.
• If 24 volts are not present, go to Test 16.
• If 24 volts are present, go to Test 7.

Test 7. Check for 24 volts at jumper wire 279 on terminal No. 4 of winch OUT switch.
• If 24 volts are not present, repair or replace wire 279 between terminals No. 4 and
NC 1. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 8.

Test 8. Press and hold winch OUT switch. Check for 24 volts on terminal No. 3 of winch
OUT switch.
• If 24 volts are not present, replace winch OUT switch.
• If 24 volts are present, go to Test 9.

Test 9. Depress and hold winch OUT switch. Check for 24 volts at wire 279 on terminal
NC2 of winch IN switch.
• If 24 volts are present, go to Test 10.
• If 24 volts are not present, repair or replace jumper wire 279 between No. 3
terminal on winch OUT switch and terminal NC2 on winch IN switch. Refer to
paragraph 7-48 in this manual.

Test 10. Depress and hold winch OUT switch. Check for 24 volts at NC1 on winch IN switch.
• If 24 volts are present, go to Test 11.
• If 24 volts are not present, replace winch IN switch. Refer to paragraph 7-48 in
this manual.

Test 11. Check for 24 volts at NC2 terminal of winch OUT switch.
• If 24 volts are present, go to Test 12.
• If 24 volts are not present, replace winch OUT switch. Refer to paragraph 19-4 in
this manual.

Test 12. Check for 24 volts at terminal No. 3 on winch IN switch.


• If 24 volts are present, go to Test 13.
• If 24 volts are not present, repair jumper wire between winch IN and winch OUT
switch. Refer to paragraph 19-4 in this manual.

2-441
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 13. Depress and hold winch IN switch. Check for 24 volts at terminal No. 4 on winch IN
switch.
• If 24 volts are present, go to Test 14.
• If 24 volts are not present, replace winch IN switch. Refer to paragraph 19-4 in
this manual.

2-442
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
Do Test 14 to check winch IN circuit. Do Test 15 to check winch OUT circuit.

Test 14. Check for 24 volts at wire 682 (pin A) at both sides of connector MC19 with winch
IN switch depressed.
• If 24 volts are present, repair or replace wire 682 between connector MC19 and
connector MC21. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 682 between terminal No. 4 on
winch IN switch and connector MC19.

Test 15. Check for 24 volts at wire 681 (pin C) at both sides of connector MC19 with winch
OUT switch depressed.
• If 24 volts are present, repair or replace wire 681 between connector MC19 and
connector MC21. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, repair or replace wire 681 between connector MC19
and connector MC21. Refer to paragraph 7-48 in this manual.

Test 16. Check both sides of connector MC19 for 24 volts on wire 844 (pin B).
• If 24 volts are present on both sides of connector MC19, repair or replace wire
844 between connector MC19 and winch control switch. Refer to paragraph 7-48
in this manual.
• If 24 volts are present on one side of connector MC19 and not on the other side,
clean, repair or replace connector MC19. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 17.

2-443
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 17. Check both sides of connector MC18 for 24 volts on wire 844 (pin N).
• If 24 volts are present on both sides of connector MC18, repair or replace wire
844 between connector MC18 and connector MC19. Refer to paragraph 7-48 in
this manual.
• If 24 volts are present on one side of connector MC18 and not on the other side,
clean, repair or replace connector MC18 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 18.

Test 18. Check both sides of connector MC6 for 24 volts on wire 844 (pin 8).
• If 24 volts are present on both sides of connector MC6, repair or replace wire 844
between connector MC6 and connector MC18. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present on one side of connector MC6 and not on the other side,
clean, repair or replace connector MC6 as needed. Refer to paragraph 7-48 in this
manual.
• If 24 volts are not present, go to Test 19.

2-444
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 19. Check for 24 volts at wire 844 at circuit breaker No. 12.
• If 24 volts are present, repair or replace wire 844 between circuit breaker 12 and
connector MC6.
• If 24 volts are not present, go to Test 20.

Test 20. Check for 24 volts at input terminal at circuit breaker No. 12.
• If 24 volts are present, replace circuit breaker No. 12.
• If 24 volts are not present, go to Test 21.

2-445
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 21 . Check for 24 volts at wire No. 640 at input terminal at circuit breaker No. 11.
• If 24 volts are present, replace buss bar connecting circuit breaker No. 11 and No.
12. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 22.

2-446
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 22. Check for 24 volts on wire 640 at ignition switch.


• If 24 volts are present, repair or replace wire 640 between ignition switch and
circuit breaker. Refer to paragraph 7-48 in this manual.
• If 24 volts are not present, go to Test 23.

Test 23. Check for 24 volts on wire 431 at ignition switch.


• If 24 volts are present, replace ignition switch.
• If 24 volts are not present, go to Test 24.

Test 24. Check for 24 volts on wire 431 on input side of circuit breaker No. 5.
• If 24 volts are present, repair or replace wire 431 from circuit breaker No. 5 to
ignition switch.
• If 24 volts are not present, go to ELECTRICAL SYSTEM, Malfunction No. 3.

END Of TEST

2-447
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

SUSPENSION

1. Vehicle Wanders or Shimmies

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


• If not correct, service tire.
• If correct, go to Test 2.

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

Test 3. Check shock absorbers for damage or leaks.


• Replace damaged or leaking shock absorber(s). Refer to paragraph 17-3 of this
manual.
• If shock absorbers are not damaged or leaking, go to Test 4.

Test 4. Check torque rod mounting capscrews for damage or looseness.


• Replace or tighten all damaged or loose capscrews. Refer to paragraph 17-4 of
this manual.
• If problem still exists, go to Test 5.

2-448
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for binding or damage to tie rod on front axle.


• If binding or damage is found, repair or replace as needed. Refer to paragraph
15-8 in this manual.
• If no binding or damage is found, go to Test 6.

Test 6. Check tie rod ends, bellcrank, pitman arm and drag links for looseness, binding or
damage.
• If binding or damage is found, repair or replace components as needed. Refer to
paragraphs 15-7, 15-9 and 15-10 in this manual.
• If no binding or damage is found, go to Test 7.

Test 7. Check power steering gear for looseness or damage.


• If power steering gear is loose or damaged, send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If power steering gear is not loose or damaged, go to Test 8.

2-449
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check front axle ball and socket assemblies for looseness, binding or damage.
• If looseness, binding or damage is found, send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If no looseness, binding or damage is found, go to Test 9.

Test 9. Inspect wheel bearings for looseness, binding damage or wear. Refer to paragraph
14-3 or 14-4 in this manual.
• If looseness, binding, damage or wear is found, replace and/or adjust wheel
bearings. Refer to paragraph 143 or 14-4 in this manual.
• If no looseness, binding, damage or wear is found, go to Test 10.

Test 10. Check steering and front alignment.


• If steering and front alignment is correct, refer to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If steering and front alignment is not correct, perform front alignment. Refer to
paragraph 15-17 in this manual.

END OF TEST

2-450
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Vehicle Leans To One Side

Test 1. Check all torque rods for damage.


• Replace all damaged torque rods. Refer to paragraph 17-4 and 17-5 in this
manual.
• If torque rods are not damaged, go to Test 2.

Test 2. Check all torque rod mounting capscrews for damage or looseness.
• Replace or tighten all damaged or loose capscrews. Refer to paragraph 17-4 and
17-5 of this manual.
• If problem still exists, send to Direct Support/Intermediate (Third Echelon)
Maintenance.

END OF TEST

2-451
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

CRANE ELECTRIC- MK15A1 AND MK17A1

1. Crane Does Not Operate

NOTE
• Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches
must be in the ON position for all voltage checks.

• Selector valve must be pulled out.

• Before performing crane troubleshooting procedures, the following items must be


verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Attempt to extend/lower outrigger beams/jack cylinders using crane controls on main
control valve bank.
• If outrigger beams/jack cylinders begin to extend and/or lower, problem is with
the crane electrical system. Refer to Test 3.
• If outrigger beams/jack cylinders do not move, go to Test 2.

2-452
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Push in Hydraulic Pressure Manual Override button and attempt to extend/lower
outrigger beams/jack cylinders, using crane controls on main control valve bank.
• If outrigger beams/jack cylinders begin to extend and/or lower, the problem is
with the crane electrical system or the hydraulic system shutdown solenoid, go to
Test 3.
• If the outrigger beams/jack cylinders do not move, the problem is with the
hydraulic system, go to Test 14.

Test 3. Loosen four screws and clips and open crane junction box cover. Check for 24 volts
between junction box terminal strip, position 1 and known good ground.
• If 24 volts are present, go to Test 8.
• If 24 volts are not present, go to Test 4.

2-453
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Turn the IGNITION switch OFF. Disconnect rear module to crane connector MC20.
Check for 24 volts at wire 840, pin A.
• If 24 volts are present, the rear module electrical system is OK, the problem is in
the crane electrical system. Reconnect crane connector MC20 and go to Test 5.
• If 24 volts are not present, the problem is with the front or rear module electrical
system. Go to CRANE ELECTRIC Troubleshooting, Malfunction 1, Crane
Inoperative, Tests 5.1 through 5.6.

2-454
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for 24 volts between junction box terminal strip, position 2 and known good
ground.
• If 24 volts are present, go to Test 6.
• If 24 volts are not present, repair black wire between terminal strip, position 2 and
crane connector MC20. Refer to the electrical schematics and paragraph 7-48 in
this manual.

Test 6. Check for 24 volts at crane MAIN POWER switch (white wire).
• If 24 volts are present, go to Test 7.
• If 24 volts are not present, repair white wire between terminal strip, position 2 and
crane MAIN POWER switch. Refer to the electrical schematics and paragraph
7-48 in this manual.

Test 7. Check for 24 volts at crane MAIN POWER switch (black wire).
• If 24 volts are present, repair black wire from crane MAIN POWER switch to
terminal strip, position 1. Refer to the electrical schematics and paragraph 7-48 in
this manual.
• Reset crane MAIN POWER switch to OFF then to ON. If 24 volts are found
intermittently, check for shorts in the circuit. If no shorts are found and 24 volts
are still present intermittently or not at all, replace the crane MAIN POWER
switch. Refer to paragraph 21-3 in this manual.

Test 8. Check for 24 volts between junction box terminal strip, position 17 and a known good
ground.
• If 24 volts are present, go to Test 10.
• If 24 volts are not present, go to Test 9.

2-455
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-456
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. With ignition switch in the OFF position, remove the three electrical connectors from
the Overload Shutdown System central unit. Inspect the electrical terminals for
damage or moisture.
• If electrical terminals are damaged or corroded, repair connector(s). Refer to
paragraph 7-48 in this manual.
• If there is moisture inside the connectors, let the connectors dry out. After the
plugs have completely dried out, apply a light coat of dielectric grease to the wire
terminals of the plug. Reassemble the connectors and close the shell tight. Make
sure the cable strain reliefs are tight.
• If the electrical terminals appear to be OK, send to Direct Support/Intermediate
(Third Echelon) Maintenance.

2-457
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Check for 24 volts between junction box terminal strip, position 5 and known good
ground.
• If 24 volts are present, go to Test 13.
• If 24 volts are not present, go to Test 11.

Test 11. Check for 24 volts between shutdown relay, black wire, located in the junction box
and known good ground.
• If 24 volts are present, go to Test 12.
• If 24 volts are not present, repair black wire from terminal strip, position 17, to
shutdown relay. Refer to paragraph 7-48 in this manual.

Test 12. With ignition switch in the OFF position, check for continuity between black wire
and white wire (pins 3 & 4) on shutdown relay located in junction box.
• If no continuity is found, replace shutdown relay. Refer to paragraph 21-3 in this
manual.
• If continuity is found, repair white wire from shutdown relay to terminal strip,
position 5. Refer to paragraph 7-48 in this manual.

Test 13. Remove electrical connector from hydraulic system shutdown solenoid. With
ignition and MAIN POWER switches ON, check for 24 volts between terminals on
solenoid connector, position terminal on terminal 1 and negative terminal on terminal
2.
• If 24 volts are present, replace hydraulic system shutdown solenoid. Refer to TM
08780B-34, paragraph 19-43.
• If 24 volts are not present, repair white wire from terminal strip, position 5, to
hydraulic system shutdown solenoid or black wire from hydraulic system
shutdown solenoid to junction box ground strip. Refer to paragraph 7-48 in this
manual.

Test 14. Check hydraulic lines, hoses and fittings for leaks or damage that could restrict flow.
• If leaking or damaged lines are found, repair or replace lines as needed. Refer to
paragraph 23-14 in this manual.
• If no leaks or damage are found, go to Test 15.

Test 15. Replace crane high pressure hydraulic filter, refer to paragraph 23-7. Start engine and
attempt to extend/lower jack cylinders.
• If jack cylinders operate properly, problem has been corrected.
• If problem remains, send to Direct Support/Intermediate (Third Echelon)
Maintenance.

END OF TEST

2-458
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-459
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Remote Control Does Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in

• NEUTRAL. Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Disconnect remote control cable from remote control hook-up connector on crane
sub-frame. Check for 24 volts between terminal H and known good ground.
• If 24 volts are not present, no power is getting to the remote control cable. There
is an open circuit in the black wire between terminal strip positions 1 and 7 or an
open circuit in the violet wire between terminal strip position 7 and the remote
control hook-up, terminal H. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 2.

2-460
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-461
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Is there continuity measured between remote control hook-up connector, terminal B
and known good ground?
• If continuity is not found, repair green wire between remote control hook-up
connector and ground terminal strip in crane junction box. Refer to paragraph
7-48 in this manual.
• If continuity is found, go to Test 3.

Test 3. Disconnect the remote control cable from the remote control unit. Check the cable
for continuity between the two cable ends on terminals B and H, one at a time.
• If continuity is not found on either location, replace the remote control cable.
• If continuity is found, reconnect the cable to the remote control unit and the
remote control hook-up connector. Then, go to Test 4.

2-462
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Turn MAIN POWER switch to the OFF position. Remove swing controller from
remote control unit for access to EMERGENCY STOP switch. Remove
EMERGENCY STOP switch from remote control unit, but do not disconnect wires.
Refer to paragraph 21-18 in this manual for specific instructions.

CAUTION

DO NOT ALLOW EMERGENCY STOP SWITCH, SWING CONTROLLER WIRES OR


TERMINALS TO CONTACT REMOTE CONTROL UNIT DURING TEST. FAILURE TO
COMPLY MAY RESULT IN DAMAGE TO EQUIPMENT.

Turn MAIN POWER switch to ON position. Check for 24 volts at terminal of wire 4
of EMERGENCY STOP switch.
• If 24 volts are not present, turn MAIN POWER switch OFF and repair wire 4
inside remote control unit between EMERGENCY STOP switch and remote
control unit cable connector.
• If 24 volts are present, go to Test 5.

2-463
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Place EMERGENCY STOP switch in ON position. Check for 24 volts at terminal of
wire 8A of EMERGENCY STOP switch.
• If 24 volts are not present, EMERGENCY STOP switch is faulty. Refer to
paragraph 21-18 in this manual.
• If problem remains, send to Direct Support/Intermediate (Third Echelon)
Maintenance.

END OF TEST

2-464
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-465
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Hoist Does Not Lower With Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Loosen screw and remove connector from hoist DOWN solenoid. Place MAIN
POWER and EMERGENCY STOP switches in ON position. Hold remote control
unit hoist controller in DOWN position and check for 24 volts between solenoid
connector, terminal 1 and known good ground. Connect connector and tighten screw.
• If 24 volts are not present, go to Test 2.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 8.

Test 2. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal G.
• If no continuity is found on terminal G, replace the remote control cable.
• If continuity is found, go to Test 3.

2-466
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove hoist controller from remote control unit. Refer to paragraph 21-18 in this
manual. Place EMERGENCY STOP switch in ON position. Check for continuity
between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8E
Check 2 G 16
Check 3 B 2G

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 4.

2-467
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Tag and mark connectors on hoist controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full UP position No continuity (open)
Check 4 NO to COM Full UP position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 5.

Test 5. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, blue wire, with controller lever in DOWN
position, to known good ground. Turn MAIN POWER switch OFF.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 6.

Test 6. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
16 and known good ground with hoist controller held in the DOWN position. Turn
MAIN POWER switch to the OFF position.
• If 24 volts are not present, repair orange wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 7.

Test 7. Check for continuity between terminal strip, position 16 and hoist DOWN solenoid
connector, position 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 16 and hoist DOWN solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 8.

2-468
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for continuity between hoist DOWN solenoid connector, position 2 and known
good ground.
• If no continuity is found, repair hoist DOWN solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.

Test 9. Perform a resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specification, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

END OF TEST

2-469
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-470
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Hoist Does Not Raise With Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Are the boom up and down and telescope out functions also not working?
• If none of the above listed functions operate, send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If boom up/down and telescope out function properly, go to Test 2.

Test 2. Loosen screw and remove connector from hoist UP solenoid. Place ignition and
EMERGENCY STOP switches in ON position. Hold remote control unit hoist
controller in UP position and check for 24 volts between solenoid connector, terminal
1 and known good ground.
• If 24 volts are not present, go to Test 3.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 9.

Test 3. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal F.
• If no continuity is found on terminal F, replace the remote control cable.
• If continuity is found, go to Test 4.

2-471
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-472
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Remove hoist controller from remote control unit. Refer to paragraph 21-18 in this
manual for specific instructions. Place EMERGENCY STOP switch in ON position.
Check for continuity between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8E
Check 2 F 15
Check 3 B 2G

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 5.

2-473
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Tag and mark connectors on hoist controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full UP position No continuity (open)
Check 4 NO to COM Full UP position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 6.

2-474
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, white wire, with controller lever in UP
position, to known good ground. Turn MAIN POWER switch OFF.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 7.

Test 7. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
15 and known good ground with hoist controller held in the UP position. Turn MAIN
POWER switch to the OFF position.
• If 24 volts are not present, repair black wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 8.

2-475
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-476
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for continuity between terminal strip, position 15 and hoist UP solenoid
connector, terminal 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 15 and hoist UP solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.

Test 9. Check for continuity between hoist UP solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair hoist UP solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 10.

2-477
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Perform a resistance check of solenoid coil. Resistance should between 23.7 and 26.3
ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

END OF TEST

2-478
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

5. Boom Does Not Lower With Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Are the boom up, hoist up and telescope out functions also not working?
• If none of the above listed functions operate, send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If boom up, hoist up and telescope out function properly, go to Test 2.

Test 2. Loosen screw and remove connector from boom DOWN solenoid. Place
EMERGENCY STOP switch in ON position. Hold remote control unit boom
controller in DOWN position and check for 24 volts between solenoid connector,
terminal 1 and known good ground.
• If 24 volts are present, go to Test 3.
• If 24 volts are not present, turn MAIN POWER switch OFF and go to Test 9.

Test 3. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal N.
• If no continuity is found on terminal N, replace the remote control cable.
• If continuity is found, go to Test 4.

2-479
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-480
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Remove boom controller from remote control unit. Refer to paragraph 21-18 in this
manual. Place EMERGENCY STOP switch in ON position. Check for continuity
between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8D
Check 2 N 13
Check 3 B 2F

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 5.

Test 5. Tag and mark connectors on boom controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full UP position No continuity (open)
Check 4 NO to COM Full UP position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 6.

2-481
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-482
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, blue wire, with controller lever in DOWN
position, to known good ground. Turn MAIN POWER switch OFF.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 7.

Test 7. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
13 and known good ground with boom controller held in the DOWN position. Turn
MAIN POWER switch to the OFF position.
• If 24 volts are not present, repair pink wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 8.

2-483
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-484
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for continuity between terminal strip, position 13 and boom DOWN solenoid
connector, terminal 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 13 and boom DOWN solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.

Test 9. Check for continuity between boom DOWN solenoid connector, terminal 2 and
known good ground.
• If no continuity is found , repair boom DOWN solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 10.

Test 10. Perform a resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

END OF TEST

2-485
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-486
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

6. Boom Does Not Raise With Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Are the boom down, hoist up and telescope out functions also not working?
• If none of the above listed functions operate, send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If boom down, hoist up and telescope out function properly, go to Test 2.

Test 2. Loosen screw and remove connector from boom UP solenoid. Place EMERGENCY
STOP switch in ON position. Hold remote control unit boom controller in UP
position and check for 24 volts between solenoid connector, terminal 1 and known
good ground.
• If 24 volts are not present, go to Test 3.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 9.

Test 3. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, socket M.
• If no continuity is found on terminal M, replace the remote control cable.
• If continuity is found, go to Test 4.

2-487
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-488
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Remove boom controller from remote control unit. Refer to paragraph 21-18 in this
manual. Place EMERGENCY STOP switch in ON position. Check for continuity
between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8D
Check 2 M 14
Check 3 B 2F

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 5.

2-489
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Tag and mark connectors on boom controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full UP position No continuity (open)
Check 4 NO to COM Full UP position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.

2-490
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, white wire, with controller lever in UP
position, to known good ground. Turn MAIN POWER switch OFF.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 7.

Test 7. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
14 and known good ground with boom controller held in the UP position. Turn
MAIN POWER switch to the OFF position.
• If 24 volts are not present, repair brown wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 8.

2-491
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-492
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for continuity between terminal strip, position 14 and boom UP solenoid
connector, position 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 14 and boom UP solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.

Test 9. Check for continuity between boom UP solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair boom UP solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 10.

Test 10. Perform a resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

2-493
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-494
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. Boom Does Not Telescope In With Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Loosen screw and remove connector from telescope IN solenoid. Place
EMERGENCY STOP switch in ON position. Hold remote control unit telescope
controller in IN position and check for 24 volts between solenoid connector, terminal
1 and known good ground.
• If 24 volts are not present, go to Test 2.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test B.

Test 2. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal D.
• If no continuity is found on terminal D, replace the remote control cable.
• If continuity is found, go to Test 3.

2-495
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-496
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove telescope controller from remote control unit. Refer to paragraph 21-18 in
this manual. Place EMERGENCY STOP switch in ON position. Check for
continuity between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8B
Check 2 D 12
Check 3 B 2C

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 4.

2-497
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Tag and mark connectors on telescope controller switches. Remove the connectors
from the two controller switches. Check each switch for continuity between the
following switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full OUT position No continuity (open)
Check 4 NO to COM Full OUT position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 5.

2-498
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, white wire, with controller lever in UP
position to known good ground. Turn MAIN POWER switch to the OFF position.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 6.

2-499
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
12 and known good ground with telescope controller held in the IN position. Turn
MAIN POWER switch to the OFF position.
• If 24 volts are not present, repair white wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 7.

2-500
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for continuity between terminal strip, position 12 and telescope IN solenoid
connector, terminal 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 12 and telescope IN solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 8.

Test 8. Check for continuity between telescope IN solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair telescope IN solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 9

Test 9. Perform a resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

END OF TEST

2-501
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

8. Boom Does Not Telescope Out With Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Are the boom up and down and hoist up functions also not working?
• If none of the above listed functions operate send to Direct Support/Intermediate
(Third Echelon) Maintenance.
• If boom up/down and hoist-up function properly, go to Test 2.

Test 2. Loosen screw and remove connector from telescope OUT solenoid. Place MAIN
POWER and EMERGENCY STOP switches in ON position. Hold remote control
unit telescope controller in OUT position and check for 24 volts between solenoid
connector, terminal 1 and known good ground.
• If 24 volts are not present, go to Test 3.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 9.

Test 3. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal C.
• If no continuity is found on terminal C, replace the remote control cable.
• If continuity is found, go to Test 4.

2-502
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-503
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Remove telescope controller from remote control unit. Refer to paragraph 21-18 in
this manual. Place EMERGENCY STOP switch in ON position. Check for
continuity between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8B
Check 2 C 11
Check 3 B 2C

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 5.

2-504
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Tag and mark connectors on telescope controller switches. Remove the connectors
from the two controller switches. Check each switch for continuity between the
following switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full OUT position No continuity (open)
Check 4 NO to COM Full OUT position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 6.

2-505
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, blue wire, with controller in DOWN
position to known good ground. Turn MAIN POWER switch OFF.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 7.

2-506
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
11 and known good ground with telescope controller held in the OUT position. Turn
MAIN POWER switch to the OFF position.
• If 24 volts are not present, repair yellow wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 8.

2-507
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Check for continuity between terminal strip, position 11 and telescope OUT solenoid
connector, terminal 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 11 and telescope OUT solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.

Test 9. Check for continuity between telescope OUT solenoid connector, terminal 2 and
known good ground.
• If no continuity is found, repair telescope OUT solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 10.

Test 10. Perform a resistance check of solenoid coil. Resistance should be 23.7 to 26.3 ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

2-508
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. Crane Will Not Swing Clockwise Using Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Loosen screw and remove connector from swing CW solenoid. Place MAIN
POWER and EMERGENCY STOP switches in ON position. Hold remote control
unit swing controller in CW position and check for 24 volts between solenoid
connector, terminal 1 and known good ground.
• If 24 volts are not present, go to Test 2.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 8.

Test 2. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal L.
• If no continuity is found on terminal, replace the remote control cable.
• If continuity is found, go to Test 3.

2-509
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-510
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove swing controller from remote control unit. Refer to paragraph 21-18 in this
manual. Place EMERGENCY STOP switch in ON position. Check for continuity
between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8C
Check 2 L 10
Check 3 B 2B

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 4.

2-511
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Tag and mark connectors on swing controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full CW position No continuity (open)
Check 4 NO to COM Full CW position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 5.

2-512
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, blue wire, with controller lever to CW
position to known good ground. Turn MAIN POWER switch to OFF position.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 6.

2-513
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position
10 and known good ground with swing controller held in the CW position. Turn
MAIN POWER switch to OFF position.
• If 24 volts are not present, repair tan wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 7.

2-514
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for continuity between terminal strip, position 10 and swing CW solenoid
connector, position 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 10 and swing CW solenoid. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 8.
Test 8. Check for continuity between swing CW solenoid connector, terminal 2 and known
good ground.
• If no continuity is found, repair swing CW solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.
Test 9. Perform a resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

END OF TEST

2-515
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-516
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

10. Crane Will Not Swing Counterclockwise Using Remote Control

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Loosen screw and remove connector from swing CCW solenoid. Place MAIN
POWER and EMERGENCY STOP switches in ON position. Hold remote control
unit swing controller in CCW position and check for 24 volts between solenoid
connector, terminal 1 and known good ground.
• If 24 volts are not present, go to Test 2.
• If 24 volts are present, turn MAIN POWER switch OFF and go to Test 8.

Test 2. Disconnect the remote control cable from the remote control unit and remote control
hook-up connector on crane sub-frame. Check the cable for continuity between the
two cable ends, terminal A.
• If no continuity is found on terminal A, replace the remote control cable.
• if continuity is found, go to Test 3.

2-517
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-518
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove swing controller from remote control unit. Refer to paragraph 21-18 in this
manual. Place EMERGENCY STOP switch in ON position. Check for continuity
between the following locations:

From remote control cable connector pin To controller connector terminal


location: location:
Check 1 H 8C
Check 2 A 9
Check 3 B 2B

• If no continuity is found, repair the wiring within the remote control unit. Refer
to paragraph 7-48 in this manual.
• If continuity is found, go to Test 4.

2-519
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Tag and mark connectors on swing controller switches. Remove the connectors from
the two controller switches. Check each switch for continuity between the following
switch terminal locations, with the controller lever in the position noted:

Switch Terminals: Controller handle Test results:


position:
Check 1 NC to COM Neutral Continuity
Check 2 NO to COM Neutral No continuity (open)
Check 3 NC to COM Full CCW position No continuity (open)
Check 4 NO to COM Full CCW position Continuity

• If the above test results are not obtained, replace switch(es). Refer to paragraph
21-18 in this manual.
• If the above test results are obtained, reinstall the controller switch connectors and
go to Test 5.

2-520
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Connect the remote control cable to the remote control unit and remote control hook-
up connector on crane sub-frame. Turn MAIN POWER switch to ON position.
Check for 24 volts from controller harness, blue wire, with controller lever in CCW
position to known good ground. Turn MAIN POWER switch to OFF position.
• If 24 volts are not present, replace controller circuit card. Refer to paragraph
21-18 in this manual.
• If 24 volts are present, reassemble remote control unit and go to Test 6.

2-521
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Loosen four screws and clips and open crane junction box cover. Turn MAIN
POWER switch to ON position. Check for 24 volts between terminal strip, position 9
and known good ground with swing controller held in the CCW position. Turn
MAIN POWER switch to OFF position.
• If 24 volts are not present, repair red wire between remote control hook-up
connector on crane sub-frame and junction box terminal strip. Refer to paragraph
7-48 in this manual.
• If 24 volts are present, go to Test 7.

2-522
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for continuity between terminal strip, position 9 and swing CCW solenoid
connector, terminal 1.
• If no continuity is found, repair white wire between junction box terminal strip,
position 9 and swing CCW solenoid connector, terminal 1. Refer to paragraph
7-48 in this manual.
• If continuity is found, go to Test 8.

Test 8. Check for continuity between swing CCW solenoid connector, position 2 and known
good ground.
• If no continuity is found, repair swing CCW solenoid ground circuit. Refer to
paragraph 7-48 in this manual.
• If continuity is found, go to Test 9.

Test 9. Perform resistance check of solenoid coil. Resistance should be between 23.7 and
26.3 ohms.
• If coil resistance is not within specifications, send to Direct Support/Intermediate
(Third Echelon) Maintenance for coil replacement.

END OF TEST

2-523
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-524
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

11. Tilt Alarm Does Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

• Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches
must be in the ON position for all voltage checks.

• Tilt alarm must be properly adjusted before troubleshooting is attempted. Refer to


paragraph 21-5 for adjustment procedure.

Test 1. Remove tilt alarm from mounting bracket to gain access to red wire. Are 24 volts
present at red wire on tilt alarm.
• If 24 volts are present, go to Test 2.
• If 24 volts are not present, repair red wire between tilt alarm and terminal 1 in
crane electrical junction box. Refer to paragraph 7-48 in this manual.

2-525
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Does tilt alarm sound when green wire terminal on tilt alarm is jumpered to a known
good ground
• If tilt alarm sounds, go to Test 3.
• If tilt alarm does not sound, replace tilt alarm. Refer to paragraph 21-5 in this
manual.

2-526
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Loosen four screws and clips and open crane junction box cover. Check for
continuity on green wire between tilt alarm switch and tilt alarm.
• If continuity is found, go to Test 4.
• If is not found, repair green wire. Refer to paragraph 7-48 in this manual.

2-527
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Is continuity measured across tilt alarm switch?


• If continuity is found, go to Test 5.
• If continuity is not found, replace tilt alarm switch. Refer to paragraph 21-3 in
this manual.

2-528
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Check for continuity on black wire between tilt sensor wire harness and power
ground block in junction box.
• If continuity is found, go to Test 6.
• If continuity is not found, repair black wire. Refer to paragraph 7-48 in this
manual.

2-529
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check continuity on white wire between tilt sensor wire harness and tilt sensor
switch.
• If continuity is found, go to Test 7.
• If continuity is not found, repair white wire. Refer to paragraph 7-48 in this
manual.

2-530
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for 24 volts at tilt alarm sensor red wire.


• If 24 volts are present, go to Test 8.
• If 24 volts are not present, repair red wire. Refer to paragraph 7-48 in this
manual.

2-531
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Remove green wire at tilt alarm. Are 24 volts present at green wire?
• If 24 volts are present, go to Test 9.
• If 24 volts are not present, replace tilt alarm sensor. Refer to paragraph 21-5 in
this manual.

2-532
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 9. Press down on one corner of the tilt alarm sensor. Does voltage lower on the green
wire from 24 volts to about .6 volts?
• If voltage does not lower from 24 volts, replace tilt alarm sensor. Refer to
paragraph 21-5 in this manual.

END OF TEST

2-533
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

CRANE HYDRAULICS- MK15A1 AND MK17A1

1. Outriggers Beams/Jack Cylinders Do Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Unless advised otherwise, the ignition, MAIN POWER and TILT ALARM switches must be in
the ON position for all voltage checks.

Test 1. Push in Hydraulic Pressure Manual Override button and attempt to extend/lower
outrigger beams/jack cylinders, using crane controls on main control valve bank.
• If outrigger beams/jack cylinders begin to extend and/or lower, the problem is
with the crane electrical system or the hydraulic system shutdown solenoid, go to
Malfunction 1, Crane does not operate, Test 3.
• If the outrigger beams/jack cylinders do not move, go to Test 2.

Test 2. Check hydraulic lines, hoses and fittings for leaks or damage that could restrict flow.
• If leaking or damaged lines are found, repair or replace lines as needed. Refer to
paragraph 23-14 in this manual.
• If no leaks or damage are found, send to Direct Support/Intermediate (Third
Echelon) Maintenance,

END OF TEST

2-534
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Boom Does Not Raise or Lower

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

This malfunction applies when both the remote control and manual control operations are
affected.

Test 1. Are the two hoses and fittings between the BOOM manual control valve and boom
hydraulic cylinders free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 2.

Test 2. Are the three hoses and fittings between the two boom hydraulic cylinders free of
damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, send to Direct Support, Intermediate (Third
Echelon) Maintenance.

END OF TEST

2-535
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-536
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Boom Does Not Telescope

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

This malfunction applies when both the remote control and manual control operations are
affected.

Test 1. Are the hoses and fittings between the TELESCOPE manual control valve and
telescope hydraulic cylinder free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 2.

Test 2. Are the three hoses and fittings going to the telescope hydraulic cylinder free of
damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 3.

Test 3. Attempt to telescope boom out. Check for dry boom wear pads.
• Lubricate dry boom wear pads. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If boom wear pads are OK or boom sections cannot be telescoped out, send to
Direct Support/Intermediate (Third Echelon) Maintenance.

END OF TEST

2-537
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-538
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Hoist Does Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

This malfunction applies when both the remote control and manual control operations are
affected.

Test 1. Are tubes, hoses and fittings between the HOIST manual control valve and hoist
hydraulic motor manifold free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 2.

Test 2. Are the hoses and fittings between the hoist hydraulic motor manifold and the hoist
brake free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 3.

Test 3. Are the hoses and fittings between the hoist hydraulic motor and the return line tee
fitting free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, send to Direct Support/Intermediate (Third
Echelon) Maintenance.

END OF TEST

2-539
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-540
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

5. Crane Does Not Swing

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

This malfunction applies when both the remote control and manual control operations are
affected.

Test 1. Are tubes, hoses and fittings between the SWING manual control valve and swing
hydraulic motor manifold free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 2.

Test 2. Are the hoses and fittings between the swing hydraulic motor manifold and the swing
brake free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, go to Test 3.

Test 3. Are the hoses and fittings between the swing hydraulic motor and the return line tee
fitting free of damage, crimps or leaks?
• If leaks or damaged lines are found, repair as needed.
• If no leaks or damage are found, send to Direct Support/Intermediate (Third
Echelon) Maintenance.

END OF TEST

2-541
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-542
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

6. Mast Does Not Raise or Lower

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Push in Hydraulic Pressure Manual Override button and attempt to raise/lower mast,
using crane controls on main control valve bank.
• If mast begins to raise and/or lower, go to Malfunction 1, Crane does not operate,
Test 3.
• If the mast does not move, go to Test 2.

Test 2. Check hydraulic lines, hoses and fittings for leaks or damage that could restrict flow.
• If leaking or damaged lines are found, repair or replace lines as needed. Refer to
paragraph 23-14.
• If no leaks or damage are found, send to Direct Support/Intermediate (Third
Echelon) Maintenance.

END OF TEST

2-543
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-544
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

CRANE ELECTRIC

CAUTION

ALWAYS REINSTALL PROTECTIVE CAPS ON HYDRAULIC FITTINGS AFTER


TESTING IS COMPLETE. FAILURE TO DO SO WILL ALLOW DIRT AND MOISTURE
TO ENTER HYDRAULIC FITTINGS.

1. Crane Inoperative

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Make sure the transmission is in NEUTRAL.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

• Make sure ignition switch is in ON position.

• Make sure MANUAL-OFF-REMOTE switch is in MANUAL position.

Test 1. See if the selector valve is in the Auxiliary Hydraulics position.


• If not, pull selector valve to the Auxiliary Hydraulics position.
• If correct, go to Test 2.

GAUGE

2-545
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for low hydraulic oil at reservoir.


• If low, add hydraulic as required. Refer to LI 2320-12/9, LO 9-2320-297-12 for
correct oil type and amount.
• If level is correct, go to Test 3.

2-546
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Check hydraulic lines, hoses and fittings for leaks or damage that could restrict flow.
• If leakage or damaged lines are present, repair or replace lines as needed. Refer
to paragraph 23-14 in this manual.
• If no leaks or damage is present, go to Test 4.

Test 4. Move electrical failure valve to the CLOSED position.


• If crane will now operate manually, go to Test 5.
• If crane will not operate manually, send to Direct Support/Intermediate (Third
Echelon) Maintenance.

2-547
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Unplug connector MC20 on main power cable. Check for 24 volts on pin A.
• If 24 volts are not present, go to Test 5.1.
• If 24 volts are found, go to Test 6.

2-548
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

NOTE
When told to check both sides of a plug or connector, probe both the male and female parts.
Probe from the rear of the plug or connector, at the wire or pin called for in the test. This will
check the continuity of the plug or connector and let you know if it is usable or needs repair.

Unless told to do so in the test being done, do not disconnect plug or connector.

Test 5.1. Check for 24 volts on both sides of connector MC18, wire 840 (pin F).
• If 24 volts are found on both sides of connector MC18, repair or replace wire 840
between connector MC18 and MC20. Refer to paragraph 7-48 in this manual.
• If 24 volts are found on one side of connector MC18 and not on the other side,
clean, repair or replace connector MC18 as needed. Refer to paragraph 7-48 in
this manual.
• If 24 volts are not present, go to Test 5.2.

2-549
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5.2. Check for 24 volts on wire 840 terminal of relay No. 4.
• If 24 volts are not present, go to Test 5.3.
• If 24 volts are present, repair or replace wire 840 between connector MC18 and
relay No. 4. Refer to paragraph 7-48 in this manual.

Test 5.3. Check for 24 volts on wire 840A terminal of Relay No. 4.
• If 24 volts are not present, go to Test 5.4.
• If 24 volts are present, go to Test 5.6.

Test 5.4. Check for 24 volts on wire 840A terminal of circuit breaker No. 13.
• If 24 volts are not present, go to Test 5.5.
• If 24 volts are present, repair or replace wire 840A between circuit breaker No. 13
and relay No. 4. Refer to paragraph 7-48 in this manual.

Test 5.5. Check for 24 volts on wire 736A terminal of circuit breaker No. 13.
• If 24 volts are not present, repair or replace wire 736A between circuit breaker
No. 13 and circuit breaker No. 4. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, replace circuit breaker No. 13. Refer to paragraph 7-14 in
this manual.

Test 5.6. Check for 24 volts on wire 735 terminal of relay No. 4.
• If 24 volts are not present, repair or replace wire 735 between relay No. 4 and
circuit breaker No. 8. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 5.7.

2-550
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5.7. Check ground (wire 843) of relay No. 4.


• If ground wire is bad, repair or replace ground wire 843. Refer to paragraph 7-48
in this manual.
• If ground wire is good, replace relay No. 4. Refer to paragraph 7-28 in this
manual.

2-551
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Remove cover from junction box. Check for 24 volts on input side of circuit breaker
No. 1.
• If 24 volts are not present, repair or replace wire between circuit breaker No. 1
and pin A of connector MC20. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 7.

Test 7. Check for 24 volts on output terminal of circuit breaker No. 1.


• If 24 volts are not present, replace circuit breaker. Refer to paragraph 20-10 in
this manual.
• If 24 volts are present, go to Test 8.

2-552
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 8. Pull boot back and check for 24 volts on black wire on the neutral switch at the
electrical failure valve.
• If 24 volts are not present, repair or replace black wire between circuit breaker
No. 1 and neutral switch. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to Test 9.

Test 9. Check for 24 volts on brown wire at neutral switch on electrical failure valve.
• If 24 volts are not present, replace neutral switch. Refer to paragraph 20-8 in this
manual.
• If 24 volts are present, go to Test 10.

Test 10. Unplug connectors at crane wire harness. Leading into the solenoid dump valve.
Check female connector on harness side for 24 volts.
• If 24 volts are not present, send to Direct Support/Intermediate (Third Echelon)
Maintenance.
• If 24 volts are present, go to Test 11.

Test 11. Unplug connector at crane wire harness leading into the solenoid dump valve. Check
continuity between male connector on harness side and a known good ground.
• If continuity is not found, go to Test 12.
• If continuity is found, replace solenoid dump valve. Refer to paragraph 20-20 in
this manual.

2-553
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 12. Disconnect male connector at crane wire harness leading into remote actuator box.
Check continuity between male connector and a good ground.
• If continuity is not found, go to Test 13. Leave connector disconnected.
• If continuity is found, send to Direct Support/Intermediate (Third Echelon)
Maintenance.

Test 13. Check continuity between male connector and terminal No. 3 on terminal board
No. 2.
• If continuity is not found, repair or replace white wire between male connector
and terminal No. 3. Refer to paragraph 7-48 in this manual.
• If continuity is found, go to Test 14.

2-554
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 14. Unplug connector MC20 on main power cable. Check for continuity between pin B
on chassis side of harness and ground.
• If continuity is not found, repair or replace wire 435 between pin B and ground.
• If continuity is found, go to Test 15. Leave connector MC20 disconnected.

Test 15. Check for continuity between pin B on crane side of connector MC20 and terminal
No. 3 of terminal board No. 2.
• If continuity is not found, repair or replace white wire/and or jumper wire
between pin B of connector MC20 and terminal No. 3. on terminal board No. 2.
• If continuity is found, send to Direct Support/Intermediate (Third Echelon)
Maintenance.

END OF TEST

2-555
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Remote Control Does Not Work

WARNING

TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE SURE


THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET BEFORE
PERFORMING ANY TROUBLESHOOTING TESTS.

NOTE
Unless called for in test being done, all electrical tests will be done with ignition switch ON,
selector valve - in auxiliary position (OUT) and crane unstowed.

Test 1. Check that manual-off-remote switch is in remote position.


• If switch is not in correct position, move to remote position.
• If switch is in correct position, go to Test 2.

Test 2. Check that electrical failure valve is in open (vertical) position.


• If not in correct position, move valve handle to vertical position.
• If in correct position, go to Test 3.

2-556
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Perform remote control bypass test.


Step 1. Remove remote control and cable from stowage compartment.
Step 2. At remote control stowage compartment, remove test plug from stowage
receptacle by pushing up on latch.
Step 3. Install test plug into cable receptacle and lock in place with latch.

CAUTION
TEST PLUG BUTTON SHOULD ONLY BE PRESSED BRIEFLY, PROLONGED
APPLICATION OF BUTTON WILL RESULT IN DAMAGED ACTUATOR BOX WIRING.

Step 4. Have helper briefly press in red button on test plug. Check that all control
levers are locked into center (neutral) position. A resistance should be felt and
levers will have little movement. These levers should be in a straight line.
• If any lever will not lock or does not line up, refer to Direct
Support/Intermediate (Third Echelon) Maintenance.
• If all levers lock and are lined up, go to test 4:

Test 4. Connect a known good remote control cable to remote control and connector.
Perform pre-operational safety check steps 8 through 12. Refer to para 2-16 or 2-32
in TM 08780B-10.
• If the remote control does not operate, contact Direct Support/Intermediate (Third
Echelon) Maintenance for repair of remote control.
• If remote control now operates, replace remote control cable.

END OF TEST

2-557
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Capacity Alert System Does Not Work (Crane Overload Protection)

NOTE
• Unless called for in test, all electrical tests will be done with ignition switch ON,
selector valve in auxiliary position (OUT) and crane unstowed.

• Remove capacity alert proximity switch and housing. Manually engage switch. Refer
to paragraph 20-5 in this manual.

Test 1. Make sure manual-off-remote switch is in manual position.


• If not in manual position, place switch in manual position.
• If switch is in manual position, go to Test 2.

Test 2. Make sure electrical failure valve is in open position (vertical).


• If not in open (vertical), open valve.
• If electrical failure valve is open (vertical), go to Test 3.

2-558
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Remove cover from junction box. Check for 24 volts on input side of circuit breaker
No. 2 (black wire).
• If 24 volts are present, go to Test 4.
• If 24 volts are not present, repair or replace black jumper wire between circuit
breakers number 1 and 2. Refer to paragraph 7-485 in this manual.

Test 4. Check for 24 volts on output terminal of circuit breaker No. 2.


• If 24 volts are not present, replace circuit breaker. Refer to paragraph 20-10 in
this manual.
• If 24 volts are present, go to Test 5.

Test 5. Check for 24 volts on terminal 1 of terminal block No. 1.


• If 24 volts are not present, repair or replace wire between circuit breaker No. 2
and terminal No. 1 of terminal board No. 1. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present, go to Test b.

2-559
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Remove insulation from proximity switch on folding boom. Refer to paragraph 20-5
in this manual. Check for 24 volts on brown/green wire.
• If 24 volts are not present, repair brown/green wire between proximity switch and
terminal 1 of terminal block No. 1. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, insulate brown/green wire and go to Test 7.

2-560
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Check for continuity between blue/white wire and terminal No. 3 on terminal board
No. 2.
• If no continuity is found, repair white wire between proximity switch and terminal
No. 3 on terminal board No. 2. Refer to paragraph 7-48 in this manual.
• If continuity is found, reinsulate wires and go to Test 8.

Test 8. Remove black wire from relay terminal 85 in junction box. Using meter probe, pierce
the insulation at the black wire of proximity switch on folding boom. Check
continuity of black wire between proximity switch and end of wire.
• If no continuity is found, repair black wire. Refer to paragraph 7-48 in this
manual.
• If continuity is found, reconnect wire at relay and go to Test 9.

Test 9. Using a jumper wire, connect terminal 85 of relay to terminal 3 of terminal block No.
2. Remove black wire from relay terminal 30. Turn ignition ON and check for 24
volts on relay terminal 30.
• If 24 volts are present, replace proximity switch. Refer to paragraph 20-5 in this
manual.
• If 24 volts are not present, remove jumper wire, reconnect black wire to relay, an
go to Test 10.

2-561
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 10. Remove black wire from relay terminal 86. Check for 24 volts on black wire.
• If 24 volts are not present, repair or replace black wire between terminal 1 of
terminal block No. 1 and relay terminal 86. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present, reconnect black wire and go to Test 11.

Test 11. Remove black wire from relay terminal 87. Check for 24 volts on black wire.
• If 24 volts are not present, repair or replace black wire between terminal 1 on
terminal block No. 1 and relay terminal 87. Refer to paragraph 7-48 in this
manual.
• If 24 volts are present, reconnect black wire and go to Test 12.

Test 12. Remove black wire from relay terminal 85. Using a jumper wire, connect terminal 85
to terminal 3 on terminal block No. 2. Remove black wire from relay terminal 30.
Check for 24 volts on relay terminal 30.
• If 24 volts are not present, replace relay. Refer to paragraph 20-9 in this manual.
• If 24 volts are present, go to Test 13.

2-562
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 13. Check for 24 volts on pin A of capacity alert solenoid dump valve connector.
• If 24 volts are not present, repair or replace black wire between relay terminal 30
and pin A. Refer to paragraph 7-48 in this manual.
• If 24 volts are present, go to test 14.

Test 14. Check for continuity between ground and pin B of capacity alert solenoid dump valve
connector.
• If continuity is not found, repair or replace white wire between pin B and terminal
7 of terminal block No. 2. Refer to paragraph 7-48 in this manual.
• If continuity is found, send to Direct Support, Third Echelon, Maintenance.

END OF TEST

2-563
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

CRANE HYDRAULICS - MK15 AND MK17

CAUTION

ALWAYS REINSTALL PROTECTIVE CAPS ON HYDRAULIC FITTINGS AFTER


TESTING IS COMPLETE. FAILURE TO DO SO WILL ALLOW DIRT AND MOISTURE
TO ENTER HYDRAULIC FITTINGS.

1. Crane Functions are Slow

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Transmission in neutral.

• Make sure hydraulic steering system is functioning properly.

• Make sure the front power units electrical system is functioning properly.

Test 1. See if the selector valve is in the Auxiliary Hydraulics position.


• If not, pull selector valve to the Auxiliary Hydraulics position.
• If correct, go to Test 2.

GAUGE

2-564
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 3.

Test 3. Check hydraulic line, hoses and fittings for leaks or damage that could restrict flow.
• If leakage or damaged lines are present, repair or replace lines as needed. Refer
to paragraph 23-14 in this manual.
• If no leakage or damage is present, go to Test 4.

Test 4. Check auxiliary hydraulic relief pressure, refer to paragraph 23-3 in this manual.
• If pressure is correct, go to Test 5.
• If pressure is not correct, adjust as required to obtain operating pressure, go to
Test 5.
• If adjustment cannot be obtained, refer problem to Direct Support/Intermediate
(Third Echelon) Maintenance.

Test 5. Check main crane relief pressure. Refer to paragraph 20-33 of this manual.
• If pressure is correct, refer problem to Direct Support/Intermediate (Third
Echelon) Maintenance.
• If pressure is not correct, adjust as required to obtain operating pressure.
• If adjustment cannot be obtained, refer problem to Direct Support/Intermediate
(Third Echelon) Maintenance.

END OF TEST

2-565
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2. Outrigger Beams Will Not Extend or Retract or Operate Slowly

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied.

• Transmission in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2324-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

Test 2. See if the selector valve is fully engaged in the Auxiliary Hydraulics position.
• If not, pull selector valve to the Auxiliary Hydraulics position.
• If correct, go to Test 3.

Test 3. See if the MANUAL/REMOTE switch is in the MANUAL position.


• If not, move switch to MANUAL.
• If switch is in MANUAL, go to Test 4.

2-566
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. See if the STABILIZER CYLINDER LOCK valve is in the LOCK position.
• If not, move to the LOCK position.
• If in the LOCK position, go to Test 5.

2-567
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. See if the STABILIZER EXTENSION lock valve is in the UNLOCK position.
• If not, move to the UNLOCK position.
• If in the UNLOCK position, go to Test 6.

2-568
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

2-569
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check stabilizer controls for full travel and smoothness (lack of binding).
• If controls do not operate properly, refer to paragraphs 20-30 and 20-31 in this
manual.
• If controls operate properly, go to Test 7.

NOTE
If outrigger beams will not extend, go to Test 7. If outrigger will not retract, go to Test 9.

Test 7. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge at test port on main control valve.
Start engine and allow to run at idle. Operate NEAR SIDE and FAR SIDE stabilizer
controls to fully extend outrigger beams. Check for 1,550-1,650 psi (10,687-11,377
kPa) at 130-150°F (54-66°C) reservoir temperature.
• If pressure is within specifications, go to Test 8.
• If pressure is not within specifications, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

Test 8. Inspect hoses, lines and fittings for damage or leaks.


• If damage or leakage are present, repair or replace parts as needed. Refer to
paragraph 23-14 in this manual.
• If damage or leaks are not present, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

Test 9. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge at test port on main control valve.
Start engine and allow to run at idle. Operate NEAR SIDE and FAR SIDE stabilizer
control levers to fully retract outrigger beams. Check for 3,000 psi (20,685 kPa) at
130-150°F (54-66°C) reservoir temperature.
• If pressure is within specifications, go to Test 10.
• If pressure is not within specifications, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

Test 10. Inspect STABILIZER SELECTOR/LOCKING control valves, cylinders and lines for
damage or leaks.
• If damage or leaks are present, repair or replace parts as needed. Refer to
paragraphs 20-13, 20-14, 20-30, 20-31 and 23-14 in this manual.
• If damage or leaks are not present, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

2-570
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

GAUGE

GAUGE

2-571
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

3. Stabilizer Leg Will Not Extend or Retract or Operates Slowly

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

GAUGE

2-572
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. See if the selector valve is fully engaged in the Auxiliary Hydraulics position.
• If not, pull selector valve to the Auxiliary Hydraulics position.
• If correct, go to Test 3.

Test 3. See if the MANUAL/REMOTE switch is in the MANUAL position.


• If not, move switch to MANUAL.
• If switch is in MANUAL, go to Test 4.

2-573
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. See if the STABILIZER EXTENSION LOCK valve is in the LOCK position.
• If not, move to the LOCK position.
• If in the LOCK position, go to Test 5.

2-574
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. See if the STABILIZER CYLINDER lock valve is in the UNLOCK position.
• If not, move to the UNLOCK position.
• If in the UNLOCK position, go to Test 6.

2-575
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Check stabilizer controls for full travel and smoothness (lack of binding).
• If controls do not operate properly, refer to paragraph 20-32 in this manual.
• If controls operate properly, go to Test 7.

NOTE
If the stabilizer will not extend or moves slowly, continue to Test 7. If the stabilizer will not
retract or moves slowly, go to Test 9.

Test 7. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and allow to run at idle speed. Operate STABILIZER controls to fully
extend stabilizers. Check for 1,550-1,650 psi (10,687-11,377 kPa) at 130-150°F (54-
66°C) reservoir temperature.
• If pressure is within specifications, go to Test 8.
• If pressure is not within specifications, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

Test 8. Check for blockage or restrictions in supply lines, lock valves, return lines and
manifold.
• If blockage or restrictions are found, repair or replace parts as needed. Refer to
paragraphs 23-14, 20-22, 20-18 and 20-19 in this manual.
• If blockage or restrictions are not found, refer to Direct Support/Intermediate
(Third Echelon) Maintenance.

Test 9. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and allow to run at idle speed. Operate STABILIZER controls to fully
retract stabilizers. Check for 2,500-3,500 psi (17,237.5-24,132.5 kPa) at 130-150°F
(54-66°C) reservoir temperature.
• If pressure is within specifications, go to Test 10.
• If pressure is not within specifications, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

Test 10. Check for blockage or restrictions in supply lines, lock valves, return lines and
manifold.
• If blockage or restrictions are found, repair or replace parts as needed. Refer to
paragraphs 23-14, 20-22, 20-18 and 20-19 in this manual.
• If blockage or restrictions are not found, refer to Direct Support/Intermediate
(Third Echelon) Maintenance.

END OF TEST

2-576
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

GAUGE

GAUGE

2-577
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. Stabilizer Legs Will Not Hold Load

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

GAUGE

Test 2. Inspect all stabilizer CYLINDER LOCK AND EXTENSION LOCK valves for
damage, restrictions and blockage.
• If valve damage, restrictions or blockage are not present, go to Test 3.
• If valves are not functioning properly, repair or replace defective valves. Refer to
paragraphs 20-22, 20-23 and 20-24 in this manual.

2-578
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Inspect stabilizer for damage.


• if damage is present, replace stabilizer. Refer to paragraph 20-15 in this manual.
• If damage is not present, go to Test 4.

Test 4. Inspect hoses, lines and fittings for leaks.


• If leakage is present, repair or replace parts as needed. Refer to paragraph 23-14.
• If no leakage is present, go to Test 4.1.

Test 4.1. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and run at idle speed. Operate STABILIZER controls to fully extend
stabilizers. Check for 1,550-1,650 psi (10,687-11,377 kPa) at 130-150°F (54-66°C)
reservoir temperature.
• If pressure is within specifications, go to Test 5.
• If pressure is not within specifications, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

Test 5. Remove line from piston side of stabilizer leg and lockout valve. Install a 0-2,000 psi
(0-13,790 kPa) pressure gauge in line between stabilizer leg and lockout valve.
Extend stabilizer leg and close lockout valve. Check pressure gauge and record
reading. Have assistant operate control valve to extend stabilizer leg. Check pressure
gauge and record pressure reading.
• If pressure increase is noted, replace lockout valve. Refer to paragraph 20-22.
• If no pressure increase is noted; replace stabilizer cylinder. Refer to paragraph
20-19.

END OF TEST

GAUGE

2-579
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

5. Crane Will Not Rotate, Rotates Slowly or Rotates In Only One Direction

NOTE
• Before performing crane troubleshooting procedures, the following items must be
verified:

• Make sure the PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

GAUGE

2-580
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. See if MANUAL/REMOTE switch is in the desired operating function.


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

Test 3. See if the crane is overloaded.


• If crane is overloaded, reduce crane’s reach or load.
• If crane is not overloaded, go to Test 4.

Test 4. Check for binding at crane base.


• If binding is present, refer to Direct Support/Intermediate (Third Echelon)
Maintenance.
• If binding is not present, go to Test 5.

2-581
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 5. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and let run at idle. Operate ROTATION control lever fully in each
direction. Check in each direction for 2,700-2,800 psi (18,616.5-19,306 kPa) at 130-
150°F (54-66°C) reservoir temperature.
• If pressure is within specifications, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.
• If pressure is not within specifications, inspect hoses, lines and fittings for leaks
or damage. If no damage or leaks are found, refer to Direct Support/Intermediate
(Third Echelon) Maintenance.

END OF TEST

GAUGE

GAUGE

2-582
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

6. Main Boom Will Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical-system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

GAUGE

2-583
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. See if REMOTE/MANUAL switch is in the desired operating function.


• If in the REMOTE position and the main boom still will not operate, refer to
CRANE ELECTRICAL troubleshooting in this section of the manual.
• If in the MANUAL position and the main boom still will not operate, go to Test 3.

Test 3. Check MAIN BOOM control for full travel and smoothness (lack of binding).
• If control does not operate properly, refer to paragraphs 20-30 in this manual.
• If controls operate properly, go to Test 4.

Test 4. See if the crane is overloaded.


• If crane is overloaded, reduce crane’s reach or load.
• If crane is not overloaded, go to Test 5.

Test 5. Check for binding at the boom cylinder or restrictions in the lines.
• If binding or restrictions are present, lubricate cylinder or replace lines. Refer to
Lubrication Instruction (LI 2320-12/9, LO 9-2320-297-12) or paragraph 23-14 in
this manual.
• If binding or restrictions are not present, go to Test 6.

NOTE
If the main boom will not move upward, continue to Test 6. If the main boom will not lower,
go to Test 7.

Test 6. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and let run at idle. Lift MAIN BOOM control lever fully up. Check for
2,700-2,800 psi (18,616.5-19,306 kPa) at 130-150°F (54-66°C) reservoir temperature.
• If pressure is within specifications and boom still will not move or moves slowly,
go to Test 7.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3.

2-584
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

GAUGE

GAUGE

2-585
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and let run at idle. Hold MAIN BOOM control lever fully down. Check
for 2,450-2,550 psi (16,892.8-17,582.2 kPa) at 130-150°F (54-66°C) reservoir
temperature.
• If pressure is within specifications and boom still will not move or moves slowly,
check capacity alert system for proper operation. Refer to CRANE
ELECTRICAL troubleshooting in this section of the manual.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3.

END OF TEST

GAUGE

GAUGE

2-586
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. Folding Boom Will Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure the PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. See if the selector valve is in the Auxiliary Hydraulics position.


• If not, pull selector valve to the Auxiliary Hydraulics position.
• If correct, go to Test 2.

GAUGE

2-587
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 3.

Test 3. See if the MANUAL/REMOTE switch is in the desired operating function.


• If in the REMOTE position and the folding boom still will not operate, refer to
CRANE ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the folding boom still will not operate, go to Test
4.

2-588
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Check FOLDING BOOM control for full travel and smoothness (lack of binding).
• If control does not operate properly, refer to paragraph 20-31 in this manual.
• If control operates properly, go to Test 5.

Test 5. See if the crane is overloaded.


• If crane is overloaded, reduce crane’s reach or load.
• If crane is not overloaded, go to Test 6.

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


• If binding or restrictions are present, lubricate cylinder or replace lines. Refer to
lubrication instructions (LI 2320-12/9, LO 9-2320-297-12) or paragraph 23-14 in
this manual.
• If binding or restrictions are not present, go to Test 7.

NOTE
If the folding boom will not move upward, continue to Test 7. If folding boom will not lower,
go to Test 8.

2-589
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 7. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and run at idle. Operate FOLDING BOOM control lever to fully raise
the boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-
66°C) reservoir temperature.
• If pressure is within specifications and the folding boom will not move or moves
slowly, go to Test 8.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3 in this manual.

Test 8. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and run at idle. Operate FOLDING BOOM control lever-to fully lower
boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-66°C)
reservoir temperature.
• If pressure is within specifications and boom still will not move or moves slowly,
check capacity alert system for proper operation. Refer to CRANE
ELECTRICAL troubleshooting in this section of the manual.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3 in this manual.

END OF TEST

2-590
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

GAUGE

GAUGE

2-591
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

8. Extension Boom Will Not Operate

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

GAUGE

2-592
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. See if the MANUAL/REMOTE switch is in the desired operating function.


• If in the REMOTE position and the extension booms still will not operate, refer to
CRANE ELECTRICAL troubleshooting in this section of the manual.
• If in the MANUAL position and the extension booms still will not operate, go to
Test 3.

Test 3. Check EXTENSION BOOM control for full travel and smoothness (lack of binding).
• If control does not operate properly, refer to paragraphs 20-31 in this manual.
• If control operates properly, go to Test 4.

2-593
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. See if the crane is overloaded.


• If crane is overloaded, reduce crane’s reach or load.
• If crane is not overloaded, go to Test 5.

Test 5. Check for binding along extension beams and at cylinder. Also check for restriction
in lines.
• If binding or restrictions are present, lubricate extension beams or replace lines.
Refer to Lubrication Instructions (LI 2320-12/9, LO 9-2320-297-12) or paragraph
23-14 in this manual.
• If binding or restrictions are not present, go to Test 6.

2-594
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 6. Install a 0-5,000 psi (0-34,475 kPa) pressure gauge on test port at main control valve.
Start engine and run at idle. Operate EXTENSION BOOM control lever to fully
extend boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-
66°C) reservoir temperature.
• If pressure is within specifications and boom still will not move or moves slowly,
check capacity alert system for proper operation. Refer to CRANE
ELECTRICAL troubleshooting in this section of the manual.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3 in this manual.

END OF TEST

GAUGE

GAUGE

2-595
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. Crane Will Not Lift Load

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 23-3 in this manual.
• If correct, go to Test 2.

Test 2. See if the MANUAL REMOTE switch is in the desired operating function.
• If in the REMOTE position and the crane still will not operate, refer to CRANE
ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the crane still will not operate, go to Test 3.

Test 3. See if the crane is overloaded.


• If crane is overloaded, reduce crane’s reach or load.
• If crane is not overloaded, go to Test 4.

GAUGE

2-596
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 4. Install a 0-5,000 psi (0-34,34,475 kPa) pressure gauge on test port at main control
valve. Start engine and run at idle. Operate FOLDING BOOM control lever to fully
raise boom. Check for 2,950-3,050 psi (20,340.3-21,029.7 kPa) at 130-150°F (54-
66°O reservoir temperature.
• If pressure is within specifications and boom still will not move or moves slowly,
check capacity alert system for proper operation. Refer to CRANE
ELECTRICAL troubleshooting in this section of the manual.
• If pressure is not within specifications, check main crane relief pressure. Refer to
paragraph 20-33. If crane relief pressure cannot be obtained by adjustment, check
auxiliary selector relief setting. Refer to paragraph 23-3 in this manual.

END OF TEST

GAUGE

GAUGE

2-597
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

MK15 A-FRAME HYDRAULICS

A-Frame Cylinder Will Not Operate or Operates Slowly

NOTE
Before performing crane troubleshooting procedures, the following items must be verified:

• Make sure PARKING BRAKE is applied and transmission is in neutral.

• Make sure the hydraulic steering system is functioning properly.

• Make sure the front power unit’s electrical system is functioning properly.

Test 1. See if the selector valve is in the Auxiliary Hydraulics position.


• If not, pull selector valve to the Auxiliary Hydraulics position.
• If correct, go to Test 2.

GAUGE

2-598
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 2. Check for correct oil level and type. Refer to LI 2320-12/9, LO 9-2320-297-12.
• If wrong, change level or oil as needed. Refer to paragraph 22-3 in this manual.
• If correct, go to Test 4.

NOTE
Test 3 not required for LVSA1 series vehicles.

Test 3. See if the MANUAL/REMOTE switch is in the desired operating function.


• If in the REMOTE position and the A-Frame cylinder still will not operate, refer
to CRANE ELECTRICAL troubleshooting, in this section of the manual.
• If in the MANUAL position and the A-Frame cylinder still will not operate, go to
Test 4.

Test 4. Check hydraulic lines, hoses, quick disconnects and fittings for leaks, damage or
loose connections that could restrict flow.
• If damaged or leaking lines are present, repair or replace lines as needed. Refer to
paragraph 23-14 in this manual.
• If no damage or leaks are present, refer to Direct Support/Intermediate (Third
Echelon) Maintenance.

END OF TEST

2-599
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

ANTILOCKING BRAKE SYSTEM

One or Both ABS Warning Lights Come on and Remain on

WARNING

• TO PREVENT YAW STEERING MOVEMENT AND PERSONAL INJURY, MAKE


SURE THAT SHIFT SELECTOR IS IN NEUTRAL AND PARKING BRAKE IS SET
BEFORE PERFORMING ANY TROUBLESHOOTING TEST

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


DRAINED BEFORE REMOVING ANY AIR LINES OR AIR CONNECTIONS

Test 1. Connect Info-Centre to test port on MK48/48A1 or rear body unit, as required.
Verify passenger side sensor is properly connected and positioned by rotating
curbside hub or wheel at a rate of approximately 1 revolution every 2 seconds. Refer
to paragraph 13-43.
• Info-Centre should display a bar in the 2B location, to left of 07 display while
wheel is turning. If not proceed to Test 3.

NOTE
Info-Centre may also lock sensor display by pressing on right hand button on face of Info-
Centre. Display will show WHL to left. You may then spin wheel and display will show S2B to
indicate this sensor is sensing wheel motion. This feature allows one person to perform this
test.

Test 2. Connect Info-Centre to test port on MK48/48Al or rear body unit, as required. Verify
passenger side sensor is properly connected and positioned by rotating curbside hub
or wheel at a rate of approximately 1 revolution every 2 seconds. Refer to paragraph
13-43.
• Info-Centre should display a bar in the 2A location, to left of 07 display while
wheel is turning. If not proceed to Test 3.

NOTE
Info-Centre may also lock sensor display by pressing on right hand button on face of Info-
Centre. Display will show WHL to left. You may then spin wheel and display will show S2A to
indicate this sensor is sensing wheel motion. This feature allows one person to perform this
test.

2-600
TM 08780B-20

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Test 3. Connect Info-Centre to test port on MK48/48Al or rear body unit, as required. Drive
vehicle above 6 miles per hour. ABS indicator lights should remain off. Info-Centre
display code should change from 07 to 00 and sensor indicator bars on each side of
the 00 should be displayed.
• If code other than 00 appears, record the code and follow the procedures for that
code in Table 2-2, Antilocking Brake System Diagnostics Codes.

END OF TEST

2-601
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Table 2-2. Antilocking Brake System Diagnostics Code

CODE MALFUNCTION CORRECTIVE ACTION


06, 07, 8.8, Indicates system is working A 00 with the vehicle moving or 07 while
A4, A5, C 1 stationary indicates that there are no active
faults.

Al-A5 are configuration codes and may not be


present. Ignore these.

8.8 is a self-diagnostics test.

C1 indicates the ABS is a 2S/2M system.


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

Disconnect wire harness from ECU. Check


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

Check harness for damaged pins. Replace cable


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

2-602
TM 08780B-20

Table 2-2. Antilocking Brake System Diagnostics Code (Continued)

CODE MALFUNCTION CORRECTIVE ACTION


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

Check for loose, damaged or corroded sensor


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

Check exhaust port of ABS valve for


obstruction. Clean obstruction and retest
system.

Check primary air system for proper operation.


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

2-603
TM 08780B-20

Table 2-2. Antilocking Brake System Diagnostics Code (Continued)

pin should be between 15-18 ohms. If readings


are not within specifications, replace solenoid.
Retest system.

Check female terminals on connector for


excessive pin spread or corrosion. Clean pins
on terminal as necessary. Replace defective
hardware as required. Retest system.

Check that main wiring harness 28-pin


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

Remove harness from ECU and using a


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

Disconnect harness from ECU and using a


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

If code still exists, replace ECU and retest.


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

2-604
TM 08780B-20

Table 2-2. Antilocking Brake System Diagnostics Code (Continued)

start switch to “OFF” position. Replace


suspected components and retest system.

If code still exists, replace ECU and retest.


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

If power is coming from some where other than


the vehicle electrical system, make sure that test
battery is fully charged or voltage converter has
adequate voltage (21.0 to 33.0 volts) and current
capacity (11 amps).

NOTE
Do not use a battery charger.
92 ABS supply voltage is above Check voltage regulator for proper operation. If
33.1 volts. malfunctioning, replace.

If ABS system is being powered by a source


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

A “CC” code will be displayed during third


consecutive time that a Clear All is attempted.
This is an invitation to Clear Configuration and
should be avoided. If a “CC” is displayed,
power system down and power back up.

2-605
TM 08780B-20

Table 2-2. Antilocking Brake System Diagnostics Code (Continued)

ABS warning light stays on Power up ABS system. ABS warning lamp
permanently. should come on for 2 seconds then go off. If
light stays on, check wiring to light or for a fault
in the ABS system.

Check for diagnostic fault codes. If any code


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

If a 07 is displayed and ECU memory contains a


13, 14, 23, 24, 42 or 43 code, the vehicle must
be driven above 6 mph to cause ABS light to go
out.

If there are no stored faults and a 07 code is


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

If lamp illuminates, check 3-amp fuse connector


for continuity. Replace connectors or fuse as
needed. Retest.

If lamp still doesn’t not illuminate, check


vehicle electrical system for faults.

2-606
TM 08780B-20

Section IV. Maintenance Procedures

2-8. INTRODUCTION

This section describes general procedures that apply to all parts of this manual. To avoid
repetition, these procedures will not be described in specific maintenance sections.

2-9. GENERAL REMOVAL INSTRUCTIONS

a. Work Required. Remove only those parts needing repair or replacement, Do not
disassemble a component any further than needed.

b. Preparation. Before removing any part of the electrical, hydraulic or air systems,
make certain system is not energized or pressurized. Disconnect battery cables. Relieve all
pressure from air system. Make sure brakes are locked and that all controls are in OFF position
before starting any removal procedure.

c. Removal. Make sure there is enough clearance to remove part. Disassemble


truck or adjacent parts as needed to provide working clearance.

d. Lifting. Always use chain hoist, jack or other aid when lifting heavy parts. Make
certain load limit of lifting device exceeds weight being lifted. Position and rig lifting device
before disconnecting part for removal.

e. Identification. Tag or mark all similar parts, such as electrical leads, before
disconnecting and removing such parts. This will make proper assembly easier. Be sure to
identify mating ends of electric, hydraulic and air lines as they are disconnected.

f. Position of Valves. Before removing valve handles, mark or diagram their


positions when open and closed. This will help during assembly.

g. Electrical Wires. Electrical wires are identified on the electrical schematic by a


three digit number. The actual wire may be identified by two digits if number is less than 100.

2-10. GENERAL DISASSEMBLY INSTRUCTIONS

a. Cleanliness. Work area must be kept as clean as possible. This will prevent
contamination of internal parts. This is especially true for valves, cylinders and other hydraulic
or air system parts.

b. Expendable Parts. As indicated in this manual, all gaskets, packings and seals
removed during repair must be discarded and replaced with new parts. These items are usually
damaged during removal. In the same way, all lockwire, lockwashers, cotter pins and like items
must be replaced at time of assembly.

2-607
TM 08780B-20

c. Removing Seals. -When removing gaskets, packings or seals, do not use any
metal tool that will scratch the surfaces next to these items.

d. Disassembly. Before disassembly of any item, study the illustration carefully.


Note relationship of internal parts. Knowing details of a component will speed up disassembly
and assembly and will help avoid mistakes.

e. Parts Protection. To prevent moisture and dirt from entering open housings, lines
and other openings, apply protective caps and plugs as soon as possible after disassembly. Wrap
all removed parts in clean paper or dip parts in preservative oil.

2-11. GENERAL CLEANING INSTRUCTIONS

WARNING

• CLEANING SOLVENTS MAY BE TOXIC TO SKIN, EYES AND RESPIRATORY


TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR
PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY
ADEQUATE.

• NEVER USE GASOLINE TO CLEAN PARTS. GASOLINE IS HIGHLY


FLAMMABLE. SERIOUS PERSONAL INJURY COULD RESULT IF FUEL
IGNITES DURING CLEANING.

CAUTION

• PETROLEUM SOLVENTS MAY DAMAGE PARTS THAT ARE IN CONTACT


WITH HYDRAULIC FLUIDS.

• DO NOT CLEAN TIRES, LUBRICANT SEALS, RUBBER HOSES OR


ELECTRICAL COMPONENTS WITH SOLVENT MIXTURE.

a. Cleaning Solvents. Use only approved cleaning solvents to clean parts. Dry
cleaning solvent, PD 680 is commonly used. Always work in a well ventilated area.

WARNING

COMPRESSED AIR USED FOR CLEANING AND DRYING PURPOSES WILL NOT
EXCEED 30 PSI. USE ONLY WITH EFFECTIVE CHIP GUARDING AND PERSONAL
PROTECTIVE EQUIPMENT (GOGGLES/SHIELD, GLOVES, ETC.).

b. Removing Deposits. After soaking parts in solvent, wash away deposits by


flushing or spraying. Where necessary, brush with a soft bristle brush moistened in solvent. Use
compressed air to dry all parts, except bearings. Bearings must be allowed to air dry.

2-608
TM 08780B-20

c. Tools. Do not use scrapers, wire brushes, abrasive wheels or compounds in


cleaning parts, unless called for in detailed instructions. These procedures may weaken a highly
stressed part.

d. Ball and Roller Bearings. When cleaning ball or roller bearings, place them in a
basket and suspend them in a container of dry cleaning solvent. If needed, use a brush to remove
caked grease, chips, etc. Avoid rotating bearing before solid particles are removed to prevent
damaging races and balls. When bearings have been cleaned, coat them lightly with lubricating
oil to remove solvent.

e. Rubber Parts. Do not clean O-rings or other rubber parts in dry cleaning solvent.
These parts should be wiped clean with a clean, dry, lint-free cloth.

WARNING

STEAM CLEANING CREATES HAZARDOUS NOISE LEVELS AND SEVERE BURN


POTENTIAL. EYE, SKIN AND EAR PROTECTION IS REQUIRED.

f. Exterior Parts. Steam clean all exterior parts thoroughly before removing. This
will make inspection and disassembly easier.

WARNING

SOLVENTS USED WITH A SPRAY GUN MUST BE USED IN A SPRAY BOOTH WITH
FILTER. FACE SHIELD MUST BE USED BY PERSONNEL OPERATING SPRAY GUN.

g. Engine, Cab and Body. Use a spray gun and solvent mixture for cleaning exterior
of engine, cab and body. Allow mixture to remain on item surface for about 10 minutes before
rinsing. Rinse with hot water under 80 to 120 pounds of pressure, if available. An ordinary
garden hose with nozzle may be used if other equipment is not available. Rinse thoroughly.

h. Degreasing Machine. A degreasing machine may be used to remove heavy grease


and oil accumulations from metal parts.

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

CAUTION

TO PREVENT CORROSION, PARTS SHOULD BE DIPPED IN RUST PREVENTIVE


COMPOUND WITHIN TWO HOURS AFTER DEGREASING.

2-609
TM 08780B-20

j. Electrical Parts. Electrical parts, such as coils, junction blocks, switches and
igniters, which use insulating materials, should not be soaked or sprayed with cleaning solutions.
Clean these parts with a clean, lint-free cloth moistened with dry cleaning solvent.

CAUTION

DO NOT USE SOAP OR ALKALIES FOR CLEANING TANK INTERIORS.

k. Oil and Fuel Tanks. Pay special attention to all warnings and cautions when
working on vehicle’s fuel tank. Oil tanks and fuel tanks should be flushed, using a spray gun and
dry cleaning solvent.

l. Battery. Exterior surfaces of the electrical system and battery should be cleaned
with a weak solution of baking soda and water. Apply solution with a bristle brush to remove
any corrosion.

CAUTION
NEVER USE GASOLINE OR OTHER PETROLEUM BASE PRODUCTS TO CLEAN OR
PRESERVE HYDRAULIC SYSTEM PARTS.

m. Hydraulic System. When cleaning hydraulic system parts use dry cleaning
solvent, PD-680. Clean and dry parts thoroughly to make sure that no residue remains. If a
coating of preservative is required before assembly, apply a light film of preservative oil. If
petroleum-free solvents are not available, use the same hydraulic fluid as used in the truck’s
system.

2-12. GENERAL INSPECTION INSTRUCTIONS

a. Sealing Surfaces. Inspect all surfaces in contact with gaskets, packings or seals.
Make sure there are no nicks, burrs or scratches. If any defect is found, remove or repair it as
outlined under the General Repair Instructions in this manual.

b. Bearings. Check bearings for rusted or pitted balls, races or separators. Check
balls and races for brinnelling, abrasion and serious discoloration. Following are causes for
bearing rejection:

(1) Cuts or grooves parallel to ball or roller rotation.

(2) Fatigue pits (not minor machine marks or scratches).

(3) Cracks.

c. Inspection. Inspection consists of checking for defects such as distortion, wear,


cracks and pitting. Parts under heavy load or pressure must be inspected more thoroughly.
Clean all parts before inspection.

2-610
TM 08780B-20

d. Drain Plugs. When removing drain plugs from transmission, engine or hydraulic
system components, inspect sediment adhering to plug. A build-up of grit and/or fine metal
particles may indicate part failure. A few fine particles are normal. This inspection is effective
in determining defective parts prior to internal inspection of parts.

e. Gears. Gear inspection cannot be described in detail here. There are too many
differences in size and shape of gears. The following steps can be used to make a general visual
inspection of all gears. Follow all steps listed within repair instructions for final inspection.

(1) NORMAL WEAR. Loss of metal from the surface of gear teeth. Wear
must not prevent gears from meshing or performing properly.

(2) INITIAL PITTING. This may occur when a pair of gears is first started in
service. It may continue until most high spots have been reduced, as long as contact surfaces are
not affected. This pitting is not necessarily serious.

(3) DESTRUCTIVE PITTING. This type of pitting occurs after initial


pitting, often at an increasing rate. This will destroy contact area and reduce the gear’s ability to
carry a load. Rapid destruction will occur with use.

(4) ABRASIVE WEAR. This damage is caused by the fine particles carried
in the lubricant or imbedded in the gear teeth. These particles may come from many sources:
metal detached from gear teeth or bearings, abrasives not completely removed before assembly,
sand or scale from castings or other impurities in oil or air.

(5) SCORING. Slight scoring, scuffing, galling or other surface damage is


identified by tears or scratches in the direction of sliding. It starts in areas having the highest
stress and speed. This is usually at the tip of the teeth.

(6) BURNING. Burning is indicated by discoloration and loss of hardness


due to excessive temperature. This is caused by too much friction resulting from overload,
overspeed, lack of backlash or faulty lubrication. If discoloring can be wiped off with clean
cloth, such discoloring usually can be traced to oilburn-stains, which are not serious.

(7) ROLLING. This damage occurs mainly on plastic gears. Rolling is when
material is pushed out of shape without breaking off. This is caused by heavy, even loads,
sliding or overheating.

(8) BRINELLING. This can be identified by tiny indentation or ridges on the


shoulder or race of a bearing.

f. Splines. Inspect shaft splines for wear, pitting, rolling, peening and fatigue
cracks. In many cases, the same inspection procedure will apply to gears. However, the
problem, if present, will often be much less pronounced. Have a magnetic particle inspection
performed on splines, if needed.

2-611
TM 08780B-20

g. Tubing and Hose. Check all hose surfaces for broken or frayed fabric. Check for
breaks caused by sharp kinks or rubbing against other parts of the truck. Inspect copper tubing
lines for kinks. Inspect the fitting threads for damage. Replace any part found defective.
Following assembly and during initial truck operation, check for leaks.

h. Electrical Parts. Inspect all wiring harnesses for chafed or burned insulation.
Inspect all terminal connectors for loose connections and broken parts.

i. Metal Parts. Visually inspect all castings and weldments for cracks. Parts that
carry a great load should receive magnetic particle inspection. Critical nonferrous parts may be
inspected with fluorescent penetrant.

2-13. GENERAL REPAIR INSTRUCTIONS

WARNING

DRILLING AND GRINDING OPERATIONS ARE HAZARDOUS TO THE EYES. EYE


PROTECTION IS REQUIRED.

a. Burrs. Remove burrs from gear teeth with a fine-cut file or hand grinder.

b. Exterior Parts. Chassis and exterior painted parts may be resurfaced where paint
is damaged or where parts have been repaired, by using an abrasive disc driven by a flexible
shaft.

c. Bearings. Remove residue and oil stain from bearing races with crocus cloth.

d. Protective Parts. During repair operations, protect bare steel surfaces from rusting
when not actually undergoing repair work. Dip parts in or spray them with corrosion preventive
compound. The same protective coating may be applied to other metals to prevent rust.
Aluminum parts may require protection in atmospheres having a high salt content. Steel parts
must always be protected.

NOTE
The above procedure is used with polished and machined steel parts not protected by
cadmium, tin, copper or other plating or surface treatment. Bare metal surfaces must be free
of moisture when protective coating is applied.

e. Welding. Welding and brazing may be used to repair cracks in external steel
parts, such as brackets, panels and light framework. These repairs should be made only when
replacement parts are not available. Do not weld or braze castings, running parts or parts under
great stress except in emergencies.

2-612
TM 08780B-20

f. Stud Installation. When installing studs in engine block and axle housings, use a
driver designed for the stud to be installed. A worn stud driver may damage the end thread. This
makes it necessary to use a chasing die before a nut can be screwed on. This procedure will
remove cadmium plating and allow corrosion, which will make future disassembly difficult and
cause stud to be backed out with nut. Before driving a stud, inspect hole for chips and liquid.
Blow out any foreign matter. Start stud by hand. If it will not start into hole, it is too large or
has defective end thread. Before final insertion, coat thread with antiseize compound, turn stud
in slowly to prevent overheating and galling of casting metal.

g. Electrical Parts. Replace all broken worn or burned electrical wiring. Wires with
several broken strands must be replaced. Broken strands will increase the resistance of the wire
and impair efficiency of electrical components, especially the ignition system.

h. Hoses. Replace all broken, frayed, crimped or soft flexible lines and hoses.
Replace stripped or damaged fittings. Replace entire flexible hose if fittings are damaged. Make
sure hose clamps do not crimp hoses.

i. Fasteners. Replace any bolt, screw, nut or fitting with damaged threads. Inspect
tapped holes for thread damage. If cross-threading or galling is evident, retap the holes for the
next oversize screw or stud. When retapping will weaken the part or when the cost of the part
makes retapping impractical, replace the damaged part. Chasing threads with the proper size tap
or die may often be enough.

j. Dents. Straighten minor body dents by bumping with a soft-faced hammer while
using a wooden block backing.

k. Sheet Metal Repair. Repair minor skin cracks by installing patches.

l. Mounting Holes. Reshape oval mounting holes to round. Drill to receive bushing
with required inner diameter. Stake bushing in place with center punch.

2-14. GENERAL ASSEMBLY INSTRUCTIONS

a. Preparation. Remove grease from new parts before installation.

b. Packing Installation. Lubricate all packings with a thin coating of light mineral
oil before installation. Slightly stretch packing and place into position. Rotate component on
flat surface or uniformly press the packing into position.

c. Pipe joints. Use nonhardening pipe-joint compound or thread sealing tape when
joining piping.

d. Gaskets. To provide added sealing for gasket, coat both sides with sealant.
Remove all traces of previous gasket and sealant before installing new gasket.

2-613
TM 08780B-20

e. Silicone Sealant

WARNING

ON DIRECT CONTACT, UNCURED SILICONE SEALANT IRRITATES EYES. IN CASE


OF CONTACT FLUSH EYES WITH WATER AND SEEK MEDICAL ATTENTION.
AVOID PROLONGED CONTACT WITH SKIN.

Silicone sealant is often used instead of a gasket to seal mating parts. The mating parts must be
clean, dry and free of oil or grease for proper adhesion. After silicone sealant has been applied,
the mating parts must be assembled within 15 minutes. Silicone sealant starts to set-up in 15
minutes and takes 24 hours to completely cure. Excess silicone sealant should be wiped off after
assembling the mating parts.

f. Oil Seals. Install oil seals with seal lip facing towards lubricant, applying an even
force to outer edge of seal. Coat oil seals evenly with grease before installing. If oil seals will be
installed over keyed or splined shafts, use a guide. This will prevent sharp edge of keyway or
splines from cutting the leather or neoprene seal. Construct guides of very thin gauge sheet
metal and shape to required diameter. However, make certain guide edges are not sharp. Bend
them slightly inward so they do not cut the seal.

g. Seal Rings. Coat seal rings with oil and carefully install into their bores. If seal
rings must be installed over threaded parts, temporarily wrap the threads with tape to protect the
seal ring. Then remove the tape.

h. Bearings and Shafts. During assembly of shafts and bearings in housings, first
mount bearing on shaft. Then install the assembly by applying force to shaft. When mounting
bearings on shafts, always apply force to the inner races of the bearing.

i. Bearing Lubrication. Lubricate bearings before reassembly with the type of


lubricant normally used in the related housing or container. This will provide lubrication during
the first run-in until lubricant from the system can reach the bearings.

2-614
TM 08780B-20

CHAPTER 3

ENGINE

3-1. OVERVIEW

This chapter provides information authorized for Second Echelon Maintenance level mechanics.
The following chapter covers maintenance procedures for the vehicle’s engine.

3-2. DESCRIPTION AND DATA

a. Detroit 8V92TA Diesel Engine. The Detroit 8V92TA diesel engine is a


turbocharged, aftercooled, two cycle engine with eight cylinders in a V-type configuration. Each
cylinder has 92 cubic inches for a total displacement of 736 cubic inches.

The following information describes engine components that are maintained at the
Organizational Maintenance level.

b. Rocker Cover. The engine’s rocker covers encloses valves, Jacobs brake and fuel
injector assemblies at the top of each cylinder head. Rocker covers also incorporate breather
housings.

c. Oil Filter and Adapter. The oil filter is a spin-on type that attaches to the oil fitter
adapter. The adapter has a by-pass valve that opens at 18-21 psi (124-145 kPa). The by-pass
valve will open should the oil filter become clogged.

d. Fuel Pump. A positive gear-type fuel pump transfers fuel from fuel tanks through
the filter to fuel injectors. The fuel pump is attached to the governor housing. It is driven off the
right-hand blower rotor by means of a drive coupling fork. It is not mandatory to time fuel pump
because the fuel injectors are self-timing.

3-1
TM 08780B-20

e. Shutdown Solenoid. This is an electrically controlled solenoid used to shut down


or stop the engine. The solenoid is attached to the stop lever on the governor. When activated,
the shutdown solenoid pulls in the stop lever. The stop lever operates a series of internal fuel
rods to shut off the fuel injectors.

f. Throttle Cylinder. This is an air actuated cylinder that is controlled by the


vehicle’s treadle valve. The throttle cylinder attaches to the speed control lever on the governor.
When regulated air reaches the cylinder, a push rod moves the speed control lever. The control
lever moves internal fuel rods and levers that regulate the amount of fuel in the injector.

g. Thermostats and Housing. Engine coolant temperature is controlled by two


thermostats. Each thermostat is located in a housing attached to the water outlet end of each
cylinder head. Thermostats will stay closed, letting coolant circulate within the engine. When
coolant temperature reaches 160°F - 197°F (71°C - 91.6°C) thermostats open and allow coolant
to circulate to the radiator where it cools.

3-2
TM 08780B-20

h. Water Pump. This is a centrifugal-type pump that circulates engine coolant


through the cylinder block, cylinder heads, oil cooler and radiator. Pump is mounted on engine
front cover and is driven off of right front camshaft gear.

i. Alternator. This is a flanged mounted alternator that is driven by the blower drive
gear by means of a drive coupling. The alternator has an integral regulator that regulates voltage,
keeping it at approximately 24 volts. The regulator can be slightly adjusted to provide the
desired output.

j. Starter. The starter is an electric motor with a solenoid and drive gear. When the
starter is activated, the drive moves outward and meshes with the flywheel ring gear. The starter
is mounted on the left side of flywheel housing.

3-3
TM 08780B-20

3-3. ENGINE OIL SERVICE

THIS TASK COVERS: a. Draining


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Reference


LI 2320-12/9
Applicable Configurations LO 9-2320-297-12
MK48
Equipment
Materials/Parts Condition Condition
Engine oil (item 35, Appendix D) TM Description
Pipe sealant (item 48, Appendix D) TM 08780B-20 Right side panel
Oil element filter (23518524) item 3 removed (para 18-15).

a. Draining

WARNING

DO NOT DRAIN OIL WHEN ENGINE IS HOT. SEVERE BURNS WILL RESULT.

NOTE
• Oil capacity is 24 quarts. Make certain container used to catch oil is large enough.

• It is necessary to use a pipe or funnel to direct flow of oil around nose box and into the
container.

(1) Place a large container under the drain plug (1).

(2) Remove drain plug (1) and allow oil to drain into container.

(3) Remove magnetic plug (2).

3-4
TM 08780B-20

(4) Place a container under oil filter element (3).

(5) Using oil filter wrench, remove oil filter element (3) and discard.

b. Cleaning/Inspection

(1) Clean drain plug (1). Refer to paragraph 2-11.

(2) Clean magnetic plug (2). Refer to paragraph 2-11.

(3) Clean oil filter adapter (4) with a clean, lint free cloth.

(4) Inspect threads on plugs (1 and 2). Refer to paragraph 2-12.

(5) Replace all parts failing inspection.

c. Installation
CAUTION

TO PREVENT DAMAGE TO SEAL (5), DO NOT OVERTIGHTEN OIL FILTER


ELEMENT (3).

(1) Coat seal (5) with clean engine oil. Install new oil filter element (3) into
oil filter adapter (4) and hand tighten until seal (5) touches oil filter adapter (4).

(2) Tighten oil filter element (3) an additional 2/3 turn.

3. Oil Filter Element


4. Oil Filter Adapter
5. Seal

3-5
TM 08780B-20

(3) Apply pipe sealant to threads on drain and magnetic plugs (1 and 2).

(4) Install magnetic plug (2). Torque magnetic plug (2) to 33-37 foot-pounds
(45-50 N*m).

(5) Install drain plug (1). Torque drain plug (1) 33-37 foot-pounds (45-50
N*m).

(6) Remove cap (6) from filler tube (7).

(7) Add 24 quarts (22.70 liters) of clean engine oil. Refer to LI 2320-12/9,
LO 9-2320-297-12.

(8) Check dipstick (8) for proper oil level. Fill as needed.

(9) Install cap (6) onto filler tube (7).

(10) Start engine and run for 10 minutes. Refer to paragraph 2-13 (TM
08780B-10). Check for leaks.

(11) Shut down engine. Wait five minutes, then recheck dipstick (8) for proper
oil level. Fill as needed.

END OF-TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Install right side
panel (para 18-15).

3-6
TM 08780B-20

3-7
TM 08780B-20

3-4. ROCKER COVER AND GASKET REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP

Applicable Configurations Equipment


MK48 Condition Condition
TM Description
Materials/Parts TM 08780B-10 Engine access door
Engine oil (item 35, Appendix D) open (para 2-1).
Gasket, rocker cover (5104081) item 8
Seal, breather housing (5103646) item 13
Seal, oil tube (5104105) item 19

a. Removal

CAUTION

CLEAN AROUND EACH ROCKER COVER BEFORE REMOVING FROM ENGINE.


THIS WILL KEEP DUST AND DIRT FROM ENTERING ENGINE.

NOTE
Follow steps (1) thru (6) for right and left rocker covers.

(1) Loosen hose clamp (1) and remove breather vent tube (2) from breather
housing (3).

(2) Remove two 12 point capscrews (4), retainers (5) and isolators (6) from
rocker cover (7).

(3) Remove rocker cover (7) and gasket (8). Discard gasket (8).

(4) Remove three screws (9) and retainer (10).

(5) Remove element (11) and retainer (12).

(6) Using a rubber mallet, tap breather housing (3) from inside rocker cover
(7). Remove breather housing (3) and seal (13). Discard seal (13).

NOTE
Follow steps (7) thru (9) for right rocker cover only.

(7) Remove oil cap (14) from chain (15).

3-8
TM 08780B-20

(8) Remove three screws (16) from strainer (17) and remove strainer and
chain (15).

(9) Remove oil fill tube (18) and seal (19). Discard seal (19).

(10) Remove engine data plates (20) if damaged.

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect rocker cover (7) for cracks or dents.

(3) Inspect isolators (6) for cracks or wear.

(4) Inspect oil cap (14) for cracks.

(5) Replace all parts failing inspection.

c. Installation

(1) Install new seal (13) in rocker cover (7),

(2) Install breather housing (3) into rocker (7) with vent tube facing rear of
engine.

(3) Install retainer (12) and element (11) into breather housing (3).

(4) Place retainer (10) over element (11). Install three screws (9).

(5) Install new seal (19) and oil fill tube (18) in right rocker cover (7).

(6) Install strainer (17) and chain (15).

(7) Install three screws (16). Connect fill tube cap (14) to chain (15).

(8) Install new gasket (8) into groove of cover (7).

(9) Coat mating surface of gasket (8) and cylinder head with light coat of
clean engine oil.

(10) Install rocker cover (7) on engine.

(11) Install isolators (6), retainers (5) and 12 point caps-crews (4). Torque
capscrews (4) to 15-20 foot-pounds (20.3 - 27 N*m).

3-9
TM 08780B-20

(12) Install breather tube (2) and clamp (1) onto breather housing (3). Tighten
hose clamp (1).

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-10 Close engine access
door (para 2-1).

1. Hose Clamp
2. Breather Vent Tube
3. Breather Housing
4. 12 Point Capscrew (4)
5. Retainer (4)
6. Isolator (4)
7. Rocker Cover (2)
8. Gasket
9. Screw (3)
10. Retainer
11. Element
12. Retainer
13. Seal
14. Oil Cap
15. Chain
16. Screw (3)
17. Strainer
18. Oil Fill Tube
19. Seal
20. Data Plate (2)

3-10
TM 08780B-20

3-5. OIL FILTER ADAPTER REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
M K48 TM 08780B-20 Access cover
removed (para 18-15).
Materials/Parts
Gasket (8921312) item 5
Lockwasher (6) (MS 35338-46) item 2 Oil filter removed
(para 3-3).

a. Removal

(1) Tag and remove two capscrews (1) and lockwashers (2). Discard
lockwashers (2).

(2) Tag and remove four capscrews (3) and lockwashers (2). Discard
lockwashers (2).

(3) Remove oil filter adapter (4) and gasket (5). Discard gasket (5).

WARNING

SPRING (8) IS UNDER TENSION. RELEASE SPRING SLOWLY TO PREVENT INJURY.

(4) Remove screw (6), retainer (7), spring (8) and piston (9) from oil filter
adapter (4).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

c. Installation

(1) Install piston (9), spring (8), retainer (7) and screw (6) into oil filter
adapter (4). Tighten screw (6) securely.

3-11
TM 08780B-20

(2) Install gasket (5) and oil filter adapter (4).

(3) Install four shorter capscrews (3) with new lockwashers (2) and tighten
securely.

(4) Install two capscrews (1) with new lockwashers (2) and tighten securely.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Install oil filter
(para 3-3).

TM 08780B-10 Start engine and


check for oil leaks (para 2-13).

TM 08780B-20 Install access cover


(para 18-15).

1. Capscrew (2)
2. Lockwasher (6)
3. Capscrew (4)
4. Oil Filter Adapter
5. Gasket
6. Screw
7. Retainer
8. Spring
9. Piston

3-12
TM 08780B-20

3-6. OIL PAN AND GASKET REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Personnel Required


1 MOS 3521
Applicable Configurations 1 Assistant
MK48
Equipment
Materials/Parts Condition Condition
Silicone sealant (item 5, Appendix D) TM Description
Gasket (NSN 5330-00-972-8108) item 13 TM 08780B-20 Engine oil drained
Lockwasher (30) (MS35338-46) items 8 and 11 (para 3-3).

a. Removal

(1) Remove filler tube (1) and elbow (2).

(2) Loosen nut (4) and remove dip stick (5). Remove adapter (6).

(3) Remove two capscrews (7) and lockwashers (8) from oil pan brackets (9).
Discard lockwashers (8).

(4) Remove 28 capscrews (10) and lockwashers (11) from oil pan (3).
Discard lockwashers (11).

(5) Pull oil pan (3) from engine block (12).

(6) Remove and discard gasket (13).

(7) Remove pipe plugs (14 and 15).

(8) Remove pipe plug (16) only if oil pan (3) is being replaced.

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect oil pan (3) for warpage, cracks or dents.

(3) Clean all gasket material, sealant or debris, from mating surfaces of oil
pan (3) and engine block (12).

(4) Inspect all other parts. Refer to paragraph 2-12.

3-13
TM 08780B-20

(5) Replace all parts failing inspection.

c. Installation

(1) If removed, install pipe plug (16). Torque to 75-85 foot-pounds (102-115
N*m).

(2) Install pipe plugs (14 and 15). Torque to 33-37 foot-pounds (45-50 N*m).

(3) Apply sealant and install new gasket (13) on oil pan (3).

(4) Install oil pan (3) on engine block (12) so oil pan brackets (9) are at rear of
engine.

(5) Install 28 capscrews (10) and new lockwashers (11). Hand tighten only.

CAUTION

OVERTIGHTENING CAPSCREWS (7 AND 10) MAY DAMAGE GASKET (13).

(6) Install two capscrews (7) and new lockwashers (8) on oil pan brackets (9).
Torque to 10-20 foot-pounds (13-27 N*m).

(7) Starting with center capscrew on each side, tighten capscrews (10),
working alternately toward each end of pan (3). Torque capscrews to 10-20 foot-pounds (13-27
N*m).

(8) Install elbow (2) and filler tube (2). Tighten nut (1) securely.

(9) Install adapter (6) and dipstick (5). Tighten nut (4) securely.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Fill oil pan with
clean engine oil (para 3-3).

TM 08780B-10 Start engine and


check for oil leaks (para 2-13).

3-14
TM 08780B-20

1. Filler Tube
2. Elbow
3. Oil Pan
4. Nut
5. Dipstick
6. Adapter
7. Capscrew (2)
8. Lockwasher (2)
9. Oil Pan Brackets
10. Capscrew (28)
11. Lockwasher (28)
12. Engine Block
13. Gasket
14. Pipe Plug
15. Pipe Plug
16. Pipe Plug

3-15
TM 08780B-20

3-7. EXHAUST MANIFOLD AND GASKET REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48 TM 08780B-10 Engine access door
open (para 2-1).
Materials/Parts
Cleaning solvent (item 53, Appendix D) TM 08780B-20 Air cleaner assembly
Exhaust gasket (4) (NSN 5330-00-862-6929) removed (para 4-6).
item 7

a. Removal

WARNING

ALLOW EXHAUST SYSTEM TO COOL BEFORE SERVICING. EXHAUST PARTS CAN


BE HOT ENOUGH TO CAUSE SEVERE BURNS.

(1) Loosen clamp (1) on right exhaust manifold (2). Slide clamp (1) back and
out of the way.

(2) Remove two nuts (3) and hold down crabs (4).

(3) While holding right exhaust manifold (2), remove three nuts (5) and
washers (6).

(4) Remove right exhaust manifold (2) and gasket (7). Discard gasket (7).

(5) Loosen clamp (8) and remove elbow (9).

(6) Repeat steps (2) thru (4) to remove left exhaust manifold.

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect manifold studs (10) and nuts (3 and 5) for damage.

(3) Clean carbon from exhaust manifold ports and engine mating surface.

3-16
TM 08780B-20

(4) Using straightedge, check exhaust manifold mating surface for


straightness.

(5) Check manifolds (2) for cracks.

(6) Replace all parts failing inspection.

c. Installation

(1) Install new manifold studs (10) if removed. Torque manifold studs (10) to
25-40 foot-pounds (34-54 N*m).

(2) Install new gasket (7) with crimped side of gasket (11) facing cylinder
head.

(3) Install elbow (9) on right exhaust manifold (2). Leave clamp (1) loose.

WARNING

EXHAUST MANIFOLD (2) IS HEAVY. USE CARE WHEN INSTALLING TO PREVENT


PERSONAL INJURY.

(4) Install right exhaust manifold (2) so manifold guide (12) lies on top of
block rest (13) and elbow (9) aligns with turbocharger bracket (14).

(5) While holding exhaust manifold, install three washers (6), dish side
towards nut and nuts (5), on studs. Hand tighten nuts (5).

(6) Install two hold down crabs (4) and nuts (3). Hand tighten nuts (3).

(7) Tighten five nuts (3 and 5) starting in the center of exhaust manifold,
alternating toward each end. Torque nuts (3 and 5) to 30-35 foot-pounds (41-47 N*m).

(8) Tighten two clamps (8 and 1) securely.

(9) Repeat steps (1) thru (7) for left exhaust manifold.

END OF TASK

3-17
TM 08780B-20

NOTE
Follow-On Maintenance
TM 08780B-20 Install air cleaner
assembly (para 4-6).

TM 08780B-10 Close engine access


door (para 2-1).

Start engine and check


for exhaust leaks (para 2-13).

1. Clamp
2. Right Exhaust Manifold
3. Nut (2)
4. Hold Down Crabs
5. Nut (3)
6. Washer (3)
7. Gasket (2)
8. Clamp
9. Elbow
10. Manifold Stud (5)
11. Crimped Side Of Gasket
12. Manifold Guide
13. Block Guide
14. Turbocharger Bracket

3-18
TM 08780B-20

3-8. ENGINE OIL SAMPLING VALVE (LVSA1 SERIES VEHICLES ONLY)

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Assembly

INITIAL SETUP

Applicable Configurations
MK48A1

Materials/Parts
Locknut (2) (1600460) item 6
Pipe sealant (item 48, Appendix D)

a. Removal

(1) Remove oil sampling valve (1) from reducer (2).

(2) Remove reducer (2) from adapter (3).

(3) Remove hose (4) from adapter (3).

(4) Remove adapter (3) from bracket (5).

(5) Remove two locknuts (6), capscrews (7) and bracket (5) from filter
bracket(8). Discard locknuts (6).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11,

(2) Inspect all parts for damage. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

c. Installation

(1) Install bracket (5) on filter bracket (8) using two capscrews (7) and new
locknuts (6). Tighten locknuts (6) securely.

(2) Install adapter (3) on bracket (5). Tighten adapter (3) securely.

(3) Install hose (4) on adapter (3). Tighten hose (4) securely.

3-19
TM 08780B-20

NOTE
Apply pipe sealant to all pipe threads before installing.

(4) Install reducer (2) on adapter (3). Tighten reducer (2) securely.

(5) Install sampling valve (1) on reducer (2). Tighten sampling valve (1)
securely.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-10 Start engine and
check for leaks (para 2-13).

1. Oil Sampling Valve


2. Reducer
3. Adapter
4. Hose
5. Bracket
6. Locknut (2)
7. Capscrew (2)
8. Filter Bracket

3-20
TM 08780B-20

3-9. NEW REPLACEMENT DIPSTICK INSTALLATION

THIS TASK COVERS: a. Dipstick Preparation

INITIAL SETUP

Applicable Configurations
MK48

a. Dipstick Preparation

CAUTION

REPLACEMENT DIPSTICK AS RECEIVED WILL NOT BE THE CORRECT LENGTH.


DIPSTICK MUST NOT BE INSTALLED WITHOUT FIRST CUTTING TO CORRECT
LENGTH AND MARKING THE LOW AND HIGH OIL LEVELS.

(1) Cut dipstick (1) to total length (x dimension).

NOTE
Dipstick can be marked in a number of ways. Scribe, punch mark or drill (.05 in., 1.27 mm)
the level indicators on the flat surface of the dipstick.

(2) Mark LOW oil level (dimension z) on dipstick (1).

(3) Mark HIGH oil level (dimension y) on dipstick (1).

END OF TASK

DIMENSION IN. CM
X CUT TO 14.25 36.20
Z MARK AT 1.38 3.50
Y MARK AT 12.09 30.70

3-21/(3-22 blank)
TM 08780B-20

CHAPTER 4

FUEL SYSTEMS

4-1. OVERVIEW

This chapter provides information authorized for Second Echelon Maintenance level mechanics.
The following chapter covers principles of operation, repair and replacement procedures for the
vehicle’s fuel system.

4-2. FUEL SYSTEM PRINCIPLES OF OPERATION

a. General Description. With one 75 gallon tank on each fender, the LVS has a total
fuel capacity of 150 gallons. Diesel fuel from the tanks reaches the engine through a fuel/water
separator, a filter, a pump and injectors. A priming pump is included in the system for use when
air has gotten into the system. This pump is by-passed under ordinary operating conditions.

4-1
TM 08780B-20

b. Fuel Tanks. Two 75 gallon diesel fuel tanks. One fuel tank is mounted on each
fender, above the No. 2 axle.

c. Priming Pump. Hand pump used to prime fuel system when air has gotten into
the fuel system (as when the vehicle has run out of fuel). After air has entered the system, the
system must be primed before the engine will start.

d. Fuel/Water Separator. Three stage device used to separate water from fuel and
filter out solid particles. In the first stage, a centrifuge separates large solid particles and water
from the fuel. The water and large particles sink to the bottom of the fuel bowl where they
remain, until the fuel bowl is drained because they are heavier than fuel. In the second stage,
water that is still in the system condenses on the separator shell. When droplets form, their
weight causes them to fall to the bottom of the fuel bowl. In the third stage, a replaceable filter
element traps solid particles still in the fuel.

e. Secondary Filter. Replaceable filter that traps extremely fine particles that have
passed through previous filtration.

4-2
TM 08780B-20

f. Fuel Pump. Draws fuel from fuel tanks and sends it to injectors on the engine.
The fuel pump must be primed if air has gotten into the system. Otherwise, it will not work.

g. Injectors. Devices that atomize, meter and inject the correct amount of fuel into
the appropriate cylinder at the right moment. There is one injector per cylinder.

4-3
TM 08780B-20

4-3. FUEL SUPPLY PUMP REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Equipment


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

General Safety Instructions


Do not smoke or use open flame. Fuel is
flammable and may explode. Keep fire
extinguisher within reach.

a. Removal

(1) Tag and remove two fuel lines (1).

(2) Remove three capscrews (2).

NOTE
Drive fork is loose on fuel pump shaft and may fall off when pump is removed.

(3) Remove fuel pump (3) and drive fork (4).

(4) Remove and discard gasket (5).

NOTE
Remove two fuel line elbows (6), coupling (7), nipple (8) and plugs (9) only if fuel pump will
be replaced.

(5) Remove two elbows (6), coupling (7), nipple (8) and two plugs (9) from
fuel pump (3).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

4-4
TM 08780B-20

(3) Replace all parts failing inspection.

c. Installation

(1) If removed, install two plugs (9) on fuel pump (3).

(2) Install new gasket (5) on fuel pump (3).

(3) Install drive fork (4) on fuel pump shaft (10).

NOTE
Open drain hole in fuel pump (3) must face down.

(4) Align drive fork (4) with slots in adaptor plate in governor housing (11).

(5) Install fuel pump (3) with three capscrews (2). Tighten capscrews (2)
securely.

(6) If removed, apply pipe sealant to elbow threads and install two elbows (6),
coupling (7) and nipple (8).

(7) Install two fuel lines (1). Tighten fuel lines (1) securely.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Tighten bypass tube
hose clamps (para 6-6).

Install engine access panel (para 18-15).

TM 08780B-10 Start engine and


check for fuel or coolant leaks (para 2-13).

4-5
TM 08780B-20

1. Fuel Line (2)


2. Capscrew (3)
3. Fuel Pump
4. Drive Fork
5. Gasket
6. Elbow (2)
7. Coupling
8. Nipple
9. Plug (2)
10. Fuel Pump Shaft
11. Governor
Housing

4-6
TM 08780B-20

4-4. FUEL SUPPLY PUMP REPAIR

THIS TASK COVERS: a. Disassembly


b. Cleaning/Inspection
c. Assembly

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48 TM 08780B-20 Fuel pump removed
(para 4-3).
Special Tools
Fuel pump tool set J1508-D

Materials/Parts
Adhesive-sealant, silicone (item 5, Appendix D)
Grease (item 21, Appendix D)
Engine oil (item 35, Appendix D)
Gasket (NSN 5330-00-599-5577) item 11
Oil seal (2) (NSN 5330-01-083-3063) items 15 and 16

a. Disassembly

(1) Mount fuel pump assembly (1) in a holding fixture (2).

1. Fuel Pump Assembly


2. Holding Fixture (Tool)

(2) Remove eight capscrews (3) and separate cover (4) from body (5).

(3) Remove drive shaft (6), drive gear (7) and gear retaining ball (8) as an
assembly.

NOTE
Do not remove drive gear (7) from drive shaft unless damaged. If drive shaft assembly is not
damaged, go to step (7).

(4) Place drive shaft (6) in a press with square end of shaft towards press bed.

4-7
TM 08780B-20

CAUTION

DO NOT PRESS SQUARE END OF DRIVE SHAFT THROUGH GEAR. SEAL CONTACT
AREA COULD BE DAMAGED.

NOTE
Gear retaining ball (8) is small. Be careful not to lose it.

(5) Press drive shaft (6) just far enough to remove gear retaining ball (8).

(6) Turn drive shaft (6) so square end is away from press. Press drive shaft
(6) off drive gear (7).

CAUTION
DO NOT REMOVE GEAR FROM DRIVEN SHAFT. DRIVEN GEAR AND SHAFT
ASSEMBLY (9) IS SERVICED ONLY AS AN ASSEMBLY.

(7) Remove driven gear and shaft assembly (9) from body (5).

(8) Remove plug (10) and gasket (11). Discard gasket (11).

(9) Remove spring (12), pin (13) and relief valve (14).

NOTE
Do not remove oil seals (15 and 16) unless damaged or leaking.

(10) Clamp body (5) in soft-jawed vise.

CAUTION

OBSERVE POSITION OF OIL SEAL LIPS FOR ASSEMBLY. INCORRECT POSITION


OF SEAL LIPS WOULD RESULT IN FUEL LEAKAGE.

(11) Using a hammer and a drift pin, remove two oil seals (15 and 16). Discard
oil seals (15 and 16).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Check gear teeth for scoring, chipping or wear. Check slot in drive gear
(7) for wear.

4-8
TM 08780B-20

(3) Inspect drive shafts (6 and 9) for scoring or wear. Driven gear and shaft
assembly (9) is replaced as an assembly only.

(4) Check mating surfaces of cover (4) and body (5) for scratches or wear
around area where gears contact.

(5) Check relief valve (14) for score marks.

(6) Inspect reducer bushing (17) in cover (4) for wear.

3. Capscrew (8)
4. Cover
5. Body
6. Drive Shaft
7. Drive Gear
8. Gear Retaining Ball
9. Driven Gear And Shaft Assembly
10. Plug
11. Gasket
12. Spring
13. Pin
14. Relief Valve
15. Inner Oil Seal
16. Outer Oil Seal
17. Reducer Bushing

4-9
TM 08780B-20

(7) Inspect all other parts. Refer to paragraph 2-12.

(8) Replace all parts failing inspection.

c. Assembly

(1) Grease lips of new oil seals (15 and 16).

(2) Place inner oil seal (15) on seal installer (18) so that inner seal lip (19)
faces towards body (5).

(3) Support body (5) on wooden blocks.

(4) Insert seal installer (18) into body (5) and install inner oil seal (15).

5. Body
15. Inner Oil Seal
18. Seal Installer (Tool)
19. Inner Seal Lip

(5) Install installer adaptor (20) on seal installer (18) so that short end of
installer adaptor (20) is away from installer handle.

(6) Place outer oil seal (16) on seal installer (18) so that outer seat lip (21)
faces towards installer adaptor (20).

(7) Insert seal installer (18) into body (5) and drive the seal in until installer
adaptor (20) makes contact with body (5).

4-10
TM 08780B-20

5. Body
16. Outer Oil Seal
18. Seal Installer (Tool)
20. Installer Adaptor (Tool)
21. Outer Seal Lip

5. Body
10. Plug
11. Gasket
12. Spring
13. Pin
14. Relief Valve
22. Relief Valve Port

(8) Clamp body (5) in a soft-jawed vise so that relief valve port (22) is facing
up.

(9) Lubricate outside diameter of relief valve (14) with clean engine oil.
Insert relief valve (14) into body (5) so the valve’s hollow end is up.

(10) Insert spring (12) into relief valve (14) and insert pin (13) into spring (12).

4-11
TM 08780B-20

(11) Install plug (10) and new gasket (11). Torque plug (10) to 18-22 foot-
pounds (24-30 N*m).

NOTE
If gear was not removed from shaft, go to step (15).

(12) Install gear (7) on end of shaft (6) which is not squared. Slot in gear must
face the plain end of shaft.

(13) Press gear (7) beyond ball notch on shaft (6).

6. Shaft
7. Gear

(14) Place gear retaining ball (8) in notch and press gear (7) back until end of
slot contacts ball.

(15) Lubricate shaft (6) with clean engine oil. Insert the square end of shaft (6)
into the opening on the gear side of body (5).

NOTE
If a service replacement gear is used, the slot must face toward cover.

(16) Install driven gear and shaft assembly (9) i n body (5).

(17) Lubricate gears (7 and 9) and shafts (6 and 9) with clean engine oil.

CAUTION

WHEN APPLYING SEALANT TO COVER, MAKE SURE NO SEALANT IS APPLIED TO


CONTACT AREA OF GEARS. EXCESSIVE SEALANT CAN DAMAGE INTERNAL
PARTS.

(18) Apply thin coat of adhesive sealant to mating surface of cover (4).

(19) Install cover (4) on body (5) so that dowel pins in body align with proper
holes in cover (4).

4-12
TM 08780B-20

(20) Install eight capscrews (3). Tighten capscrews (3) alternately and evenly.

(21) After assembly, rotate shaft (6) by hand, checking that parts rotate freely.
If shaft does not rotate freely, attempt to free it by tapping a corner of the pump. If shaft still
sticks, disassemble pump and recheck the parts.

NOTE
If pump will not be installed immediately, place plastic shipping plugs in inlet and outlet
openings.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Install fuel pump (para 4-3).

Check coolant level (para 6-3).

3. Capscrew (8)
4. Cover
5. Body
6. Drive Shaft
7. Drive Gear
8. Gear Retaining Ball
9. Driven Gear and
Shaft Assembly

4-13
TM 08780B-20

4-5. HAND PRIMING PUMP REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP General Safety Instructions


Do not smoke or use open flame. Fuel
Applicable Configurations is flammable and may explode. Keep
MK48 fire extinguisher within reach.

Materials/Parts
Oil, Fuel (item 28, Appendix D)
Pipe sealant (item 48, Appendix D)

a. Removal

(1) Loosen nut (1).

(2) Place a drain pan below handle assembly(2). Pull handle assembly (2)
from barrel (3).

(3) Remove nut (4).

(4) Push barrel (3) through and away from bracket (5).

(5) Loosen fittings (6 and 7).

(6) Tag and remove hoses (8 and 9).

(7) Remove two elbows (10 and 11).

(8) Remove washer (12) and nut (13).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

4-14
TM 08780B-20

c. Installation

NOTE
To install a new priming pump, nut (4), handle assembly (2) and nut (1) must be removed
from barrel (3).

(1) Install nut (13) and washer (12) onto barrel (3) two inches (5.08 cm) from
handle end.

(2) Coat threads of elbows (10 and 11) with pipe sealant and install into barrel
(3).

(3) Connect hoses (8 and 9) to elbows (10 and 11). Tighten fittings (6 and 7)
securely.

(4) Insert barrel (3) through hole in bracket (5).

(5) Install nut (4). Tighten nut (4) securely.

(6) Lubricate O-rings (14) with clean fuel.

(7) Carefully install handle assembly (2) into barrel (3).

(8) Tighten nut (1) securely.

END OF TEST

NOTE

Follow-On Maintenance
TM 08780B-10 Prime fuel
system (para 2-13).

Run engine and check


for leaks (para 2-13).

4-15
TM 08780B-20

1. Nut
2. Handle Assembly
3. Barrel
4. Nut
5. Bracket
6. Fitting
7. Fitting
8. Hose
9. Hose
10. Elbow
11. Elbow
12. Washer
13. Nut
14. O-Ring (2)

4-16
TM 08780B-20

4-6. AIR CLEANER ASSEMBLY REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP

Applicable Configurations
MK48

Materials/Parts
Pipe sealant (item 48, Appendix D)
Locknut (2) (1600460) item 8
Locknut (7) (MS51922-1) items 5.3, 10.1,11 and 14
Lockwasher (2) (MS35338-45) item 34

a. Removal

(1) Loosen clamp (1) on air inlet duct (2).

(2) Loosen clamp (3) on hose (4) at check valve assembly (5) and remove
hose(4).

NOTE
Perform steps (3) and (4) on LVSA1 series vehicles only.

(3) Remove four capscrews (5.1) from right, left and rear sides of weather-
hood (5.2).

(4) Remove two locknuts (5.3) and capscrews (5.4) from tabs of weatherhood
(5.2). Remove weatherhood (5.2). Discard locknuts (5.3).

NOTE
Mounting hardware for the LVSA1 worklight bracket has changed from capscrews,
lockwashers and hex nuts to flanged type capscrews and locknuts. When repairing a non-A1
vehicle, use the new style flanged mounting hardware to replace the old style hardware. Refer
to TM 08780B-24P for correct part identification.

(5) Remove two capscrews (6), locknuts (8), worklight (9) and bracket (10).
Discard locknuts (8).

(6) Remove two locknuts (10.1) capscrews (10.2), washers (10.3) and bracket
(10.4). Discard locknuts (10.1).

(7) Remove two locknuts (11) and capscrews (12). Discard locknuts (11).

4-17
TM 08780B-20

1. Clamp
2. Air Inlet Duct
3. Clamp
4. Hose
5. Check Valve Assembly
5.1. Capscrew (4)*
5.2. Weatherhood*
5.3. Locknut (2)*
5.4. Capscrew (2)*
6. Capscrew (2)
7. Deleted
8. Locknut (2)
9. Worklight
10. Bracket
10.1. Locknut (2)
10.2. Capscrew (2)
10.3. Washer (2)
10.4. Bracket
11. Locknut (2)
12. Capscrew (2)

*LVSA1 Series Vehicles Only

4-18
TM 08780B-20

(8) Remove capscrew (13) and locknut (14) from hanger (15). Discard
locknut (14).

(9) Remove capscrew (16), nut (17) and bracket (18) from air cleaner (19).

(10) Remove four capscrews (20) and flanged nuts (21) from air cleaner
brackets (22). Remove air cleaner (19).

(11) Remove capscrew (23) and nut (24) to remove clamp (25).

(12) Loosen clamp (26) at air inlet housing (27) and remove hose (28).

13. Capscrew
14. Locknut
15. Hanger
16. Capscrew (2)
17. Nut (2)
18. Bracket
19. Air Cleaner
20. Capscrew (4)
21. Flanged Nut (4)
22. Air Cleaner Bracket (2)
23. Capscrew
24. Nut
25. Clamp
26. Clamp
27. Air Inlet Housing
28. Hose

4-19
TM 08780B-20

(13) Loosen two clamps (29 and 30). Remove check valve assembly (31).

(14) Remove two elbows (32).

(15) Remove two capscrews (33), lockwashers(34), nuts (35) and bracket (36).
Discard lockwashers (34).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

c. Installation

(1) Install bracket (36), two capscrews (33), new lockwashers (34) and nuts
(35). Tighten capscrews (33) and nuts (35) securely.

(2) Coat elbows (32) with pipe sealant and install. Tighten securely.

(3) Install check valve assembly (31) and two clamps (29 and 30). Tighten
clamps (29 and 30) securely.

(4) Align air cleaner (19) with holes in brackets (22) and install four
capscrews (20) and flanged nuts (21). Tighten capscrews (20) and flanged nuts (21) securely.

(5) Install hose (28) and clamp (26) at air inlet housing (27). Tighten clamp
(26) securely.

(6) Install bracket (18), two capscrews (16) and nuts (17) at the third hole
from the end of air cleaner (19). Tighten capscrews (16) securely.

(7) Position clamp (25) and install capscrew (23) and nut (24). Tighten
capscrew (23) and nut (24) securely.

(8) Install hanger (15), capscrew (13) and locknut (14). Tighten capscrew
(13) and locknut (14) securely.

(9) Install two capscrews (12) and new locknuts (11). Tighten locknuts (11)
securely.

4-20
TM 08780B-20

29. Clamp
30. Clamp
31. Check Valve Assembly
32. Elbow (2)
33. Capscrew (2)
34. Lockwasher (2)
35. Nut (2)
36. Bracket

4-21
TM 08780B-20

1. Clamp
2. Air Inlet Duct
3. Clamp
4. Hose
5. Check Valve Assembly
5.1. Capscrew (4)*
5.2. Weatherhood*
5.3. Locknut (4)*
5.4. Capscrew (2)*
6. Capscrew (2)
7. Deleted
8. Locknut (2)
9. Worklight
10. Bracket
10.1. Locknut (2)
10.2. Capscrew (2)
10.3. Washer (2)
10.4. Bracket
11. Locknut (2)
12. Capscrew (2)
13. Capscrew
14. Locknut
15. Hanger
16. Capscrew (2)
17. Nut (2)
18. Bracket
19. Air Cleaner
20. Capscrew (4)
21. Flanged Nut (4)
22. Air Cleaner Bracket (2)
23. Capscrew
24. Nut
25. Clamp
26. Clamp
27. Air Inlet Housing
28. Hose

*LVSA1 Series Vehicles Only

4-22
TM 08780B-20

(10) Install bracket (10.4) and two washers(10.3), capscrews (10.2) and new
locknuts (10.1). Tighten locknuts (10.1) securely.

(11) Install worklight (9), bracket (10), two capscrews (6) and new locknuts
(8). Tighten locknuts (8) securely.

NOTE
Perform steps (12) and (13) for LVSA1 series vehicles only.

(12) Install weatherhood (5.2) using two capscrews (5.4) and new locknuts
(5.3). Tighten locknuts (5.3) securely.

(13) Install four capscrews (5.1) in right, left and rear sides of weatherhood
(5.2). Tighten capscrews (5.1) securely.

(14) Install hose (4) and clamp (3) on check valve assembly (5). Tighten clamp
(3) securely.

(15) Install air inlet duct (2) on air cleaner (19) and tighten clamp (1).

END OF TASK

4-23
TM 08780B-20

4-7. AIR CLEANER ELEMENT REPLACEMENT

THIS TASK COVERS: a. Disassembly


b. Cleaning/Inspection
c. Assembly

INITIAL SETUP

Applicable Configurations Equipment


MK48 Condition Condition
TM Description
TM 08780B-20 Weatherhood
Materials/Parts removed (para 4-6
Primary filter element (124210) item 11 LVSA1 series
Secondary filter element (C-60238) item 15 vehicles only).

a. Disassembly

(1) Remove capscrew (1) and nut (2) from each side of super clone (3).
Position super clone (3) out of the way.

(2) Remove two capscrews (4) and two nuts (5) from each end of two
clamping straps (6). Remove two clamping straps (6).

(3) Remove two capscrews (7) and nuts (8) from each side of sealing frame
(9). Remove sealing frame (9) and worklight bracket (10).

(4) Remove primary filter element (11) from plenum pan (12). Discard
primary filter element (11).

(5) Loosen four capscrews (13) and nuts (14) at each corner of secondary
filter element (15).

(6) Swing each holding tab (16) away from secondary filter element (15).

(7) Remove and discard secondary filter element (15).

b. Cleaning/Inspection

(1) Clean plenum pan (12) and super clone (3).

(2) Clean all parts. Refer to paragraph 2-11.

(3) Inspect all parts. Refer to paragraph 2-12.

(4) Replace all parts failing inspection.

4-24
TM 08780B-20

c. Assembly

(1) Install new secondary filter element (15).

(2) Swing holding tabs (16) over secondary filter element (15) so that
secondary filter element (15) is secured in plenum pan (12).

(3) Tighten four capscrews (13) and nuts (14) securely.

(4) Install new primary filter element (11) with open side of primary filter
element (11) facing away from locating strap (17).

NOTE
When tightening capscrews (7), lightly tap sealing frame (9) to insure it is fully seated.

(5) Install sealing frame (9) on primary filter element (11). Align holes in
sealing frame (9) with plenum pan (12) and install four capscrews (7), worklight bracket (10) and
nuts (8). Tighten capscrews (7) and nuts (8) securely.

(6) Install two clamping straps (6). Install two capscrews (4) and two nuts (5)
on each end of clamping straps (6). Tighten capscrews (4) and nuts (5) securely.

(7) Install super clone (3), two capscrews (1) and nuts (2) on sealing frame
(9). Tighten two capscrews (1) and nuts (2) securely.

NOTE
Follow-On Maintenance
TM 08780B-20 Install weatherhood
(para 4-6 LVSA1 series vehicles only).

4-25
TM 08780B-20

1. Capscrew (2)
2. Nut (2)
3. Super Clone
4. Capscrew (4)
5. Nut
6. Clamping Strap (2)
7. Capscrew (4)
8. Nut (4)
9. Sealing Frame
10. Work Light Bracket
11. Primary Filter Element
12. Plenum Pan
13. Capscrew (4)
14. Nut (4)
15. Secondary Filter Element
16. Holding Tab (4)
17. Locating Strap

END OF TASK

4-26
TM 08780B-20

4-8. AIR RESTRICTION INDICATOR REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Materials/Parts


Lockwasher (2) (MS35338-44) item 6
Applicable Configurations
MK48

a. Removal

(1) Unscrew air restriction indicator (1) from elbow (2).

(2) Remove elbow (2) from mounting flange (3).

NOTE
If mounting flange (3) must be removed, remove dashboard (4). This will allow access to nuts
(5) and lockwashers (6). Refer to paragraph 7-11 of this manual.

(3) Loosen fitting (7) and remove vacuum line (8).

(4) Remove two capscrews (9), nuts (5) and lockwashers (6). Discard
lockwashers (6).

(5) Pull mounting flange (3) away from dashboard (4).

(6) Remove adapter (10) from mounting flange (3).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

c. Installation

(1) Install adapter (10) into mounting flange (3). Tighten securely.

(2) Install vacuum line (8) onto adapter (10). Tighten fitting (7) securely.

(3) Install mounting flange (3), two capscrews (9), new lockwashers (6) and
nuts (5). Tighten capscrews (9) and nuts (5) securely.

4-27
TM 08780B-20

(4) Install elbow (2) onto mounting flange (3). Tighten elbow (2) securely.

(5) Install air restriction indicator (1). Tighten air restriction indicator (1) by
hand.

END Of TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Install dashboard
(4) if removed (para 7-11).

1. Air Restriction Indicator


2. Elbow
3. Mounting Flange
4. Dashboard
5. Nut (2)
6. Lockwasher (2)
7. Fitting
8. Vacuum Line
9. Capscrew (2)
10. Adapter

4-28
TM 08780B-20

4-9. INTAKE DUCTING REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Materials/Parts


Lockwasher (MS35338-44) item 9
Applicable Configurations Lockwasher (2) (MS35338-45) item 18
MK48

a. Removal

(1) Loosen clamp (1) and remove hose (2).

(2) Loosen fitting (3) and remove hose (4).

(3) Loosen clamp (5) at the turbocharger (6).

(4) Remove capscrew (7), nut (8) and lockwasher (9) from hanger (10) behind
air cleaner assembly (11). Discard lockwasher (9).

(5) Loosen clamp (12) at air cleaner assembly (11). Pull rubber elbow (13)
away from air cleaner assembly (11).

(6) Pull intake ducting (14) free from air cleaner assembly (11) and
turbocharger (6).

1. Clamp 8. Nut
2. Hose 9. Lockwasher
3. Fitting 10. Hanger
4. Hose 11. Air Cleaner Assembly
5. Clamp 12. Clamp
6. Turbocharger 13. Rubber Elbow
7. Capscrew 14. Intake Ducting

4-29
TM 08780B-20

NOTE
Two clamps (15) may be used.

(7) Loosen clamp (15) and separate rubber elbow (13) from pipe (16).

(8) Remove two nuts (17), lockwashers (18), washers (19), clamp (20) and
bracket (10). Discard lockwashers (18).

(9) Loosen clamp (21) and separate reducer elbow (22) from pipe (16).

(10) Loosen clamp (23) and separate tube (24) from reducer elbow (22).

(11) Loosen clamp (25) and separate reducer elbow (26) from tube (24).

(12) Slide clamp (12) off of elbow (13).

10. Hanger
12. Clamp
13. Rubber Elbow
14. Intake Ducting
15. Clamp
16. Pipe
17. Nut (2)
18. Lockwasher (2)
19. Washer (2)
20. Clamp
21. Clamp
22. Reducer Elbow
23. Clamp
24. Tube
25. Clamp
26. Reducer Elbow

4-30
TM 08780B-20

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

c. Installation

NOTE
Assemble parts of intake ducting(14) as shown for proper installation.

(1) Install reducer elbow (26) and clamp (25) on tube (24). Tighten clamp
(25) securely. Slide clamp (23) onto reducer elbow (22).

(2) Install reducer elbow (22) and clamp (23) on tube (24). Tighten clamp
(23) securely.

(3) Install pipe (16) and clamp (21) on reducer elbow (22). Tighten clamp
(21) securely.

(4) Install clamp (20) with hanger (10), two washers (19), new lockwashers
(18) and two nuts (17). Tighten nuts (17) securely.

(5) Install rubber elbow (13) and clamp (15) on pipe (16). Tighten clamp (15)
securely.

(6) Slide clamp (12) onto rubber elbow (13).

4-31
TM 08780B-20

10. Hanger
12. Clamp
13. Rubber Elbow
14. Intake Ducting
15. Clamp
16. Pipe
17. Nut (2)
18. Lockwasher (2)
19. Washer (2)
20. Clamp
21. Clamp
22. Reducer Elbow
23. Clamp
24. Tube
25. Clamp
26. Reducer Elbow

1. Clamp
2. Hose
3. Fitting
4. Hose
5. Clamp
6. Turbocharger
7. Capscrew
8. Nut
9. Lockwasher
10. Hanger
11. Air Cleaner Assembly
12. Clamp
13. Rubber Elbow
14 Intake Ducting
16. Pipe
27. Reducer Elbow

4-32
TM 08780B-20

CAUTION
TO PREVENT PARTS DAMAGE, POSITION INTAKE DUCTING (14) AWAY FROM THE
AIR COMPRESSOR AND COOLANT PIPES.

(7) Install intake ducting (14). Position reducer elbow (27) and clamp (5) on
turbocharger (6). Tighten clamp (5) securely.

(8) Position rubber elbow (13) and clamp (12) on air cleaner assembly (11).
Tighten clamp (12) securely.

(9) Install hose (2) and clamp (1) on pipe (16). Tighten clamp (1) securely.

(10) Install hose (4) on pipe (16). Tighten fitting (3) securely.

(11) Install hanger (10) to air cleaner assembly (11) and secure with capscrew
(7), new lockwasher (9) and nut (8). Tighten capscrew (7) and nut (8) securely.

(12) Torque two nuts (17) to 15 foot-pounds (20 N*m).

END OF TASK

4-33
TM 08780B-20

4-10. LEFT FUEL TANK REPLACEMENT

THIS TASK COVERS: a. Draining


b. Removal
c. Cleaning/Inspection
d. Installation

INITIAL SETUP General Safety Instructions


Do not smoke or use open flame. Fuel is
Applicable Configurations flammable and may explode. Keep
MK48 fire extinguisher within reach.

Materials/Parts
Pipe sealant (item 48, Appendix D)
Cable tie (66182AX) item 16.1
Lockwasher (2) (MS35338-45) item 5
Locknut (2) (1437220) item 23
Locknut (4) (MS51943-39) Items 17 and 20
Lockwasher (351AX) item 27

a. Draining

NOTE
A siphon pump can be used to drain fuel, if available.

(1) Close valve (1) and (1.1) at left fuel tank (2) and right fuel tank (2.1) on
crossover hose (3).

NOTE
Fuel tank capacity is 75 gallons. Make certain container used to catch fuel is large enough.

(2) Remove capscrew (4), lockwasher (5), washer (5.1) and clamp (6).
Discard lockwasher (5).

(3) Place containers large enough to hold entire contents of left fuel tank (2)
near valve (1).
1. Valve
1.1. Valve
2. Left Fuel Tank
2.1. Right Fuel Tank
3. Crossover Hose
4. Capscrew
5. Lockwasher
5.1. Washer
6. Clamp

4-34
TM 08780B-20

(4) Loosen fitting (9) at right fuel tank (2.1). Remove crossover hose (3) and
place inside container. Open valve (1) at left fuel tank (2).

(5) Allow entire contents of left fuel tank (2) to drain.

(6) Connect fitting (9) to right fuel tank (2.1). Tighten securely.

1. Valve
2. Left Fuel Tank
2.1. Right Fuel Tank
9. Fitting

4-35
TM 08780B-20

b. Removal

(1) Loosen fitting (8) and allow crossover hose (3) to hang loose.

(2) Remove adapter (10), valve (1), nipple (11), elbow (12) and nipple (13).

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Disassembly steps are the same for old and new vehicles, except that the
nipple (13) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct
parts identification.

(3) Remove hose (14), check valve (15) and adapter (16).

NOTE
Perform step (4) for LVSA1 series vehicles only.

(4) Cut cable tie (16.1) and remove vent line (16.2) and vent valve (16.3).

(5) Remove two locknuts (17) from hold down straps (18) at radiator support
(19). Discard locknuts (17).

(6) Remove two locknuts (20) from hold down straps (18) under fender (21).
Discard locknuts (20).

(7) Remove two hold down straps (18) and two hold down strap liners (22).

NOTE
Perform steps (8) and (9) for LVSA1 series vehicles only.

(8) Remove two locknuts (23) and capscrews (24) from grab handle (25).
Discard locknuts (23).

(9) Remove capscrew (26), lockwasher (27), washer (28) and grab handle
(25). Discard lockwasher (27).

4-36
TM 08780B-20

1. Valve 17. Locknut (2)


2. Left Fuel Tank 18. Hold Down Strap (2)
3. Crossover Hose 19. Radiator Support
8. Fitting 20. Locknut (2)
10. Adapter 21. Fender
11. Nipple 22. Hold Down Strap Liner (2)
12. Elbow 23. Locknut (2)
13. Nipple 24. Capscrew (2)*
14. Hose 25. Grab Handle*
15. Check Valve 26. Capscrew
16. Adapter 27. Lockwasher
16.1. Cable Tie* 28. Washer
16.2. Vent Line*
16.3. Vent Valve* *LVSA1 Series Vehicles Only

4-37
TM 08780B-20

(10) With help from assistant, remove left fuel tank (2). Tip left fuel tank (2)
up to drain any remaining fuel.

(11) Remove pipe plug (23).

(12) Remove five screws (24), cover (25) and gasket (26). Discard gasket (26).

(13) Remove fuel tank cap (27) with strainer (28) and retainer (29).

(14) Remove pipe plugs (30 and 31).

c. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect hold down strap liners (22) for wear. Replace if worn.

(3) Inspect all other parts. Refer to paragraph 2-12.

(4) Replace all parts failing inspection.


2. Left Fuel Tank
23. Pipe Plug
24. Screw (5)
25. Cover
26. Gasket
27. Fuel Tank Cap
28. Strainer
29. Retainer
30. Pipe Plug
31. Pipe Plug

4-38
TM 08780B-20

d. Installation

CAUTION

TO PREVENT CONTAMINATION OF FUEL SYSTEM, DO NOT COAT FIRST TWO


THREADS OF ANY FITTING WITH PIPE SEALANT.

NOTE
Apply pipe sealant to threads on all fittings, elbows, adapters and pipe plugs.

(1) Install pipe plugs (30 and 31) into left fuel tank (2). Tighten securely.

(2) Install new gasket (26), cover (25) and five screws (24). Tighten screws
(24) securely.

(3) Install and tighten pipe plug (23).

(4) Install retainer (29), strainer (28) and fuel tank cap (27).

2. Left Fuel Tank


23. Pipe Plug
24. Screw (5)
25. Cover
26. Gasket
27. Fuel Tank Cap
28. Strainer
29. Retainer
30. Pipe Plug
31. Pipe Plug

4-39
TM 08780B-20

(5) With help from assistant, lift left fuel tank (2) into place on fender (21).

(6) Place hold down straps (18) on left fuel tank (2). Make sure two hold
down strap liners (22) are in place.

(7) Install new locknuts (17 and 20) onto hold down straps (18). Tighten
locknuts (17 and 20) securely

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Assembly steps are the same for old and new vehicles, except that the
nipple (13) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct
parts identification.

(8) Install nipple (13) and elbow (12) into left fuel tank (2). Tighten securely.

(9) Install nipple (11), valve (1) and adapter (10) into left fuel tank (2) and
tighten securely.

(10) Connect crossover hose (3) and tighten fitting (8) securely.

(11) Install clamp (6) using capscrew (4), new lockwasher (5) and washer (5.1).
Torque capscrew (4) to 8 foot-pounds (11 N*m).

(12) Install adapter (16) and tighten securely.

(13) Install check valve (15). Tighten securely.

(14) Connect hose (14) to check valve (15).

NOTE
Perform steps (15 thru 18) for LVSA1 series vehicles only.

(15) Install vent valve (16.3). Tighten securely.

(16) Connect vent line (16.2) to barbed nozzle of vent valve (16.3) and secure
with cable tie (16.1).

(17) Install grab handle (25) with two capscrews (24) and new locknuts (23).
Tighten securely.

(18) Install new lockwasher (27), washer (28) and capscrew (26) in grab handle
(25). Tighten securely.

END OF TASK

4-40
TM 08780B-20

NOTE

Follow-On Maintenance
TM 08780B-10 Fill fuel tanks and
prime fuel system (para 2-13).

Run engine and check for leaks


(para 2-13).

1. Valve 12. Elbow 20. Locknut (2)


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

* LVSA1 Series Vehicles Only

4-41
TM 08780B-20

4-11. RIGHT FUEL TANK REPLACEMENT

THIS TASK COVERS: a. Draining


b. Removal
c. Cleaning/Inspection
d. Installation

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48 TM 08780B-20 Fuel level sending
unit removed (para
Materials/Parts 7-40).
Pipe sealant (item 48, Appendix D)
Cable tie (66182AX) item 19.1
Lockwasher (MS35338-45) item 5 General Safety Instructions
Locknut (4) (MS51943-39) items 20 and 23 Do not smoke or use open flame. Fuel is
Locknut (2) (1437220) item 19.4 flammable and may explode. Keep fire
Lockwasher (351AX) item 19.9 extinguisher within reach.

a. Draining

NOTE
A siphon pump can be used to drain fuel, if available.

(1) Close valve (1) and (1.1) at left fuel tank (2) and right fuel tank (2.1) on
crossover hose (3).

NOTE
Fuel tank capacity is 75 gallons. Make certain container used to catch fuel is large enough.

(2) Remove capscrew (4), lockwasher (5), washer (5.1) and clamp (6).
Discard lockwasher (5).

(3) Place container large enough to hold entire contents of right fuel tank (2.1)
near valve (1).

(4) Loosen fitting (8), remove crossover hose (3) from valve (1) and place
crossover hose (3) inside container. Open valve (1.1).

(5) Allow entire contents of right fuel tank (2.1) to drain.

4-42
TM 08780B-20

1. Valve
1.1. Valve
2. Left Fuel Tank
2.1. Right Fuel Tank
3. Crossover Hose
4. Capscrew
5. Lockwasher
5.1. Washer
6. Clamp
8. Fitting

4-43
TM 08780B-20

b. Removal

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Disassembly steps are the same for old and new vehicles, except that the
nipple (10.1) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct
parts identification.

(1) Remove adapter (10), valve (1.1) and nipple (10.1).

(2) Loosen fitting (11) and remove hose (12).

(3) Loosen fitting (13) and remove hose (14).

(4) Loosen fitting (15) and remove hose (16).

(5) Remove hose (17), check valve (18) and adapter (19).

NOTE
Perform steps (6 through 8) for LVSA1 series vehicles only.

(6) Cut cable tie (19.1) and remove vent line (19.2) and vent valve (19.3).

(7) Remove two locknuts (19.4) and capscrews (19.5) from grab handle
(19.6). Discard locknuts (19.4).

(8) Remove capscrew (19.7), washer (19.8), lockwasher (19.9) and grab
handle (19.6). Discard lockwasher (19.9).

(9) Remove two locknuts (20) from hold down straps (21) at radiator support
(22). Discard locknuts (20).

(10) Remove two locknuts (23) from hold down straps (21) under fender (24).
Discard locknuts (23). Remove two hold down straps (21). If damaged, remove and discard two
hold down strap liners (25).

(11) With help from assistant, remove right fuel tank (2.1). Tip right fuel tank
(2.1) up to drain any remaining fuel.

4-44
TM 08780B-20

1.1. Valve 19.2. Vent Line*


2.1. Right Fuel Tank 19.3. Vent Valve*
10. Adapter 19.4. Locknut (2)*
10.1. Nipple 19.5. Capscrew (2)*
11. Fitting 19.6. Grab Handle*
12. Hose 19.7. Capscrew
13. Fitting 19.8. Washer
14. Hose 19.9. Lockwasher
15. Fitting 20. Locknut (2)
16. Hose 21. Hold Down Strap (2)
17. Hose 22. Radiator Support
18. Check Valve 23. Locknut (2)
19. Adapter 24. Fender
19.1. Cable Tie* 25. Hold Down Strap Liner (2)

*LVSA1 Series Vehicles Only

4-45
TM 08780B-20

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Disassembly steps are the same for old and new vehicles, except that the
nipples (28 and 31) are not required on LVSA1 series vehicles. Refer to TM 08780B-24P for
correct parts identification.

(12) Remove adapter (26), check valve (27), nipple (28), elbow (29),
reducer(30) and nipple (31).

(13) Remove adapters (32 and 33), tee (34) and nipple (35).

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Disassembly steps are the same for old and new vehicles, except that the
nipple (37) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct
parts identification.

(14) Remove tee (36) and nipple (37).

(15) Remove pipe plugs (38 and 39).

(16) Remove fuel tank cap (40), strainer (41) and retainer (42).

c. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all other parts. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

4-46
TM 08780B-20

26. Adapter 35. Nipple


27. Check Valve 36. Tee
28. Nipple 37. Nipple
29. Elbow 38. Pipe Plug
30. Reducer 39. Pipe Plug
31. Nipple 40. Fuel Tank Cap
32. Adapter 41. Strainer
33. Adapter 42. Retainer
34. Tee

4-47
TM 08780B-20

d. Installation
CAUTION

TO PREVENT CONTAMINATION OF FUEL SYSTEM, DO NOT COAT FIRST TWO


THREADS OF ANY FITTING WITH PIPE SEALANT.

NOTE
Apply pipe sealant to threads on all fittings, elbows, adapters and pipe plugs.

(1) Install pipe plugs (38 and 39) into right fuel tank (7). Tighten securely.

(2) Install retainer (42), strainer (41) and fuel tank cap (40).

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have. changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Assembly steps are the same for old and new vehicles, except that the
nipples (28 and 31) are not required on LVSA1 series vehicles. Refer to TM 08780B-24P for
correct parts identification

(3) Install nipple (31), reducer (30) and elbow (29). Tighten securely.

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Assembly steps are the same for old and new vehicles, except that nipple
(37) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct parts
identification.

(4) Install nipple (28), check valve (27) and adapter (26). Tighten securely.

(5) Install nipple (37), tee (36), nipple (35) and tee (34). Tighten securely.

(6) Install nipple (45) and tee (34). Tighten securely.

(7) Install adapters (32 and 33).

(8) With help from assistant, lift right fuel tank (2.1) into place on fender (24).

4-48
TM 08780B-20

26. Adapter 35. Nipple


27. Check Valve 36. Tee
28. Nipple 37. Nipple
29. Elbow 38. Pipe Plug
30. Reducer 39. Pipe Plug
31. Nipple 40. Fuel Tank Cap
32. Adapter 41. Strainer
33. Adapter 42. Retainer
34. Tee

4-49
TM 08780B-20

(9) If removed, install two hold down strap liners (25). Place two hold down
straps (21) on right fuel tank (2.1).

(10) Install four new locknuts (20 and 23) onto hold down straps (21). Tighten
locknuts (20 and 23) securely.

(11) Install adapter (19) and tighten securely.

(12) Install check valve (18) and tighten securely. Connect hose (17) to check
valve (18).

NOTE
Perform step (13) for LVSA1 series vehicles only.

(13) Install vent valve (19.3) and tighten securely. Connect hose (19.2) to
barbed nozzle of vent valve (19.3) and secure with cable tie (19.1).

(14) Connect hose (16) to adapter (26). Tighten fitting (15) securely.

NOTE
Fuel tank lines and fittings for LVSA1 series vehicles have changed to a larger diameter for
improved fuel flow. Fittings have changed to brass and parts are not interchangeable between
old and new vehicles. Assembly steps are the same for old and new vehicles, except that nipple
(10.1) is not required on LVSA1 series vehicles. Refer to TM 08780B-24P for correct parts
identification.

(15) Install nipple (10.1), valve (1.1) and adapter (10). Tighten securely.

(16) Connect crossover hose (3) to adapter (10). Tighten fitting (9) securely.

NOTE
Perform steps (17 and 18) for LVSA1 series vehicles only.

(17) Install grab handle (19.6) with two capscrews (19.5) and new
locknuts(19.4). Tighten locknuts (19.4) securely.

(18) Install washer (19.8), lockwasher (19.9) and capscrew (19.7) in grab
handle (19.6). Tighten capscrew (19.7) securely.

(19) Install clamp (6) using capscrew (4), new lockwasher (5) and washer (5.1).
Tighten capscrew (4) to 8 foot-pounds (11 N*m).

4-50
TM 08780B-20

1. Valve
3. Crossover Hose
4. Capscrew
5. Lockwasher
5.1. Washer
6. Clamp
8. Fitting

(20) Install crossover hose (3) to valve (1). Tighten fitting (8) securely. Place
valve (1) in open position.

(21) Connect hose (12) to adapter (33). Tighten fitting (11) securely.

(22) Connect hose (14) to adapter (32). Tighten fitting (13) securely.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-10 Fill fuel tanks and
prime fuel system (para 2-13).

Run engine and check for


leaks (para 2-13).

TM 08780B-20 Install fuel level sending


unit (para 7-40).

4-51
TM 08780B-20

1.1. Valve 19.3. Vent Valve*


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

4-52
TM 08780B-20

4-12. FUEL LINE, VENT, AND FITTING REPLACEMENT

THIS TASK COVERS: a. Removal


c. Cleaning/Inspection
d. Installation

INITIAL SETUP
General Safety Instructions
Applicable Configurations Do not smoke or use open flame. Fuel is
MK48 flammable and may explode. Keep fire
extinguisher within reach.
Materials/Parts
Pipe sealant (item 48, Appendix D)
Cable tie (AR) (MS3367-1-9)
Cable tie (2) (66182AX) item 4.1

a. Removal

NOTE
• The following procedures describe service of all fuel lines and fittings shown.

• Tag or mark all fuel lines to ensure proper installation.

• If fuel line is under pressure crack or open line to bleed off pressure. Use a cloth or
container to catch run-off fuel. Dispose of fuel properly.

• Fuel lines and fittings on LVSA1 series vehicles are larger than fuel lines and fittings
on non-A1 vehicles. Repair procedures are identical for LVSA1 and non-A1 vehicles.
Refer to TM 08780B-24P for correct parts identification.

(1) Use proper size line wrench to remove fuel lines (1) as necessary.

(2) Remove fittings (2) as necessary.

(3) Remove check valves (3) as necessary.

(4) Remove vent lines (4) as necessary.

NOTE
Perform steps (5 and 6) for LVSA1 series vehicles only.

(5) Cut cable ties (4.1) and remove vent line (4.2) as necessary.

(6) Remove vent valve (4.3).

(7) Remove cable ties as necessary.

4-53
TM 08780B-20

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all hoses for cuts, cracks, breaks or bends.

(3) Inspect elbows, fittings and tubing for stripped threads, cracks or breaks.

(4) Inspect check valves for proper operation. Air or fluid must be able to
pass in one direction.

(5) Replace all parts failing inspection.

c. Installation

NOTE
Apply proper sealant to all fitting threads before installing.

(1) Install vent lines (4) or as necessary.

(2) Install check valves (3) as necessary.

NOTE
Perform steps (3 and 4) for LVSA1 series vehicles only.

(3) Install vent valve (4.3) as necessary.

(4) Install vent line (4.2) as necessary and secure with cable tie (4.1).

(5) Install fittings (2) as necessary.

(6) Install fuel lines (1) as necessary.

(7) Install nylon ties to secure hoses in place.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-10 Prime fuel system
(para 2-13).

Start engine and check


for leaks (para 2-13).

4-54
TM 08780B-20

1. Fuel Lines
2. Fittings
3. Check Valves
4. Vent Line
4.1. Cable Tie (2)*
4.1. Vent Line*
4.2. Vent Valve*

*LVSA1 Series Vehicles Only

4-55
TM 08780B-20

4-13. SHUTDOWN SOLENOID REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Installation
c. Installation
d. Adjustment

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48 TM 08780B-20 Batteries
disconnected
Materials/Parts (para 7-45).
Lockwasher (MS35338-46) item 15
Lockwasher (7) (MS35338-44) items 6, 20,23,25 and 31 Engine access panel
Copper washer (MS51092-1) item 26 removed (para 18-15).

Personnel Required General Safety Instructions


1 MOS 3521 To prevent personal injury, make sure
1 Assistant batteries are disconnected before working
on electrical components.

a. Removal

(1) Remove two flange nuts (1). Tag and remove four wires (2, 3, 4 and 4.1).

(2) Remove two nuts (5), lockwashers (6), washers (7) and capscrews (8)
from bracket (9). Discard lockwashers (6).

(3) Remove nut (10), two star washers (10.1), wire (4) and capscrew (10.2).
Discard star washers (10.1).
1 Flange Nut 8. Capscrew (2)
2. Wire (No. 019) 9. Bracket
3. Wire (No. 817) 10. Nut
4. Wire Ground 10.1. Star Washer (2)
4.1. Wire (718) 10.2. Capscrew
5. Nut (2) 11. Governor Control Lever
6. Lockwasher (2) 12. Shaft
7. Washer (2)

4-56
TM 08780B-20

NOTE
Locate engine serial number. Engines prior to 8VF 98256 use a short style mounting bracket
(13). Engines after that serial number use a long style mounting bracket (13) and spacer (17).

(4) Remove nut (14), lockwasher (15), washers (16), spacer (17) if used and
capscrew (18). Discard lockwasher (15).

(5) Remove capscrew (19) and lockwasher (20) from governor control lever
(11). Remove governor control lever (11). Discard lockwasher (20).

(6) Remove shutdown solenoid (21).

(7) Remove two capscrews (22), lockwashers (23) and bracket (9). Discard
lockwashers (23).

(8) Remove capscrew (24), lockwashers (25), bracket (13), copper washer
(26) or nut (27) if used. Discard lockwashers (25) and copper washer (26).

(9) Remove capscrew (28) and nut (29) from governor control lever (11).

(10) Remove nut (30), lockwasher (31), washer (32), bracket clip (33), washer
(34) and nut (35) from shutdown solenoid (21). Discard lockwasher (31).
9. Bracket
11. Governor Control Lever
12. Shaft
13. Bracket
14. Nut
15. Lockwasher
16. Washer
17. Spacer
18. Capscrew
19. Capscrew
20. Lockwasher
21. Shutdown Solenoid
22. Capscrew (2)
23. Lockwasher (2)
24. Capscrew
25. Lockwasher
26. Copper Washer
27. Nut
28. Capscrew
29. Nut
30. Nut
31. Lockwasher
32. Washer
33. Bracket Clip
34. Washer
35. Nut
4-57
TM 08780B-20

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect wires (2, 3, 4 and 4.1) and connections.

(3) Inspect all parts. Refer to paragraph 2-12.

(4) Replace all parts failing inspection.

c. Installation

(1) Install nut (35), washer (34), bracket clip (33), washer (32), lockwasher
(31) and nut (30) onto shutdown solenoid (21). Leave nuts (30 and 35) fingertight for
adjustment.

(2) Install bracket (13), with a new copper washer (26), new lockwashers (25),
capscrew (24) and nut (27). Tighten.

(3) Install bracket (9), two capscrews (22) and new lockwashers (23). Tighten
capscrews (22) securely.

(4) Install capscrew (18) with spacer (17) if used, through brackets (9 and 13).
Install washers (16), new lockwasher (15) and nut (14). Tighten nut (14) securely.

(5) Install control lever (11), new lockwasher (20) and capscrew (19).

(6) Align marks on governor control lever (11) and shaft (12) and tighten
capscrew (19) securely.

(7) Align hole in bracket clip (33) with hole in governor control lever (11).
Install capscrew (28) and nut (29). Tighten capscrew (28) and nut (29) securely.

(8) Align holes in shutdown solenoid (21) with holes in bracket (9). Install
shutdown solenoid (21) with bracket clip (33) facing governor control lever (11). Install ground
wire (4), two new star washers (10.1), capscrew (10.2) and nut (10). Tighten capscrew (10.2)
and nut (10) securely.

(8.1) Install two capscrews (8), washers (7), lockwashers (6) and nuts (5).
Tighten capscrews (8) and nuts (5) securely.

(9) Loosen nuts (30 and 35) on shutdown solenoid (21).

4-58
TM 08780B-20

9. Bracket 23. Lockwasher (2)


11. Governor Control Lever 24. Capscrew
12. Shaft 25. Lockwasher
13. Bracket 26. Copper Washer
14. Nut 27. Nut
15. Lockwasher 28. Capscrew
16. Washer 29. Nut
17. Spacer 30. Nut
18. Capscrew 31. Lockwasher
19. Capscrew 32. Washer
20. Lockwasher 33. Bracket Clip
21. Shutdown Solenoid 34. Washer
22. Capscrew (2) 35. Nut

4-59
TM 08780B-20

(10) Install wires (2, 3, 4 and 4.1) in their marked locations.

(11) Install two flange nuts (1). Tighten nuts (1) securely.

(12) Connect batteries. Refer to paragraph 7-41.

d. Adjustment

(1) Have assistant position governor control lever (11) in no fuel position and
push shaft (36) in all the way. Tighten nut (30) until snug. Tighten nuts (30 and 35) securely.

NOTE
Make sure shaft (36) does not bind when operated. Adjust mounting bolts as required to
prevent binding.

(2) Check operation of shutdown solenoid (21). If shutdown solenoid will


not stop engine, back off nut (35) and tighten nut (30) until properly adjusted.

END OF TASK

NOTE
Follow-On Maintenance
TM 08780B-20 Install engine access
panel (para 18-15).

1. Flange Nut
2. Wire (No. 019)
3. Wire (No. 817)
4. Wire Ground
4.1. Wire (No. 718)
5. Nut (2)
6. Lockwasher (2)
7. Washer (2)
8. Capscrew
9. Bracket
10.1. Star Washer (2)
10.2. Capscrew
11. Governor Control Lever
12. Shaft
21. Shutdown Solenoid
30. Nut
33. Bracket Clip
35. Nut
36. Shaft

4-60
TM 08780B-20

4-14. SHUTDOWN SOLENOID REPLACEMENT (LVSA1 SERIES VEHICLES ONLY)

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48A1 TM 08780B-20 Batteries
disconnected
Materials/Parts (para 7-46)
Lockwasher (7) (MS35338-44) items 2, 6, 29 and 34
Copper washer (MS51092-1) item 36 Engine access panel
Lockwasher (P/N 351 AX) item 12 removed (para 18-15)
Locknut (2) (P/N 25003FX) item 17 and 22
Locknut (P/N 112556A) item 24 General Safety Instructions
Compound, Corrosion preventive (item 11.1 To prevent personal injury, make sure
Appendix D) batteries are disconnected before working
on electrical components.

a. Removal

(1) Remove nut (1), Lockwasher (2) and washer (3) from shaft (4). Discard
lockwasher (2).

(2) Remove two nuts (5), lockwashers (6), three washers (7) and two screws
(8) from solenoid (9) and plate (10). Discard lockwashers (6).

NOTE
Tag and mark wires before removal.

(3) Remove capscrew (11), lockwasher (12), flat washer (13) and ground wire
(14). Discard Lockwasher (12).

4-61
TM 08780B-20

1. Nut 5. Nut (2) 9. Solenoid 13. Flat Washer


2. Lockwasher 6. Lockwasher (2) 10. Plate 14. Ground Wire
3. Washer 7. Washer (3) 11. Capscrew
4. Shaft 8. Screw (2) 12. Lockwasher

(4) Remove two nuts (15), three wires (16) and ground wire (17).

NOTE
Screw (22) may need to be loosened to remove locknut (18).

(5) Remove locknut (18). Pull up on shutdown link (19) and remove bracket
(20) and stop lever (21) from screw (22). Discard locknut (18).

(6) Remove locknut (23), two washers (24) and screw (22). Discard locknut
(23).

(7) Remove locknut (25) and shutdown link (19) from shutdown cable (26).
Discard locknut (25).

(8) Loosen two nuts (27) and remove shutdown cable (26) from cable bracket
(28).

NOTE
Crossover tube may need to be loosened to remove screw (29).

(9) Remove screw (29), lockwasher (30) and plate (10). Discard lockwasher
(30).

(10) Remove two nuts (31), lockwashers (32), washers (33), screws (34) and
cable bracket (28). Discard lockwashers (32).

(11) Remove solenoid (9).

4-62
TM 08780B-20

NOTE
Matchmark stop lever and stop lever shaft.

(12) Loosen screw (35) and remove stop lever (21).

NOTE
Note location of ties prior to removal to ensure proper installation.

(13) Remove screw (36), copper washer (37) and bracket (38). Discard copper
washer (37).

9. Solenoid 22. Screw 31. Nut (2)


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

4-63
TM 08780B-20

26. Shutdown Cable


39. Nut
40. Handle
41. Nut

(14) Remove three ties connecting shutdown cable (26) to cab and transmission
shift cable.

(15) Loosen nut (41) and unscrew handle (40) from shutdown cable (26).

(16) Remove nuts (39 and 41) and pull shutdown cable (26) downward through
opening in cab.

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect wires (14, 16 and 17) and connections.

(3) Inspect all parts. Refer to paragraph 2-12.

(4) Replace all parts failing inspection.

c. Installation

(1) Route shutdown cable (26) upward through opening in cab. Secure using
nuts (39 and 41).

(2) Screw handle (40) on shutdown cable (26) and tighten nut (39).

(3) Secure shutdown cable (25) to transmission shift cable and cab with ties in
positions noted during removal.

(4) Install bracket (38), new copper washer (37) and screw (36).

(5) Align matchmarks and install stop lever (21).

(6) Tighten screw (35).

4-64
TM 08780B-20

(7) Position solenoid (9) on plate (10).

(8) Install cable bracket (28) with two screws (34), washers (33), new
lockwashers (32) and nuts (31).

(9) Install plate (10) with screw (29) and new lockwasher (30).

(10) Install shutdown cable (26) on cable bracket (28) and tighten two nuts
(27).

(11) Install shutdown link (19) on shutdown cable (26) with new locknut (25).
Do not tighten locknut (25).

(12) Install bracket (20) on screw (22).

(13) Install screw (22) in shutdown link (19) with two washers (24) and new
locknut(23). Tighten new locknut (23) to provide 0.03 in. (0.76 mm) clearance above and below
shutdown link (19).

(14) Install stop lever (21) and bracket (20) on screw (22) with new locknut
(18). Tighten new locknut (18) to provide 0.03 in. (0.76 mm) clearance above and below
bracket (20).

(15) Adjust locknut (25) until shutdown link (19) has approximately 0.38 in.
(9.65 mm) free play in slot before shutdown link contacts screw (22). Tighten locknuts.

(16) Install ground wire (17), three wires (16) and nuts (15).

4-65
TM 08780B-20

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

1. Nut
2. Lockwasher
3. Washer
4. Shaft
5. Nut (2)
6. Lockwasher (2)
7. Washer (2)
8. Screw (2)
9. Solenoid
10. Plate
11. Capscrew
12. Lockwasher
13. Flat Washer
14. Ground Wire
20. Bracket
42. Nut

4-66
TM 08780B-20

(17) Install capscrew (11), new lockwasher (12), flat washer (13) and ground
wire (14).

(18) Coat capscrew (11) at ground wire (14) with corrosion preventive
compound.

(19) Install two screws (8), three washers (7), two new lockwashers (6) and
nuts (5) on solenoid (9) and plate (10).

(20) Install washer (3), new lockwasher (2) and nut (1) on shaft (4) finger tight
and take slack out of bracket (19).

(21) Tighten nuts (42) and (1) against bracket (20).

d. Adjustment

(1) Hold stop lever (1) in run position.

(2) Adjust nut (2) to touch bracket (3).

(3) Tighten nuts (2 and 4) against bracket (3).

(4) Move stop lever (1) to stop position; if it binds, loosen mounting bolts and
re-align solenoid (5).

(5) Move stop lever (1); if lever binds with shutdown link (6), loosen locknut
(7) until lever moves freely within slot of shutdown link.

END OF TASK

NOTE

Follow-On Maintenance
TM 08780B-20 Install engine access
panel (para 18-15).

Connect batteries
(para 7-46).

4-67
TM 08780B-20

1. Stop Lever
2. Nut
3. Bracket
4. Nut
5. Solenoid
6. Shutdown Link
7. Locknut

4-68
TM 08780B-20

4-15. THROTTLE CONTROL SOLENOID REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48 TM 08780B-20 Exhaust crossover
tube removed (para
Materials/Parts 5-4).
Pipe sealant (item 48, Appendix D)
Lockwasher (2) (MS35338-43) item 15
Gasket (731740-002) item 1.3 TM 08780B-10 Air system
drained (para 3-5).

a. Removal

(1) Unplug boot connector (1).

NOTE
Perform steps (2 and 7) for LVSA1 series vehicles only.

(2) Loosen screw (1.1) and remove connector (1.2) and gasket (1.3). Discard
gasket (1.3).

(3) Loosen fitting (2). Tag and remove air line (3).

(4) Loosen fitting (4). Tag and remove air line (5).

(5) Remove capscrew (6), washer (7) and bracket (11) from throttle control
wire (8).

(6) Remove capscrew (9), washer (10), solenoid (12) from transmission (13).

(7) Remove two capscrews (6 and 9), washers (7 and 10), bracket (11) and
throttle control solenoid (12.1) from transmission (13).

(8) Remove two screws (14) and lockwashers (15) from throttle control
solenoid (12) or (12.1). Remove bracket (11) and throttle control solenoid (12 or 12.1). Discard
lockwashers (15).

(9) Remove two elbows (16) from throttle control solenoid (12 or 12.1).

4-69
TM 08780B-20

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect parts for damage. Refer to paragraph 2-12.

(3) Replace all parts failing inspection.

c. Installation

(1) Coat two elbows (16) with pipe sealant and install on throttle control
solenoid (12 or 12.1). Tighten elbows (16) securely.

(2) Install bracket (11), two screws (14) and new lockwashers (15) on throttle
control solenoid (12 or 12.1). Tighten screws (14) securely.

(3) Install throttle control solenoid (12), bracket (11), wire (8), two capscrews
(6 and 9) and washers (7 and 10) on transmission (13). Tighten capscrews (6 and 9) securely.

NOTE
Perform steps (4 and 8) for LVSA1 series vehicles only.

(4) Install throttle control solenoid (12.1), bracket (11), two capscrews (6 and
9) and washers (7 and 10) on transmission (13). Tighten capscrews(6 and 9) securely.

(5) Install air line (5) in tagged location. Tighten fitting (4) securely.

(6) Install air line (3) in tagged location. Tighten fitting (2) securely.

(7) Reconnect boot connector (1).

(8) Install new gasket (1 .3) on connector (1.2) and reconnect. Tighten screw
(1.1) securely.

END OF TASK

4-70
TM 08780B-20

NOTE

Follow-On Maintenance
TM 08780B-20 Install exhaust
crossover tube
(para 5-4).

TM 08780B-10 Start and run


engine (para 2-13).

Check to make sure


engine speed increases when
winch is operated.

1. Boot Connector
1.1. Screw*
1.2. Connector*
1.3. Gasket*
2. Fitting
3. Air Line
4. Fitting
5. Air Line
6. Capscrew
7. Washer
8. Wire
9. Capscrew
10. Washer
11. Bracket
12. Throttle Control Solenoid
12.1. Throttle Control Solenoid
13. Transmission
14. Screw (2)
15. Lockwasher (2)
16. Elbow (2)
*LVSA1 Series Vehicles Only

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TM 08780B-20

4-16. THROTTLE CYLINDER REPLACEMENT

THIS TASK COVERS: a. Removal


b. Cleaning/Inspection
c. Installation

INITIAL SETUP Equipment


Condition Condition
Applicable Configurations TM Description
MK48 TM 08780B-10 Air system drained
(para 3-5).
Materials/Parts
Pipe sealant (item 48, Appendix D) TM 08780B-20 Access panel
Lockwasher (7) (MS35338-44) removed
items 10, 14 and 20 (para 18-15, item 9).

a. Removal

(1) Loosen fittings (1, 2 and 3). Tag and remove air lines (4, 5 and 6).

(2) Line mark throttle lever (7) and shaft (8).

(3) Remove two capscrews (9), lockwashers (10) and nuts (11) from throttle
lever (7). Discard lockwashers (10).

(4) Remove two capscrews (12), nuts (13), lockwashers (14) and washers (15)
from throttle cylinder (16) and bracket (17). Discard lockwashers (14).

(5) Remove throttle cylinder (16).

(6) Remove throttle lever (7) and spring (18).

(7) Remove three capscrews (19), lockwashers (20) and bracket (17). Discard
lockwashers (20).

(8) Remove check valve (21) from throttle cylinder (16).

(9) Remove tee (22) and adapter (23) from check valve (21).

(10) Remove elbow (24).

b. Cleaning/Inspection

(1) Clean all parts. Refer to paragraph 2-11.

(2) Inspect all parts. Refer to paragraph 2-12.

4-72
TM 08780B-20

(3) Replace all parts failing inspection.

c. Installation

NOTE
Coat all pipe threads with pipe sealant during installation.

(1) Install elbow (24), tee (22) and adapter (23) into check valve (21).
Tighten elbow (24), tee (22) and adapter (23) securely.

(2) Thread check valve (21) into throttle cylinder (16). Tighten check valve
(21) securely.

(3) Install bracket (17) with three capscrews(19) and new lockwashers (20).
Tighten capscrews (19) securely.

(4) Install throttle lever (7) onto shaft (8).

(5) Install throttle cylinder (16) with rod (25) in throttle lever (7).

(6) Install two capscrews (12), new lockwashers (14), washers (15) and
nuts(13). Tighten capscrews (12) and nuts (13) securely.

(7) Install two capscrews (9), new lockwashers (10) and nuts (11) into throttle
lever (7). Align throttle lever (7) and shaft (8) with line marks. Tighten capscrews (9) securely.

(8) Install spring (18).

(9) Install air lines (4, 5 and 6) in their tagged locations. Tighten fittings (1, 2
and 3) securely.

END OF TASK

NOTE

Follow-On Maintenance
LI 2320-12/9 Lubricate throttle
LO 9-2320-297-12 cylinder.

TM 08780B-20 Install access panel


(para 18-15, item 9).

TM 08780B-10 Run engine to build air


pressure. Check system for
leaks (para 2-13).

4-73
TM 08780B-20

1. Fitting 14. Lockwasher (2)


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

4-74
TM 08780B-20

4-17. THROTTLE CYLINDER REPAIR

THIS TASK COVERS: a. Disassembly


b. Cleaning/Inspection
c. Assembly

INITIAL SETUP References


LI 2320-12/9
Applicable Configurations LO 9-2320-297-12
MK48
Equipment
Materials/Parts Condition Condition
Adhesive (item 3, Appendix D) TM Description
Grease (item 22, Appendix D) TM 08780B-20 Throttle
Silicone lubricant (item 26, Appendix D) cylinder removed
Soap solution (item 54, Appendix D) (para 4-16).
Lockwasher (2) (MS35338-44) item 18
Repair kit (117612)

a. Disassembly

(1) Remove eight screws (1) and cover (2) from rear of throttle cylinder (3).
Discard eight screws (1).

(2) Install an Allen wrench (4) into piston (5) to prevent piston (5) from
t