Professional Documents
Culture Documents
TECHNICAL MANUAL
NOTE
a
TM 5-3810-307-24-1-1
TECHNICAL MANUAL
PETER J. SCHOOMAKER
General, United States Army
Official: Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0615301
Distribution:
Page No. *Change No. Page No. *Change No. Page No. *Change No.
Cover 0 Divider 0 2-7-22 0
Blank 0 Blank 0 2-7-23 1
Warning 0 2-1-1 2-1-2 0 2-7-242-7-25 0
Blank 0 2-1-3 1 2-7-262-7-27 1
i ii 1 2-1-4 2-1-24 0 2-7-282-7-29 0
iii 0 2-1-25 1 2-7-302-7-38 1
iv vi 1 2-1-262-1-31 0 2-8-1 1
vii 0 2-1-32 1 2-8-2 2-8-18 0
viii x 1 2-1-33 0 2-8-18a2-8-18b 1
Divider 0 2-1-34 1 2-8-192-8-20 0
Blank 0 2-1-352-1-100 0 2-8-21 1
1-1-1 1-1-2 0 2-1-1012-1-102 1 2-8-222-8-29 0
1-1-3 1 2-2-1 2-2-26 0 2-8-30 1
1-1-4 1-1-6 0 2-2-27 1 2-8-31 0
1-1-7 1 2-2-282-2-29 0 2-8-32 1
1-1-8 1-1-10 0 2-2-30 1 2-8-332-8-36 0
1-2-1 1-2-5 0 2-2-312-2-42 0 2-8-37 1
1-2-6 1 2-3-1 2-3-36 0 2-8-382-8-42 0
1-2-7 1-2-10 0 2-4-1 2-4-36 0 2-8-43 1
1-3-1 1-3-4 0 2-5-1 0 2-8-442-8-46 0
1-3-5 1-3-6 1 2-5-2 1 2-8-47 1
1-3-7 0 2-5-3 2-5-22 0 2-8-482-8-52 0
1-3-8 1 2-5-232-5-24 1 2-8-53 1
1-3-9 0 2-6-1 2-6-6 0 2-8-542-8-60 0
1-3-10 1 2-7-1 2-7-4 1 2-8-612-8-63 1
1-3-111-3-12 0 2-7-5 2-7-10 0 2-8-642-8-78 0
1-4-1 1-4-4 0 2-7-112-7-12 1 2-9-1 2-9-5 0
1-4-5 1-4-6 1 2-7-132-7-17 0 2-9-6 1
1-4-7 0 2-7-18 1 2-9-7 2-9-17 0
1-4-8 1 2-7-192-7-20 0 2-9-18 1
1-4-9 1-1-14 0 2-7-21 1
1-5-1 1-5-34 0
* Zero in this column indicates an original page.
A C-1
TM 5-3810-307-24-1-1
Page No. *Change No. Page No. *Change No. Page No. *Change No.
2-10-12-10-3 0
2-10-4 1
2-10-52-10-10 0
2-10-11 1
2-10-122-10-22 0
2-11-12-11-16 0
2-12-12-12-14 0
2-13-12-13-12 0
2-14-12-14-30 0
2-15-12-15-10 0
2-16-12-16-2 1
2-16-32-16-4 0
A-1 A-22 1
Index-1
Index-20 1
FO-1 FO-14 0
TABLE OF CONTENTS
VOLUME 1
Page
i C-1
TM 5-3810-307-24-1-1
Page
ii C-1
TM 5-3810-307-24-1-1
Page
iii
TM 5-3810-307-24-1-1
Page
APPENDICES
FOLDOUTS
Page
iv C-1
TM 5-3810-307-24-1-1
VOLUME 2
SM07-005-0 Reservoirs
SM07-006-0 Low Pressure Indicating Switch
SM07-008-0 Throttle Control Cylinder
SM07-012-0 Pressure Protection Valve
SM07-014-0 R-12 Relay Valve
SM07-017-0 Stop Light Switch
v C-1
TM 5-3810-307-24-1-1
APPENDICES
B Red Dot Heavy Duty Air Conditioning and Heating Service Training Manual
(P/N RD-5-5900-0)
C Cummins Master Repair Manual - Holset Air Compressors,
Bulletin No. 3810321-01
D Delco Remy 21-S1 Delctron Generator (Alternator), Service Manual 1G-286
E Delco Remy Cranking Motors, Service Bulletin 1M-157 and Delco Remy Service
Test Specifications, Service Bulletin 1M-188
F Not Used
G PAT DS350 LMI Troubleshooting Handbook for Grove AT422T
H ZF Semi-Integral Power Steering Gear, Type 7421 Instructions for
Operation, Maintenance, and Inspection
I Cummins Field Service Procedures for Wabco Air Compressor
J Winterizing the ATEC Crane AT422T
K Berminghammer Pile Driver System, Instructions for Maintenance, Troubleshooting, and
Repair
vi C-1
TM 5-3810-307-24-1-1
This manual contains troubleshooting and maintenance instructions for the Army's AT422T, 22-ton All-
Terrain Crane (ATEC). Other manuals in the set contain operation instructions and operator maintenance
and diesel engine maintenance.
Although these manuals do not conform with the format specified for other Army vehicles, the technical
data presented herein is essential for properly operating and maintaining the vehicle.
These manuals were developed to help you operate and maintain the equipment. All task descriptions
will take you step-by-step through the procedure. Don't take shortcuts. Before you begin any task, you
should read through the complete procedure, make sure you know what needs to be done, then go back
and follow the steps as written.
Pay particular attention to WARNINGS , CAUTIONS, and NOTES. This will prevent injury to personnel,
damage to equipment, and provide clear instructions.
Use the alphabetical index at the back of the manual to find a topic not listed in the tables of contents.
The definitions of WARNING , CAUTION, and NOTE as used in this manual apply as follows:
WARNING
A warning or danger is used to emphasize that if an
operation, procedure, or practice is not followed exactly,
death or injury to personnel may result.
CAUTION
A caution is used to emphasize that if an operation,
procedure, or practice is not followed exactly, equipment
damage may result.
NOTE
A note is used to emphasize an important procedure or
condition.
The following paragraphs provide a general description of each ATEC technical manual.
Volume one, the service manual, is divided into chapters and sections. Chapter One contains 5
sections that cover: general maintenance information; preventive maintenance; lubrication; and
troubleshooting. Chapter Two, divided into 16 sections, covers specific vehicle component
removal/replacement procedures. At the beginning of each section is a Table of Contents listing the
specific system/components contained in the section. Where vehicle components are repairable, the
replacement procedure may refer to an SM package for repair. Volume One also contains the
Maintenance Allocation Chart (MAC) as Appendix A.
Volume Two, the SM packages, contains repair procedures for selected components of the
vehicle. Each SM package is complete with its own Table of Contents. Any requirements for tools and
materials to perform each repair task are also listed. Volume Two also includes Appendices consisting of
vendor repair data for components not addressed elsewhere in the manual and instructions for winterizing
the ATEC (AT422T).
TM 5-3810-307-24-2 - Diesel Engine Operation and Maintenance Manual. This manual also consists of
two volumes: Volume one is the Cummins operation and maintenance handbook while volume two
contains engine repair information. Each manual has been edited specifically for the ATEC. Included are
preventive maintenance, troubleshooting, adjustment/repair/replacement specifications/torques values,
and warranty data.
TM 5-3810-307-24P Repair Parts and Special Tools List (RPSTL). Contains a complete illustrated
parts breakdown for the ATEC. Also included are:
viii C-1
TM 5-3810-307-24-1-1
WARNINGS
GENERAL
It is mandatory that all hydraulic hoses and fittings be correctly tagged and identified before
they are disconnected to effect repairs or service. Failure to correctly tag and identify
hoses and fittings can cause wrong reconnection, which can result in death or injury to
personnel.
SECTION 1
GENERAL DESCRIPTION
TABLE OF CONTENTS
Page
1-1-1/(1-1-2 Blank)
TM 5-3810-307-24-1-1
GENERAL DESCRIPTION
DESCRIPTION
This Manual provides information for the rotation in either direction. All crane functions are
maintenance personnel of the AT422T Grove All- controlled from the fully-enclosed cab mounted on the
Terrain Crane (ATEC). superstructure. On-site travel can also be accom-
plished using driving controls located in the super-
The lift capacities are listed on the Load Chart in the structure cab. The crane is equipped with a three-
cab. section, trapezoidal, cable synchronized boom.
Lifting is provided by a main hoist and an auxiliary
The all terrain crane incorporates an all welded steel hoist.
frame, using planetary drive axles to provide select-
able four-wheel drive. Axle steering is accomplished The crane is also capable of supporting and
utilizing hydraulic steer cylinders. The engine is operating a clamshell bucket, a pile driver, a concrete
mounted at the front of the crane and provides motive bucket, and a grapple. Special hardware adapters
power through a six speed transmission. Hydraulic, and hydraulic quick disconnects have been provided
double box, sliding beam outriggers are integral with for attaching these components.
the carrier frame.
NOTE
The carrier frame incorporates oscillation lockout
cylinders to which the axles are mounted. Axle Throughout this manual, reference is made
oscillation is provided through the front and rear axle to left, right, front, and rear when describing
suspension cylinders. locations. These reference locations are to
be considered as those viewed from the
The superstructure is capable of continuous 360 carrier cab operator seat with the
degree superstructure facing forward over the front
of the carrier frame.
LIST OF SPECIFICATIONS
GENERAL.
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT422T
Rated Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Load Chart, Appendix E
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4x4x4
Gross Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Lifting and Transportation decal located
on the side of the right-front deck
DIMENSIONS.
NOTE
1-1-3 C-1
TM 5-3810-307-24-1-1
CAPACITIES.
Fuel Tank
(Reservoir Capacity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 gal. (166.6 L)
(Draw Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 gal. ( 160.0 L)
Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid - 10.5 gal. (39.7 L)
Radiator only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 qts (33.1 L)
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3 qts (16.4 L)
Hydraulic Tank
(Total Reservoir Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.8 gal. (275.6 L)
(Full Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.4 gal. (243.0 L)
(Low Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.9 gal. (226.7 L)
Hoist
Grove Model HO-15C-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 qt (8.5 L)
Swing Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 qts (1.9 L)
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 pt (.24 L)
Axle Planetary Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 qts (1.5 L)
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 qts (13 L)
Transmission and Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 qts (26.5 L)
ENGINE.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clark
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9 LFHR24658 w/APC 100 Auto Shift
Speeds. . . . . . . . . . . . ..................................................... 6
Gear Ratios
Fwd 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.07:1
2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19:1
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.83:1
Rev 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.07:1
2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19:1
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote mounted
Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote mounted
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clark 13.9 w/Lockup and Freewheel
1-1-4
TM 5-3810-307-24-1-1
AXLES.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kessler
Model (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LT 51 PL 375
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,475 lbs @ 55 mph
(10,194 kg @ 88 km/h)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.06:1
Track (Front and Rear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.38 in. (199.1 cm)
BRAKES.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WABCO
Size
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 16 (2 per wheel)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 20 (1 per wheel)
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WABCO
Size
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 16 (1 per wheel)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 24 (1 per wheel)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc
Rim Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 in. (25.4 cm)
Bead Seat Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.0 in. (53.3 cm)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,050 lbs-55 mph (5,012 kg-88 km/h)
Lugs
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 Ft-Lbs (651 Nm)
Tires:
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 R21
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Ply
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,540 lbs-55 mph (6,595 kg-88 km/h)
Load Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ M
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For roading and lifting pressures
see the Tire Inflation Decal
SUSPENSION.
1-1-5
TM 5-3810-307-24-1-1
CARRIER STEERING.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-1012-002
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8 cu in. (242.5 cu cm) per rev.
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 gpm (30 lpm)
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 3
GPM @ 2500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 gpm (147 lpm)
39 gpm (147 lpm)
16 gpm (61 lpm)
SWING MOTOR.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H Series
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit
Displacement per rev . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 in (15.7 cm)
SWING GEARBOX.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary Gear Reduction
Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.98:1
1-1-6
TM 5-3810-307-24-1-1
BOOM.
Elevation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3 to 78
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three, fully synchronized
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-70 ft (8.2-21.3 m)
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single stage telescoping cylinder w/
cable synchronization
HOISTS - MAIN AND AUXILIARY.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HO-15C-16
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary gear reduction
Drum Dimension
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 in. (30.5 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 in. (40.6 cm)
Wire Rope
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.625 in. (16 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 ft (111.0 m)
Permissible Line Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Load Chart
OUTRIGGERS.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double box beam and inverted jack
Spread
Extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 ft (5.6 m)
Retracted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 ft (2.3 m)
AIR COMPRESSOR.
NOTE
Check the identification plate on the air compressor to determine which model (Holset or
Wabco) is installed on your crane.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins/Wabco
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250CC
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................. 1
Piston Displacement @ 1250 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 ft/min (71,736 cm/sec)
AIR/HYDRAULIC SWIVEL.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove
Ports
Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL SYSTEM.
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC negative ground (chassis ground)
Starter
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delco Remy
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37MT
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1993904 (Delco Remy) 10479108 (Cummins)
Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max: 75
Min: 50
Batteries
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6TL (MS52149-2)
1-1-7 C-1
TM 5-3810-307-24-1-1
Alternator
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delco-Remy
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-SI Series, Negative-Ground
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1117900
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 amperes
Slip Ring Assembly
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . United Equipment Accessories
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Conductor, RC850 A Series
Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S15AP49GR1
Carrier Heater.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hunter
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HW30-5
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Water
Superstructure Heater.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hunter
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DH22-17A
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Combustion
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volts
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State (6000 V)
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,000 BTU/hr
Refrigerant Compressor
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Dot Corporation
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove PN 6332000552
Max Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 rpm
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134A
Refrigerant Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 lbs
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAG
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 oz
1-1-8
TM 5-3810-307-24-1-1
FIRE EXTINGUISHER.
1-1-9/(1-1-10 Blank)
TM 5-3810-307-24-1-1
SECTION 2
GENERAL MAINTENANCE
TABLE OF CONTENTS
Page
GENERAL MAINTENANCE
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Keep the System Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Sealing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
LIST OF FIGURES
Title Page
1-2-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 1-2-5
WARNING 1-2-6
1-2-2
TM 5-3810-307-24-1-1
MAINTENANCE
These general suggestions should be helpful in apply when access covers or inspection plates are
following the instructions in this manual. In analyzing removed.
a system malfunction, use a systematic procedure to
locate and correct the problem. Clean and inspect all parts. Be sure all passages
and holes are open. Cover all parts to keep them
1. Determine the problem. clean. Be sure parts are clean when they are
installed. Leave new parts in their containers until
2. List possible causes. ready for assembly.
8. Functionally test the failed part in its system. When using hoisting equipment, follow the hoist
manufacturers recommendations and use lifting
NOTE devices that will allow you to achieve the proper
balance of the assemblies being lifted and to ensure
Your safety and that of others is always safe handling.
the number one consideration when
working around machines. Safety is a Unless otherwise specified, all removals requiring
matter of thoroughly understanding the job hoisting equipment should be accomplished using an
to be done and the application of good adjustable lifting attachment. All supporting members
common sense. It is not just a matter of (chains and cables) should be parallel to each other
do's and don'ts. Stay clear of all moving and as near perpendicular as possible to the top of
parts. the object being lifted.
CLEANLINESS. CAUTION
An important item in preserving the long life of the The capacity of an eyebolt diminishes as
machine is keeping dirt out of working parts. the angle between the object becomes
Enclosed compartments, seals, and filters have been less than 90 degrees. Eyebolts and
provided to keep the supply of air, fuel, and lubricants brackets should never be bent and should
clean. It is important that these enclosures be only have stress in tension.
maintained.
Some removals require the use of lifting fixtures to
Whenever hydraulic, fuel, lubricating oil lines, or air obtain proper balance. The weights of some
lines are disconnected, clean the adjacent area as components are given in their respective sections of
well as the point of disconnect. As soon as the the manual.
disconnection is made, cap, plug or tape each line or
opening to prevent entry of foreign material. The
same recommendations for cleaning and covering
1-2-3
TM 5-3810-307-24-1-1
If a part resists removal, check to be certain all nuts cables, tag each one to ensure proper identification
and bolts have been removed and that an adjacent during assembly.
part is not interfering.
GROUNDS.
DISASSEMBLY AND ASSEMBLY.
Effective mechanical grounding of electrical
When assembling or disassembling a component or components and systems is important for proper
system, complete each step in turn. Do not partially operation as well as reducing EMI/EMC effects. The
assemble one part and start assembling some other following procedures apply to all mechanical ground
part. Make all adjustments as recommended. points, where grounding may occur:
Always check the job after it is completed to see that
nothing has been overlooked. Recheck the various directly, through the inherently-grounded
adjustments and verify complete functional (case-grounded) mounting hardware of a
performance by operating the machine before component.
returning it to the job.
through a discrete wire, connected to a
PRESSING PARTS. single component's insulated ground
terminal, or to several components (e.g. as
When pressing one part into another, use an anti- in a ground wire emanating from a harness
seize compound or a molybdenum disulfide base assembly).
compound to lubricate the mating surfaces.
To ensure adequate grounding, it is essential that all
Assemble tapered parts dry. Before assembling paint, rust, grease, etc. is removed from the contact
parts with tapered splines, be sure the splines are area of the frame, component, and any intermediate
clean, dry, and free from burrs. Position the parts contact surfaces, before the connection is made. It is
together by hand to mesh the splines before applying also important that the various components making
pressure. up the connection are installed in the exact order/
locations depicted (e.g. mounting hardware).
Parts which are fitted together with tapered splines
are always very tight. If they are not tight, inspect the To prevent subsequent formation of rust, fungus, etc.
tapered splines, discard the part if splines are worn. that may grow between the contact surfaces, and
thus eventually impair the ground connection, each
LOCKS. ground connection is to be sprayed with fungus-
resistant varnish per MIL-V-173 or commercial
Lockwashers, flat metal locks, or cotter pins are used equivalent, immediately following installation.
to lock nuts and bolts.
SHIMS.
Flat metal locks must be installed properly to be
effective. Bend one end of the lock around the edge When shims are removed, tie them and identify them
of the part. Bend the other end against one flat as to location. Keep shims clean and flat until they
surface of the nut or bolt head. are reinstalled.
Preload. WARNING
Exercise extreme care around press-
Preload is an initial load placed on the bearing at the urized hydraulic systems. Do not work
time of assembly. Whether a tapered roller bearing on a hydraulic system while it is in
should have preload could depend on any of several operation or until all pressure is
conditions: rigidity of the housings and shaft, bearing released.
spread, speed of operation, etc.
Cleanliness.
To determine whether a bearing requires preload or
end clearance, consult the disassembly and Contaminants in a hydraulic system affect operation
assembly instructions pertaining to that bearing. and will result in serious damage to the system
components. Dirty hydraulic systems are a major
Care should be exercised in applying preload. cause of component failures.
Misapplication of preload to bearings requiring end
clearance can result in bearing failure.
1-2-5
TM 5-3810-307-24-1-1
Keep The System Clean. The following are known high stress areas applicable
to Grove machines, and visual inspection of these
When removing components of a hydraulic system, areas should be made part of an owner's planned
cover all openings on both the component and the preventive maintenance program:
crane.
a. Power Telescope Boom - wear pad
If evidence of foreign particles is found in the retaining structures, hydraulic cylinder attaching
hydraulic system, flush the system. points, boom pivot shaft retaining structures.
Disassemble and assemble hydraulic components on b. Outrigger pads, beams, boxes and
a clean surface. attachment structures.
Clean all metal parts in a nonflammable cleaning c. Main frames - generally in the area of
fluid. Then lubricate all components to aid in doubler plates and crossmembers; at the junction of
assembly. front and rear frame members on truck cranes.
When installing metal tubes, tighten all bolts finger- g. Hydraulic cylinder end connections.
tight. Then, in order, tighten the bolts at the rigid end,
the adjustable end, and the mounting brackets. After The above is provided only as a guide, your
tubes are mounted, install the hoses. Connect both inspection plan should not be limited to the areas
ends of the hose with all bolts finger-tight. Position listed. A thorough visual inspection of all weldments
the hose so it does not rub the machine or another is good practice.
hose and has a minimum of bending and twisting.
Tighten bolts in both couplings. Anyone requiring more detailed inspection
instructions and/or procedures many request same
Due to manufacturing methods there is a natural by contacting: Manitowoc Crane CARE, PO Box 21,
curvature to a hydraulic hose. The hose should be Shady Grove, PA. 17256-0021
installed so any bend is with this curvature.
LOCTITE.
FATIGUE OF WELDED STRUCTURES.
1-2-6 C-1
TM 5-3810-307-24-1-1
The following types of Loctite brand adhesives are lubricant, plating, or other factors that might require
available from Grove Worldwide, Product Support. variation from standard torque values.
Loctite Number Grove Part Number When maximum recommended torque values have
been exceeded. the fastener should be replaced.
277 9999100806
242 9999100805 When referring to the applicable torque charts, use
592 9999100804 values as close as possible to the torque values
shown to allow for wrench calibration tolerance. An
FASTENERS AND TORQUE VALVES. erratic or jerking motion of the wrench can easily
result in excessive torque. ALWAYS use a slow
Use bolts of the correct length. A bolt which is too wrench movement and STOP when the
long may bottom before the head is tight against the predetermined value has been reached.
part it is to hold. If a bolt is too short, there may not
be enough threads engaged to hold the part securely. Torque wrenches are precision instruments and are
Threads can be damaged. Inspect them and replace to be handled with care to ensure calibrated
fasteners, as necessary. Hardened flat washers accuracy. Calibration checks should be made on a
must be used with high strength fasteners (Grade 5 scheduled basis. Whenever the wrench might be
and 8). Be sure a hardened flat washer is installed either over stressed or damaged, it should
under the end to be rotated/torqued. immediately be removed from service until
recalibrated.
Torque values should correspond to the type bolts,
studs, and nuts being used. KNOW YOUR TORQUE WRENCH! Flexible beam
type wrenches, even though they might have a
The torque tables in this section are provided by preset feature, must be pulled at right angles and
Grove Worldwide for reference when performing the force must be applied at the exact center of
maintenance. These tables shall be followed unless the handle. Force value readings must be made
specific values are cited in the detailed maintenance while the tool is in motion.
instruction.
Rigid handle type torque wrenches are available
Use of proper torque values is extremely important. with torque limiting devices that can be preset to
Improper torquing can seriously affect performance required values and which eliminate dial
and reliability. Identification of fastener grade is readings.
always necessary. When marked as a high strength
part (Grade 5 and 8.), the mechanic must be aware NOTE
that he is working with a highly stressed component
and the fastener should be torqued accordingly. Metric tools may be marked using either
Newton-meter (N-m), or kilogram /meter
NOTE (kg/m) units. To convert pounds-foot of
torque to metric units, multiply the
Some special applications require pounds-foot value by 1.36 for the (N-m)
variation from standard torque values. equivalent, or multiply by 0.014 for the
Reference should always be made to (kg/m) value,
component overhaul procedures for
recommendations. NOTE
Special attention should be given to the existence of When multiplier and/or special tools are
used to reach hard to get at spots,
ensure torque readings are precisely
calculated.
1-2-7
TM 5-3810-307-24-1-1
1-2-8
TM 5-3810-307-24-1-1
1-2-9
TM 5-3810-307-24-1-1
Torque Values Range (Metric)
1-2-10
TM 5-3810-307-24-1-1
SECTION 3
ORGANIZATIONAL PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS)
TABLE OF CONTENTS
Page
LIST OF TABLES
Title Page
1-3-1/(1-3-2 Blank)
TM 5-3810-307-24-1-1
GENERAL
To ensure the crane is ready for operation at all times, inspect it systematically so that any defects can be
discovered and corrected before they result in serious damage or failure. The table on the next few pages
contains the organizational level PMCS.
Record all deficiencies and shortcomings, along with the corrective action taken on a DA Form 2404. The Item
Number column of the table is the source for the numbers used in the TM Number column on DA Form 2404.
PMCS GUIDANCE
WARNING
Dry cleaning solvent PD-680 is toxic and
flammable. Wear protective goggles and gloves
and use only in a well ventilated area. Avoid
contact with skin, eyes, and clothes and don't
breather vapors. Do not use near open flame or
excessive heat. The flash point is 100 to 138F
(38 to 59C). If you become dizzy while using
solvent, get fresh air immediately and get
medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid
immediately.
WARNING
Compressed air, used for cleaning purposes will
not exceed 30 psi. Use only with effective chip
guarding and personnel protective equipment
(goggles/ shield/ loves, etc.).
Keep it clean: dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as you
work and as needed. Use dry cleaning solvent (PD-680) to clean metal surfaces. Use soap and water when you
clean rubber or plastic material.
Bolts, nuts, and screws: Check that they are not loose, missing, bent, or broken. You can't try them all with a
tool, of course, but look for chipped paint, bare metal or rust around bolt heads. Tighten any bolt, nut, or screw
that you find loose.
Welds: Look for loose or chipped paint, rust or gaps where parts are welded together. If you find a bad weld,
report it to direct support maintenance.
Electric wires and connectors: Look for cracked or broken insulation, bare wires and loose or broken connectors.
Tighten loose connections and make sure the wires are in good condition.
Hoses and fluid lines: Look for wear, damage, and leaks. Make sure clamps and fittings are tight. Wet spots
show leaks, but a stain around a fitting or connector can also mean a leak. If leakage comes from a loose fitting
or connector, tighten the fitting or connector. If something is broken or worn out, either correct it or report it to
direct support maintenance (refer to the Maintenance Allocation Chart).
If anything looks wrong and you can't fix it, write it down on your DA Form 2404.
1-3-3
TM 5-3810-307-24-1-1
LEAKAGE DEFINITIONS
The following are definitions of the types/classes of leakage you need to know to be able to determine the status
of your equipment.
CLASS I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form
drops.
CLASS II Leakage of fluid great enough to form drops, but not enough to cause drops to drip from
the item being checked/inspected.
CLASS III Leakage of fluid great enough to form drops that fall from the item being
checked/inspected.
CAUTION
Equipment operation is allowable with minor
leakage (Class I or II). Of course consideration
must be given to the fluid capacity in the
item/system being checked/inspected. When
operating with Class I or II leaks, continue to
check fluid levels as required on your PMCS.
Class II leaks should be reported to your
supervisor.
PMCS TABLE
The items listed in the table indicate the minimum inspection requirements. Perform at the intervals shown below:
1-3-4
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1-3-5 C-1
TM 5-3810-307-24-1-1
1-3-6 C-1
TM 5-3810-307-24-1-1
1-3-7
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NOTE
For secondary fuel
filter only. If filter
change is occurring in
temperatures at or
below 30F (-1C),
use the filter install-
ation procedures an-
notated on cartridge
PLUS 1/4 turn.
(20) 500 Air Governor Filter Inspect and clean or Two (2) each filters
(Strainer) Elements replace filter (strainer) (NSN 4730-002250710)
elements as required. required.
(21) 500 Hoist Mounting Bolts Check for proper torque
[250 lbs-ft (339 Nm)].
(22) 2000 Boom Check hoist to boom
alignment. Refer to
Section 11 for
procedures.
(23) 500 Hook Block Disassemble hook block, Hook deformed or
inspect hook for nut/threaded areas
deformation, and nut and corroded or improper fit.
threaded areas for
corrosion and proper fit.
(24) Air System Disassemble valve, clean
Automatic Drain parts, inspect for wear
Valve and deterioration, and
lubricate.
(25) Lubrication Perform Semiannual
Lubrication Chart
requirements.
(26) 1000 Brake Linings Inspect linings for Linings worn or
excessive wear (to rivet saturated with grease.
heads) or grease
saturation.
1-3-8 C-1
TM 5-3810-307-24-1-1
1-3-9
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1-3-10 C-1
TM 5-3810-307-24-1-1
1-3-11/(1-3-12 Blank)
TM 5-3810-307-24-1-1
SECTION 4
LUBRICATION
TABLE OF CONTENTS
Page
LUBRICATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-4
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-11
LIST OF FIGURES
Title Page
1-4-1/(1-4-2 Blank)
TM 5-3810-307-24-1-1
LUBRICATION
GENERAL
Following the designated lubrication procedures is important in ensuring maximum crane lifetime and utilization.
The procedures and lubrication charts in this section include information on the types of lubricants to be used, the
location of the lubrication points, the frequency of lubrication, and other information.
The service intervals specified are for normal operation where moderate temperature, humidity, and atmospheric
conditions prevail. In areas of extreme conditions, the service periods and lubrication specifications should be
altered to meet existing conditions.
LUBRICANTS
CAUTION
SYMBOL DESCRIPTION
AFC Anti-Freeze Coolant. Formulated for engine coolant systems to provide effective engine cooling
and anti-freeze properties as provided in MIL-A-46153.
ASC Anti-Seize Compound. This compound is of such composition, structure, and consistency to
prevent the seizure of mating components and meet the requirements of MIL-A-907.
GAA Multipurpose Grease. Lubrication grease of such composition, structure, and consistence to meet
the performance requirements of MIL-G-10924. Grease is inhibited to prevent rusting and have
excellent resistance to both heat and water.
HFC R-134a Refrigerant. Environmentally friendly refrigerant formulated to meet the requirements of
Grove Specification A6-829-013460 and SAE J1503.
GO Extreme Pressure Multipurpose Gear Lubricant. This gear lubricant is compounded to achieve high
load carrying capacity and meet the requirements of MIL-2105C. SAE 85/140 viscosity will be used
for year-round service except as specified for specific components.
OE/HDO A high quality multipurpose engine\hydraulic oil formulated to provide desired engine performance
levels, chatter-free performance of wet brake and wet clutches, good gear lubrication, and hydraulic
performance. Shall meet the requirements of MIL-L-2104. Refer to specific component for
viscosity and temperature requirements.
OEA Multipurpose Arctic Lubricant. This is a high quality multipurpose oil formulated to meet the
performance requirements of MIL-L-46167 and provide desired component performance in
temperatures between -50F and +10F (-59C and 50C).
PAG Refrigeration Oil. Specially formulated oil for use with refrigeration components. Meets the
requirements of Grove Specification A6-829-013436 and compatible with R-134a.
1-4-3
TM 5-3810-307-24-1-1
LUBRICATION POINTS
All oil levels are to be checked with the crane parked on a level surface in transport position, and while the oil is
cold, unless otherwise specified.
On plug type check points, the oil levels are to be at the bottom edge of the check port.
On all hoists with a check plug in the drum, the fill plug shall be directly on top of the hoist, and the check plug
level.
All grease fittings are SAE STANDARD unless otherwise indicated. Grease nonsealed fittings until grease is
seen extruding from the fitting. One pump of a standard one pound (0.45 kg) grease gun equals one ounce (28
grams) of GAA.
Over lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely
lead to a shorter lifetime.
On sealed U-joints, care must be exercised to prevent rupturing seals. Fill only until expansion of the seals first
becomes visible.
Unless otherwise indicated, items not equipped with grease fittings, such as linkages, pins, levers, etc., should be
lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help
prevent the formation of rust. An Anti-Seize compound may be used if rust has not formed, otherwise the
component must be cleaned first.
Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be
replaced.
Where wear pads are used, cycle the components and relubricate to ensure complete lubrication of the entire
wear area.
The following describe the lubrication points and gives the lube type, lube interval, lube amount, and application
of each. Each lubrication point is numbered, and this number corresponds to the index number shown on the
Lubrication Chart.
1. Angle Gearbox.
2. Not Used
3. Differentials.
1-4-4
TM 5-3810-307-24-1-1
9. Not Used
10. Engine.
NOTE
If oil filter elements are being changed in temperatures at or below 30F (-1C) or oil is being
changed to arctic grade (OEA), use filter element installation procedures annotated on
cartridge plus turn.
1-4-5 C-1
TM 5-3810-307-24-1-1
Complete the following steps after each engine oil change to make sure the engine receives the correct oil
flow through the lubricating oil system.
NOTE
When checking oil level, the oil temperature must be stabilized at 180 degrees to 200
degrees F (82.2 degrees to 93.3 degrees C) to properly check the oil level. Do not at-tempt
an oil level check with cold oil. To bring the oil temperature to this range, it is necessary to
either work the crane or stall the converter. Converter stall should be accomplished by
engaging the shift levers in forward and high range with the brakes applied and then
accelerating the engine to half or three-quarter throttle. Hold the stall until the desired
converter temperature is reached and stabilized.
CAUTION
Full throttle stall speeds for an excessive length of time will over-heat the converter and
cause serious damage.
(Text Deleted)
Lube Interval - Check level daily. Drain and refill every 1000 hours. Change oil filter element when
changing oil.
NOTE
If oil filter element is being changed in temperatures at or below 30F (-1C) or oil is being
changed to arctic grade (OEA), use filter element installation procedures annotated on
cartridge plus turn.
1-4-6 C-1
TM 5-3810-307-24-1-1
CAUTION
When checking the swing gear box oil level, place the dipstick into the sleeve until the cap is
flush with the end of the sleeve. Do not screw the cap onto the sleeve to check the level.
Lube Interval - Check every 200 hours. Drain and refill every 1000 hours
Lube Amount - Capacity 2 quarts (1.89 L)
Application - Fill to full mark on dipstick
NOTE
Apply after each pressure wash.
Lube Amount - Coat all teeth
Application - By brush
1-4-7
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1-4-8 C-1
TM 5-3810-307-24-1-1
1-4-9
TM 5-3810-307-24-1-1
1-4-10
TM 5-3810-307-24-1-1
Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and adjust
as the rope moves and bends. A wire rope cannot be lubricated sufficiently during manufacture to last its entire
life. Therefore, new lubricant must be added throughout the life of a rope to replace factory lubricant which is
used or lost.
The surface of some ropes may become covered with dirt, rock dust, or other material during their operation.
This covering can prevent field applied lubricants from properly penetrating into the rope. Therefore, these ropes
should be cleaned before being lubricated.
Lubricant may be applied effectively by various methods. It may be dripped on, sprayed on, or put on by
brushing, but in any case it should be applied at a place where the rope is being bent, such as at a sheave. It
should be applied at the top of the bend, because at that point the strands are spread by bending and are more
easily penetrated. The service life of rope will be directly proportional to the amount of lubricant reaching the
working parts of the rope.
When properly applied, the lubricant will reduce friction, protect against corrosion, adhere to every wire, and be
pliable and not crack or separate when cold and yet not drip when warm.
1-4-11
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1-4-12
TM 5-3810-307-24-1-1
1-4-13
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1-4-14
TM 5-3810-307-24-1-1
SECTION 5
TROUBLESHOOTING
TABLE OF CONTENTS
Page
TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3
Organizational Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3
Direct/General Support Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . 1-5-11
LIST OF TABLES
Title Page
1-5-1/(1-5-2 Blank)
TM 5-3810-307-24-1-1
TROUBLESHOOTING
GENERAL
This section includes troubleshooting tables for use by Organizational level and Direct/General Support level
maintenance personnel. The tables list common symptoms of trouble, probable cause, and the corrective action
to remedy the trouble. The tables are to assist maintenance personnel in diagnosing and correcting trouble that
may occur during normal operation. Tests/inspections and corrective actions should be performed in the order
listed.
The tables cannot list all symptoms that may occur, nor all tests or inspections and corrective actions. If symptom
occurs that is not listed or is not corrected by listed corrective actions, notify your supervisor.
Refer to the appropriate appendix for troubleshooting components and systems listed in appendices and refer to
engine manual for engine troubleshooting.
ORGANIZATIONAL TROUBLESHOOTING
SYMPTOM INDEX
Symptom Troubleshooting
Procedures
Page
TRANSMISSION
HYDRAULIC SYSTEM
AIR SYSTEM
STEERING SYSTEM
SWING SYSTEM
1-5-3
TM 5-3810-307-24-1-1
Symptom Troubleshooting
Procedures
Page
TELESCOPE SYSTEM
LIFT CIRCUIT
OUTRIGGER CIRCUIT
HOISTS
HOIST MOTOR
DIESEL HEATER
1-5-4
TM 5-3810-307-24-1-1
Organizational Troubleshooting
1. Transmission OIL TEMP a. Transmission oil pump a. Check and tighten oil line
gauge indicates suction line loose (sucking connections.
transmission over- air).
heating.
2. Low power. a. Low engine rpm at converter a. Check and adjust idle speed.
stall.
HYDRAULIC SYSTEM
1. No oil flow in system. a. Reservoir to pump supply a. Replace or clear line as
line broken or restricted. necessary.
1-5-5
TM 5-3810-307-24-1-1
1-5-6
TM 5-3810-307-24-1-1
1-5-7
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1. Boom lift circuit operation a. Air in lift circuit. a. Bleed air from lift circuit.
erratic.
b. Clogged joystick pilot control b. Replace filter as necessary.
system filter.
2. Boom lift circuit operation a. Return hydraulic line a. Clear restriction or replace line
slow. restricted. as necessary.
1. Slow or erratic operation a. Loose hydraulic pump a. Tighten suction line or fittings.
of outrigger extension suction line or fittings.
cylinders.
b. Damaged electrical wiring to b. Repair or replace wiring.
solenoid valve.
1-5-8
TM 5-3810-307-24-1-1
1. Hoist will not raise or a. Clogged, broken, or loose a. Clean, tighten, or replace lines
lower load. hydraulic lines or fittings. or fittings.
1-5-9
TM 5-3810-307-24-1-1
1. Heater fails to start - a. Loose or broken electrical a. Check and tighten connections
motor does not run. connections at control panel as necessary.
or heater.
1-5-10
TM 5-3810-307-24-1-1
SYMPTOM INDEX
Symptom Troubleshooting
Procedures
Page
TRANSMISSION/TORQUE CONVERTER
HYDRAULIC SYSTEM
AIR SYSTEM
STEERING SYSTEM
SWING SYSTEM
1-5-11
TM 10-3810-307-24-1-1
Symptom Troubleshooting
Procedures
Page
TELESCOPE SYSTEM
LIFT CIRCUIT
OUTRIGGER CIRCUIT
HOISTS
HOIST MOTOR
1-5-12
TM 5-3810-307-24-1-1
Symptom Troubleshooting
Procedures
Page
DIESEL HEATER
1-5-13
TM 10-3810-307-24-1-1
1-5-14
TM 5-3810-307-24-1-1
1-5-15
TM 5-3810-307-24-1-1
1-5-16
TM 5-3810-307-24-1-1
1-5-17
TM 5-3810-307-24-1-1
1-5-18
TM 5-3810-307-24-1-1
1-5-19
TM 5-3810-307-24-1-1
1-5-20
TM 5-3810-307-24-1-1
1-5-21
TM 5-3810-307-24-1-1
1. Boom raises erratically. a. Main relief valve damaged. a. Repair or replace relief valve.
1-5-22
TM 5-3810-307-24-1-1
1-5-23
TM 5-3810-307-24-1-1
1. Outrigger extension a. Damaged relief valves. a. Remove relief valve and clean
cylinder operation slow or or replace.
erratic.
b. Solenoid valve spool b. Repair or replace spool valve.
sticking.
1-5-24
TM 5-3810-307-24-1-1
1-5-25
TM 5-3810-307-24-1-1
1-5-26
TM 5-3810-307-24-1-1
4. Hoist up operation slow. a. Damaged circuit relief valve. a. Repair or replace valve.
1-5-27
TM 5-3810-307-24-1-1
1-5-28
TM 5-3810-307-24-1-1
1-5-29
TM 5-3810-307-24-1-1
1-5-30
TM 5-3810-307-24-1-1
1-5-31
TM 5-3810-307-24-1-1
1-5-32
TM 5-3810-307-24-1-1
1-5-33
TM 5-3810-307-24-1-1
1-5-34
CHAPTER TWO
DETAILED DESCRIPTION AND MAINTENANCE
TM 5-3810-307-24-1-1
SECTION 1
CABS
TABLE OF CONTENTS
Page
CABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
CARRIER CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
SUPERSTRUCTURE CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Seat Belt (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Seat Assembly (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Seat Belt (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Seat Assembly (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Windshield Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
Skylight Wiper (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Heater (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-24
Heater (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
HI-LO Control and Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-35
Air Conditioner (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-43
2-1-1
TM 5-3810-307-24-1-1
2-1-2
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
2-1-1 Seat Assembly and Seat Belt Installation (Carrier Cab) . . . . . . . . . . . . . . . . . . . 2-1-10
2-1-2 Seat Assembly and Seat Belt Installation (Superstructure Cab) . . . . . . . . . . . . . . 2-1-13
2-1-3 Windshield Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-16
2-1-4 Skylight Wiper (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-20
2-1-5 Heater (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-22
2-1-6 Heater Installation (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28
2-1-7 Air Conditioner (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-38
2-1-8 Air Conditioner (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-48
2-1-9 Tilt Steering Column (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-64
2-1-10 Tilt Steering Column (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-67
2-1-11 Defroster Control (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-70
2-1-12 Heater Control (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-72
2-1-13 Trailer Air Supply and Parking Brake Control Assy (Carrier Cab) . . . . . . . . . . . . . 2-1-74
2-1-14 Heater Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-78
2-1-15 Parking Brake Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-80
2-1-16 Throttle Control (Superstructure Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-82
2-1-17 Swing Lock Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-84
2-1-18 Shift Control Assembly (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
2-1-19 Shift Control Assembly (Superstructure Cab). . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-88
2-1-20 Dash Panel (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-90
2-1-21 Dash Panel (Superstructure Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-93
2-1-22 Carrier Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-95
2-1-23 Superstructure Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-98
2-1-24 Superstructure Cab Heater Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-100
2-1-3 C-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
2-1-21
WARNING
2-1-94
Engine must be cool to the touch prior to working on coolant system
components. Failure to follow could result in scalding or serious burns.
2-1-25
WARNING
2-1-97
Diesel fuel is combustible and an irritant. Skin and eye protection is
required. Good general ventilation is normally adequate. Keep away
from open flame and other ignition sources.
WARNING 2-1-35
2-1-37
WARNING
Fins on evaporator coil are sharp and easily bent. Wear gloves to protect
cuts, and handle evaporator coil with crane to prevent bending fins.
Straighten any bent fins to ensure maximum efficiency.
WARNING 2-1-58
Compressed air used for cleaning can create airborne particles that may
enter the eyes. Wear safety goggles and limit air pressure to 30 psi (207
kpa).
WARNING 2-1-73
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.
2-1-4
TM 5-3810-307-24-1-1
WARNING 2-1-73
Be careful to maintain and release pressure slowly when removing
retaining caps. Internal components are assembled with spring tension
and could cause personal injury if allowed to pop free.
WARNING 2-1-83
Apply positive swing lock to ensure turntable does not move during
maintenance.
2-1-5/(2-1-6 Blank)
TM 5-3810-307-24-1-1
CABS
DESCRIPTION
The crane is equipped with two cabs, a carrier cab Both cabs utilize international symbols to label the
and a superstructure cab. The carrier cab contains various crane controls. A symbol identification decal
all controls and indicators necessary for crane travel. is located in each cab.
The superstructure cab contains all controls and
indicators necessary to perform craning operations. For a more detailed description of the cabs, refer to
either CARRIER CAB or SUPERSTRUCTURE CAB
in this section.
2-1-7
TM 5-3810-307-24-1-1
CARRIER CAB
DESCRIPTION
The carrier cab contains all of the controls and by a lever on the steering column. A windshield
indicators necessary for traveling and parking washer system is also installed to spray a cleaning
functions. The cab is all-steel, acoustically treated, solution onto the windshield. It consists of two
fully enclosed with tinted safety glass windows nozzles (one on each side of the wiper arm), a
throughout. Access to the cab is provided by a canister, and a pump assembly. The electric pump
hinged left side door which features a latch handle draws the solution from the canister and forces it
and keyed lock. A grab handrail is provided to aid through a hose to the two nozzles that spray it onto
the operator in getting in and out of the cab. A the windshield.
suspension seat installed in the cab is adjustable
both vertically and horizontally. The seat is also The carrier cab also features a hot-water heater and
equipped with a seat belt. a roof-mounted air conditioning unit. The cab heater
circulates hot engine coolant through a heat
A 1-A:10-B:C rated, 2.50 lb (1.13 kg) dry type fire exchanger. Hot air is blown out of the heater into the
extinguisher is mounted inside the cab, between the cab by a variable speed blower motor. The air
door and the operator's seat. conditioning unit is comprised of a self-contained
evaporator and condenser coil unit, a remote engine-
A single blade windshield wiper is installed to mounted compressor, and a control panel which
remove moisture from the windshield. The wiper allows the operator to control temperature and fan
arm is driven by an electric motor which is controlled speed.
SUPERSTRUCTURE CAB
DESCRIPTION
The superstructure cab contains all of the controls A safety device in the armrests disables the
and indicators necessary for craning operations and controllers when the armrests are in the up position.
traveling on the job site. The cab is all-steel, In addition to the safety device in the armrests, a
acoustically-treated, and fully enclosed with tinted tape switch incorporated in the cab seat, deactivates
safety glass windows throughout. Access to the cab the controllers when the operator leaves the seat.
is provided by a sliding door which features a latch
handle and keyed lock. Grab handrails are provided A 1-A:10-B:C rated, 2.5 lb (1.13 kg) dry type fire
beside the door opening to aid the operator in getting extinguisher is mounted in the cab under the
in and out of the cab. operator's seat.
The cab has a skylight with a tinted safety glass A single blade windshield wiper is installed to
window. A manually operated skylight wiper is remove moisture from the windshield. The wiper
provided to remove moisture from the skylight. arm is driven by an electric motor which is controlled
by a two speed switch located on the front console
The cab seat is mounted on a track assembly, panel. A windshield washer system is also installed
allowing it to be adjusted to a comfortable distance to spray a cleaning solution onto the windshield. It
from the steering wheel and front console. The seat consists of two nozzles (one on each side of the
has a lever at the front of the bottom cushion to wiper arm), a canister which is located beneath the
adjust the tilt of the seat back. An armrest on each cab, and a pump assembly.
side of the seat houses the hydraulic remote controls
used to control the crane functions. The armrests Located beneath the cab, is a diesel fuel burning
swing up beside the seat and latch in place to make heater which provides heat to the cab. The heater
it easier for traveling and entering and exiting the tank is located on the right side of the turntable. All
cab.
2-1-8
TM 5-3810-307-24-1-1
heater controls are located within the cab. The superstructure cab also features an air
Windshield defroster controls and tubing are conditioning unit. The air compressor and a
provided with the heater. hydraulic motor are housed behind a cover on the
left side of the boom on the forward side of the
counterweight. The condenser unit is mounted on
the bottom of the counterweight. The air conditioner
controls including the air handler (evaporator) and
blower unit are located in the cab.
MAINTENANCE
Removal
a. Remove nuts (1, Figure 2-1-1) and lockwashers (2) securing anchor belts (14) to cab floor on both sides of
seat.
b. Remove nut (3), lockwasher (4), and capscrew (5) securing inertia reel for shoulder harness (13) to lower
mounting bracket on side wall of cab.
c. Remove nut (6), lockwasher (7), capscrew (8) and bushing (9) securing shoulder harness (13) to upper
mounting bracket on side wall of cab.
d. Remove nuts (10), lockwashers (11), capscrews (12), shoulder harness (13), and anchor belts (14) from
pivot links (21) on both sides of seat.
e. Remove nut (15), lockwasher (16), cap (17), capscrew (18), washers (19), fiber washer (20), pivot link
(21), and latch belt (22) from right side of seat.
Installation
a. Secure latch belt (22, Figure 2-1-1) and pivot link (21) to right side of seat with fiber washer (20), washers
(19), capscrew (18), lockwasher (16), nut (15), and cap (17).
b. Secure shoulder harness (13) and anchor belts (14) to pivot links (21) on both sides of seat with
capscrews (12), lockwashers (11) and nuts (10).
c. Secure shoulder harness (13) to upper mounting bracket on side wall of cab with bushing (9), capscrew
(8), lockwasher (7), and nut (6).
d. Secure inertia reel for shoulder harness (13) to lower mounting bracket on side wall of cab with capscrew
(5), lockwasher (4), and nut (3).
e. Secure anchor belts (14) to floor on both sides of seat with lockwashers (2) and nuts (1).
2-1-9
TM 5-3810-307-24-1-1
LEGEND
Figure 2-1-1. Seat Assembly and Seat Belt Installation (Carrier Cab)
2-1-10
TM 5-3810-307-24-1-1
Removal
a. Remove nuts (10, Figure 2-1-1), lockwashers (11), and capscrews (12) securing anchor belts (14) and
shoulder harness (13) to pivot links (21) on sides of seat (25).
b. Remove locknuts (23), washers (24), seat (25), cone washers (26), and support plates (27) from cab.
c. If necessary, remove nut (15), lockwasher (16), cap (17), capscrew (18), washers (19), fiber washer (20),
pivot link (21), and latch belt (22) from right side of seat.
Installation
a. If removed, secure latch belt (22, Figure 2-1-1) and pivot link (21) to right side of seat with fiber washer
(20), washers (19), capscrew (18), lockwasher (16), nut (15), and cap (17).
b. Position support plates (27) and cone washers (26) on cab floor.
c. Position seat (25) on cone washers (26) and secure with washers (24) and locknuts (23).
d. Secure shoulder harness (13) and anchor belts (14) to pivot links (21) on sides of seat with capscrews
(12), lockwashers (11), and nuts (10).
2-1-11
TM 5-3810-307-24-1-1
Removal
a. Remove nuts (1, Figure 2-1-2), lockwashers (2), and capscrews (3) securing seat belt halves (4) to
mounting brackets on both sides of seat.
Installation
b. Secure seat belt halves (4) to mounting brackets on both sides of seat with capscrews (3), lockwashers
(2), and nuts (1).
2-1-12
TM 5-3810-307-24-1-1
LEGEND
Figure 2-1-2. Seat Assembly and Seat Belt Installation (Superstructure Cab)
2-1-13
TM 5-3810-307-24-1-1
Removal
b. Tag and disconnect electrical connectors at rear of seat assembly (8, Figure 2-1-2).
NOTE
Be careful that mounting hardware does not drop through heater louvers under
seat.
c. Remove nuts (5), lockwashers (6), washers (7), and seat assembly (8) from mounting plate assembly (12).
d. Remove bottom covers from arm rests, tag and disconnect electrical leads for joysticks and arm switches,
and tag and disconnect hydraulic lines from fittings on joysticks, refer to Joysticks (Superstructure Cab) Removal
procedures.
e. Remove nuts (9), lockwashers (10), washers (11), and mounting plate assembly (12) from cab floor
mounting brackets.
Repair
a. Remove hog rings securing fabric to seat bottom frame at rear and sides of frame and pull fabric forward
off seat bottom.
b. Replace weight sensing safety switch (13, Figure 2-1-2) positioned on seat bottom cushion.
c. Pull fabric back over seat bottom, stretch fabric, and secure fabric to seat frame with hog rings.
Installation
a. Install mounting plate assembly (12, Figure 2-1-2) on cab floor mounting brackets with washers (11),
lockwashers (10), and nuts (9).
b. Connect hydraulic lines to joysticks, connect electrical leads for joysticks and arm switches, remove tags,
and install bottom covers on arm rests, refer to Joysticks (Superstructure Cab) Installation procedures.
c. Install seat assembly (8) on mounting plate assembly (12) with washers (11), lockwashers (10), and nuts
(9).
d. Connect electrical connectors at rear of seat assembly (8) and remove tags.
2-1-14
TM 5-3810-307-24-1-1
WINDSHIELD WIPER/WASHER
NOTE
Procedures are typical for carrier cab and superstructure cab, except for
location of windshield washer reservoirs. Reservoir for carrier cab is located
on rear wall of cab interior. Reservoir for superstructure cab is located beneath
and outside of cab.
Removal
(1) Disconnect washer hose (1, Figure 2-1-3) from connector below windshield.
(2) Remove cap nuts (2 and 3), washers (4 and 5), and wiper arm (6) from plate (17) and pivot shaft
(31).
(3) Remove locknut (7), capscrew (8), and wiper blade (9) from wiper arm (6).
(1) Tag and disconnect electrical wires from electrical harness for wiper motor (24).
(2) Remove drive gear (10), rubber boot (11), nut (12), washer (13), and lockwasher (14) securing pivot
shaft (31) in plate (17).
(3) Remove capscrews (15), lockwashers (16), plate (17), seal (18), lockwasher (19), and wiper motor
(24) with bracket (27) from cab.
(4) Remove locknut (20) and washer (21) securing drive arm (29) to shaft of wiper motor (24).
(5) Remove capscrews (22), lockwashers (23), and wiper motor (24) from bracket (27).
(1) Remove screws (25), lockwashers (26), and drive linkage assembly from bracket (27).
(2) Remove c-clip (28) and drive arm (29) from linking arm (32).
(3) Remove c-clip (30) and pivot shaft (31) from linking arm (32).
(4) Remove nut (33), lockwasher (34), and pin (35) from pivot shaft (31).
(3) Remove nuts (37), lockwashers (38), washers (39), washer reservoir (40), and spacers (41) from
cab.
2-1-15
TM 5-3810-307-24-1-1
LEGEND
2-1-16
TM 5-3810-307-24-1-1
Repair
Installation
(1) Position spacers (41, Figure 2-1-3) and washer reservoir (40) on mounting studs and secure with
washers (39), lockwashers (38), and nuts (37).
(1) Install pin (35) in the top hole of pivot shaft (31) and secure with lockwasher (34) and nut (33).
(2) Install pin (35) of pivot shaft (31) in hole nearest cutout of linking arm (32) and secure with c-clip
(30).
(3) Install drive arm (29) on linking arm (32) with c-clip (28).
(4) Position drive linkage in bracket (27) and secure pivot shaft (31) with lockwashers (26) and screws
(25).
(1) Insert shaft of wiper motor (24) into hole of bracket (27) while positioning drive arm (29) on shaft so
that arm is parallel with motor housing. Secure drive arm (29) on motor shaft with washer (21) and
locknut (20). Torque locknut (20) 150-180 lbs-in. (17-20 Nm).
NOTE
Ensure drive arm (29) remains parallel with motor housing when tightening
locknut (20). If arm moves, cycle motor (using 24 vdc) to position arm prior to
further installation.
(2) Secure wiper motor (24) to bracket (27) with lockwashers (23) and capscrews (24). Ensure motor
ground wire is installed under right side capscrew.
(3) Position seal (18) and plate (17) on outside of cab. Insert capscrews (15) with lockwashers (16)
through plate (17), seal (18), and wall of cab.
(4) Position lockwashers (19) on capscrews (15) and secure bracket (27) with wiper motor (24) in cab
by tightening capscrews (15).
(5) Connect electrical wires for wiper motor and remove tags.
(6) Install lockwasher (14), washer (13), and nut (12) on pivot shaft (31), and then position boot (11) and
drive gear (10) on pivot shaft.
2-1-17
TM 5-3810-307-24-1-1
(1) Install wiper blade (9) on wiper arm (6) with capscrew (8) and locknut (7).
(2) Install wiper arm (6) on pivot shaft (31) and plate (17) with washers (4 and 5) and cap nuts (2 and 3).
2-1-18
TM 5-3810-307-24-1-1
Removal
(1) Remove cap nuts (1 and 2, Figure 2-1-4), washers (3 and 4), and wiper arm (5) from plate (16) and
pivot shaft assembly (18).
(2) Remove locknut (6), capscrew (7), and wiper blade (8) from wiper arm (5).
(1) Remove drive gear (9), boot (10), nut (11), washer (12), and lockwasher (13) securing pivot shaft
assembly (18) in plate (16).
(2) Remove capscrews (14), lockwashers (15), plate (16), seal (17), and pivot shaft assembly (18) from
cab.
Repair
Installation
(1) Position seal (17, Figure 2-1-4) and plate (16) on outside of cab roof. Insert capscrews (14) with
lockwashers (15) through plate (16), seal (17), and roof of cab.
(2) Align pivot shaft assembly (18) mounting bar holes to capscrews (14) and secure pivot shaft
assembly to cab roof by tightening capscrews (14).
(3) Install lockwasher (13), washer (12), and nut (11) on pivot shaft assembly (18), then position boot
(10) and drive gear (9) on pivot shaft.
(1) Install wiper blade (8) on wiper arm (5) with capscrew (7) and locknut (6).
(2) Install wiper arm (5) on pivot shaft assembly (18) and plate (16) with washers (3 and 4) and cap nuts
(1 and 2).
2-1-19
TM 5-3810-307-24-1-1
LEGEND
2-1-20
TM 5-3810-307-24-1-1
Removal
b. Remove capscrews (1, Figure 2-1-5) and heater vent (2) from inside of cab.
d. Remove screw (3) and clamp (4) securing outer casing of defroster control cable to bottom of heater
plenum.
e. Disconnect defroster control cable from heater flap lever at bottom of heater plenum.
f. Remove screw (5) and clamp (6) securing outer casing of heat control cable, and disconnect heat control
cable from shutoff valve (17).
g. Loosen clamp (7) and disconnect defroster duct (8) from side of heater plenum.
WARNING
Engine must be cool to the touch prior to working on coolant system components.
Failure to comply could result in scalding or serious burns.
h. Place suitable container under heater hoses to catch residual coolant, loosen clamps (9), and remove
heater hoses (10 and 11) from elbows on side of heater (14).
i. Remove capscrews (12), star washers (13), and heater (14) from bottom of cab.
j. If necessary, loosen clamps (15) and remove shutoff valve (17) from hoses (11 and 16).
Repair
a. Disassemble heater (14, Figure 2-1-5) as necessary to replace damaged or defective parts.
(1) Remove screws (18), star washers (19), and lift cover (20) with coil (21) from case (26).
(2) Remove coil (21) with grommet (22) from cover (20), and grommet (21) from tubes of coil (21).
(3) Remove screws (23), star washers (24), and blower housing (25) from case (26).
(4) Remove screws (27), star washers (28), and motor (29) from blower housing (25).
(5) Loosen setscrew in retainer (30), and remove retainer and fan wheel (31) from shaft of motor (29).
(1) Install fan wheel (31) on shaft of motor (29) with retainer (30).
(2) Install motor (29) on blower housing (25) with star washers (28) and screws (27).
(3) Install blower housing (25) on case (26) with star washers (24) and screws (23).
(4) Install grommet (22) on tubes of coil (21), and coil (21) with grommet (22) on cover (20).
2-1-21
TM 5-3810-307-24-1-1
LEGEND
2-1-22
TM 5-3810-307-24-1-1
2-1-23
TM 5-3810-307-24-1-1
(5) Install cover (20) with coil (21) on case (26) with star washers (19) and screws (18).
Installation
a. If removed, install shutoff valve (17, Figure 2-1-5) between hoses (11 and 16) and secure with clamps
(15).
b. Position heater (14) under carrier cab and secure in place with capscrews (12) and star washers (13).
c. Connect hoses (10 and 11) to elbows on side of heater (14) and secure with clamps (9).
d. Connect defroster duct (8) to side of heater plenum and secure with clamp (7).
e. Ensure defroster control cable knob on dash panel is pushed in and flap lever on bottom of heater plenum
is positioned as far toward left side of carrier as possible, then connect defroster control cable to flap lever on
bottom of heater plenum and secure outer casing of cable to plenum with clamp (4) and screw (3).
f. Ensure heater control cable knob on dash panel is pushed in and shutoff lever is closed, then connect
heater control cable to shutoff valve (17) and secure outer casing of cable with clamp (6) and screw (5).
h. Start engine, pull heater control knob, and check for coolant leaks at heater hoses.
2-1-24
TM 5-3810-307-24-1-1
Removal
NOTE
c. Disconnect electrical power plug from front of heater (18, Figure 2-1-6).
d. Remove screw (2) and clamp (4), disconnect control cable (1) from control lever (107) at front of heater
(18), and remove control cable from heater.
f. Remove nut (5) and ground wire from rear of heater (18).
g. Remove nut (6), lockwasher (7), clamp (8), and electrical lead from bottom of heater (18). Reinstall
lockwasher (7) and nut (6).
WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.
h. Place suitable container under fuel line (9) to catch any residual fuel that may be present, and disconnect
fuel line (9) from elbow (22) at rear of heater (18).
i. Loosen clamp (10) and disconnect heater duct (11) from side of heater (18).
j. Remove nuts (12), washers (13), and clamp (14) securing exhaust pipe (21) to superstructure frame.
k. Remove nuts (15), lockwashers (16), washers (17), and heater (18) from bottom of cab.
l. If necessary, remove nuts (6), lockwashers (7), capscrews (19), and mounting straps (20) from heater
(18).
o. If necessary, remove intake duct (23) from rear of heater (18), and outlet duct (24) from front of heater
(ducts secured with captured clips on case).
Repair
a. Disassemble heater assembly (18, Figure 2-1-6) as necessary to replace worn, damaged, or defective
components:
(1) Remove screws (25), cross bar (26), cover (27), and cover (28) from heater (18).
2-1-25 C-1
TM 5-3810-307-24-1-1
(2) Remove fuel line (29) and fittings (32) at carburetor assembly (31) and rear wall of case (89).
(3) Tag and disconnect electrical leads for carburetor assembly (31).
(4) Remove screws (30) and carburetor assembly (31) from burner head (37).
(5) Loosen clamps (33), and remove air hose (34) from burner head (37) and blower housing (62).
(6) Tag and disconnect electrical leads from igniter (39) and glow plug (41).
(7) Remove screws (35), pressure pads (36), burner head (37), and gasket (38) from heat exchanger
(84).
(8) Remove igniter (39), gasket (40), glow plug (41), and hose (42) from burner head (37).
(9) Remove screws (43), star washers (44), and ignition pack (45) from bracket on bottom of case (89).
(10) Loosen clamps (46), and remove air hose (47) from blower cover (52) and bottom of case (89).
(12) Remove screws (48), washers (49), and motor (50) with blower assembly attached from mount plate
(72).
NOTE
(13) Loosen clamp (51), and remove blower cover (52) and clamp (51) from blower housing (62).
(14) Release tension on captured spring clip (part of fan wheel hub), and remove fan wheel (53) and
spacer (54) from shaft of motor (50).
(15) Remove screws (55) and stationary wheel (56) from blower housing (62).
(16) Release tension on captured spring clip (part of fan wheel hub), and remove fan wheel (57) from
shaft of motor (50).
(17) Remove nuts (58), lockwashers (59), washers (60), washer (61), blower housing (62), washer (63),
and gasket (64) from motor (50).
(18) Mark position of bracket (67) on motor (50), and remove screw (65), washer (66), and bracket (67)
from motor (50).
(19) Mark position of fan (69) on shaft of motor (50), and remove setscrews (68) and fan (69) from shaft
of motor (50).
(20) Remove screws (70), star washers (71), and mount plate (72) from bracket (88).
(21) Tag and disconnect electrical lead for overheat switch (83) from terminal board (111).
(22) Remove screws (73), star washers (74), and cover (75) with baffle (78) from bracket (88).
2-1-26
TM 5-3810-307-24-1-1
(23) Disconnect electrical lead from overheat switch (83), and remove screws (76), star washers (77),
and cover (75) from baffle (78).
(24) Remove electrical lead (79) and grommet (80) from cover (75).
(25) Remove screws (81), star washers (82), and overheat switch (83) from baffle (78).
(27) Remove locknut (85) and disconnect lever of bracket assembly (96) from pivot arm (108).
(28) Tag and disconnect electrical leads for microswitch (91) and flame switch (102) from terminal board
(111).
(29) Remove screws (86), star washers (87), and bracket (88) from case (89).
(30) Remove screws (90), microswitch (91), and insulator (92) from bracket assembly (96).
(31) Remove grommet (93), screws (94), heat shield (95), and bracket assembly (96) from bracket (88).
(32) Mark position of actuator stop (98) on actuating rod (99), loosen setscrews (97), and remove stop
(98), rod (99), and bi-metal blade (100) from bracket assembly (96).
(33) Remove nuts (101), flame switch (102), and spacers (103) from bracket assembly (96).
(34) Remove nut (104) and collar (105), loosen setscrew (106), and remove control lever (107) and pivot
arm (108) from case (89).
(35) Tag and disconnect electrical leads for harness (109) from terminal board (111) and receptacle
(116), and remove harness (109) from case (89).
(36) Remove screws (110), terminal board (111), spacers (112), and star washer (113) from case (89).
(37) Remove screws (114), star washers (115), and receptacle (116) from case (89).
(38) Remove nut (117), fuel line connector (118), terminal connector (119), screws (120), lockwashers
(121), exhaust connector (122), gasket (123), and washer (124) from case (89).
(1) Install washer (124), gasket (123), and exhaust connector (122) on case (89) with lockwashers
(121) and screws (120).
(2) Install terminal connector (119) and fuel line connector (118) with nut (117) in case (89).
(3) Install receptacle (116) in case (89) with star washers (115) and screws (114).
(4) Install terminal board (111) on case (89) with star washers (113), spacers (112), and screws (110).
(5) Position harness (109) in case (89), connect electrical leads to receptacle (116) and terminal board
(111), and remove tags.
(6) Position pivot arm (108) and control lever (107) in case (89), tighten set screw (106), and install
collar (105) and nut (104) on control lever (107).
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(7) Install flame switch (102) on bracket assembly (96) with spacers (103) and nuts (101).
(8) Install actuating rod (99) and bi-metal blade (100) on bracket assembly (96), position actuator stop
(98) on rod (99) as marked during removal, and secure stop (98) with setscrews (97).
(9) Position bracket assembly (96) and heat shield (95) in bracket (88) with lever of bracket assembly
(96), mounting area for microswitch (91), and wires for flame switch protruding through appropriate
holes in bracket (88). Secure bracket assembly (96) and heat shield (95) to bracket (88) with
screws (94).
(10) Install insulator (92) and microswitch (91) on bracket assembly (96) with screws (90).
(11) Install bracket (88) in case (89) with star washers (87) and screws (86).
(12) Install grommet (93) over wires for flame switch (102) and into bracket (88). Route and connect
wires for flame switch (102) and microswitch (91) to terminal board (111). Remove tags.
(13) Install heat exchanger (84) in bracket (88) ensuring flame switch (102) contacts heat exchanger.
Reposition flame switch as necessary to achieve contact.
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TM 5-3810-307-24-1-1
(14) Connect lever of bracket assembly (96) to pivot arm (108) with nut (85).
(15) Install overheat switch (83) in baffle (78) with star washers (82) and screws (81).
(16) Install electrical lead (79) and grommet (80) in cover (75).
(17) Position baffle (78) under cover (75), connect electrical lead to overheat switch (83), and secure
baffle (78) to cover (75) with star washers (77) and screws (76).
(18) Install cover (75) on bracket (88) with star washers (74) and screws (73). Route and connect
electrical leads for overheat switch (83) to terminal board (111) and remove tags.
(19) Install mount plate (72) on bracket (88) with star washers (71) and screws (70).
(20) Apply thread sealant to threads of setscrews (68), then install fan (69) on shaft of motor (50) as
marked during removal with setscrews (68) ensuring setscrews engage flats on motor shaft.
(21) Install bracket (67) on motor (50) as marked during removal with washer (66) and screw (65).
NOTE
(22) Install gasket (64), washer (63), and blower housing (62) on motor (50) with washer (61), washers
(60), lockwashers (59), and nuts (58).
(23) Install fan wheel (57) on shaft of motor (50) and secure with spring clip (part of fan wheel hub).
(24) Install stationary wheel (56) on blower housing (62) with screws (55).
(25) Install spacer (54) and fan wheel (53) on shaft of motor (50). Secure fan wheel (53) with spring clip
(part of fan wheel hub).
(26) Install blower cover (52) on blower housing (62) with clamp (51).
(27) Install motor (50) with blower assembly on mount plate (72) with washers (49) and screws (48).
(28) Connect electrical leads for motor (50) and remove tags.
(29) Install air hose (47) to blower cover (52) and bottom of case (89) with clamps (46).
(30) Install ignition pack (45) on bracket at bottom of case (89) with star washers (44) and screws (43).
(31) Install hose (42), glow plug (41), gasket (40), and igniter (39) on burner head (37).
(32) Install gasket (38) and burner head (37) on heat exchanger (84) with pressure pads (36) and screws
(35).
(33) Connect electrical leads to glow plug (41) and igniter (39). Remove tags.
(34) Install air hose (34) on burner head (37) and blower housing (62) with clamps (33).
(35) Install carburetor assembly (31) on burner head (37) with screws (30). Connect electrical leads for
carburetor assembly (31) and remove tags.
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(36) Install fittings (32) and fuel line (29) at carburetor (31) and rear wall of case (89).
(37) Position covers (27 and 28) on heater assembly (18), and install cross bar (26) on heater assembly
with screws (25).
Installation
a. If removed, install intake duct (23, Figure 2-1-6) on rear of heater and outlet duct (24) on front of heater
(ducts snap in place with captured clips on case).
d. If removed, install mounting straps (20) on heater (18) with capscrews (19), lockwashers (7), and nuts (6).
e. Position heater (18) under superstructure cab and secure in place with washers (17), lockwashers (16),
and nuts (15).
f. Connect heater duct (11) on side of heater (18) and secure with clamp (10).
h. Connect plug for fuel pump at rear of heater (18) remove nut (6) and lockwasher (7), and secure electrical
lead for fuel pump to heater with clamp (8), lockwasher (7), and nut (6).
j. Ensure control cable knob on right side console in superstructure cab is pushed all the way in, position
control lever (107) at front of heater to LO, connect control cable (1) to control lever (107), and secure outer
casing of cable to heater with clamp (4) and screw (2).
l. Secure exhaust pipe (21) to superstructure frame with clamp (14), washers (13), and nuts (12).
Adjustment
Carburetor Adjustment.
NOTE
The carburetor is factory adjusted for the proper air/fuel ratio for diesel fuel DF-
2, using sophisticated equipment. After adjustment, the fuel needle adjust
knob is installed with the pointed side of knob pointing to the 6 o'clock position.
This setting should not be changed unless the fuel type is changed or the
adjust knob has been inadvertently moved. If necessary, adjust the carburetor
as follows.
a. Turn fuel needle adjust knob (125, Figure 2-1-6) clockwise until it bottoms, then back adjust knob out one
full turn counterclockwise.
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WARNING
Diesel heater produces exhaust gases when operating. Brain damage or
death can result from heavy exposure to exhaust gases. Operate heater in a
well ventilated area or duct exhaust to the outside if operating in an enclosed
area.
c. Observe that heater is burning evenly and smoothly, and that no smoke is visible in exhaust.
d. Slowly turn adjust knob (125) counterclockwise just to the point that no smoke is visible in exhaust.
a. Remove heater (18, Figure 2-1-6) from bottom of superstructure cab, refer to Removal procedures.
c. Loosen setscrews (97) securing actuator stop (98) to actuator rod (99).
d. Hold actuator rod (99) and move actuator stop (98) toward microswitch (91) to increase the temperature
within the control range. Move stop (98) toward bi-metal blade (100) to decrease the temperature within
the control range.
NOTE
There must be a minimum gap of .050 in. (1.27 mm) between bi-metal blade
(100) and actuator stop (98) when lever of bracket assembly (96) is in the LO
position [lever is pulled to burner head side of bracket (88)].
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TM 5-3810-307-24-1-1
Test
Inspect
Removal
(1) Remove nuts (1, Figure 2-1-7), lockwashers (2), washers (3), and hose cover (4) from cab roof.
(2) Remove capscrews (5), washers (6), and cover (7) from air conditioner unit (14).
(3) Discharge/recover system refrigerant, refer to instructions for assigned recovery system and
Appendix B.
(4) Disconnect refrigerant hoses (8 and 9) from air conditioner unit (14).
(5) Remove capscrews (10), release control panel (11), tag and disconnect cab harness electrical leads
from switch assembly (85), and allow control panel to hang from bottom of air conditioner unit (14)
inside cab.
(6) Remove capscrews (12) and washers (13) from interior cab roof securing air conditioner unit (14) to
exterior cab roof.
CAUTION
Use care to ensure control panel (11) does not catch on opening in roof when
removing air conditioner unit (14) from cab. Wiring and thermostat sensor lead
may be damaged.
(7) Remove air conditioner unit (14) with control panel (11) and rubber spacers (15 and 16) from cab
roof.
(2) Recover system refrigerant, refer to instructions for assigned recovery system and Appendix B.
(3) Disconnect refrigerant hoses (8 and 9, Figure 2-1-7) from compressor (33). Cap hoses to prevent
entry of contaminants.
(4) Remove nut (18), star washer (19), washer (20), capscrew (21), and ground wire (39) from
compressor (33) housing.
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(5) Loosen nuts (22 and 27), rotate compressor (33) toward engine to relieve tension on drive belt (41),
and remove drive belt (41) from compressor pulley.
(6) Remove nuts (22 and 27), lockwashers (23 and 28), washers (24 and 29), capscrews (25 and 30),
washers (26 and 31), bushing (32) and compressor (33) from bracket (40).
(7) If necessary, remove capscrews (34 and 36), washers (35 and 38), star washer (37), compressor
ground wire (39), and bracket (40) from engine.
Repair
a. Disassemble air conditioner unit (14, Figure 2-1-7) as necessary to replace worn, damaged, or defective
components:
NOTE
(1) Tag and disconnect electrical connector for condenser fan motor (43).
(2) Remove clamp (42) and condenser fan motor (43) from air conditioner frame (83).
(3) Loosen setscrew and remove retainer (44) and fan (45) from condenser fan motor (43).
(4) Tag and disconnect electrical connector for relay (48), remove nut (46), lockwasher (47), and relay
(48) from air conditioner frame (83).
(5) Tag and remove tube (49) from drier (52) and condenser coil (57).
(6) Tag and remove tube (50) from drier (52) and expansion valve (59).
(7) Tag and disconnect electrical connector for switch (53), remove clamp (51) and drier (52) from air
conditioner frame (83).
(9) Remove capscrews (54 and 55), washers (56), and condenser coil (57) from air conditioner frame
(83).
(10) Unhook straps (80) and remove cover (61) from air conditioner frame (83).
(11) Disconnect tubes of evaporator coil (62) from expansion valve (59).
(12) Remove locknuts (58), expansion valve (59), and capscrews (60) from air conditioner frame (83).
WARNING
Fins on evaporator coil are sharp and easily bent. Wear gloves to prevent
cuts, and handle evaporator coil with care to prevent bending fins. Straighten
any bent fins to ensure maximum efficiency.
(13) Pull thermostat sensor lead out of evaporator coil (62) and remove evaporator coil (62) from air
conditioner frame (83).
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(14) Tag and disconnect electrical connectors for motor (75) and resistor (77).
(15) Remove capscrews (63), washers (64), bracket (65), and evaporator fan motor (75) with fans from
air conditioner frame (83).
(16) Remove capscrews (66) and rings (67) from fan housings (73 and 74).
(17) Loosen setscrews, and remove retainers (68) and fan wheels (69 and 70) from shafts of motor (75).
(18) Remove nuts (71), lockwashers (72), and fan housings (73 and 74) from fan motor (75).
(19) Remove capscrews (76) and resistor (77) from fan housing (73).
(20) Remove locknuts (78), washers (79), and straps (80) from air conditioner frame (83).
(21) Remove plenum gasket (81) and drain hoses (82) from air conditioner frame (83).
(22) Remove screws (84) and switch assembly (85) from control panel (11).
NOTE
2-1-41
TM 5-3810-307-24-1-1
(2) Install switch assembly (85) on control panel (11) with screws (84) and route electrical wiring and
thermostat sensor lead from switch assembly through bottom of air conditioner frame (83).
(3) Install plenum gasket (81) and drain hoses (82) on air conditioner frame (83).
(4) Install straps (80) on air conditioner frame (83) with washers (79) and locknuts (78).
(5) Install resistor (77) on fan housing (73) with capscrews (76).
(6) Install fan housings (73 and 74) on motor (75) with lockwashers (72) and nuts (71).
(7) Position fan wheels (69 and 70) and retainers (68) on shafts of motor (75) and secure retainers by
tightening setscrews.
(8) Install rings (67) on fan housings (73 and 74) with capscrews (66).
(9) Install evaporator fan motor (75) with fans on air conditioner frame (83) with bracket (65), washers
(64), and capscrews (63).
(10) Connect electrical connectors for motor (75) and resistor (77). Remove tags.
(11) Position evaporator coil (62) in air conditioner frame (83), and insert thermostat sensor lead into coil
fins near middle of coil.
(12) Install expansion valve (59) on air conditioner frame (83) with capscrews (60) and locknuts (58).
(14) Position cover (61) on air conditioner frame (83), pull straps (80) over cover and hook straps at rear
of frame to secure cover.
(15) Install condenser coil (57) on air conditioner frame (83) with washers (56) and capscrews (54 and
55).
(16) Screw switch (53) into drier (52), install drier (52) on air conditioner frame (83) with clamp (51),
connect electrical connector for switch (53), and remove tag.
(17) Install tube (50) on drier (52) and expansion valve (59). Remove tag.
(18) Install tube (49) on drier (52) and condenser coil (57). Remove tag.
(19) Install relay (48) on air conditioner frame (83) with lockwasher (47) and nut (46). Connect electrical
connector for relay (48) and remove tag.
(20) Position fan (45) and retainer (44) on shaft of condenser fan motor (43), and secure retainer by
tightening setscrew.
(21) Install condenser fan motor (43) on air conditioner frame (83) with clamp (42).
(22) Connect electrical connector for condenser fan motor (43) and remove tag.
NOTE
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TM 5-3810-307-24-1-1
c. Disassemble compressor (33, Figure 2-1-7) as necessary to replace worn, damaged, or defective
components:
(1) Hold drive plate (88) from turning and remove capscrew (87) from compressor (33).
(2) Using suitable puller, remove drive plate (88) and shim(s) (89) from compressor (33).
(3) Remove snap ring (90) and cover (91) from shaft of compressor (33).
CAUTION
To prevent damage to pulley, ensure claws of bearing puller are hooked into
the top groove of the pulley, not under the grooves.
(4) Using standard gear puller, remove pulley (92) from compressor (33).
(5) Remove electrical lead for coil (94) from holder on compressor (33), then remove screws (93), and
coil (94) from compressor.
(2) Install electrical lead for coil (94) in holder on compressor (33).
(3) Using hand press, install pulley (92) onto shaft of compressor (33).
(4) Install cover (91) and snap ring (90) on shaft of compressor (33).
NOTE
(5) Install shim(s) (89) and drive plate (88) on compressor (33). Press drive plate down as far as
possible by hand, install capscrew (87), and torque to 9 to 10 lbs-ft (12 to 14 Nm).
(6) Measure for drive plate clearance of 0.01 to 0.02 in. (0.3 to 0.6 mm). Adjust thickness of shims (89)
to achieve clearance.
Installation
(1) If removed, install bracket (40, Figure 2-1-7) on engine with washers (38 and 35), one end of ground
wire (39), star washer (37), and capscrews (36 and 34).
(2) Position compressor (33) on bracket (40) and install bushing (32), capscrews (30 and 25), washers
(31, 29, 26, and 24), lockwashers (28 and 23), and nuts (27 and 22). Do not tighten nuts at this
time.
(3) Position drive belt (41) on engine fan drive pulley and outer groove of compressor pulley, rotate
compressor (33) away from engine to tension drive belt until there is approximately 1/2 inch
deflection at midspan, then tighten nuts (22 and 27).
(4) Attach other end of ground wire (39) to compressor (33) housing with capscrew (21), washer (20),
star washer (19), and nut (18).
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TM 5-3810-307-24-1-1
NOTE
(7) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 2.50 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.
(2) Position rubber spacers (15 and 16), equaling 2 inches high in front and 1 inch high in back, over
mounting holes in cab roof.
CAUTION
Guide control panel (11) through opening in cab roof being careful not to
damage wiring and thermostat sensor lead when positioning air conditioner
unit (14) on cab roof.
(3) Position air conditioner unit (14) on rubber spacers (15 and 16). Ensure unit mounting holes are
aligned with spacers and cab roof holes.
(4) Secure air conditioner unit (14) to cab roof with washers (13) and capscrews (12).
(5) Lift control panel (11) into position, connect cab harness electrical leads to switch assembly (85),
remove tags, and secure control panel to interior cab roof with capscrews (10).
NOTE
(7) If no other air conditioner component is removed, evacuate and charge air conditioner system with
2.50 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned charging
system and Appendix B.
(8) Install cover (7) over air conditioner unit (14) and secure with washers (6) and capscrews (5).
(9) Install hose cover (4) over hoses (8 and 9) and onto cab roof with washers (3), lockwashers (2), and
nuts (1)
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TM 5-3810-307-24-1-1
Test
Inspect
Removal
(2) Remove screws (12, Figure 2-1-8) and access cover (13) from compressor/motor mounting bracket.
(3) Discharge/recover refrigerant from system at service ports at compressor (18), refer to instructions
for assigned recovery system and Appendix B.
(5) Open clamps (3 and 4) on left side of condenser mounting bracket and left side of turntable, and
remove refrigerant hoses (1 and 2) from clamps.
(6) Remove nuts (5), lockwashers (6), washers (7), and condenser (8) from mounting brackets, and set
on spare tire.
(7) Remove capscrews (9), lockwashers (10), and cover (11) from condenser assembly (8).
(8) Disconnect refrigerant supply hose (1) from drier (99) and return hose (2) from condenser coil (74).
Cap hoses to prevent entry of contaminants and pull hoses out of condenser assembly (8).
(1) Remove screws (12, Figure 2-1-8) and access cover (13) from compressor/motor mounting bracket.
(2) Loosen capscrews (14), release tension on drive belt (15), and remove belt from compressor pulley.
(3) Disconnect electrical connector and ground wire for compressor (21).
(4) If necessary, discharge/recover refrigerant from system, refer to instructions for assigned recovery
system and Appendix B.
(5) Tag and disconnect refrigerant return hose (2), and supply hose (16) from compressor (21). Cap
hoses to prevent entry of contaminants.
(6) Remove nuts (22), lockwashers (23), washers (24), capscrews (14), lockwashers (25), washers
(26), adjustment capscrew bushing (27), and compressor (21) from bracket (28).
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TM 5-3810-307-24-1-1
NOTE
(7) If necessary, remove nuts (17), lockwashers (18), washers (19), capscrews (20), and bracket (28)
from compressor/motor mounting bracket.
(1) If necessary, remove screws (12, Figure 2-1-8) and access cover (13) from compressor/motor
mounting bracket.
(2) If necessary, loosen capscrew (14) releasing tension on drive belt (15) and remove belt from motor
pulley.
CAUTION
(3) Disconnect hydraulic hoses (29 and 30) from adapter (46) and tee (47) at top of motor (43).
(4) Disconnect hydraulic hose (31) from tee (45) at rear of motor (43).
(5) Remove hydraulic tubes (32 and 33) from elbow (44) and tee (45) at rear of motor (43) and adapters
(53 and 54) at valve (52).
(6) Remove capscrews (34) and lockwashers (35), retainer (36), key (37), and pulley (38) from motor
(43).
(7) Remove nuts (39), lockwashers (40), washers (41), capscrews (42), and motor (43) from
compressor/motor mounting bracket.
(8) If necessary, remove elbow (44), tee (45), adapter (46), and tee (47) from motor (43).
CAUTION
(1) Disconnect hose (30, Figure 2-1-8) from tube (55) at front of flow divider valve (52).
(2) If necessary, remove hydraulic tubes (32 and 33) from elbow (44) and tee (45) at rear of motor (43)
and adapters (53 and 54) at valve (52).
(3) Remove nuts (48), lockwashers (49) washers (50), capscrews (51), and flow divider valve (52) from
bracket (62).
(4) If necessary, remove adapters (53 and 54), tube (55), and relief valve (56) from valve (52).
(5) If necessary, remove nut (57), lockwasher (58), washer (59), capscrew (60), washer (61), and
bracket (62) from compressor/motor mounting bracket.
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TM 5-3810-307-24-1-1
(1) If necessary, discharge/recover refrigerant from system, refer to instructions for assigned recovery
system and Appendix B.
(2) Disconnect electrical connector for evaporator assembly (68, Figure 2-1-8).
(3) Disconnect refrigerant hose (1), and refrigerant hose (16) from right side of evaporator assembly
(68).
(4) Remove nuts (63), lockwashers (64), washers (65), capscrews (66), washers (67), and evaporator
assembly (68) from brackets on rear interior wall of cab.
Repair
a. Disassemble condenser assembly (8, Figure 2-1-8) as necessary to replace worn, damaged, or defective
components:
(2) Remove capscrews (70 and 72), lockwashers (71 and 73), and lift coil (74) out of case (103).
(3) Tag and disconnect electrical connectors for fan motors (94).
(4) Remove relay (75) from socket (77), then remove screw (76) and socket (77) from mount bracket
(80).
(5) Remove capscrews (78), lockwashers (79), and mount bracket (80) with fan motors (94) from case
(103).
NOTE
Both fan motors are disassembled the same. Steps (6) thru (9) apply to either
motor.
(6) Remove capscrews (81), lockwashers (82), and brackets (83 and 84) with fan motor (94) from
mount bracket (80).
(7) Remove cotter pin (85), retainer (86), and fan (87) from shaft of fan motor (94).
(8) Remove nuts (88), star washers (89), and bracket (84) from fan motor (94).
(9) Remove nuts (90), star washers (91), capscrews (92), clamp halves (93), and brackets (83) from fan
motor (94).
(11) Remove nuts (95), star washers (96), capscrews (97), clamp halves (98), and drier (99) from
bracket in case (103).
(12) If necessary, remove refrigerant hose (69) and switch (100) from drier (99).
(13) If necessary, remove grommet (101) and electrical harness (102) from case (103).
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(1) If removed, route electrical harness (102) through hole in case (103), and install grommet (101) over
electrical harness (102) and into hole of case (103).
(3) Install drier (99) on bracket in case (103) with clamp halves (98), capscrews (97), star washers (96),
and nuts (95).
2-1-55
TM 5-3810-307-24-1-1
NOTE
Both fan motors are assembled the same. Steps (5) thru (8) apply to either
motor.
(5) Install brackets (83) and clamp halves (93) on motor (94) with capscrews (92), star washers (91),
and nuts (90).
(6) Install bracket (84) on fan motor (94) with star washers (89) and nuts (88).
CAUTION
Fan blades bend easily. Handle fan with care to prevent bending fan blades.
(7) Install fan (87) on shaft of fan motor (94) with retainer (86) and new cotter pin (85).
(8) Install brackets (83 and 84) with motor (94) on mount bracket (80) with lockwashers (82) and
capscrews (81). Ensure ground wire for fan motor (94) is installed under head of one capscrew
(81).
(9) Install mount bracket (80) with fan motors (94) in case (103) with lockwashers (79) and capscrews
(78).
(10) Install relay socket (77) on mount bracket (80) with screw (76) and plug in relay (75).
(11) Connect electrical connectors for fan motors (94). Remove tags.
(12) Install coil (74) in case (103) with lockwashers (71 and 73) and capscrews (70 and 72).
(13) Install refrigerant hose (69) between coil (74) and drier (99).
c. Disassemble compressor (21, Figure 2-1-8) as necessary to replace worn, damaged, or defective
components:
(1) Hold drive plate (105) from turning and remove capscrew (104) from compressor (21).
(2) Using suitable puller, remove drive plate (105) and shim(s) (106) from compressor (21).
(3) Remove snap ring (107) and cover (108) from shaft of compressor (21).
CAUTION
To prevent damage to pulley, ensure claws of bearing puller are hooked into
the top groove of the pulley, not under the grooves.
(4) Using standard gear puller, remove pulley (109) from compressor (21).
(5) Remove grommet and electrical lead for coil (111) from holder on compressor (21), then remove
screws (110), and coil (111) from compressor.
(2) Install grommet and electrical lead for coil (111) in holder on compressor (21).
2-1-56
TM 5-3810-307-24-1-1
(3) Using hand press, install pulley (109) onto shaft of compressor (21).
(4) Install cover (108) and snap ring (107) on shaft of compressor (21).
NOTE
(5) Install shim(s) (106) and drive plate (105) on compressor (21). Press drive plate down as far as
possible by hand, install capscrew (104), and torque to 9 to 10 lbs-ft (12 to 14 Nm).
(6) Measure for drive plate clearance of 0.01 to 0.02 in. (0.3 to 0.6 mm). Adjust thickness of shims
(106) to achieve clearance.
e. Disassemble motor (43, Figure 2-1-8) as necessary to replace worn, damaged, or defective components:
(1) Mount motor (43) in a vise with shaft end pointed down and match mark all sections.
(2) Remove capscrews (112) and washers (113) securing sections together.
CAUTION
(3) Remove cover (114) from gear housing (115). If necessary pry loose with two large flat tip
screwdrivers.
(4) Using standard bearing puller, remove bearings (116) from cover (114).
(5) Using standard seal removal tool, remove seal ring (117) from cover (114). Discard seal ring.
(6) Remove gear housing (115) from gear (119), shaft (120), and cover (118).
(7) Carefully remove gear (119) and shaft (120) from cover (118).
NOTE
Gear (119) and shaft (120) are a matched set and must be replaced as a set.
Mark gear (119) to ensure it is installed in the same direction as removed
during assembly.
(8) Only if necessary, use drill bit of the same diameter as check valve (121) to drill out peened material
from hole for check valve (121), and unscrew check valve (121) from cover (118).
(9) Remove gaskets (122), thrust plate (123), and pocket seals (124) from gear housing (115). Remove
pocket seal from thrust plate (123) and discard all pocket seals and gaskets.
(10) Being careful not to distort thrust plate (125) or damage machined surface of cover (118), pry thrust
plate (125) from cover (118).
(11) Remove pocket seals (126) from cover (118) and thrust plate (125). Discard all pocket seals.
(12) Using standard bearing puller, remove bearings (127) from cover (118).
2-1-57
TM 5-3810-307-24-1-1
(13) Using standard seal removal tool, remove seal ring (128) from cover (118). Discard seal ring.
(14) Remove snap ring (129), and using a standard bearing puller, remove bearing (130) from cover
(118).
(15) Using standard seal removal tool, remove retainer (131) and seal (132) from cover (118). Discard
retainer and seal.
(1) Stone off all machined surfaces with a medium grit carborundum stone, deburr bearing bores, rinse
parts in solvent, dry parts with compressed air, and wipe with a clean, lint-free cloth.
(2) Coat outer edge of new seal (132) and its recess with Form-a-Gasket No. 3 non-hardening sealant,
and press seal (132) into cover (118) until seal is flush with face of recess. Wipe off extra sealant.
(3) Press new retainer (131) and bearing (130) into cover (118), then install snap ring (129).
(4) If removed, install check valve (121) in cover (118) and peen edge of hole with a 1 in. (3.8 cm)
steel ball.
(5) Press new seal ring (128) into shaft bearing hole of cover (118) ensuring notch in ring will be next to
bearing (127).
(7) Cut two pocket seals (126) 7/32 in. (5.5 mm) long, grease seals well with multi-purpose grease, and
install them in the middle slots on the reverse side of thrust plate (125).
(8) With pocket seals (126) facing down, position thrust plate (125) over bearings (127), and tap thrust
plate down to approximately 1/32 in. (0.8 mm) from machined surface of cover (118).
(9) Cut four pocket seals (126) 1/4 in. (6.4 mm) long and insert one pocket seal into each slot in thrust
plate (125). Press pocket seals down until they touch bearings (127), tap thrust plate down firmly
against machined surface of cover (118), and trim pocket seals flush with top of thrust plate.
(10) Tape splined end of shaft (120), lightly grease tape and shaft, and insert shaft into cover (118) with a
twisting motion until gear of shaft rests against thrust plate (125). Remove tape.
(11) Insert gear (119), as marked during disassembly, into cover (118) meshing gears with gears on
shaft (120).
(12) Apply multipurpose grease to new gaskets (122) and install gaskets in grooves on both sides of gear
housing (115).
(13) Carefully install gear housing (115) over shaft (120) and gear (119), line up match marks on cover
(118) with marks on gear housing (115), and gently tap gear housing with a plastic hammer until
seated against cover (118). Squirt oil over gears to provide initial lubrication for pump.
2-1-58
TM 5-3810-307-24-1-1
(14) Cut two pocket seals (124) 7/32 in. (5.5 mm) long, grease seals well with multi-purpose grease, and
install them in the middle slots on the reverse side of thrust plate (123).
(15) With pocket seals (124) facing down, position thrust plate (123) over shaft (120) and gear (119), and
tap thrust plate down to approximately 1/32 in. (0.8 mm) from machined surface of gear housing
(115).
(16) Cut four pocket seals (124) 1/4 in. (6.4 mm) long and insert one pocket seal into each slot in thrust
plate (123). Press pocket seals down until they touch gears, tap thrust plate down firmly against
machined surface of gear housing (115), and trim pocket seals flush with top of thrust plate.
(17) Press new seal ring (117) into shaft bearing hole in cover (114) ensuring notch in ring will be next to
bearing (116).
(19) Carefully install cover (114) over drive shaft (120) and gear shaft (119), line up match marks on
cover (114) with marks on gear housing (115), and gently tap cover with a plastic hammer until
seated against gear housing (115).
(20) Install washers (113) and capscrews (112), and cross-tighten capscrews.
g. Disassemble evaporator assembly (68, Figure 2-1-8) as necessary to replace worn, damaged, or defective
components:
(1) Remove capscrews (133) and cover (134) from case (160).
(2) Remove capscrews (135) and retainer bar (136) securing mount bracket (137) from case (160).
(3) Tag and disconnect electrical connectors (159) for fan motor (148) and resistor (143), then lift mount
bracket (137) with fan motor (148) from case (160).
(4) Remove screws (138) and retainer plates (139) from mount bracket (137).
(5) Remove clips (140) and fan wheels (141) from shafts of motor (148).
(6) Remove capscrews (142) and resistor (143) from right side of mount bracket (137).
(7) Remove nuts (144), star washers (145), capscrews (146), clamp halves (147), and fan motor (148)
from mount bracket (137).
(9) Pull thermostat sensor lead from coil (153), remove capscrews (149) and thermostat (150) from
case (160).
(10) Remove capscrews (151) and side cover (152) from case (160).
(11) Disconnect refrigerant tubes for coil (153) from connection block (157), and lift coil (153) out of case
(160).
(12) Remove nuts (154), star washers (155), capscrews (156), and connection block (157) from case
(160).
(13) Remove grommet (158) and electrical harness (159) from case (160).
2-1-59
TM 5-3810-307-24-1-1
(1) Insert electrical harness (159) through side of case (160), and install grommet (158) over harness
and into hole of case.
(2) Install connection block (157) on side of case (160) with capscrews (156), star washers (155), and
nuts (154).
(3) Position coil (153) in case (160), and connect refrigerant tubes for coil to connection block (157).
(4) Install side cover (152) on case (160) with capscrews (151).
(5) Install thermostat (150) on side wall of case (160) with capscrews (149), and insert thermostat
sensor lead into center of coil (153).
(7) Install fan motor (148) on mount bracket (137) with clamp halves (147), capscrews (146), star
washers (145), and nuts (144).
(8) Install resistor (143) in right side of mount bracket (137) with capscrews (142).
(9) Install fan wheels (141) on shafts of fan motor (148) with clips (140).
(10) Install retainer plates (139) on mount bracket (137) with screws (138).
(11) Position mount bracket (137) with fan motor (148) in case (160), connect electrical connectors for
fan motor (148) and resistor (143), and remove tags.
(12) Secure mount bracket (137) in case (160) with retainer bar (136) and capscrews (135).
Installation
(1) Place condenser assembly (8, Figure 2-1-8, Sheet 1) on carrier spare tire.
(2) Insert refrigerant hoses (1 and 2) through side of condenser assembly (8), connect refrigerant
supply hose (1) to drier (99) and return hose (2) to condenser coil (74).
(3) Install cover (11) on condenser assembly (8) with lockwashers (10) and capscrews (9).
(4) Install condenser assembly (8) in mounting brackets with washers (7), lockwashers (6), and nuts (5).
(5) Position refrigerant hoses (1 and 2) in clamps (3 and 4), close, and secure clamps.
(7) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 3.5 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.
(8) Install access cover (13) on compressor/motor mounting bracket with screws (12).
2-1-60
TM 5-3810-307-24-1-1
(1) If removed, install bracket (28, Figure 2-1-8, Sheet 2) on compressor/motor mounting bracket as
marked during removal, with capscrews (20), washers (19), lockwashers (18), and nuts (17).
(2) Install compressor (21) on bracket (28) with adjustment capscrew bushing (27), washers (26),
lockwashers (25), capscrews (14), washers (24) lockwashers (23), and nuts (22). Do not tighten
mounting hardware at this time.
(3) Connect refrigerant supply hose (16) and refrigerant return hose (2) to compressor (18). Remove
tags.
(4) Connect electrical connector and ground wire for compressor (21).
(5) Position drive belt (15) on inner pulley groove of compressor (21), adjust belt tension by pressing
down on compressor until there is approximately 1/2 inch deflection in belt at mid span, and tighten
capscrews (14) securing compressor to mount (28).
(6) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 3.5 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.
(7) Install access cover (13) on compressor/motor mounting bracket with screws (12).
(1) If removed, install tee (47, Figure 2-1-8, Sheet 2), adapter (46), tee (45), and elbow (44) on motor
(43).
(2) Install motor (43) on compressor/motor mounting bracket with capscrews (42), washers (41),
lockwashers (40), and nuts (39).
(3) Install sheave (38) on motor (43) with key (37), retainer (36), lockwashers (35), and capscrews (34).
(4) Install hydraulic tubes (32 and 33) on adapters (53 and 54) at valve (52) and tee (45) and elbow (44)
at rear of motor (43).
(5) Connect hydraulic hose (31) to tee (45) at rear of motor (43).
(6) Connect hydraulic hoses (29 and 30) to tee (47) and adapter (46) at top of motor (43).
(7) Position drive belt on pulley of motor (43), and if compressor (21) is not removed, adjust belt tension
by pressing down on compressor until there is approximately 1/2 inch deflection in belt at mid span,
and tighten capscrews (14) securing compressor to mount (28).
(8) If compressor is not removed, install cover (13) on compressor/motor mounting bracket with screws
(12).
(1) If removed, install bracket (62, Figure 2-1-8, Sheet 2) on compressor/motor mounting bracket with
washer (61), capscrew (60), washer (59), lockwasher (58), and nut (57).
(2) If removed, install relief valve (56), tube (55), and adapters (54 and 53) on flow divider valve (52).
2-1-61
TM 5-3810-307-24-1-1
(3) Install flow divider valve (52) on bracket (62) with capscrews (51), washers (50), lockwashers (49),
and nuts (48).
(4) If motor is not removed, install hydraulic tubes (32 and 33) on adapters (53 and 54) at valve (52) and
tee (45) and elbow (44) at rear of motor (43).
(1) Position evaporator assembly (68, Figure 2-1-8, Sheet 3) to brackets on rear interior wall of cab and
secure with washers (67), capscrews (66), washers (65), lockwashers (64), and nuts (63).
(2) Connect refrigerant hoses (1 and 16) to right side of evaporator (68).
(4) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 3.5 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.
2-1-62
TM 5-3810-307-24-1-1
Removal
b. Disconnect electrical connector for tilt steering column (17, Figure 2-1-9).
c. Remove capscrews (1), lockwashers (2 and 5), washers (3 and 6), nuts (4), bracket (7), filler plate (8), and
clamp (9) securing tilt steering column (17) to cab weldment (18) and dash panel.
NOTE
Prior to disconnecting tilt steering column from steering shaft, position steering
wheel so spokes are horizontal.
d. Remove nut (10) and capscrew (11) securing tilt steering column (17) to steering shaft (12).
e. Remove nuts (13), lockwashers (14), washers (15), and tilt steering column (17) from cab weldment (18).
Repair
a. Replace steering wheel and/or horn as follows (may be accomplished with steering column installed):
(2) Remove horn cover (19, Figure 2-1-9) from steering wheel (22).
(3) Disconnect electrical lead from horn button (20) and remove horn button from steering wheel (22).
(4) Remove nut (21) and using wheel puller, remove steering wheel (22) from steering column.
(5) Slide collar (23) off steering column and remove horn spring and plate assembly (24).
(7) Position horn spring and plate assembly (24) on steering column and slide collar (23) onto column
maintaining downward pressure to hold parts in place.
(8) Install steering wheel (22) on steering column with nut (21) ensuring electrical lead for horn button
(20) is inserted through hole provided in steering wheel hub. Torque nut (21) to 110 lbs-ft (149 Nm).
(9) Connect electrical lead to horn button (20) and install cover (19).
b. Replace turn signal/hazard switch as follows (may be accomplished with steering column and steering
wheel installed):
(2) Remove upper cover (25, Figure 2-1-9) and lower cover (26) from steering column.
(3) Tag and disconnect electrical leads to turn signal/hazard switch (29).
(4) Remove screws (27), lockwashers (28), and turn signal/hazard switch (29) from steering column.
2-1-63
TM 5-3810-307-24-1-1
LEGEND
2-1-64
TM 5-3810-307-24-1-1
(5) Install new turn signal/hazard switch (29) on steering column with lockwashers (28) and screws (27).
(6) Connect electrical leads to turn signal/hazard switch (29), remove tags, and install upper cover (25)
and lower cover (26) on steering column. Ensure covers are secure by snapping slots in covers
onto studs on steering column.
Installation
a. Insert tilt steering column (17, Figure 2-1-9) through cab weldment (18) and secure to weldment with
capscrews (16), lockwashers (15), washers (14), and nuts (13).
NOTE
Prior to sliding splines of steering shaft onto tilt steering column, position
steering wheel so spokes are horizontal.
b. Slide splines of steering shaft (12) onto tilt steering column (17) and secure with capscrew (11) and nut
(10).
c. Position clamp (9), filler plate (8), and bracket (7) to cab weldment (18) and dash panel ensuring clamp
ends extend through bracket (7).
d. Secure bracket (7), filler plate (8) and clamp (9) with washers (3 and 6), lockwashers (2 and 5), nuts (4)
and capscrews (1).
2-1-65
TM 5-3810-307-24-1-1
Removal
b. Disconnect electrical connector for tilt steering column (15, Figure 2-1-10).
c. Remove capscrews (1), lockwashers (2 and 5), washers (3 and 6), nuts (4), bracket (7), filler plate (8), and
clamp (9) securing tilt steering column (15) to cab weldment (16) and dash panel.
d. Tag, disconnect, and cap hydraulic lines (10) from steering valve (11).
e. Support steering valve (11), remove capscrews (12), lockwashers (13), washers (14), tilt steering column
(15), and steering valve (11) from cab weldment (16).
Repair
a. Replace steering wheel and/or horn as follows (may be accomplished with steering column installed):
(2) Remove horn cover (19, Figure 2-1-10) from steering wheel (22).
(3) Disconnect electrical lead from horn button (20) and remove horn button from steering wheel (22).
(4) Remove nut (21) and using wheel puller, remove steering wheel (22) from steering column.
(5) Slide collar (23) off steering column and remove horn spring and plate assembly (24).
(7) Position horn spring and plate assembly (24) on steering column and slide collar (23) onto column
maintaining downward pressure to hold parts in place.
(8) Install steering wheel (22) on steering column with nut (21) ensuring electrical lead for horn button
(20) is inserted through hole provided in steering wheel hub. Torque nut (21) to 110 lbs-ft (149 Nm).
(9) Connect electrical lead to horn button (20) and install cover (19).
b. Replace turn signal/hazard switch as follows (may be accomplished with steering column and steering
wheel installed):
(2) Remove upper cover (25, Figure 2-1-10) and lower cover (26) from steering column.
(3) Tag and disconnect electrical leads to turn signal/hazard switch (29).
(4) Remove screws (27), lockwashers (28), and turn signal/hazard switch (29) from steering column.
2-1-66
TM 5-3810-307-24-1-1
LEGEND
2-1-67
TM 5-3810-307-24-1-1
(5) Install new turn signal/hazard switch (29) on steering column with lockwashers (28) and screws (27).
(6) Connect electrical leads to turn signal/hazard switch (29), remove tags, and install upper cover (25)
and lower cover (26) on steering column. Ensure covers are secure by snapping slots in covers
onto studs on steering column.
Installation
a. Position steering valve (11, Figure 2-1-10) below cab weldment (16), insert tilt steering column (15)
through cab weldment (16), and into splines of steering valve (11).
b. Secure tilt steering column (15) and steering valve (11) to cab weldment (16) with capscrews (12),
lockwashers (13), and washers (14).
c. Remove caps and connect hydraulic lines (10) to steering valve (11).
d. Position clamp (9), filler plate (8), and bracket (7) to cab weldment (16) and dash panel ensuring clamp
ends extend through bracket (7).
e. Secure bracket (7), filler plate (8) and clamp (9) with washers (3 and 6), lockwashers (2 and 5), nuts (4)
and capscrews (1).
2-1-68
TM 5-3810-307-24-1-1
Removal
b. Loosen clamp securing defroster control cable (1, Figure 2-1-11) to bottom of heater and remove cable
from clamp.
c. Disconnect defroster control cable (1) from lever at bottom of heater (under cab).
e. Remove nuts (3 and 4), and push defroster control cable (1) out of dash panel.
f. Remove washer (5) from defroster control cable (1), so it does not fall off cable and get lost.
g. Remove all cable ties/clamps securing defroster control cable (1) to carrier, and remove cable from carrier.
Installation
a. Position defroster control cable (1, Figure 2-1-11) in carrier, and secure with all cable ties/clamps removed
during removal procedures.
b. Place washer (5) on defroster control cable (1) and insert cable through hole in dash panel.
c. Secure defroster control cable (1) to dash panel with nuts (4 and 6).
d. Install knob (2) on defroster control cable (1) and tighten nut (3) to knob.
e. Insert defroster control cable (1) through clamp at bottom of heater and connect cable to lever.
NOTE
Ensure control cable knob is pushed all the way in and lever on bottom of
heater is positioned as far as possible toward left side of vehicle before
tightening clamp.
f. Pull slack from cable and tighten clamp at heater to secure defroster control cable to heater.
2-1-69
TM 5-3810-307-24-1-1
LEGEND
2-1-70
TM 5-3810-307-24-1-1
Removal
b. Loosen clamp and disconnect heater control cable (1, Figure 2-1-12) from lever on heater shutoff valve at
left side of heater.
d. Remove nuts (3 and 4), and push heater control cable (1) out of dash panel.
e. Remove washer (5) from heater control cable (1), so it does not fall off and get lost.
f. Remove all cable ties/clamps securing heater control cable (1) to carrier, and remove cable from carrier.
Installation
a. Position heater control cable (1, Figure 2-1-12) in carrier, and secure with all cable ties/clamps removed
during removal procedures.
b. Place washer (5) on heater control cable (1) and insert cable through hole in dash panel.
c. Secure heater control cable (1) to dash panel with nuts (4 and 6).
d. Install knob (2) on heater control cable (1) and tighten nut (3) to knob.
NOTE
Ensure control cable knob is pushed all the way in and lever on shutoff valve is
positioned as far as possible toward rear of vehicle before tightening clamp.
e. Connect heater control cable (1) to lever on heater shutoff valve, pull slack from cable, and tighten clamp.
2-1-71
TM 5-3810-307-24-1-1
LEGEND
2-1-72
TM 5-3810-307-24-1-1
CONTROL ASSEMBLY, TRAILER AIR SUPPLY AND PARKING BRAKE (CARRIER CAB)
Removal
b. Relieve system air pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are drained.
Wear eye protection when disconnecting air lines to prevent injury.
c. Tag and disconnect air lines (1, 2, and 3, Figure 2-1-13) from connectors (8, 9, and 10).
d. Unscrew TRAILER AIR SUPPLY knob (4) and PARKING BRAKE knob (5) from control assembly (7).
e. Support control assembly (7), remove screws (6) and control assembly (7) from dash panel.
f. If necessary, remove connectors (8, 9, and 10) from control assembly (7).
Repair
WARNING
Be careful to maintain and release pressure slowly when removing retaining
caps. Internal components are assembled with spring tension and could cause
personal injury if allowed to pop free.
a. Remove retaining caps (11, Figure 2-1-13) from control body (33).
b. Remove holders (12), spools (13), seals (14), and springs (15) from control body (33). Discard seals and
springs.
c. Remove o-rings (16 and 17) from holders (12). Discard o-rings.
d. Remove o-rings (18, 19, and 20) from spools (13). Discard o-rings.
NOTE
WARNING
Be careful to maintain and release pressure slowly when removing retaining
plug. Internal components are assembled with spring tension and could cause
personal injury if allowed to pop free.
2-1-73
TM 5-3810-307-24-1-1
LEGEND
Figure 2-1-13. Trailer Air Supply and Parking Brake Control Assy (Carrier Cab) (Sheet 1 of 2)
2-1-74
TM 5-3810-307-24-1-1
Figure 2-1-13. Trailer Air Supply and Parking Brake Control Assy (Carrier Cab) (Sheet 2 of 2)
2-1-75
TM 5-3810-307-24-1-1
f. Remove sleeve (22), springs (23 and 24), and check valve (25) from control body (33). Discard springs
and check valve.
g. Remove o-ring (26) from plug (21) and o-ring (27) from sleeve (22). Discard o-rings.
h. Remove retaining ring (28) and shuttle valve (29) from control body (33). Discard shuttle valve and
retaining ring.
i. Install new o-rings (30, 31, and 32) on new shuttle valve (29).
j. Install shuttle valve (29) in control body (33) and secure with retaining ring (28).
k. Install new o-ring (27) on sleeve (22) and new o-ring (26) on retaining plug (21).
l. Insert new check valve (25), new springs (24 and 23), and sleeve (22) in control body (33). Secure
components in control body with retaining plug (21).
o. Insert new springs (15), new seals (14), spools (13), and holders (12) in control body (33). Secure
components in control body with retaining caps (11).
Installation
a. If removed, install connectors (8, 9, and 10, Figure 2-1-13) in control assembly (7).
b. Position control assembly (7) in dash panel, and secure with screws (6).
c. Install PARKING BRAKE knob (5) and TRAILER AIR SUPPLY knob (4) on control assembly (7). Tighten
knobs until fully seated, then position so text is upright.
NOTE
If the park brake control valve does not operate as described, or leakage is
excessive, it is recommended that it be replaced.
b. With the PARK BRAKE control pulled out (exhaust position), coat the exhaust port and plunger stem with a
soap solution. A 1 in. (254 cm) bubble in five seconds is permitted. There should be no leakage between the
upper and lower body.
c. Push the PARK BRAKE control in (applied position). A 1 in. (254 cm) bubble in three seconds is
permitted.
d. Reduce system air pressure and observe the PARK BRAKE control. It should pop out when the air
pressure drops to approximately 40 psi (275 kPa), exhausting the delivery line and engaging the park brakes.
2-1-76
TM 5-3810-307-24-1-1
Removal
b. Unplug heater power cord plug from receptacle at front of heater (under cab).
c. Loosen clamp (4, Figure 2-1-6) securing heater control cable (7, Figure 2-1-14) to front of heater and
remove cable from clamp.
g. Remove nuts (5 and 6), and push heater control cable (7) out of cab.
h. Remove screws (1), pull heater control panel (2) from cab wall, and disconnect electrical connector for
control.
i. Remove heater control panel (2) with cord and shims (3) from cab.
Installation
a. Position shims (3, Figure 2-1-14) and heater control panel (2) with power cord on cab wall.
b. Connect electrical connector for heater control panel (2) and secure heater control panel (2) and shims (3)
to cab wall with screws (1).
c. Insert heater control cable (7) through hole in cab mounting bracket and secure with nuts (5, 6, and 8).
d. Install knob (4) on heater control cable (7). Ensure knob (4) is pushed all the way in.
e. Insert heater control cable (7) through clamp (4, Figure 2-1-6) and connect cable to heater lever (under
cab). Ensure lever is positioned as far to the left as possible.
f. Pull slack from control cable (7, Figure 2-1-14) between heater lever and clamp (4, Figure 2-1-6), then
tighten clamp (4) to secure heater control cable (7, Figure 2-1-14) to heater.
g. Plug heater power cord plug into receptacle at front of heater (under cab).
h. Secure heater control cable (7) to bottom of cab with the two clamps removed during removal procedures.
2-1-77
TM 5-3810-307-24-1-1
LEGEND
2-1-78
TM 5-3810-307-24-1-1
Removal
b. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
c. Loosen setscrews (3, Figure 2-1-15) and remove knob (4) from control assembly (7).
d. Remove retaining nut (5), shim washer (6) and push control assembly (7) from dash panel.
e. Tag and disconnect air lines (1 and 2) from elbows (8 and 9).
Installation
c. Position control assembly (7) in dash panel and secure with retaining nut (5) and shim washer (6).
d. Install knob (4) on control assembly (7) and tighten setscrews (3).
NOTE
If the park brake control valve does not operate as described, or leakage is
excessive, it is recommended that it be replaced.
b. With the PARK BRAKE control pulled out (exhaust position), coat the exhaust port and plunger stem with a
soap solution. A 1 in. (254 cm) bubble in five seconds is permitted. There should be no leakage between the
upper and lower body.
c. Push the PARK BRAKE control in (applied position). A 1 in. (254 cm) bubble in three seconds is
permitted.
d. Reduce system air pressure and observe the PARK BRAKE control. It should pop out when the air
pressure drops to approximately 40 psi (275 kPa), exhausting the delivery line and engaging the park brakes.
2-1-79
TM 5-3810-307-24-1-1
LEGEND
2-1-80
TM 5-3810-307-24-1-1
Removal
a. Remove screws (1, Figure 2-1-16), washers (2) and clamp (3) securing throttle cable (8) to cab weldment.
b. Remove clip (10) and pin (11). Then loosen nut (4) and remove clevis (12) from cable (8).
c. Remove nut (5), washer (6), lockwasher (7), and throttle cable (8) from dash panel.
d. Remove clip (14) and pin (13). Then disconnect cable (15) from bracket (24).
e. Remove clip (16), pin (17), and roller (18) from clevis (20).
f. If necessary, loosen nut (19) and remove clevis (20) and nut (19) from stud in cab floor.
g. If necessary, remove nuts (21), lockwashers (22), screws (23), and bracket (24) from air throttle pedal.
Repair
Installation
a. If removed, install bracket (24, Figure 2-1-16) on air throttle pedal with screws (23), lockwashers (22), and
nuts (21).
b. If removed, install nut (19) and clevis (20) on stud in cab floor. Do not tighten nut (19) at this time.
c. Attach cable (15) to bracket (24) with pin (13) and clip (14).
d. Install throttle cable (8) in dash panel with lockwasher (7), washer (6), nut (5), and nut (9). Then install nut
(4) and clevis (12) on end of throttle cable (8).
e. Route cable (15) through clevis (20), and install roller (18) in clevis (20) with pin (17) and clip (16).
f. Attach clevis (12) to cable (15) with pin (11) and clip (10).
Adjustment
a. Ensure knob of throttle cable (8, Figure 2-1-16) is pushed all the way in until all slack is out of cables
without moving throttle pedal. If necessary, remove clip (10) and pin (11) and reposition clevis (12). Then install
pin (11) and clip (10) and recheck throttle cable travel. Tighten nut (4).
b. Ensure clevis (20) is positioned so cable (15) runs smoothly on roller (18) when knob is moved in and out,
then tighten nut (19).
c. Secure throttle cable (8) to cab weldment with clamp (3), washers (2), and screws (1).
2-1-81
TM 5-3810-307-24-1-1
LEGEND
2-1-82
TM 5-3810-307-24-1-1
Removal
a. Rotate boom over the left side to allow access to swing lock pin from under the superstructure cab. Shut
down diesel engine and position battery disconnect switch to OFF.
WARNING
Engage positive swing lock, using the positive swing lock handle, to ensure
turntable does not move during maintenance. Refer to Operator's Manual, TM
5-3810-307-10 for definition and operation of positive swing lock and positive
swing lock handle.
b. Remove clip (14, Figure 2-1-16), pin (13), clip (16), pin (17), roller (18), and move cable (15) aside.
c. Remove capscrews (1, Figure 2-1-17), lockwashers (2), mounting plate (3), and clamp (4) securing cable
(5) to side wall of cab.
d. Move handle of swing lock control (13) to the LOCKED position so clevis (6) is accessible under
superstructure cab.
e. Loosen nut (7), remove clevis (6) with chain assembly (23) and swing lock pin (24), and nut (7) from cable
(5).
f. Remove screws (8), collars (9), nut (10), lockwasher (11), washer (12), and swing lock control (13) with
bracket (16) and cable (5) from dash panel.
NOTE
g. Remove nuts (14), screws (15), and bracket (16) from swing lock control (13).
h. If necessary, remove clamp (17) and boot (18) from cab floor, and clamp (19) and guide (20) from boot
(18).
i. If necessary, remove clip (21), pin (22), and clevis (6) from chain assembly (23).
j. If necessary, remove swing lock pin (24) from chain assembly (23).
Repair
2-1-83
TM 5-3810-307-24-1-1
LEGEND
2-1-84
TM 5-3810-307-24-1-1
Installation
a. If removed, apply LOCTITE 272 to threads of chain assembly (23, Figure 2-1-17), and install chain
assembly (23) in swing lock pin (24).
b. If removed, install clevis (6) on chain assembly (23) with pin (22) and clip (21).
c. If removed, install guide (20) in top of boot (18) with clamp (19), and secure boot (18) to cab floor with
clamp (17).
d. Install bracket (16) on swing lock control (13) with screws (15) and nuts (14).
e. Insert cable (5) through dash panel and route cable through boot (18) so cable extends through floor of
cab.
f. Secure swing lock control (13) with bracket (16) to dash panel with collars (9), screws (8), washer (12),
lockwasher (11), and nut (10).
NOTE
If mounting hardware for shift control was removed, secure shift control to dash
panel, refer to Shift Control Assembly (Superstructure Cab) Installation
procedures.
g. Install nut (7) and clevis (6) with chain assembly (23) and swing lock pin (24) on cable (5). Screw clevis
(6) onto cable (5) until approximately 1/2 in. of cable threads extend through clevis, then tighten nut (7) onto
clevis (6).
h. Place handle of swing lock control (13) in the UNLOCKED position, and install clamp (4) over cable (5)
and onto side wall of cab with mounting plate (3), lockwashers (2), and capscrews (1). Do not tighten capscrews
(1).
i. Pull up on cable (5) until swing lock pin (24) bottoms out in the up position, and tighten capscrews (1).
j. Install cable (15, Figure 2-1-16) with pin (13) and clip (14), and roller (18) with pin (17) and clip (16).
k. Disengage positive swing lock, using positive swing lock handle, start engine and carefully rotate boom
over front of carrier ensuring swing lock pin clears carrier.
l. Operate swing lock control several time to ensure proper operation and shut down engine.
2-1-85
TM 5-3810-307-24-1-1
Removal
b. Remove screws (1, Figure 2-1-18) and lockwashers (2) securing shift control assembly (3) in side console.
c. Lift shift control assembly (3), disconnect electrical connector, and remove shift control assembly from side
console.
Installation
a. Position shift control assembly (3, Figure 2-1-18) near side console and connect electrical connector.
b. Lower shift control assembly (3) into side console and secure with lockwashers (2) and screws (1).
LEGEND
1. Screw
2. Lockwasher
3. Shift control assembly
2-1-86
TM 5-3810-307-24-1-1
Removal
b. Remove knob (1, Figure 2-1-19) from lever of shift control switch (3).
c. Remove screws (2) and remove shift control switch (3) from rear of housing (4).
d. Tag and disconnect electrical leads for shift control switch (3).
NOTE
e. If necessary, remove nuts (4), lockwashers (5), screws (6), and shift control housing (7) from dash panel.
Installation
a. If removed, install shift control housing (7, Figure 2-1-19) on dash panel with screws (6), lockwashers (5),
and nuts (4).
b. Connect electrical leads for shift control switch (3) and remove tags.
c. Insert shift control switch (3) into housing (7) from rear of dash panel, and secure to housing with screws
(2).
NOTE
If swing lock control bracket was moved, secure in dash panel with mounting
hardware.
2-1-87
TM 5-3810-307-24-1-1
LEGEND
1. Knob 5. Lockwasher
2. Screw 6. Screw
3. Shift control switch 7. Housing
4. Nut
2-1-88
TM 5-3810-307-24-1-1
Removal
(1) Remove heater control from dash panel only, refer to Heater Control (Carrier Cab) Removal
procedures, steps a. thru c.
(2) Remove defroster control from dash panel only, refer to Defroster Control (Carrier Cab) Removal
procedures, steps a. thru d.
(3) Tag and disconnect air lines from trailer air supply/parking brake control assembly, refer to Control
Assembly, Trailer Air Supply and Parking Brake (Carrier Cab) Removal procedures.
(4) Remove screws (1, Figure 2-1-20) and collars (2) securing dash panel (3) to front console.
(5) Tilt dash panel (3) to lay against steering column, tag and disconnect all electrical leads from
gauges, switches, and indicator lights, and remove dash panel from cab.
(1) Remove screws (4) and collars (5) securing dash panel (6 or 7) to front console.
(2) Tilt dash panel (6 or 7) back, tag and disconnect all electrical leads from switches, and remove dash
panel from cab.
Installation
(1) Position dash panel (3) on steering column, connect all electrical leads to gauges, switches, and
indicator lights, and remove tags.
(2) Position dash panel (3) on front console and secure with collars (2) and screws (3).
(3) Mount heater control in dash panel, refer to Heater Control (Carrier Cab) Installation procedures.
(4) Mount defroster control in dash panel, refer to Defroster Control (Carrier Cab) Installation
procedures.
(5) Connect air lines to trailer air supply/parking brake control assembly, refer to Control Assembly,
Trailer Air Supply and Parking Brake (Carrier Cab) Installation procedures.
(1) Position dash panel (6 or 7) near front console, connect all electrical leads to switches, and remove
tags.
(2) Position dash panel (6 or 7) on front console and secure with collars (5) and screws (4).
2-1-89
TM 5-3810-307-24-1-1
LEGEND
1. Screw 4. Screw
2. Collar 5. Collar
3. Top dash panel 6. Left dash panel
7. Right dash panel
2-1-90
TM 5-3810-307-24-1-1
Removal
(1) Disconnect swing lock control cable, refer to Swing Lock Control (Superstructure Cab) Removal
procedures, steps a. thru e.
(2) Tag and disconnect air lines from parking brake control, refer to Parking Brake Control
(Superstructure Cab) Removal procedures.
(3) Remove screws (1, Figure 2-1-21) and collars (2) securing dash panel (3) to front console.
(4) Tilt dash panel (3) to lay against steering column, tag and disconnect all electrical leads from
gauges, switches, and indicator lights, and remove dash panel from cab.
(1) Remove clip (10, Figure 2-1-16) and pin (11) to disconnect throttle control cable (8) and clevis (12).
Then remove clamp (3), refer to Throttle Fast/Slow Control (Superstructure Cab) Removal
procedures.
(2) Remove screws (4, Figure 2-1-21) and collars (5) securing dash panel (6) to front console.
(3) Tilt dash panel (6) back, tag and disconnect all electrical leads from switches, and remove dash
panel from cab.
(1) Remove screws (7) and collars (8) securing dash panel (9) to front console.
(2) Tilt dash panel (9) back, tag and disconnect all electrical leads from switches, and remove dash
panel from cab.
Installation
(1) Position dash panel (3) on steering column, connect all electrical leads to gauges, switches, and
indicator lights, and remove tags.
(2) Position dash panel (3) on front console and secure with collars (2) and screws (3).
(3) Connect air lines to parking brake control, refer to Parking Brake Control (Superstructure Cab)
Installation procedures.
(4) Connect swing lock cable, refer to Swing Lock Control (Superstructure Cab) Installation procedures.
2-1-91
TM 5-3810-307-24-1-1
(1) Position dash panel (6) near front console, connect all electrical leads to switches, and remove tags.
(2) Position dash panel (6) on front console and secure with collars (5) and screws (4).
(3) Connect throttle control cable, refer to Throttle Fast/Slow Control (Superstructure Cab) Installation
procedures.
(1) Position dash panel (9) near front console, connect all electrical leads to switches, and remove tags.
(2) Position dash panel (9) on front console and secure with collars (8) and screws (7).
2-1-92
TM 5-3810-307-24-1-1
LEGEND
2-1-93
TM 5-3810-307-24-1-1
CARRIER CAB
Removal
d. Discharge air conditioner system (refer to instructions for assigned recovery system and Appendix B),
disconnect air conditioner hoses from roof-mounted air conditioner, and remove hose guards and hoses from
exterior of cab.
e. Match mark yokes and disconnect steering shaft from upper connection of 900 angle gearbox.
WARNING
Engine must be cool to the touch prior to working on coolant system
components. Failure to comply could result in scalding or serious burns.
f. Tag and disconnect coolant system hoses from heater, and heater control cable from shutoff valve.
g. Tag and disconnect air lines from air brake valve under cab.
h. Tag and disconnect three trailer/parking brake air lines from unions under cab.
i. Tag and disconnect three large round electrical connectors and one square electrical cable from chassis
wiring harness under cab.
j. Tag and disconnect four cab wiring harness ground wires from chassis under cab.
m. Install lifting eyes (manufacture per Detail A, Figure 2-1-22) at upper corners of cab using existing
hardware, and attach suitable lifting device to lifting eyes.
n. Remove locknuts (1, Figure 2-1-22), washers (2), capscrews (3), and washers (4) securing cab assembly
to carrier at four mounting points.
o. Slowly lift cab assembly from carrier frame ensuring all disconnected lines, cables, etc. are clear and free
of carrier.
NOTE
Mark location and number of washers (5) removed from each shock mount.
q. If necessary, remove locknuts (6), washers (7), capscrews (8), and shock mounts (9) from carrier
mounting brackets.
2-1-94
TM 5-3810-307-24-1-1
LEGEND
2-1-95
TM 5-3810-307-24-1-1
Installation
a. If removed, install shock mounts (9, Figure 2-1-22) on carrier mounting brackets with capscrews (8),
washers (7), and locknuts (6).
b. Using suitable lifting device, lift cab assembly, position washers (5), as marked, on shock mounts (9),
lower cab onto mounts while positioning lines, cables, etc. for further routing, and align cab mounting holes with
mounts.
c. Secure cab assembly to carrier with capscrews (3), washers (2 and 4), and locknuts (1).
d. Remove lifting eyes from upper corners of cab, apply RTV to threads of bolts and install bolts in holes at
upper corners of cab.
g. Connect four cab wiring harness ground wires to chassis and remove tags.
h. Connect three large round electrical connectors and one square electrical connector to chassis wiring
harness and remove tags.
i. Connect three trailer/parking brake air lines at unions under cab, and remove tags.
j. Connect coolant system hoses to heater, heater control cable to shutoff valve, and remove tags.
k. Connect steering shaft, aligning match marks, to upper connection of 900 angle gearbox.
l. Route and connect air conditioner hoses to roof-mounted air conditioner, and install hose guards. Charge
air conditioner system, refer to instructions for assigned charging system, Lubrication Chart, and Appendix B.
n. Route and install main hydraulic pump disconnect cable on side console.
2-1-96
TM 5-3810-307-24-1-1
SUPERSTRUCTURE CAB
Removal
d. Tag and disconnect six air lines exiting right side of cab from swivel.
e. Tag and disconnect four electrical connectors from superstructure wiring harness at bracket on right side
of cab.
f. Remove superstructure wiring harness bracket and three cab wiring harness ground wires from right side
of cab.
g. Tag and disconnect seven hydraulic hoses exiting right side of cab at nearest connection point.
h. Disconnect positive swing lock cable from positive swing lock mechanism at turntable gear.
i. Disconnect swing lock pin cable, refer to Swing Lock Control (Superstructure Cab) Removal procedures,
steps a. thru e.
j. Discharge air conditioner system (refer to instructions for assigned recovery system and Appendix B), and
disconnect air conditioner hoses from right side of evaporator. Pull hoses from cab.
WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.
k. Place suitable container under heater to catch fuel, then disconnect fuel line, ground wire, and fuel pump
electrical lead from heater under cab. Cap fuel line and wipe up any spilled fuel.
m. Tag and disconnect superstructure wiring harness electrical leads from low air pressure switches, horn,
and windshield washer reservoir pump.
n. Tag and disconnect twelve hydraulic hoses exiting bottom rear of cab at nearest connection point.
o. Tag and disconnect hydraulic hoses from auxiliary hoist control valve under cab.
p. Disconnect cab ground strap from superstructure frame near left rear cab mount.
q. Install lifting eyes (manufacture per Detail A, Figure 2-1-22) at upper corners of cab using existing
hardware, and attach suitable lifting device to lifting eyes.
r. Remove locknuts (1, Figure 2-1-23) and washers (2) securing cab to superstructure at four mounting
points.
2-1-97
TM 5-3810-307-24-1-1
LEGEND
2-1-98
TM 5-3810-307-24-1-1
NOTE
Count number of washers (8) removed from turntable mounting point and
retain for installation.
s. Remove locknut (3), washer (4), capscrew (5), washer (6), shock mount (7), and washer(s) (8) securing
cab to side of turntable.
t. Slowly lift cab assembly from superstructure ensuring all disconnected lines, cables, etc. are clear and free
of superstructure.
NOTE
Mark position and number of washers (9) removed from each shock mount and
retain for installation.
u. Remove washers (9) and shock mounts (10) from four superstructure mounting points.
NOTE
Installation
a. Install shock mounts (10, Figure 2-1-23) in four superstructure mounting points and position washers (9),
as marked during removal, on shock mounts.
b. Using suitable lifting device, lift cab assembly above mounts, then lower cab onto mounts while positioning
lines, cables, etc. for further routing, and align cab mounting studs with mounts.
c. Secure cab assembly to four superstructure mounting points with washers (2) and locknuts (1).
d. Secure cab assembly to side of turntable with washer(s) (8), as noted during removal, shock mount (7),
washer (6), capscrew (5), washer (4), and locknut (3).
e. Remove lifting eyes from upper corners of cab, apply RTV to threads of bolts and install bolts in holes at
upper corners of cab.
f. Connect cab ground strap to frame near left rear cab mount.
g. Connect hydraulic hoses to auxiliary hoist control valve under cab and remove tags.
h. Route and connect twelve hydraulic lines exiting bottom rear of cab and remove tags.
i. Connect superstructure wiring harness electrical leads to windshield washer reservoir pump, horn, and low
air pressure switches. Remove tags.
k. Connect fuel pump electrical lead, ground wire, and fuel line to heater.
l. Insert air conditioner hoses into cab and connect hoses to right side of evaporator. Charge air conditioner
system, refer to instructions for assigned charging system, Lubrication Chart, and Appendix B.
m. Connect swing lock pin cable, refer to Swing Lock Control (Superstructure Cab) Installation procedures.
2-1-99
TM 5-3810-307-24-1-1
n. Connect positive swing lock cable to positive swing lock mechanism at turntable gear.
o. Route and connect seven hydraulic hoses exiting right side of cab and remove tags.
p. Install superstructure wiring harness bracket and three cab wiring harness ground wires to right side of
cab.
q. Connect four electrical connectors to superstructure wiring harness at bracket on right side of cab and
remove tags.
r. Route and connect six air lines exiting right side of cab to swivel and remove tags.
2-1-100
TM 5-3810-307-24-1-1
Removal
WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.
c. Place suitable container under heater tank drain plug to catch fuel, then drain the fuel tank. Capacity
approximately 2 gallons (3.8 liters). Reinstall the drain plug.
e. Disconnect two fuel lines (1 and 2, Figure 2-1-24) at heater fuel pump (3).
f. Remove two nuts (4), lockwashers (5), and flat washers (6) securing heater fuel pump (3) and bracket (9).
g. Remove sediment bowl (7) with nipple from heater fuel pump (3). Clean sediment bowl with clean cloth
and retain for installation on new heater fuel pump.
h. Remove nuts (12), lockwashers (11), and capscrews (10). Separate bracket (9) and heater fuel pump (3).
i. Remove elbow fitting (8) and retain for installation on new heater fuel pump.
Installation
a. Install sediment bowl (7, Figure 2-1-24) on new heater fuel pump (3).
c. Assemble heater fuel pump (3) to bracket (9) with two capscrews (10), new lockwashers (11), and nuts
(12).
d. Using existing mounting studs, install bracket (9) with nuts (4), new lockwashers (5), and flat washers (6).
f. Attach EMI filter (13) to boom superstructure with a single -inch screw (14).
g. Connect heater fuel pump power lead to heater board in superstructure cab.
j. Turn battery disconnect switch to the on position and check superstructure cab heater for proper
operation. If necessary, troubleshoot superstructure cab heater. Refer to TM 5-3810-307-24-1-2.
2-1-101 C-1
TM 5-3810-307-24-1-1
Legend:
2-1-102 C-1
TM 5-3810-307-24-1-1
SECTION 2
ENGINE
TABLE OF CONTENTS
Page
ENGINE
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Engine and Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9
Engine Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Throttle Air Cylinder and Throttle Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Heated Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Heated Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Cold Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-30
WATER COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Radiator and Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-35
2-2-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
2-2-2
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-2-7
The engine and transmission assembly weighs approximately 2500 lbs (1134 kg).
Use a suitable lifting device to remove the engine and transmission assembly.
Using too small of a device may result in personal injury.
WARNING 2-2-9
The engine and transmission assembly weighs approximately 2500 lbs (1134 kg).
Use a suitable lifting device to install the engine and transmission assembly.
Using too small of a device may result in personal injury.
WARNING 2-2-15
There may be residual pressure in air lines after air reservoirs are drained. Wear
eye protection when disconnecting air lines to prevent injury.
WARNING 2-2-20
2-2-22
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame and
other ignition sources.
WARNING 2-2-26
The starting fluid used in the cold start system contains ethyl ether and is
extremely flammable and toxic. Do not smoke and make sure you are in a well-
ventilated area away from heat, open flames, or sparks when installing,
maintaining, testing, or troubleshooting the cold start system.
Wear goggles and make sure openings are pointed away from you when
activating system with lines or fittings disconnected to avoid eye injury. If fluid
enters the eyes or fumes irritate the eyes, they should be flushed with large
quantities of clean water for 15 minutes. A physician should be contacted.
Contents of cylinder are under pressure. Store in a cool dry place. Do not
incinerate, puncture, or attempt to remove cores from cylinder.
2-2-3
TM 5-3810-307-24-1-1
WARNING 2-2-32
Engine must be cool to the touch prior to working on coolant system components.
Failure to comply could result in scalding or serious burns.
WARNING 2-2-38
WARNING 2-2-39
Exhaust system components can get very hot. Use care to avoid serious burns.
2-2-4
TM 5-3810-307-24-1-1
ENGINE
DESCRIPTION
The AT422T crane is equipped with the Cummins The cylinder is connected by linkage to the engine
B5.9-190 diesel engine. This manual does not fuel injection pump throttle lever.
include detailed information on the engine itself. A
separate manual, TM 5-3810-307-24-2, prepared in The engine and its components are enclosed in a
detail by the engine manufacturer, is supplied with hood assembly with a grill in the front and rear of the
the crane. However, a short description and hood for adequate air circulation. Access to the
maintenance of certain engine-related components engine is gained through side doors in the hood
are provided in this section. assembly.
Engine speed is controlled mechanically from the To aid in starting the engine in cold weather, a cold
carrier cab by a throttle cable connected to a foot start system is provided. The system consists of a
pedal in the cab and the engine fuel injection pump temperature switch, solenoid valve, starting fluid in a
throttle lever. From the superstructure cab, engine pressurized container, atomizer, and connecting
speed is controlled pneumatically from a foot tubing.
operated throttle valve in the cab to a throttle air
cylinder on the engine.
MAINTENANCE
Removal
a. Start crane, set outriggers, and position boom to left side of carrier so hardware for deck plate over
transmission is accessible.
c. Disconnect drive lines from transmission, refer to Drive Lines Removal procedures.
d. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
i. Remove radiator and air cooler, refer to Radiator and Air Cooler Removal procedures.
j. Disconnect engine/transmission electrical harness connector and four ground wires (located at front left
side of engine on carrier frame crossmember).
k. Disconnect throttle cable (49, Figure 2-2-3) from bracket (57) and clamp (40) at air compressor.
2-2-5
TM 5-3810-307-24-1-1
l. Disconnect hydraulic pump disconnect cable from lever at top front left side of transmission.
m. Disconnect cold start tube (5, Figure 2-2-6) from atomizer (13).
n. Remove carrier cab air conditioner compressor, refer to Air Conditioner (Carrier Cab) Removal procedures,
steps c. (4) thru (6).
o. Tag and disconnect heater supply hose from rear of engine cylinder head and heater return line from right
side of engine.
p. Tag and disconnect fuel line to fuel filter/water separator from fuel heater at right engine well wall.
q. Tag and disconnect fuel return line from fuel injection pump.
r. Tag and disconnect air line from rear of throttle air cylinder, refer to Throttle Air Cylinder and Throttle
Linkage Removal procedures.
s. Tag and disconnect hydraulic hoses for main hydraulic pump from tubes below pump.
t. Tag and disconnect transmission oil lines to lockup modulator valve from bottom of transmission sump and
right side of transmission just forward of dipstick.
u. Tag and disconnect two transmission oil lines to lockup solenoid valve (right side transmission well wall)
from right side of torque converter and two oil lines from solenoid valve.
w. Remove emergency steering pump from transmission and allow to hang from oil lines, refer to Emergency
(Standby) Steering Valve and Pump Removal procedures, step c. (3).
x. Tag and disconnect transmission and engine oil hoses from oil filters under battery box.
y. Tag and disconnect electrical cables to batteries and battery disconnect switch from alternator and starter
motor.
z. Tag and disconnect engine ground cable from carrier frame at right side engine well wall.
aa. Tag and disconnect air line to air dryer from air compressor.
bb. Tag and disconnect air line to air compressor unloader valve from air governor.
cc. Tag and disconnect hydraulic hoses to main hydraulic pump from hydraulic tank.
dd. Tag and disconnect oil hoses to transmission oil cooler from front left side of transmission.
ee. Tag and disconnect electrical connector for cold start valve (9, Figure 2-2-6).
ff. Tag and disconnect electrical leads from lockup switch and ground wire from lockup solenoid valve at right
transmission well wall.
gg. Tag and disconnect electrical connector to lockup modulator valve from engine/transmission wiring harness
(rear of transmission).
2-2-6
TM 5-3810-307-24-1-1
WARNING
The engine and transmission assembly weighs approximately 2500 lbs (1134
kg). Use a suitable lifting device to remove the engine and transmission
assembly. Using too small of a device may result in personal injury.
hh. Attach suitable lifting device to engine lifting eyes and overhead hoist. Take up slack.
ii. Remove locknuts (1, Figure 2-2-1), washers (2), capscrews (3), and washers (4) securing engine mount to
carrier frame.
jj. Remove locknuts (5), washers (6), capscrews (11), and washers (12) securing transmission mount brackets
(13) to transmission and carrier frame.
kk. Slowly lift engine and transmission assembly from carrier ensuring that all components, wiring, and hoses
are free and do not catch on carrier.
ll. Lower engine and transmission assembly onto suitable work stand.
nn. Remove capscrews (7), washers (8), transmission mount brackets (13), and shock mounts (10) from
transmission mounts on carrier frame.
NOTE
Left and right transmission mount brackets are not symmetrical. Mark brackets
as necessary to ensure proper installation.
(1) Tag and disconnect wiring harness electrical leads from transmission components.
(2) Remove capscrews (14), lockwashers (15), and flywheel access cover (16) from left side of flywheel
housing.
(3) Bar engine to align flywheel to transmission flex plate mounting hardware with access hole, and
remove capscrews (17) and lockwashers (18).
(5) Mark mounting location of main hydraulic pump disconnect lever bracket (21), and remove nuts (19),
washers (20), and bracket (21) from flywheel housing studs.
pp. If replacing engine, set new engine beside old engine, and build-up new engine from components removed
from old engine. Refer to individual component removal and installation procedures.
qq. If replacing transmission, set new transmission beside old transmission, and build-up new transmission
from components removed from old transmission. Refer to individual component removal and installation
procedures.
2-2-7
TM 5-3810-307-24-1-1
LEGEND
2-2-8
TM 5-3810-307-24-1-1
Installation
(1) Apply zinc chromate paste on transmission mating surface with flywheel housing, and anti-seize
compound on flex plate and flywheel mating surfaces
(2) Using suitable lifting device, carefully position transmission and main hydraulic pump disconnect lever
bracket (21, Figure 2-2-1) on flywheel housing studs.
(3) Secure transmission and bracket (21) to engine with washers (20) and nuts (19), and remove lifting
device from transmission.
(4) Bar engine and turn transmission drive line coupling as necessary to align flywheel holes and
transmission flex plate holes with each other and access hole on flywheel housing.
(5) Apply anti-seize compound to shanks of capscrews (17), and secure flywheel to transmission flex
plate with lockwashers (18) and capscrews (17). Torque capscrews 25 to 30 lbs-ft (34 to 41 Nm).
(6) Install access cover (16) on left side of flywheel housing with capscrews (14) and lockwashers (15).
(7) Connect wiring harness electrical leads to transmission components and remove tags.
b. Position shock mounts (10) and transmission mount brackets (13), as marked during removal, on
transmission mounting brackets on carrier frame, and install washers (8), capscrews (7), washers (6), and nuts
(5). Do not tighten nuts (5).
WARNING
The engine and transmission assembly weighs approximately 2500 lbs (1134
kg). Use a suitable lifting device to install the engine and transmission
assembly. Using too small of a device may result in personal injury.
d. Attach suitable lifting device to engine lifting eyes and overhead hoist. Lift engine and transmission
assembly from work stand.
e. Slowly lower engine and transmission assembly into carrier ensuring that all components, wiring, and hoses
do not catch on carrier or other components.
f. Align transmission to mount brackets (13), and install washers (12) and capscrews (11) through
transmission mount brackets (13) into transmission mounting holes. Do not tighten capscrews (11).
g. Align engine mount to mounting bracket on carrier frame, and install washers (4) and capscrews (3) through
engine mount.
h. Tighten capscrews (11) to 260 lbs-ft (353 Nm) securing transmission mount brackets (13) to transmission,
completely lower engine and transmission assembly onto frame mounting brackets, and remove lifting device.
j. Secure engine to carrier frame mount with washers (2) and locknuts (1).
2-2-9
TM 5-3810-307-24-1-1
k. Connect electrical connector to engine/transmission wiring harness for lockup modulator valve and remove
tag.
l. Connect electrical leads to lockup switch and ground wire to lockup solenoid valve at right transmission well
wall. Remove tags.
m. Connect electrical connector for cold start valve (9, Figure 2-2-6) and remove tag.
n. Connect oil hoses from transmission oil cooler to front left side of transmission and remove tags.
o. Connect hydraulic hoses from main hydraulic pump to hydraulic tank and remove tags.
p. Connect air line from air compressor unloader valve to air governor and remove tag.
q. Connect air line from air dryer to air compressor and remove tag.
r. Connect engine ground cable to carrier frame at right side engine well wall and remove tag.
s. Connect electrical leads from batteries and battery disconnect switch to starter and alternator. Remove
tags.
t. Connect engine and transmission oil hoses to oil filters under battery box and remove tags.
u. Install emergency steering pump on transmission, refer to Emergency (Standby) Steering Valve and Pump
Installation procedures.
w. Connect two oil lines from lockup solenoid valve to right side of transmission and remove tags.
x. Connect two oil lines to lockup solenoid valve and remove tags.
y. Connect oil lines from lockup modulator valve to bottom of transmission sump and to right side of
transmission just forward of dipstick.
z. Connect hoses for main hydraulic pump to tubes below pump and remove tags.
aa. Connect air line to rear of throttle air cylinder and remove tag.
bb. Connect fuel return line to fuel injection pump and remove tag.
cc. Connect fuel filter/water separator inlet fuel line to fuel heater and remove tag.
dd. Connect heater supply hose to rear of engine cylinder head and heater return hose to right side of engine
and remove tags.
ee. Install carrier cab air conditioner compressor on engine bracket, refer to Air Conditioner (Carrier Cab)
Installation procedures.
ff. Connect cold start tube (5, Figure 2-2-6) to atomizer (13).
gg. Connect main hydraulic pump disconnect cable to lever at top front left side of transmission.
hh. Connect throttle cable (49, Figure 2-2-3) to bracket (57) and to air compressor with clamp (40).
2-2-10
TM 5-3810-307-24-1-1
ii. Connect engine/transmission electrical harness connector and four ground wires at front left side of engine
on carrier frame crossmember.
jj. Install radiator, refer to Radiator and Air Cooler Installation procedures.
nn. Connect drive lines to transmission, refer to Drive Lines Installation procedures.
oo. Start crane and check for leaks and proper operation.
ss. Start crane, position boom back onto boom rest, and shutdown crane.
2-2-11
TM 5-3810-307-24-1-1
ENGINE HOOD
Removal
(1) Remove capscrews (1, Figure 2-2-2), washers (2) and grill (3) from front cowl (10).
(2) Remove capscrews (5), lockwashers (4), and washers (6) securing front cowl (10) to bracket on
boom rest.
(3) Remove nut (7), lockwasher (8), washer (9), and front cowl (10) from crane.
(1) Remove top engine panel and door assembly (17), refer to step c.
(2) Remove coolant recovery tank (do not disconnect hoses) from center cowl (13) and set aside, refer to
Radiator and Air Cooler Removal procedures.
(3) Remove exhaust tube and adapter between turbocharger and flexible exhaust tube, refer to Exhaust
System Removal procedures.
(4) Remove locknuts (11), washers (12), nylon washers (14), and center cowl (13) from crane.
(1) Remove clips (15), pins (16), and top panel and door assembly (17) from crane.
(2) If necessary, remove doors from top panel, and handles, latch brackets, and support rods from doors.
(1) Remove top engine panel and door assembly (17), refer to step c.
(2) Remove air intake tubing between air cleaner and turbocharger.
(3) Remove locknuts (18), washers (19), nylon washers (21), and rear cowl (20) from crane.
(4) If necessary, remove grill from rear cowl by removing capscrews and washers.
Installation
(1) Position front cowl (10, Figure 2-2-2) on crane and secure left side to stud on boom rest with washer
(9), lockwasher (8), and nut (7).
(2) Secure right side of front cowl (10) to bracket on boom rest with capscrews (5), lockwashers (4), and
washers (6).
(3) Apply LOCTITE 242 to threads of capscrews (1), and install grill (3) on front cowl (10) with capscrews
(1) and washers (2).
2-2-12
TM 5-3810-307-24-1-1
(1) Position center cowl (13) over studs on crane and secure with nylon washers (14), washers (12) and
locknuts (11).
(2) Install coolant recovery tank on center cowl (10), refer to Radiator and Air Cooler Installation
procedures.
(3) Install exhaust tube and adapter between turbocharger and flexible exhaust tube, refer to Exhaust
System Installation procedures.
(4) Install engine top panel and door assembly (17), refer to step c.
(1) If removed, install support rods, handles, and latch brackets on doors, and doors on top panel.
(2) Install engine top panel and door assembly (17) on crane with pins (16) and clips (15).
(1) If removed, install grill on rear cowl (20) with washers and capscrews.
(2) Position rear cowl (20) over studs on crane and secure with nylon washers (21), washers (19) and
locknuts (18).
(3) Install engine top panel and door assembly (17), refer to step c.
2-2-13
TM 5-3810-307-24-1-1
LEGEND
2-2-14
TM 5-3810-307-24-1-1
Removal
b. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
c. Remove engine top panel and door assembly, and rear cowl, refer to Engine Hood Removal procedures.
d. Disconnect electrical leads at idle switch (20, Figure 2-2-3) and electrical connector at throttle position
switch (35).
WARNING
There may be residual pressure in air lines after air reservoirs are drained.
Wear eye protection when disconnecting air lines to prevent injury.
d. Disconnect air line from fitting (24) at rear of throttle air cylinder (15).
e. Remove nut (1), lockwasher (2), capscrew (3), and aft end of throttle rod (4) from lever (28).
f. Remove springs (5) from eye bolts (23) and bracket (52).
g. Remove nuts (6), lockwashers (7), capscrews (8), washers (9), oil pressure sender and switch bracket
assembly (10), throttle position switch (35) with attached brackets, and throttle air cylinder (15) with attached
components from engine mounting bracket.
h. Remove nuts (11), lockwashers (12), washers (13), capscrews (14), and separate throttle air cylinder (15)
from lever (27) and bracket (28).
i. Remove screws (16) and bracket (17) from throttle air cylinder (15). These screws are part of the cylinder
and should be reinstalled at this time.
j. Remove nut (18), washer (19), and idle switch (20) from bracket (17).
k. If necessary, remove nuts (21), washers (22), and eye bolts (23) from bracket (17).
m. Remove cotter pin (25), washer (26), and separate lever (27) and bracket (28).
n. If necessary, remove nut (29) and carriage bolt (30) from bracket (28).
o. Remove nuts (31), lockwashers (32), screws (33), washers (34), and throttle position switch (35) from
adjusting bar (39) and bracket (43).
p. If necessary, remove capscrew (36), washers (37), nuts (38), and adjusting bar (39) from bracket (43).
q. If necessary, remove capscrews (40), lockwashers (41), washers (42), and bracket (43) from bracket (44).
2-2-15
TM 5-3810-307-24-1-1
2-2-16
TM 5-3810-307-24-1-1
r. Remove capscrew (45), washer (46), and throttle cable (49) from bracket (57).
s. Remove nuts (47), clamp (48), and throttle cable (49) from bracket on air compressor.
t. Remove capscrews (50), washers (51), bracket (52), spacers (53 and 54), washer (55), throttle rod (4), nut
(56), and bracket (57) from fuel injection pump lever.
Installation
a. Install washer (51, Figure 2-2-3) on upper capscrew (50) and insert through upper hole in bracket (52).
b. Install bushing (54), washer (55), throttle rod (4), and nut (56) on upper capscrew (50). Tighten nut (56)
until assembled parts are secured tightly together.
c. Position bracket (52) on bracket (57) with upper capscrew (50) through upper hole of bracket (57).
d. Install bracket (57) on fuel injection pump lever with assembled hardware in upper hole and lower capscrew
(50), washer (51), and spacer (53) in lower hole.
e. Connect throttle cable (49) to bracket (57) with capscrew (45) and washer (46).
f. Ensure throttle cable (49) is fully extended and fuel injection pump lever is in its most rearward position,
then secure throttle cable (49) to bracket on air compressor with clamp (48) and nuts (47) ensuring there is no
slack in cable.
g. If removed, install bracket (43) on bracket (44) with capscrews (40), lockwashers (41), and washers (42).
Do not fully tighten capscrews (40).
h. If removed, install adjusting bar (39) on bracket (43) with capscrew (36), washers (37), and nuts (38). Do
not fully tighten nuts (38).
2-2-17
TM 5-3810-307-24-1-1
i. Install throttle position switch (35) on adjusting bar (39) and bracket (43) with capscrews (33), washers (34),
lockwashers (32), and nuts (31). Do not fully tighten nuts (31).
j. If removed, install carriage bolt (30) on bracket (28) with nut (29).
k. Install lever (27) on bracket (28) with washer (26) and cotter pin (25).
l. If removed, install eye bolts (23) on bracket (17) with washers (22) and nuts (21). Distance from front of
bracket (17) to center of eyes of eye bolts (23) should be 1-1/2 in. (3.8 cm).
m. Install idle switch (20) on bracket (17) with washer (19) and nut (18).
n. Install bracket (17) on throttle air cylinder (15) with screws (16) which are part of the throttle cylinder (15).
o. Install lever (27) with bracket (28) on throttle air cylinder (15) with capscrews (14), washers (13),
lockwashers (12), and nuts (11).
p. Adjust carriage bolt (30) so that button on idle switch (20) is fully depressed when throttle air cylinder lever
is fully rearward, then tighten nut (29).
q. Position throttle air cylinder (15), bracket (44), and oil sender and switch bracket assembly (10) to engine
mounting bracket, then secure components with capscrews (8), washers (9), lockwashers (7), and nuts (6).
r. Place lever of throttle air cylinder (15) in mid-stroke position (straight up and down), then adjust capscrew
(36) and throttle position switch (35) until roller of throttle position switch just contacts front of lever (28), see
Detail A. Tighten nuts (38), capscrews (40), and nuts (31) to secure throttle position switch in position.
s. Place fuel injection pump lever and lever of throttle air cylinder (15) fully rearward, adjust throttle rod (4) as
necessary, and connect throttle rod (4) to bracket (28) with capscrew (3), lockwasher (2), and nut (1).
u. Install fitting (24) in rear of throttle air cylinder (15), and connect air line to fitting.
v. Connect electrical leads at idle switch (20) and electrical connector at throttle position switch (35).
x. Perform test procedures for APC 100 to ensure shift points are correct, refer to Chapter Two, Section 3.
y. Install engine rear cowl, and top panel and door assembly, refer to Engine Hood Installation procedures.
Operating Test
With normal air pressure in the system, actuate the foot throttle to various positions and observe that the throttle
cylinder responds quickly, smoothly, and proportionately.
Leakage Test
1. With foot throttle fully depressed and air pressure at cylinder port, there should be no noticeable leakage at
port connector, cylinder cover, control cylinder boot, or exhaust port of the throttle valve.
2. Leakage of not more than a 1 in. (2.54 cm) soap bubble in one second is permissible in above test. If
excessive leakage is present, repair or replacement of cylinder and valve is recommended.
2-2-18
TM 5-3810-307-24-1-1
FUEL SYSTEM
DESCRIPTION
The fuel system consists of a fuel tank, fuel filter/ Surplus fuel, returning from the injectors, is bypassed
water separator, fuel pump, engine fuel filter, and fuel back to the fuel tank. The continuous flow of fuel
injectors. All components except the fuel tank and through the injectors helps to cool the injectors and to
heated fuel filter/water separator come installed on remove air from the system.
the engine.
FUEL FILTER.
FUEL TANK.
The engine fuel filter, which comes as a component
The fuel tank is a steel tank located on the right side of the engine, incorporates a
of the machine. The fuel tank has a capacity of 44 replaceable-element-type filter to remove impurities
gallons (166.6 liters). The fuel line connected to the from the fuel. The filter is mounted on the engine
top of the tank provides the fuel supply to the engine between the fuel pump and fuel injection pump.
and the fuel line connected to the bottom front side of
the tank carries the return surplus fuel from the HEATED FUEL FILTER/WATER SEPARATOR.
engine. The tank is equipped with a screw-type filler
cap and a fuel level sender unit which provides a The heated fuel filter/water separator removes water
signal to a fuel gauge on the instrument panels in the from the fuel before it reaches the engine. It is
cabs. mounted on the top left rear of the engine. As fuel
passes through the outer wrap of the first stage of the
FUEL PUMP. filter paper, large droplets of water are formed as it is
stripped from the fuel. The water falls out into the
The Cummins engine has a positive displacement void between the two paper elements and goes to a
gear-type metering fuel pump driven by an engine reservoir in the bottom of the housing where it can be
power take-off through a coupling to one of the drained through a drain valve at the bottom of the
accessories. The pump supplies fuel at low pressure housing. This filter is installed in the system between
through the engine fuel filter to the fuel injection pump the fuel tank and pump and operates under suction.
which distributes the fuel to the injectors.
The fuel filter/water separator also incorporates an
The fuel is finely atomized by the injector as it is electrically operated heater which is actuated by a
injected into the cylinder and ignited by the heat of temperature switch to warm the fuel whenever the
the compression. It is also metered before injection, temperature of the fuel falls below 30 F (-1 C).
to meet the load requirements imposed upon the
engine.
2-2-19
TM 5-3810-307-24-1-1
MAINTENANCE
WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.
Removal
b. Tag and disconnect electrical connectors for fuel level sender (8, Figure 2-2-4).
c. Open drain cock (1) and drain fuel into a suitable container [capacity 44 gals (166.6 L)]. Close drain cock
(1).
d. Loosen clamp (15) and disconnect fuel return hose from fitting (12).
f. Support step assembly (5). Remove nuts (2) and washers (3) from straps (4) at bottom of mounting
brackets.
g. Remove step assembly (5), and fuel tank (6) from carrier frame brackets.
h. If necessary, remove screws (7) and fuel level sender (8) from fuel tank (6).
i. If necessary, remove clamp (9) and vent hose (10) from elbow (11), and elbow (11) from fuel tank (6).
j. If necessary, remove fitting (12), elbows (13 and 14), and drain cock (1) from fuel tank (6).
Installation
a. If removed, install drain cock (1, Figure 2-2-4), elbows (13 and 14), and fitting (12) in fuel tank (6).
b. If removed, install elbow (11) in fuel tank (6) and vent hose (10) to elbow (11) with clamp (9).
c. If removed, install fuel level sender (8) in fuel tank (6) with screws (7).
d. Position fuel tank (6) and step assembly (5) on mounting brackets.
e. Secure fuel tank (6) and step assembly (5) on mounting brackets with straps (4), washers (3), and nuts (2).
f. Connect fuel return hose to fitting (12), tighten clamp (15), and connect fuel supply hose to elbow (14).
g. Connect electrical connectors for fuel level sender (8) and remove tags.
2-2-20
TM 5-3810-307-24-1-1
LEGEND
2-2-21
TM 5-3810-307-24-1-1
WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.
Removal
(2) Disconnect electrical connector for heater unit (3, Figure 2-2-5).
(3) Loosen clamp (1) and disconnect drain tube (2) from heater unit (3).
(4) Unscrew heater unit (3) and remove gasket (4) from filter element (5). Discard gasket.
(5) Unscrew filter element (5) and remove gasket (6) from filter head (13). Pour fuel from element into a
suitable container and discard element and gasket.
(1) Disconnect fuel inlet hose (7) from elbow (14) and fuel outlet hose (8) from elbow (15).
(2) Remove nuts (9), lockwashers (10), capscrews (11), washers (12) and filter head (13) from engine
mounting bracket.
(3) If necessary, remove elbows (14 and 15) from filter head (13).
Installation
(1) If removed, install elbows (14 and 15, Figure 2-2-5) in filter head (13).
(2) Install filter head (13) on engine mounting bracket with capscrews (11), washers (12), lockwashers
(10), and nuts (9).
(3) Connect fuel outlet hose (8) to elbow (15) and fuel inlet hose (7) to elbow (14).
(1) Fill new filter element (5) with clean diesel fuel and install new gasket (6) and filter element (5) on filter
head (13). Tighten filter element hand tight and an additional 1/2 turn.
(2) Install heater unit (3) with new gasket (4) on filter element (5). Tighten heater unit hand tight and an
additional 1/2 turn.
(3) Connect drain hose (2) on heater unit (3) and tighten clamp (1).
2-2-22
TM 5-3810-307-24-1-1
(2) Activate hand pump until fuel begins to flow from around vent plug with no air bubbles.
2-2-23
TM 5-3810-307-24-1-1
LEGEND
2-2-24
TM 5-3810-307-24-1-1
DESCRIPTION
The engine air intake system consists of an air The cold weather starting system consists of a
cleaner and associated piping for channeling the air temperature switch, valve assembly, starting fluid
from the atmosphere to the engine intake manifold. bottle (customer supplied), and an atomizer. The
The intake pipe also provides the necessary cold start system is used during cold weather
connection for starting fluid to be injected into the air operations to facilitate engine starting. The system
intake for cold starts and a restriction indicator to operates automatically whenever the ambient
indicate a dirty air cleaner. temperature is below 30 F (-1 C) and the ignition
switch is in the start (2) position. The temperature
The air cleaner is the dry-type with a replaceable switch actuates the valve assembly, passing starting
element. It is located on the front right wheel fender fluid from the bottle through the atomizer into the air
beside the engine hood. A restriction indicator, intake manifold where it mixes with the intake air to
designed to display red when servicing is required, is facilitate engine combustion.
used on this system.
2-2-25
TM 5-3810-307-24-1-1
MAINTENANCE
NOTE
Wear goggles and make sure openings are pointed away from you when
activating system with lines or fittings disconnected to avoid eye injury. If fluid
enters the eyes or fumes irritate the eyes, they should be flushed with large
quantities of clean water for 15 minutes. A physician should be contacted.
Contents of cylinder are under pressure. Store in a cool dry place. Do not
incinerate, puncture, or attempt to remove cores from cylinder.
Inspection
a. Remove fluid cylinder (3, Figure 2-2-6), refer to Removal procedures, and weigh cylinder to determine
remaining fluid as follows:
(1) 21 oz cylinder:
Full - weighs 37 oz (1049 gr)
Empty - weighs 16 oz (454 gr)
(2) Present weight minus empty weight = remaining weight. To convert to liquid volume, one oz of weight
= 39 ml of liquid (one gr = 1.4 ml). Example:
Present weight = 26 oz (733 gr)
Empty weight = 16 oz (454 gr)
Remaining weight = 10 oz (279 gr)
Liquid volume = 10 oz (279 gr) X 39 ml (1.4 ml) = 390 ml or cylinder approximately 1/2 full
b. Inspect all system tubing for damage and cleanliness (obstructions). Clean or replace as necessary.
c. Remove atomizer (13), refer to Removal procedures, and inspect for damage and cleanliness. Clean or
replace as necessary.
d. Inspect system electrical wiring for security and damaged connectors or insulation. Tighten or replace as
necessary.
2-2-26
TM 5-3810-307-24-1-1
NOTE
The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (9) has left-hand threads.
e. Remove metered orifice elbow (10) and filter (11) from bottom port of valve (9), refer to Removal
procedures, and inspect for damage and cleanliness. Clean or replace as necessary.
f. Inspect valve assembly (9) for damage and security of mounting. Tighten or replace as necessary.
NOTE
The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (9) has left-hand threads.
g. Install fluid cylinder (3), filter (11), metered orifice elbow (10), and atomizer (13), refer to Installation
procedures.
Test
(3) Connect multimeter, set for ohms, across terminals of switch connector. Multimeter should indicate
switch is open (no continuity).
(4) Suspend temperature switch in water chilled to below 45 F (7 C). Multimeter should indicate closed
circuit (continuity).
(5) If indications are other than above, switch is defective and must be replaced.
(6) Apply thread sealant to threads of temperature switch (14) and install temperature switch, refer to
Installation procedures.
(2) Disconnect electrical connector for fuel shutoff solenoid (refer to TM 5-3810-307-24-2-1, page A-33),
position battery disconnect switch to on position, and actuate cold start valve by positioning ignition
switch to START.
2-2-27 C-1
TM 5-3810-307-24-1-1
LEGEND
2-2-28
TM 5-3810-307-24-1-1
NOTE
(3) Valve plunger should move up and remain up until ignition switch is released from START position.
(4) If valve plunger does not move up, apply 24 vdc directly to valve electrical connector. If plunger still
does not move up, valve is defective and must be replaced. If plunger moves up, electrical wiring is
faulty.
(5) Position ignition switch to OFF, place battery disconnect switch to off position, and connect fuel
shutoff solenoid electrical connector.
(6) If jumper wire was used, remove jumper wire and connect electrical connector for temperature switch.
(7) Install fluid cylinder (3) on valve assembly (9), refer to Installation procedures.
Removal
b. Disconnect electrical connector for cold start valve assembly (9, Figure 2-2-6) from engine harness.
d. Loosen clamp (2), unscrew fluid cylinder (3) from valve assembly (9), then remove gasket (4) from inside of
valve.
f. Remove capscrews (6), lockwashers (7), washers (8), and valve assembly (9) from crane.
NOTE
The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (8) has left-hand threads.
g. Remove metered orifice elbow (10) from valve assembly (9) and filter (11) and o-ring (12) from elbow (10).
h. Disconnect tube (5) from atomizer (13) and remove tube (5) from crane.
j. Drain radiator.
k. Disconnect electrical connector for cold start temperature switch (14) and unscrew switch from tee at top
front center of cylinder head.
2-2-29
TM 5-3810-307-24-1-1
Installation
a. Apply thread sealant to threads of cold start temperature switch (14, Figure 2-2-6), and install cold start
temperature switch (14) in tee at top front center of cylinder head.
b. Install atomizer (13) in engine air inlet tube. Ensure atomizer port is directed toward incoming air (red dot
on fitting indicates position of port).
c. Connect tube (5) to atomizer (13) and route tube (5) to cold start valve assembly (9) mounting area.
d. Install valve assembly (9) with washers (8), lockwashers (7), and capscrews (6).
CAUTION
Always replace gasket (4) when installing a new fluid cylinder (3). Gasket
comes with cylinder.
e. Spread a light film of clean engine oil on gasket (4) and threads of cylinder (3).
f. Position gasket (4) in valve (9) and screw cylinder (3) into valve until o-ring on cylinder contacts valve.
Then tighten cylinder 1-1/2 additional turns.
g. Tighten clamp (1) and connect valve electrical connector to engine harness.
CAUTION
h. Disconnect electrical connector for fuel shutoff solenoid (refer to TM 5-3810-307-24-2-1, page A-33),
position battery disconnect switch to on position, and actuate cold start valve by positioning ignition switch to
START. This will purge any debris that did not settle from valve.
NOTE
i. Position ignition switch to OFF, place battery disconnect switch to off position, and connect fuel shutoff
solenoid electrical connector.
j. If jumper wire was used, remove jumper wire and connect electrical connector for temperature switch.
NOTE
The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (9) has left-hand threads.
k. Position o-ring (12) and filter (11) in metered orifice elbow (10) and install elbow (10) in valve assembly (9).
2-2-30 C-1
TM 5-3810-307-24-1-1
2-2-31
TM 5-3810-307-24-1-1
DESCRIPTION
The cooling system consists of the radiator, engine At all times, the coolant should be properly inhibited
cooling circuit, and the connecting hoses. The against corrosion. Ensure that the proper antifreeze,
temperature is controlled by a 180 degree F (82 in the proper proportion is used, to ensure adequate
degrees C) thermostat located between the top of the protection in reference to cooling system capacity.
engine and the top of the radiator. Attached to the Only the antifreeze listed in the Lubrication Chart
radiator as part of the assembly, is an air cooler should be used.
(aftercooler) which cools the intake air prior to
entering the air intake manifold.
MAINTENANCE
NOTE
Removal
b. Place appropriate container under radiator (34, Figure 2-2-7), open drain valve (49) and drain coolant from
radiator [capacity - 10.5 gals. (39.7 L)]. Close drain valve (49).
c. Remove engine top panel and side access doors, refer to Engine Hood Removal procedures.
d. Remove nut (1), lockwasher (2), washer (3), clamp (4), and drain hose (5) from carrier frame.
e. Loosen clamp (6) and disconnect recovery coolant hose (7), from radiator (34) filler neck.
f. Remove capscrews (8) and clamps (9) securing recovery tank overflow hose (10) to radiator shroud (44).
g. Remove exhaust tube and adapter between turbocharger and flexible tubing, refer to Muffler and Piping
Removal procedures.
h. Remove engine hood center cowl, refer to Engine Hood Removal procedures.
i. Loosen clamps (11) and disconnect air cooler tubes from flexible hoses (12).
j. Loosen clamps (13) and disconnect top radiator hose (14) from radiator (34), and bottom radiator hose (15)
from engine.
2-2-32
TM 5-3810-307-24-1-1
k. Loosen clamp (16) and disconnect aeration hose (17) from adapter (52).
l. Remove capscrews (18), lockwashers (19), large washers (20), fan guard (21), and spacers (22) from
shroud (44).
m. Remove capscrews (62), lockwashers (63), washers (64), and plate (60) from shroud (44) to access cooling
fan (25) attaching hardware.
n. Remove capscrews (23), washers (24), cooling fan (25), and three-piece adapter (26) from engine.
o. Remove nut (27), lockwasher (28), and disconnect support rod (29) from bottom of radiator (34).
p. Remove locknuts (30), washers (31), capscrews (32), and washers (33) securing radiator (34) to frame
mounting brackets.
CAUTION
Ensure radiator and air cooler components do not catch on carrier baffling or
other components resulting in equipment damage when lifting assembly from
carrier.
q. Attach lifting device to radiator (34), lift radiator (34) and air cooler (39) from carrier as an assembly, then
remove rubber mounts (35) from frame mounting brackets.
(1) Remove capscrews (36), lockwashers (37), washers (38), air cooler (39), and baffle (40) from radiator
(34).
(2) Remove capscrews (41), lockwashers (42), washers (43), and shroud (44) from radiator (34).
(3) Remove capscrews (45), lockwashers (46), and radiator mount brackets (47) from radiator (34).
(4) Loosen clamp (48) and remove drain valve (49) from radiator drain hose (5).
(5) Loosen clamp (50) and remove hose (5) from adapter (51) and adapters (51 and 52) from radiator
(34).
(6) Remove nuts (53), lockwashers (54), washers (55), capscrews (56), and coolant recovery tank (57)
from engine hood center cowl.
(7) Remove clamps (58) and hoses (7 and 10) from recovery tank (57).
(8) Remove clamp (59) and lower radiator hose (15) from radiator (34).
2-2-33
TM 5-3810-307-24-1-1
2-2-34
TM 5-3810-307-24-1-1
Installation
CAUTION
Do not apply sealant to inside of radiator hose and push it onto male adapter.
This can result in excess sealant being pushed ahead of male adapter and
into hose exposing sealant to engine coolant. The coolant can then carry the
excess sealant into the radiator cores and engine water jackets, plug the
coolant passages, and result in premature engine failure.
(1) Apply LOCTITE #518 sealant on male hose adapter, and install lower radiator hose (15, Figure 2-2-7)
on radiator (34) with clamp (59).
(2) Install hoses (7 and 10) on coolant recovery tank (57) with clamps (58).
(3) Install recovery tank (57) on engine hood center cowl with capscrews (56), washers (55), lockwashers
(54), and nuts (53).
(4) Install adapters (52 and 51) in radiator (34) and drain hose (5) on adapter (51) with clamp (50).
(5) Install drain valve (49) in hose (5) with clamp (48).
(6) Install radiator mount brackets (47) on radiator (34) with lockwashers (46) and capscrews (45).
(7) Install shroud (44) on radiator (34) with washers (43), lockwashers (42), and capscrews (41).
(8) Install baffle (40) and air cooler (39) on radiator (34) with washers (38), lockwashers (37), and
capscrews (36).
CAUTION
Ensure radiator and air cooler components do not catch on carrier baffling or
other components resulting in equipment damage when lowering assembly
into carrier.
2-2-35
TM 5-3810-307-24-1-1
b. Attach lifting device to radiator (34), place rubber mounts (35) on frame mounting brackets, and lower
radiator (34) and air cooler (39) into carrier while aligning holes for rubber mounts and mounting brackets.
c. Secure radiator (34) to frame mounting brackets with washers (33), capscrews (32), washers (31), and
locknuts (30).
d. Apply LOCTITE 242 to threads of capscrews (23), position and align three-piece adapter (26) and cooling
fan (25) to engine, and secure with washers (24) and capscrews (23). Torque capscrews (23) to 32 lbs-ft (43.4
Nm).
e. Install plate (60) over opening in shroud (44) and secure with capscrews (62), lockwashers (63), and
washers (64).
f. Install fan guard (21) on shroud (44) with spacers (22), large washers (20), lockwashers (19), and
capscrews (18).
CAUTION
Do not apply sealant to inside of radiator hose and push it onto male adapter.
This can result in excess sealant being pushed ahead of male adapter and
into hose exposing sealant to engine coolant. The coolant can then carry the
excess sealant into the radiator cores and engine water jackets, plug the
coolant passages, and result in premature engine failure.
h. Apply LOCTITE #518 sealant to male hose adapters, and connect lower radiator hose (15) to engine, and
upper radiator hose (14) to radiator (34) and tighten clamps (13).
2-2-36
TM 5-3810-307-24-1-1
i. Connect air cooler tubes to flexible hoses (12) and tighten clamps (11). Torque "Breeze" clamps 50-60 lbs-
in. (5.6-6.7 Nm) or "R. G. Ray" clamps 60-75 lbs-in. (6.7-8.5 Nm).
j. Install engine hood center cowl, refer to Engine Hood Installation procedures.
k. Install exhaust tube and adapter between turbocharger and flexible tubing, refer to Muffler and Piping
Installation procedures.
l. Secure recovery tank overflow hose (10) to shroud (44) with clamps (9) and capscrews (8).
m. Connect recovery tank coolant hose (7) to radiator (34) filler neck and tighten clamp (6).
n. Connect support rod (29) to bottom of radiator (34) with lockwasher (28) and nut (27).
o. Secure drain hose (5) to carrier frame with clamp (4), washer (3), lockwasher (2), and nut (1).
p. Install engine top panel and side access doors, refer to Engine Hood Installation Procedures.
r. Using static coolant system pressure tester, perform static check of coolant system.
s. Start engine and check for leaks. Shut down engine after 15 minutes of operation. Allow system to cool.
2-2-37
TM 5-3810-307-24-1-1
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of the muffler and the muffler includes a weather cap which is installed on
tubing connecting the muffler to the exhaust side of the top of the exhaust stack to keep rain water from
the engine turbocharger. entering the muffler when the engine is not running.
A muffler guard is installed around the portion of the
The muffler is mounted vertically to direct exhaust muffler exposed above the crane deck to help protect
gases up and away from personnel operating the personnel from the potential of burns.
crane or working in the immediate vicinity. The
MAINTENANCE
Removal
b. Remove capscrews (1, Figure 2-2-9), lockwashers (2), washers (3), and cover (4) from underside of right
front fender.
c. Remove nuts (5), lockwashers (6), capscrews (7), washers (8), and cover (9) from top of right front fender.
d. Remove screws (10), lockwashers (11), washers (12), and cover (13) from underside of deck plate just
forward of right front fender.
e. Remove clamp (14), locknuts (15), clamp (16), locknuts (17), capscrews (18), both clamps (19), and
exhaust tube (20) from turbocharger. Then remove adapter (21) from flexible exhaust tube (25).
f. Remove locknuts (22), capscrews (23), clamp (24), and flexible exhaust tube (25) from exhaust pipe (28).
g. Remove locknuts (26), clamps (27) and exhaust pipe (28) from muffler (41).
h. Remove capscrews (29), lockwashers (30), washers (31), large washers (32), muffler guard (33), and cover
(34) from muffler mount bracket (50).
i. Remove weather cap (35), locknuts (36), capscrews (37), clamp (38), and exhaust stack (39) from muffler
(41).
j. Loosen screws in mounting bands (40), spread mounting bands apart, and remove muffler (41) from crane.
k. If necessary, remove nuts (42), lockwashers (43), capscrews (44), washers (45), and mounting bands (40)
from muffler mount bracket (50).
2-2-38
TM 5-3810-307-24-1-1
l. If necessary, remove nuts (46), lockwashers (47), capscrews (48), washers (49), and muffler mount bracket
(50) from crane.
Installation
a. If removed, install muffler mount bracket (50, Figure 2-2-9) on crane with washers (49), capscrews (48),
lockwashers (47), and nuts (46).
b. If removed, install mounting bands (40) on muffler mount bracket (50) with washers (45), capscrews (44),
lockwashers (43), and nuts (42).
c. Slide muffler (41) up through mounting bands (40) and place bottom of muffler onto bracket on frame.
Tighten mounting bands (40).
d. Install exhaust stack (39) with weather cap (35) on muffler (41) with clamp (38), capscrews (37), and
locknuts (36).
e. Install cover (34) and muffler guard (33) on muffler mount bracket (50) with large washers (32), washers
(31), lockwashers (30), and capscrews (29).
f. Install exhaust pipe (28) on muffler (41) and frame bracket with clamps (27) and locknuts (26).
g. Install flexible exhaust tube (25) on exhaust pipe (28) with clamp (24), capscrews (25), and locknuts (22).
h. Install adapter (21) on flexible exhaust tube (25) and exhaust tube (20) on adapter (21) with clamps (19),
capscrews (18), and locknuts (17).
i. Install exhaust tube (20) on turbocharger with clamp (14), and secure exhaust tube (20) to engine bracket
with clamp (16) and locknuts (15).
WARNING
Exhaust system components can be very hot. Use care to avoid serious
burns.
j. Start diesel engine and check exhaust system for evidence of exhaust leaks. Shutdown diesel engine,
allow exhaust system components to cool, and tighten any clamps as necessary.
k. Install cover (13) on underside of deck plate forward of right front fender with washers (12), lockwashers
(11), and screws (10).
l. Install cover (9) on top of right front fender with washers (8), capscrews (7), lockwashers (6), and nuts (5).
m. Install cover (4) on underside of right front fender with washers (3), lockwashers (2), and capscrews (1).
2-2-39
TM 5-3810-307-24-1-1
LEGEND
2-2-40
TM 5-3810-307-24-1-1
SECTION 3
DRIVE TRAIN
TABLE OF CONTENTS
Page
DRIVE TRAIN
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Drive Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
TRANSMISSION/TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Converter Lockup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Operation of Powershift Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
Transmission Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
TRANSMISSION OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
AUTOMATIC POWERSHIFT CONTROL (APC 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Direct Engagement Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Downshift Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Low Clutch Pressure Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Override System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic/Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Throttle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Lockup Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Turbine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Two Wheel Drive Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Lockup Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Overspeed and Low Clutch Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Checkout Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18
2-3-1
TM 5-3810-307-24-1-1
Page
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Test Procedures with Checkout Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Installation of Checkout Kit and Start-up Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Input and Output Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
APC 100 Checkout Kit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-25
Replacement of Checkout Kit EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-26
Test Procedures Without Checkout Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Transmission RPM/Pressure Indicator Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Shifting Problem Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Manual/Automatic Shared System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-28
APC 100 Control Box Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-29
Throttle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-31
Gear Selector Input Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-32
Speed Sender Input Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-33
Torque Converter Lockup Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-33
4WD Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-34
LIST OF FIGURES
2-3-2
TM 5-3810-307-24-1-1
LIST OF TABLES
2-3-1 Checkout Kit LEDs for Transmission Shift Control Inputs . . . . . . . . . . . . . . . . . . . . 2-3-20
2-3-2 Harness Tester LEDs for Transmission Shift Control Outputs to Solenoids. . . . . . . . . 2-3-22
2-3-3 Checkout Kit LEDs for APC 100 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-23
2-3-4 Four Wheel Drive Control System and Checkout Kit Conditions . . . . . . . . . . . . . . . . 2-3-23
2-3-5 Gear Selection Circuit Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-29
2-3-6 Gear Selector Input Signals (Voltages) to APC 100 . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-32
2-3-7 Lockup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-34
2-3-8 2WD/4WD Output Circuit Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-35
2-3-3/(2-3-4 Blank)
TM 5-3810-307-24-1-1
DRIVE TRAIN
DESCRIPTION
The drive train consists of the transmission/torque driving the hydraulic pump. The transmission is a
converter assembly and two drive shafts. powershift (six speed forward and three reverse)
transmission. The transmission is controlled by a
The transmission/torque converter is a Clark 13.9 shift control lever located on the right side console of
LFHR 24658 assembly w/APC 100 auto shift, and is the carrier cab and the right side of the front console
mounted on, and driven by the engine. The torque in the superstructure cab.
converter assembly also provides for mounting and
2-3-5
TM 5-3810-307-24-1-1
MAINTENANCE
DRIVE LINES
Removal
CAUTION
a. Scribe a match mark across drive shaft universal bearings and component drive flanges (Figure 2-3-1).
b. Support drive shaft and remove capscrews and lockwashers securing drive shaft universal bearings to
component drive flanges.
d. If necessary, remove capscrews, lockwashers, and universal bearings from drive shaft.
Installation
a. If removed, install universal bearings (Figure 2-3-1) on drive shaft with lockwashers and capscrews.
Torque capscrews to 90-110 lbs-ft (122-149 Nm).
b. Position drive shaft to component drive flange aligning match marks made during removal.
c. Secure drive shaft with lockwashers and capscrews. Torque capscrews to 90-110 lbs-ft (122-149 Nm).
Lubrication
Lubricate the universal joints in accordance with Lubrication Chart, Chapter One, Section 4.
TRANSMISSION/TORQUE CONVERTER
DESCRIPTION
The function of the transmission/torque converter is made are shown on the following chart:
to control/convert power developed by the engine
and supply power to drive the hydraulic pumps, and Shift Points at MPH/KPH
motive power to the axles. The transmission/torque
converter is a single assembly mounted directly onto Gear Up-Shift Speed Gear Down-Shift
the engine. It provides six sequential, power shifted MPH ! KPH
speeds. Torque from the transmission/torque 1st to 2nd 5 8 2nd to 1st
converter is transferred as driving power for the
axles via drive shafts connected between them. 2nd to 3rd 7 11 3rd to 2nd
THEORY OF OPERATION
The transmission and torque converter function spool works against the spring until a port is exposed
together and operate through a common hydraulic along the side of the bore. This sequence maintains
system. Therefore, it is necessary to consider both the pressure needed for control and assures proper
units in discussing operation. system operation.
With the engine running, the converter charging After entering the converter housing, the oil is
pump draws oil from the transmission sump through directed through the reaction member support, to the
the removable oil suction screen and directs it converter blade cavity, then exits in the passage
through the pressure regulating valve and oil filter. between the turbine shaft and reaction member
support. The oil then flows out of the converter to
The pressure regulating valve maintains the the oil cooler. After leaving the cooler, the oil is
pressure used to actuate the directional and speed returned to a fitting on the transmission, and directed
clutches which control the transmission. This through a series of tubes and passages where it
requires a small portion of the total volume of oil lubricates the transmission bearings and clutches,
used in the system. The remaining volume of oil is then gravity drains to the transmission sump.
directed through the torque converter circuit to the oil
cooler, then returned to the transmission. The
regulator valve consists of a hardened valve spool
operating in a closely fitted bore. The valve spool is
spring loaded to hold the valve in a closed position.
When the specified pressure is achieved, the valve
2-3-7
TM 5-3810-307-24-1-1
The torque converter consists of three basic spring in the selector spool provides one position for
elements and their related parts which multiply each speed range. A detent ball and spring in the
engine torque. The engine power is transmitted from direction spool provides three positions, one each for
the engine flywheel to the impeller element through forward, neutral, and reverse.
the impeller cover. This element is the pump portion
of the hydraulic torque converter, and is the primary With the engine running and the directional control
component which starts the oil flowing to the other lever in the neutral position, oil pressure from the
components to obtain the desired torque regulating valve is blocked at the control valve, and
multiplication. The impeller can be compared to a the transmission is in neutral. Movement of the
centrifugal pump in that it picks up fluid at its center forward and reverse spool will direct oil under
and discharges at its outer diameter. pressure, to either the forward or reverse direction
clutch as desired. When either directional clutch is
The torque converter turbine is mounted opposite the selected, the opposite clutch is relieved of pressure
impeller and is connected to the output shaft of the and vents back through the direction selector spool.
torque converter. This element receives fluid at its The same procedure is used in the speed selector.
outer diameter and discharges at its center. Fluid
directed by the impeller out into the particular design The direction or speed clutch assembly consists of a
of blading in the turbine and reaction member, drum with internal splines and a bore to receive a
provides the coupling by which the hydraulic torque hydraulically actuated piston. Sealing rings make
converter multiplies torque. the piston oil tight. A steel disc with external splines
is inserted into the drum and rests against the piston.
The reaction member of the torque converter is Next a friction disc with splines at the inner diameter
located between and at the center of inner diameters is inserted. Discs are alternated until the required
of the impeller and turbine elements. Its function is total is achieved. A heavy back-up plate is then
to capture the fluid which is exhausting from the inserted and secured with a snap ring. A hub with
inner portion of the turbine and change its direction OD splines is inserted into the splines of discs with
to allow correct entry for recirculation into the teeth on the inner diameter. The discs and hub are
impeller element. free to increase in speed, or rotate in the opposite
direction as long as no pressure is present in that
The torque converter will multiply engine torque to its specific clutch.
designed maximum multiplication ratio when the
output shaft is at zero rpm. Therefore, as the output To engage the clutch, the control valve is placed in
shaft is decreasing in speed, the torque multiplication the desired position. This allows oil under pressure
is increasing. to flow from the control valve, through a tube, to a
chosen clutch shaft. This shaft has a drilled
The torque converter is equipped with automatic passageway for oil under pressure to enter the shaft.
lockup capabilities. This feature allows the torque Pressure sealing rings located on the clutch shaft,
converter to change from a fluid coupling to a direct direct oil under pressure to the desired clutch.
mechanical link between the engine and Pressure of the oil forces the piston and discs
transmission at a predetermined rpm level. The against the heavy back-up plate. The discs, with
lockup function is controlled by the lockup solenoid teeth on the outer diameter, clamping against discs
located on the right wall of the transmission well. with teeth on the inner diameter, cause the hub and
Torque converter slippage is eliminated when in the clutch shaft to be locked together and force them to
lockup mode, allowing the engine to run at a lower drive as a unit.
rpm to maintain vehicle speed. It also provides the
advantage of using engine compression as a brake There are bleed balls in the clutch piston which allow
in downgrade conditions. quick escape for oil when the pressure to the piston
is released.
The shift control valve assembly consists of a valve
body with selector valve spools. A detent ball and
2-3-8
TM 5-3810-307-24-1-1
MAINTENANCE
NOTE
2-3-9
TM 5-3810-307-24-1-1
DESCRIPTION
The transmission control valve is mounted directly electrically controlled and functions to direct oil under
onto the side of the transmission. The valve is pressure to the desired directional and speed clutch.
MAINTENANCE
NOTE
2-3-10
TM 5-3810-307-24-1-1
DESCRIPTION
The transmission oil cooler is located at the rear of a temperature switch and a relay. The temperature
the crane carrier and is mounted on brackets switch is threaded into the oil cooler and has
between the frame rails. The oil cooler consists of a normally open contacts. When the oil temperature
radiator core and an electric motor with fan. The oil reaches approximately 165 degrees F (73.8 degrees
cooler is used to dissipate heat from the oil in the C) the switchs contacts close. This allows the oil
transmission system. The fan motor is controlled by cooler relay to energize and activate the oil cooler
fan motor.
MAINTENANCE
REMOVAL. INSTALLATION.
1. Tag and disconnect the wires for the tempera- 1. Position the oil cooler onto the mounting brack-
ture switch and the oil cooler fan motor, refer to ets and secure in place with the bolts, nuts, and
Figure 2-3-2. washers, refer to Figure 2-3-2.
2. Disconnect the transmission oil lines from the 2. Connect the transmission oil lines to the oil
oil cooler. cooler.
3. Remove the bolts, nuts, and washers securing 3. Connect the wires for the temperature switch
the oil cooler to the mounting brackets and remove and oil cooler fan motor as tagged during
the oil cooler. REMOVAL.
2-3-11
TM 5-3810-307-24-1-1
2-3-12
TM 5-3810-307-24-1-1
DESCRIPTION
From neutral, a forward or reverse gear cannot be The automatic/manual mode (override) switch is on
selected if the engine speed is above 1000 rpm. top of the APC 100 mode control fuse and relay box.
When changing direction, the engine speed must be An open switch indicates automatic mode and a
less than 1000 rpm and the vehicle speed must be closed switch indicates manual mode. A closed
less than one mph, or the transmission will shift into switch inputs battery voltage. The manual mode
neutral. must be reactivated each time the ignition switch is
turned off then back on.
If the crane is moving, drive can only be engaged
when the engine speed is less than 1200 rpm in 1st Clutch Pressure
or 2nd, 1400 rpm in 3rd or 4th, and 1600 rpm in 5th
or 6th (both forward and reverse). Clutch pressure is monitored by a clutch pressure
switch that closes if the clutch pressure becomes
DOWNSHIFT PROTECTION critically low. A closed switch inputs battery voltage.
2-3-13
TM 5-3810-307-24-1-1
2-3-14
TM 5-3810-307-24-1-1
2-3-15
TM 5-3810-307-24-1-1
Figure 2-3-5. APC 100 Mode Control Fuse and Relay Box
2-3-16
TM 5-3810-307-24-1-1
An idle switch inputs battery voltage when the throttle YELLOW LED - Illuminates when engine or
is in the idle position (switch closed). When the turbine speed reads zero. This LED will
throttle is moved from the idle position the idle switch remain lit until the engine is started.
opens and the full throttle position switch closes
inputting battery voltage to indicate throttle position. GREEN LED - Illuminates when an improper
gear selection pattern is input by the shift
Gear Selection selector.
A switch matrix of five wires decodes the gear Two Wheel Drive Solenoid
selector position. The five wires are switched
between open and battery voltage. If four wheel drive input voltage is present, the APC
100 will automatically switch to two wheel drive when
Lockup Request the transmission reaches F4 or R5. The four wheel
drive voltage opens the 2WD interlock relay allowing
The lockup switch closes and inputs battery voltage the 2WD load out relay to close and battery voltage
to enable converter lockup when conditions permit. is output to switch the vehicle to two wheel drive.
An open switch disables lockup.
Lockup Solenoid
Turbine Speed
The torque converter lockup output switches
The turbine speed is monitored by a pulsed signal between battery voltage and zero depending on the
that is generated by a speed sensor in the same engine and turbine speed input ratio. The output is
manner as the engine speed sensor. connected to a solenoid and is energized when
lockup is engaged.
OUTPUTS
Overspeed and Low Clutch Pressure Indicator
Diagnostic LEDs
This output lights a LED on the front console. The
LED will illuminate (steady) if a gear is selected that
would cause an overspeed condition and will go out
when rpm drops to a speed allowing the selection.
The LED will blink rapidly should a turbine failure
occur. The APC must be reset to clear this
condition. The LED will blink slowly if low clutch
pressure is detected for more than five seconds.
LED will go out when sufficient pressure returns.
Shift Solenoids
Figure 2-3-6. Diagnostic LEDs The shift solenoids output switch between battery
voltage and zero as associated shift speeds are
There are three diagnostic LEDs (Light Emitting reached. The output energizes the appropriate shift
Diodes), under a cover, on the top of the APC 100 solenoid when the output is switched on.
control box. These lights can be used by
2-3-17
TM 5-3810-307-24-1-1
CHECKOUT KIT The input LEDs will be either dark (off state) or
yellow/orange (on state). The output LEDs will light
Description various colors depending on the condition of the
output circuit:
The checkout kit is an APC 100 with a LCD display,
input/output signal LEDs, and diagnostic software to dark = off
help determine system and/or wiring faults. Refer to green = good
Figure 2-3-7 for identification of the parts to the yellow = open circuit or shorted to +24v
checkout kit. red = shorted to ground.
2-3-18
TM 5-3810-307-24-1-1
MAINTENANCE
TEST PROCEDURES WITH CHECKOUT KIT e. Press and release the hold button. This
will activate the "checkout" mode and will
Installation of Checkout Kit and Start-up Screens show the checkout screen:
Also all input LEDs should be (1) The "C:xx" display should match
yellow/orange and all output LEDs the position selected.
should be green. (2) The "G:xx" display will show only
F1 or R1 while vehicle is
b. Screen #2 will show: motionless.
(3) The indicator LEDs should
13.9FLHR24658 illuminate yellow/orange as
AT400MILCRANE shown in Table 2-3-1.
2-3-19
TM 5-3810-307-24-1-1
Table 2-3-1. Checkout Kit LEDs for Transmission Shift Control Inputs
a. Make sure transmission is in neutral (N) (1) LED #23 should turn off at 890-
and main hydraulic pump is disengaged. 940 engine rpm.
b. Start engine and run at idle. The "E:xxx" (2) If necessary, adjust carriage bolt
display should be approximately 840- (30, Figure 2-2-3) closer to idle
860. switch to increase rpm setting
(1) If reading is zero or erratic, check and farther away from switch to
speed sensor, harnesses, and decrease setting.
APC 100 fuse and relay box.
e. Increase engine speed farther.
(2) If reading is greater than the
range, check and adjust throttle (1) LED #08 should turn off at 2250-
cable and linkage as necessary, 2350 engine rpm.
refer to Section 2 - THROTTLE
AIR CYLINDER AND (2) If necessary, loosen mounting
THROTTLE LINKAGE. hardware slightly for adjusting bar
(39, Figure 2-2-3) and adjust
(3) If still out of range, adjust fuel capscrew (36) clockwise to
injection pump idle setscrew. decrease setting and counter-
Setscrew is located between clockwise to increase setting.
pump control lever and pump
body. Turn screw counter- NOTE
clockwise to increase and
clockwise to decrease. A slight reduction in the setting speed
usually occurs as the mounting hardware
c. Check LEDs.
is tightened. Therefore adjust toward the
upper end of range.
(1) LED #23 (idle switch) and LED
#08 (throttle position switch)
f. Increase engine speed to full throttle.
should be illuminated
yellow/orange.
(1) "E:xxx" display should be 2500-
(2) If not illuminated, check 2781.
harnesses and APC 100 fuse
and relay box for faulty (2) If out of range, check and adjust
connections/components. Check throttle cable and linkage as
appropriate throttle switch for necessary, refer to Section 2 -
proper adjustment, refer to THROTTLE AIR CYLINDER
Section 2, THROTTLE AIR AND THROTTLE LINKAGE.
CYLINDER AND THROTTLE
LINKAGE.
2-3-20
TM 5-3810-307-24-1-1
(1) LED #07 should go out (adequate (2) Position ignition switch to 1 (run);
pressure). do not start engine.
(2) If not out, check transmission (3) Place APC 100 override switch in
clutch pressure. Clutch pressure manual position.
should be 240-280 psi (1655-
1931 kPa) with oil at 180-2500 F (4) Move the transmission shift
(82-1210 C), engine at idle, and control lever to each position and
transmission in N (neutral). check that LEDs in left and right
columns of harness tester
illuminate green as shown in
Table 2-3-2.
2-3-21
TM 5-3810-307-24-1-1
Table 2-3-2. Harness Tester LEDs for Transmission Shift Control Outputs to Solenoids
(1) Place crane on outriggers. (6) Repeat steps (4) and (5) for each
of the remaining gears.
(2) Restart engine from carrier cab
and apply brakes.
2-3-22
TM 5-3810-307-24-1-1
Table 2-3-4. Four Wheel Drive Control System and Checkout Kit Conditions
2-3-23
TM 5-3810-307-24-1-1
(1) Place crane on outriggers. b. Restart engine from carrier cab and
position shift control lever in F4.
(2) Restart engine from carrier cab,
apply brakes, and position shift c. Release brakes and run transmission up
control lever to F6. to F4.
(3) Position DRIVE AXLE selector (1) As turbine speed (T:) approaches
switch to 4WD, release brakes, engine speed (E:), lockup should
and accelerate through gears. occur and LED #37 should
illuminate green.
(a) Front wheels should turn until
(2) Once lockup occurs, engine
4WD automatically disengages
speed and turbine speed should
when transmission shifts into F4
be equal.
or R5.
d. Maintaining engine speed at 2100-2200
CAUTION
rpm, move transmission shift control
lever to F5.
4WD will re-engage when transmission
reenters f2 or r3. This should not be (1) Lockup should disengage when
allowed to occur if front wheels are not turbine speed reaches
turning at same speed as rear wheels. approximately 2000 rpm.
Otherwise, damage to transmission
could occur. (2) Immediately following unlock
(LED #37 should go out),
(b) Position DRIVE AXLE transmission should upshift and
selector switch to 2WD to prevent lockup should re-occur again
transmission from re-entering when turbine speed approaches
4WD automatically when engine speed (LED #37 should
transmission reaches F2 or R3 illuminate green).
during deceleration (front wheels
will be turning at different speed). e. If behavior is different than above, check
the following:
(c) Release throttle and apply
brakes. (1) If LED #37 is a color other than
green, see output LED color
(d) If 4WD does not function as definitions in CHECKOUT KIT -
stated, recheck conditions in step Definition, and repair accordingly.
6.a. above.
(2) If LED #37 is green but the
7. Converter Lockup Output turbine and engine speeds are
not equal during lockup, check
NOTE pressure at lockup port on right
side of transmission.
This LED lights when program is
attempting to achieve torque converter (a) Pressure should equal
lockup. Lockup is only allowed in F4 thru transmission clutch pressure
F6 when certain engine speed and [240-280 psi (1655-1931 kPa).
turbine speed criteria dependent on
throttle position are met [i.e., conditions (b) If pressure is incorrect, check
indicate vehicle is cruising (not hose routing to and from
accelerating or pulling hard)]. modulator valve.
2-3-24
TM 5-3810-307-24-1-1
(a) Check the red and black tests (3) If input LEDs and displays are
points for +24 volts, refer to normal, but all output LEDs
Figure 2-3-9. remain red, remove front cover
(cover with display), remove
(b) Repair harness if no power is screws retaining bottom cover,
present. slide pc boards out, and check
output fuse. Replace with very
fast acting (FF) 10 A fuse if
necessary, refer to Figure 2-3-11.
2-3-25
TM 5-3810-307-24-1-1
REPLACEMENT OF CHECKOUT KIT EPROM. 4. Plug in new EPROM ensuring all 28 pins are
inserted straight into socket.
1. Remove front cover, screws retaining bottom
cover, and slide pc boards completely out of CAUTION
housing, refer to Figure 2-3-11.
Do not force any component. All pieces
2. Carefully separate top pc board from center pc reassemble with very minor effort.
board. Check for cause of difficulty and correct
before forcing.
3. Unplug EPROM from center pc board, refer to
Figure 2-3-12 for location of EPROM. 5. Install top pc board on center pc board.
2-3-26
TM 5-3810-307-24-1-1
a. Vehicle must slow down to extinguish. (2) If pressure is low, check for
improperly routed transmission
b. If slowing vehicle does not extinguish hoses to 4WD solenoid valve and
indicator, proceed to Speed Sensor lockup modulator valve (located
Inputs. on right wall of transmission well),
refer to FO-2, Hydraulic
2. Fast Blink - Turbine failure: The computer has Schematic for proper routing.
lost turbine speed input signal, refer to Speed Reroute hoses as necessary.
Sensor Inputs.
(3) If pressure is correct, check
3. Slow Blink - Low clutch pressure for more than pressure switch for proper
5 seconds. This condition will exist with ignition operation. Switch should be
switch on until adequate pressure is developed open with system pressure.
within transmission circuits. Replace as necessary.
2-3-27
TM 5-3810-307-24-1-1
3. Measure resistance through each transmission Figure 2-3-14. Transmission Solenoid Connector
solenoid coil. The readings should be 39-42 ohms. (Engine Harness)
If a reading is 0 ohms, solenoid must be replaced
and a fuse in the fuse and relay box is probably 5. Position ignition switch to 1 (run) and
blown requiring replacement. AUTOMATIC/MANUAL switch to MANUAL.
4. Check engine harness side of transmission 6. Place the transmission shift lever into each
solenoid connector for proper wire connection, refer position and check voltage reading at every socket of
to Figure 2-3-14. engine harness transmission solenoid connector.
The readings should match those in Table 2-3-5.
Figure 2-3-13. Transmission Solenoid Connector a. If voltage readings are correct, proceed
(Transmission Valve Body) to step 9.
2-3-28
TM 5-3810-307-24-1-1
F1 F2 F3 F4 F5 F6 N R3 R2 R1
L 789 K 1 Forward HI 24 24 24
C 788 B 2 Forward LO 24 24 24 24 24 24
E 609 D 5 Reverse 24 24 24
b. If voltage readings are not correct, gear APC 100 CONTROL BOX DIAGNOSTICS
selector or cab harness is faulty.
Correct as necessary and check vehicle 1. Remove blackout cover from APC 100 control
operation. box to expose the three diagnostic LEDs.
9. Ensure there is continuity in each output 2. With transmission selector lever in N and
circuit, refer to Table 2-3-5. Ensure that there is no ignition switch positioned to 1 (run), observe the
continuity between any two circuits and no continuity three diagnostic LEDs and the TRANSmission RPM/
between any circuit and ground. PRESSure indicator (LED) on dash panel. All four
should light for 2 seconds, then the TRANSmission
a. If continuity is as stated, proceed to step RPM/PRESSure indicator should begin to blink
10. slowly and the red diagnostic LED should turn off.
The yellow and green LEDs should remain on.
b. If continuity is not as stated, check the
harnesses and circuits in main junction a. If no LEDs light, check for 24 vDC power
box (exterior, back side of cab) for and ground at the rectangular connector
cause. Correct any fault(s) and check for the APC 100 control box harness.
vehicle operation.
(1) If no power is indicated, check
NOTE harness circuit #718. Power
should be available at sockets
Since solenoids require less than 1 amp 17, 18, and 25 of APC relay box
of current to operate, even a small strand harness. Correct any fault(s) and
of wire may cause undesirable continuity recheck LEDs.
between circuits.
(2) If no ground is indicated, check
10. Remove cover from fuse and relay box and harness circuit #51. Ground
check for loose connections, blown fuses, and bad should be available at socket 11
relays. Correct any fault(s) and check vehicle of APC 100 relay box harness.
operation. Correct any fault(s) and recheck
LEDs.
NOTE
(3) If power and ground are present,
The cab harness needs to be check input fuse under top cover
reconnected and manual mode of APC 100 control box, refer to
reactivated for the relays to be in their Figure 2-3-15. If blown, replace
manual mode position. only with a 5 x 20 mm very fast
acting (FF) 315 mA fuse.
Recheck LEDs.
2-3-29
TM 5-3810-307-24-1-1
2-3-30
TM 5-3810-307-24-1-1
(6) If no problems with the EPROM 890-940 rpm, and come back on again at 2250-2350
can be found, the APC 100 rpm.
control box must be replaced.
a. If correct, the engine idle switch and full
e. If all LEDs perform correctly, proceed to throttle switch are properly set and their
Throttle Tests. circuits are good. Proceed to Gear
Selection Diagnostics.
Throttle Tests
b. If LED operation is not correct:
1. With main hydraulic pump disengaged and
transmission shift lever in N, start engine and verify (1) Disconnect relay box harness
idle speed is 840 50 rpm. If needed, adjust as from APC 100 control box.
follows. Otherwise proceed to step 2.
(2) Check socket 23 for 24 vDC
a. If reading is greater than the range, signal at idle and drops out when
check throttle cable and throttle engine reaches 890-940 rpm.
assembly for proper installation, refer to
THROTTLE AIR CYLINDER AND (a) If signal is not present or
THROTTLE LINKAGE Installation does not drop out, check idle
procedures, Section 2. switch. Idle switch should be
closed until rpm setting is
b. If reading is still out of range, adjust fuel reached. Correct and
injection pump idle set screw located recheck operation.
between injection pump control lever
and injection pump body. Turn screw (b) If signal drops out at wrong
counter-clockwise to increase idle speed rpm setting, adjust idle switch
and clockwise to decrease idle speed. carriage bolt (30, Figure 2-2-
3) closer to idle switch to
2. Gradually increase engine speed while increase rpm setting and
observing green diagnostic LED on top of APC 100 farther from switch to
control box. It should be on at idle, turn off at decrease setting. Correct
and recheck operation.
2-3-31
TM 5-3810-307-24-1-1
(3) Check that socket 8 (full throttle b. If rpm is less than range, check throttle
switch input) has 24 vDC signal cable and throttle assembly for proper
at idle and drops out when installation, Refer to THROTTLE AIR
engine reaches 2250-2350 rpm. CYLINDER AND THROTTLE LINKAGE
Installation procedures, Section 2.
(a) If signal is not present or
does not drop out, check full Gear Selector Input Diagnostics
throttle switch. Switch should
be closed until rpm setting is 1. Disconnect relay box harness (rectangular
reached. Correct and connector) from APC 100 control box.
recheck operation.
2. Position ignition switch to 1 (run).
(b) If signal drops out at wrong
rpm setting, adjust full throttle 3. Place transmission shift lever in each position
switch by slightly loosening and check input signals (voltages) at sockets 1, 2,
the mounting screws (33, 20, 21, and 22 for 24 vDC or 0 v. Readings should
Figure 2-2-3) and turning match those in Table 2-3-6.
screw (36) clockwise to
decrease rpm setting and a. If all input signals are correct, proceed to
counterclockwise to increase Speed Sender Input Diagnostics.
setting. Correct and recheck
operation. b. If input signals are incorrect, check the
APC fuse and relay box for faults
NOTE between the manual mode relays and
APC 100 harness connector. Faults in
A slight reduction in rpm setting usually the rest of the relay box would create
occurs as mounting screws are symptoms during manual mode
tightened. Therefore, adjust toward operation and would be detected during
upper end of rpm range. that diagnosis. Correct any fault(s) and
recheck operation.
3. Check maximum engine RPM by increasing
engine speed to full throttle (2500-2800 rpm).
2-3-32
TM 5-3810-307-24-1-1
For proper lockup operation, APC 100, 7. Place crane on outriggers, with tires off the
throttle switch inputs, gear selector ground, and start engine from carrier cab.
inputs, and speed sender inputs must be
functioning properly, refer to appropriate 8. Position transmission shift lever to F4, release
procedures and check functions prior to brakes, run engine at 2200 rpm, and allow
diagnosing lockup problems. transmission to enter F4 gear. Lockup may occur in
F3 since engine speed is below full throttle switch
1. Lockup is allowed in gears F4 thru F6 and also setting.
in F3 when the throttle is less than mid-throttle. The
crane will feel sluggish, fuel economy will suffer, and 9. As turbine speed (torque converter output)
top speed will be difficult to achieve if lockup is not surpasses minimum speed (refer to Table 2-3-7) and
functioning. The operator can usually feel lockup approaches engine speed, TORQUE CONVERter
engaging (feels like a smooth prolonged shift to a UNLOCKED indicator should turn off, the voltage
higher gear) about 3 seconds after TORQUE reading at lockup solenoid should change from 0 to
CONVERter UNLOCKED indicator turns off. 24 vDC, and lockup should occur.
2-3-33
TM 5-3810-307-24-1-1
This assumes drivetrain is not inducing a 12. Keeping throttle at one position, apply brakes
load which would cause turbine speed to to reduce turbine speed to the loaded
stay well below the engine speed. The disengagement speed, refer to Table 2-3-7. While
engine will be laboring if this is the case. doing this, watch the voltage at lockup solenoid. The
The converter will normally achieve voltage should drop to 0 vDC and lockup should
lockup very easily with crane on disengage at the specified speed.
outriggers.
a. If voltage does not drop, there is a fault
b. If voltage does change, but lockup in the EPROM or the APC 100 control
engagement is not noticed, check the box, see APC 100 CONTROL BOX
hydraulic circuit related to lockup for DIAGNOSTICS and correct any fault(s).
faults. If transmission lockup port is
receiving pressure, transmission is b. If voltage drops but lockup does not
defective. disengage, check lockup hydraulic circuit
and transmission for faults.
c. If voltage changed and lockup occurred
properly, proceed to step 10. c. If lockup disengages, converter lockup
circuit is functioning properly.
10. Increase engine speed to 2400-2500 rpm and
move transmission shift lever to F5. d. Disconnect voltmeter and/or jumper wire
from wire 448.
11. Lockup should disengage. Immediately
following unlock, the transmission should upshift and 4WD Diagnosis
lockup should re-occur when the turbine speed again
approaches engine speed. 1. Place machine on outriggers, with tires off the
ground, and start engine from carrier cab.
a. If transmission does not upshift, there is
a fault in the EPROM or APC 100 control 2. Position DRIVE AXLE selector switch to 2WD,
box, see APC 100 CONTROL BOX position transmission shift lever to F2, release the
DIAGNOSTICS and correct any fault(s). brakes, and accelerate slightly. The rear wheels
should turn and the front wheels should remain
relatively still.
2-3-34
TM 5-3810-307-24-1-1
(2) If 24 vDC is not present, check (2) If 24 vDC is present, stop crane
2WD/4WD electrical circuit. and proceed to step 4.
Correct any fault(s) and recheck
operation. c. If front wheels turn but do not disengage
after entering F4, stop crane, and
3. Idle engine and apply brakes. When wheels proceed to step 4.
are stopped, place DRIVE AXLE selector switch in
4WD position, position transmission shift lever to F4, 4. Remove APC 100 fuse and relay box from cab
release brakes, and accelerate so transmission will wall mounting, and remove cover from fuse and relay
shift up to F4 gear. The front wheels should turn with box leaving APC 100 control box connected to relay
the rear wheels until transmission shifts from F3 to box harness (rectangular connector).
F4. When this occurs, 4WD should disengage and
front wheels should begin to slow. 5. Position ignition switch to 1 (run), place
transmission shift lever in F1, and check 4WD output
CAUTION circuits for voltage during the various modes as
shown in Table 2-3-8.
Be sure to position drive axle selector
switch to 2WD before decelerating. If a. Correct any faults in circuits that do not
selector switch is left in 4WD position, function as stated in table and recheck
4WD re-engagement will occur when circuit outputs.
transmission shifts into F2. Damage
may occur if 4WD is allowed to engage b. If the voltage in wire 35 is not correct,
while wheels are turning at different there is a fault in the EPROM or the APC
speeds. 100 control box, see APC 100
CONTROL BOX DIAGNOSTICS,
correct any fault(s), and recheck circuit
output.
2-3-35/(2-3-36 Blank)
TM 5-3810-307-24-1-1
SECTION 4
AXLES AND BRAKE SYSTEM
TABLE OF CONTENTS
Page
AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-6
Wheel Alignment and Lock Cylinder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-7
Boom Rest Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Hydraulic Power Bleeding and Adjustment (Front Axle) . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Rear Axle Alignment and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-12
AXLE PROXIMITY SENSOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-17
REAR AXLE STEERING UNLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Operation Check/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Mounting Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Initial Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Operational Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Actuator (Expander Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
BRAKE CHAMBER (FRONT WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-29
BRAKE CHAMBER (REAR WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-34
2-4-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
2-4-2
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-4-5
Ensure any lifting device used is capable of supporting the weight of the
axle.
WARNING 2-4-6
Do not allow the axle to twist or tilt when removing the mounting
hardware.
WARNING 2-4-22
WARNING
2-4-25
These parts are under spring tension and must be held, or caged when
snap ring is removed.
WARNING
2-4-27
There may be residual pressure in air lines after air reservoirs are 2-4-33
drained. Wear eye protection when disconnecting air lines to prevent
injury.
2-4-3
TM 5-3810-307-24-1-1
WARNING 2-4-27
2-4-27
2-4-33
2-4-33
WARNING 2-4-28
2-4-4
TM 5-3810-307-24-1-1
AXLES
DESCRIPTION
The crane is equipped with two axles, one on the either the carrier or superstructure cab. The axles
front of the carrier and one on the rear of the carrier. are mounted to the carrier frame by means of an
To provide maximum maneuverability, both axles oscillation lockout cylinder and leaf spring located at
are drive and steer axles and can be controlled from each end of each axle.
MAINTENANCE
NOTE
REMOVAL. NOTE
1. Fully extend and set the outriggers. Install Step 6 applies only to the front axle.
blocking under the frame at the outboard ends of the Mark position of washers removed from
outrigger boxes. torque rod to ensure proper positioning
during installation.
2. Deplete the air pressure in the brake system.
6. Remove the cotter pin and hex nut securing
NOTE the drag link to the steering arm and the hex nut,
washer(s), and capscrew securing the torque rod to
Each tire and wheel assembly weighs the axle assembly. Disconnect the drag link and
approximately 540 pounds (245 kg). torque rod from the axle.
3. Remove the tire and wheel assemblies from 7. Tag and disconnect the air lines to the brake
the axle to be removed. chambers. Cap or plug all lines and openings.
4. Remove the drive lines. Refer to DRIVE 8. Tag and disconnect the hydraulic lines to the
LINES in Section 3 - DRIVE TRAIN. steer cylinders. Cap or plug all lines and openings.
NOTE
WARNING
Each axle weighs approximately 1600 Ensure any lifting device used is capable
lbs (726 kg). of supporting the weight of the axle.
2-4-5
TM 5-3810-307-24-1-1
NOTE
2-4-6
TM 5-3810-307-24-1-1
2-4-7
TM 5-3810-307-24-1-1
b. Adjust the lock cylinder so that the rear Check that steer cylinders have a minimum of 0.25 in
wheels remain straight when the (6.35 mm) or a maximum of 0.28 in. (7.11 mm) with
steering lock cylinder is engaged the tie-rod(s) and/or steering arm(s). Check that
(pinned). there is a minimum of 0.50 in. (12.7 mm) clearance
between brake chambers and axle. Adjust axle
c. Torque mounting bolts to 165 pounds- stops as necessary to achieve clearances.
foot (224 Nm).
CAUTION
d. Check that rear axle toe-in was not
affected. Both wheel ends must firmly contact axle
stops. Failure to adjust steering gear
e. Perform step 6 in REAR AXLE limiters can result in damage to the steering
ALIGNMENT AND BLEEDING gear box.
procedures.
8. Turn steering wheel full left and verify that
BOOM REST SWITCH ADJUSTMENT. wheel end pushes firmly against left side axle stop
and that all clearances are taken up by the pressure.
Adjust the boom rest switch so that switch activates If wheel end is not contacting stop:
when the boom is 0.5 inches (12.7 mm) from the
boom rest. Assure the axle lockout valves open a. Shut down engine.
when the carrier ignition switch is positioned to 1
(run) and the boom is in the boom rest. Refer to b. Remove plug from upper end of steering
Figure 2-4-2. gear.
4. Open bleed fittings on each steer cylinder, turn b. Remove plug from lower end of steering
steering wheel from lock to lock, and bleed each gear.
cylinder until no air appears (Hydraulic fluid should
flow from the bleed port in a steady stream). Close c. Turn adjusting ring in direction shown to
all bleed fittings. reduce gap between wheel end and axle
stop, refer to Detail D-D.
5. Open air/bleed fittings on front side of steering
gear, turn steering wheel from lock to lock, and bleed d. Install plug and torque to 52 pounds-foot
steering gear until no air appears. Close air/bleed (71 Nm).
fittings.
e. Restart engine and repeat step 9 as
6. Rotate steer cylinders back to correct installed necessary until right wheel end pushes
position and tighten ball end clamps. firmly against axle stop and all
clearances are taken up.
7. Turn steering wheel fully in both directions.
2-4-8
TM 5-3810-307-24-1-1
2-4-9
TM 5-3810-307-24-1-1
2-4-10
TM 5-3810-307-24-1-1
2-4-11
TM 5-3810-307-24-1-1
REAR AXLE ALIGNMENT AND BLEEDING. 4. Crack the bleed fittings on each steer cylinder
and turn the steering wheel lock to lock, bleeding the
NOTE cylinders until no air appears. Tighten the fittings.
The following procedures are referenced 5. Rotate steer cylinders back to correct installed
to Figure 2-4-2. position and tighten ball end clamps.
1. Pull the steering mode control handle at the 6. Turn steering wheel fully in both directions.
side of the hydraulic tank and engage the lock. This Check that steer cylinders have a minimum of 0.25 in
will transfer the steering from the carrier to the (6.35 mm) or a maximum of 0.28 in. (7.11 mm) with
superstructure. Assure the CARRIER STEER the tie-rod(s) and/or steering arm(s). Check that
DISENGAGED indicator on carrier dash panel there is a minimum of 0.50 in. (12.7 mm) clearance
illuminates when carrier cab ignition switch is in 1 between brake chambers and axle. Adjust axle
(run) position. stops as necessary to achieve clearances.
2. Loosen steer cylinder ball end clamps and 7. Adjust sensors for rear axle proximity sensor
rotate cylinders so that fittings are vertical. assembly, refer to AXLE PROXIMITY SENSOR
ASSEMBLIES, Adjustment.
3. Start the engine from the superstructure.
Position REAR AXLE STEERING LOCK switch to
UNLOCKED. The red steering lock light (to right of
switch) will go out.
2-4-12
TM 5-3810-307-24-1-1
Description
There are two axle proximity sensor assemblies installed on the crane, one on each axle. The proximity sensor
assembly on the front axle is connected to the indicator lights for the FRONT AXLE STEERING control in the
superstructure cab. The assembly on the rear axle is connected to the indicator lights for the REAR AXLE
STEERING control in the carrier cab. The assemblies are comprised of proximity sensors connected to a wiring
harness. The assembly on the rear axle also includes a sensor which is connected to the rear axle steering lock
indicator lights in both cabs.
The purpose of the axle proximity sensor assemblies is to indicate to the operator that the wheels, for the axle
being steered with the steering control toggle switch, are turned from center. When the wheels are centered, the
center indicator light on the dash is lit. When the wheels are moved from center using the steering control toggle
switch, the right or left indicator light will be lit indicating the direction in which the crane will turn, except when
crabbing (crane will crab in opposite direction of indicator lit). When the rear axle is being steered from the
carrier cab, the center indicator light also means that the rear steering cylinder locking pin is near alignment and
can be activated. When the rear steering lock pin engages, the sensor is then close enough to the pin to
complete the circuit and light the rear axle steering lock indicator light.
Removal
b. Remove front axle proximity sensor assembly (12, Figure 2-4-3) as follows:
(1) Disconnect electrical connector for proximity sensor assembly (12) from carrier electrical harness.
(2) Remove nuts (1), lockwashers (2), washers (3), and clamps (4) securing proximity sensor assembly
(12) electrical wires to studs on axle.
(3) Loosen nuts (5), and remove screws (6), nuts (5), and ground wires for EMI shields (8) from
adjustment brackets (10).
(4) Remove clamps (7) securing EMI shields (8) to sensors of proximity sensor assembly (12).
(5) Remove nuts (9), adjustment brackets (10), proximity sensor assembly (12), and washers (13) from
axle bracket.
c. Remove rear axle proximity sensor assembly (25, Figure 2-4-3) as follows:
(1) Disconnect electrical connector for proximity sensor assembly (25) from carrier electrical harness.
(2) Remove nuts (14), lockwashers (15), washers (16), and clamps (17) securing proximity sensor
assembly (25) electrical wires to studs on axle.
(3) Loosen nuts (18), and remove screws (19), nuts (18), and ground wires for EMI shields (21) from
adjustment brackets (23).
(4) Remove clamps (20) securing EMI shields (21) to sensors of proximity sensor assembly (25).
(5) Remove nuts (22), adjustment brackets (23), proximity sensor assembly (25), and washers (26)
from axle brackets.
2-4-13
TM 5-3810-307-24-1-1
Installation
a. Install front axle proximity sensor assembly (12, Figure 2-4-3) as follows:
(1) Install adjustment brackets (10), washers (13), and sensors for proximity sensor assembly (12) on
axle bracket with nuts (9). Ensure sensor marked "CTR" is installed in the right (outboard) hole of
the axle bracket and the sensor marked "LT" is installed in the left (inboard) hole. Do not fully
tighten nuts (9) at this time, so adjustment bracket (10) can be moved.
NOTE
To identify the sensors of the axle proximity sensor assembly, the wires
are marked with an ID tag near the electrical connector.
(2) Insert screws (6) through holes in adjustment brackets (10), install ground wires for EMI shields (8)
and nuts (5) on screws (6), and turn screws (6) into axle bracket as far as possible. Do not tighten
nuts (5) at this time.
(3) Route wires of proximity sensor assembly (12) over axle and secure to axle studs with clamps (4),
washers (3), lockwashers (2), and nuts (1).
(4) Connect electrical connector for proximity sensor assembly (12) to carrier electrical harness.
(5) Adjust sensors for front axle proximity sensor assembly (12), refer to Adjustment procedures below.
b. Install rear axle proximity sensor assembly (25, Figure 2-4-3) as follows:
(1) Install adjustment brackets (23), washers (26), and sensors for proximity sensor assembly (25) on
axle brackets with nuts (22). Ensure sensor marked "CTR" is installed in the right (outboard) hole of
the right axle bracket, the sensor marked "LT" is installed in the left (inboard) hole, and the sensor
marked "LK" is installed in the right axle bracket. Adjust nuts (24 and 22) until a clearance of 0.25 in.
(6.4 mm) min. is obtained between the bottom of sensors marked "CTR" and "LT", and the steering
arm. Do not fully tighten nuts (22) at this time, so adjustment bracket (23) can be moved.
NOTE
To identify the sensors of the axle proximity sensor assembly, the wires
are marked with an ID tag near the electrical connector.
(2) Insert screws (19) through holes in adjustment brackets (23), install ground wires for EMI shields
(21) and nuts (18) on screws (19), and turn screws (19) into axle bracket as far as possible. Do not
tighten nuts (18) at this time.
(3) Route wires of proximity sensor assembly (25) over axle and secure to axle studs with clamps (17),
washers (16), lockwashers (15), and nuts (14).
(4) Connect electrical connector for proximity sensor assembly (25) to carrier electrical harness.
(5) Adjust sensors for rear axle proximity sensor assembly (25), refer to Adjustment procedures below.
2-4-14
TM 5-3810-307-24-1-1
LEGEND
2-4-15
TM 5-3810-307-24-1-1
2-4-16
TM 5-3810-307-24-1-1
Adjustment
a. Adjust sensors for front axle proximity sensor assembly (12, Figure 2-4-3) as follows:
(3) Ensure carrier cab ignition switch is in OFF position, and place superstructure cab ignition switch is
in ACC position, so FRONT AXLE STEERING indicator lights on superstructure dash panel can be
monitored.
(4) Turn screw (6) of sensor marked "CTR" out until sensor is over solid portion of the steering arm and
not over the hole in the arm.
(5) If CENTER indicator light on dash panel is off, loosen nuts (11 and 9) and adjust "CTR" sensor up
(away from steering arm) until light comes on. If CENTER indicator light is on, continue with next
step.
(6) Slowly adjust the "CTR" sensor down (toward steering arm) until CENTER indicator light goes out,
then adjust the sensor down an additional 1/4 turn.
(7) Turn screw (6) of sensor marked "CTR" in until the CENTER indicator light comes on, and mark
position of the leading edge of adjustment bracket (10) on axle bracket.
(8) Continue turning screw (6) of sensor marked "CTR" in until the CENTER indicator light goes off, and
mark position of the leading edge of adjustment bracket (10) on axle bracket.
(9) Turn screw (6) of sensor marked "CTR" out until the leading edge of adjustment bracket (10) is
positioned half way between the two marks. Check that CENTER indicator light is on.
(10) Adjust the "CTR" sensor down until the CENTER indicator light goes out.
(11) Adjust the "CTR" sensor up until the CENTER indicator light comes on, then turn sensor an
additional 1/4 turn up.
(12) Apply LOCTITE 242 to threads of screw (6), hold head of screw (6), and tighten nut (5) to secure
adjustment bracket (10) in place.
(13) Apply LOCTITE 242 to threads of "CTR" sensor, and tighten nuts (9 and 11) to hold sensor in place.
(14) With wheels centered, slide a metal object [1 3/4 in. (4.5 cm) square X 1/8 in. (.318 cm) thick]
between "CTR" sensor and steering arm to cover hole. CENTER indicator light should go out. If
CENTER indicator light stays lit, increase thickness of metal object and recheck light.
(15) Turn screw (6) of sensor marked "LT" out until sensor is over solid portion of the steering arm.
(16) If LEFT indicator light on dash panel is on, loosen nuts (11 and 9) and adjust "LT" sensor up (away
from steering arm) until light goes off. If LEFT indicator light is off, continue with next step.
(17) Slowly adjust the "LT" sensor down (toward steering arm) until LEFT indicator light comes on, then
adjust the sensor down an additional 1 turn.
(18) Turn screw (6) of sensor marked "LT" in until RIGHT indicator light comes on, and mark position of
the leading edge of adjustment bracket (10) on axle bracket.
2-4-17
TM 5-3810-307-24-1-1
(19) Turn screw (6) of sensor marked "LT" out until LEFT indicator light comes on, and mark position of
the leading edge of adjustment bracket (10) on axle bracket.
(20) Turn screw (6) of sensor marked "LT" in until the leading edge of adjustment bracket (10) is half way
between the two marks.
(21) Apply LOCTITE 242 to threads of screw (6), hold head of screw (6), and tighten nut (5) to secure
adjustment bracket (10) in place.
(22) Apply LOCTITE 242 to threads of "LT" sensor, and tighten nuts (9 and 11) to hold sensor in place.
(24) Remove steering wheel lock from carrier cab steering wheel.
(25) Start engine from superstructure cab and position boom over rear of crane. Verify that FRONT
AXLE STEERING CENTER indicator light is lit (front wheels centered). Position FRONT AXLE
STEERING toggle switch to RIGHT, ensure front axle wheels turn in direction shown on pictogram
on right side of switch, CENTER and LEFT indicator lights are out, and RIGHT indicator light comes
on. Position toggle switch to LEFT, ensure front axle wheels turn in direction shown on pictogram on
left side of switch, CENTER and RIGHT indicator lights are out, and LEFT indicator light comes on.
(26) Position EMI shield (8) over sensors and secure in place with clamps (7).
b. Adjust sensors for rear axle proximity sensor assembly (25, Figure 2-4-3) as follows:
(3) Engage rear steering lock cylinder by placing REAR AXLE STEERING LOCK switch on carrier cab
dash panel to LOCKED position.
(4) Adjust "CTR" and "LT" sensors of rear axle by performing step a.(4) thru a.(23) above, except use
REAR AXLE STEERING indicator lights on carrier cab dash panel.
(5) Loosen nuts (22 and 24) on "LK" sensor and adjust sensor to achieve a clearance of 0.31 0.03 in.
(7.9 0.8 mm) between bottom of "LK" sensor and top of rear steering lock cylinder actuator pin.
Tighten nuts (22 and 24) finger tight.
(6) Disengage rear steering lock cylinder by placing REAR AXLE STEERING LOCK switch to
UNLOCKED position. The REAR STEER LOCK ENGAGED indicator light should go out and the
REAR STEER LOCK DISENGAGED light should come on.
(7) Turn screw (19) in until the REAR STEER LOCK ENGAGED indicator light comes on, and mark
position of the leading edge of adjustment bracket (23) on axle bracket.
(8) Turn screw (19) out until the REAR STEER LOCK ENGAGED indicator light goes out and comes on
again, then mark position of the leading edge of adjustment bracket (23) on axle bracket. If REAR
STEER LOCK ENGAGED indicator light never goes out as screw (19) is turned out, adjust "LK"
sensor up (away from steering arm) 1/4 turn and repeat steps (6) and (7).
(9) Turn screw (19) of sensor marked "LK" in until the leading edge of adjustment bracket (23) is half
way between the two marks.
2-4-18
TM 5-3810-307-24-1-1
(10) Apply LOCTITE 242 to threads of screw (19), hold head of screw (19), and tighten nut (18) to secure
adjustment bracket (23) in place.
(11) Apply LOCTITE 242 to threads of "LK" sensor, and tighten nuts (22 and 24) to hold sensor in place.
NOTE
After adjustments are made, the REAR STEER LOCK ENGAGED indicator
light should come on only when the axle is centered and the axle lock cylinder
is extended.
(12) Place REAR AXLE STEERING LOCK switch to the LOCKED position and ensure REAR STEER
LOCK ENGAGED indicator light comes on, and goes out when REAR AXLE STEERING LOCK
switch is placed in the UNLOCKED position.
(13) Start engine from carrier cab. Verify that REAR STEER DIRECTION center arrow indicator light is lit
(rear wheels centered). Position REAR AXLE STEERING toggle switch to RIGHT, ensure rear axle
wheels turn in direction shown on pictogram on right side of switch, center and left arrow indicator
lights are out, and right arrow indicator light comes on. Position toggle switch to LEFT, ensure rear
axle wheels turn in direction shown on pictogram on left side of switch, center and right arrow
indicator lights are out, and left arrow indicator light comes on.
(14) Position EMI shields (21) over sensors and secure in place with clamps (20).
2-4-19
TM 5-3810-307-24-1-1
Removal
b. Tag and disconnect electrical leads from rear axle steering unlock switch (1, Figure 2-4-4).
c. Remove rear axle steering unlock switch (1) and washer(s) (2) from rear steer lock cylinder.
Installation
a. Install washer(s) (2, Figure 2-4-4) and rear steering unlock switch (1) in rear steer lock cylinder.
c. Perform operation check/adjustment of rear steering unlock switch, refer to Operation Check/ Adjustment
procedures.
Operation Check/Adjustment
a. Position battery disconnect switch to ON and place ignition switch in carrier cab to ACC position.
b. Place REAR AXLE STEERING LOCK switch to UNLOCKED position and ensure REAR STEER LOCK
DISENGAGED indicator light is on.
c. Place REAR AXLE STEERING LOCK switch to LOCKED position and ensure REAR STEER LOCK
DISENGAGED indicator light is off.
d. If REAR STEER LOCK DISENGAGED indicator light stays lit, ensure rear steer lock cylinder pin is fully
engaged in steering arm. Pin must be fully engaged for proper operation of switch.
e. If lock pin is fully engaged, and the light is lit, rear steering unlock switch must be adjusted as follows:
(1) Remove switch (1, Figure 2-4-4) and washer(s) (2) from lock cylinder, refer to Removal procedures.
(2) Install another washer (2) and switch (1) in lock cylinder.
(3) Check to see if REAR STEER LOCK DISENGAGED indicator light is now out. If light is out, remove
switch (1), add one more washer (2), install switch (1), and adjustment is complete. If light is still lit,
repeat steps e.(1) thru (3) until light goes out.
2-4-20
TM 5-3810-307-24-1-1
LEGEND
2-4-21
TM 5-3810-307-24-1-1
DESCRIPTION
The size of tires used on this crane are 16.00 x R21. Off-highway tires are designed to operate with a
certain sidewall deflection or bulge. Correct air
CAUTION pressure ensures proper deflection which, in turn,
ensures proper traction, flotation, support of load,
Do not mix tires and rims of different and prevents excessive flexing of the tire. Over
manufacturers. inflation increases rim stresses, which results in
lowered rim life.
Each wheel assembly (tire and rim) weighs
approximately 540 pounds (245 kg) and is mounted Refer to and adhere to the inflation pressures on the
on the planetary hub with 10 M22 lug nuts. Tire Inflation decal on the crane.
NOTE
The tire diameters, widths, and weights may vary slightly depending on
the manufacturer.
MAINTENANCE
NOTE
2-4-22
TM 5-3810-307-24-1-1
BRAKE SYSTEM
DESCRIPTION
The brake system is pneumatically controlled and cab), the service brake relay valves (one for each
can be operated from either cab. The components axle), park brake relay valve, spring brake control
which make up the brake system include the brake valve, brake chambers, and service brakes.
valves and park brake valves (one of each for each
THEORY OF OPERATION
Each wheel end has a spring powered brake will release, applying the brakes.
chamber. This chamber is spring actuated and must
be released by air pressure. The spring brakes The service brakes are applied by air pressure.
(parking brakes) are released by the parking brake Depressing the foot brake pedal on the cab floor
push-pull knob in the cabs. Pushing down on the causes pressurized air to enter the service brake
parking brake causes air pressure to enter the spring chamber on each wheel, applying the brakes. In the
brake chamber on each wheel and compress the event of a loss of supply pressure to the service
spring, releasing the brakes. brakes, the spring brake valve will allow the operator
to release or bleed off the air pressure in the spring
At least 40 psi (275.8 kPa) is required to keep the brake chamber by depressing the foot brake pedal to
parking brake valve engaged. If supply pressure to apply the brakes.
the valve drops below 40 psi (275.8 kPa), the valve
2-4-23
TM 5-3810-307-24-1-1
SERVICE BRAKES
DESCRIPTION
The service brakes are the drum and shoe type. The chamber (power unit) mounted on the brake backing
brakes on the rear axle are single wedge actuated plate. The brakes have automatically adjusting
and the brakes on the front axle are dual wedge plungers that ensure the brakes are properly
actuated. Each wedge is actuated by an air brake adjusted to compensate for brake lining wear.
MAINTENANCE
2-4-24
TM 5-3810-307-24-1-1
Brake Actuator (Expander Unit). 4. Remove the plugs, pins, and springs.
Before installation, coat all moving parts with CLEANING AND INSPECTION.
multipurpose grease, MIL-G-10924.
1. Clean all parts with a non-residue type
The brakes will adjust themselves automatically cleaning solvent.
during operation to a certain diameter with respect to
operating condition. 2. Inspect all parts for wear, scoring, cracks, or
other damage.
2. Remove the clip, spring clip, and brake shoe 3. Install the cage, balls, cup, and springs. Install
locator. the snap ring and the push rod assembly.
3. Remove the adjuster, adjusting ring, and 4. Install the plugs, pins, and spring.
spacer from the piston. Remove the spring washer.
2-4-25
TM 5-3810-307-24-1-1
LEGEND
2-4-26
TM 5-3810-307-24-1-1
Removal
a. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.
b. Tag and disconnect air lines from connectors (5, Figure 2-4-7) and tee (9).
c. Back off counter nut (1) and unscrew brake chamber assembly (2) from wheel.
d. Back off counter nut (3) and unscrew brake chamber assembly (4) from wheel.
e. If necessary, remove connectors (5), adapters (6), washers (7), o-rings (8), and counter nut (1) from brake
chamber assembly (2).
f. If necessary, remove tee (9), adapter (10), washer (11), o-ring (12), and counter nut (3) from brake
chamber assembly (4).
Repair
a. Disassemble brake chamber assembly (2, Figure 2-4-7) as necessary to replace damaged, worn, and
defective components.
(1) Loosen clamps (13), and remove hose (14) and clamps (13) from cover (20) and brake chamber
cylinder (19).
WARNING
Brake chamber assembly is adjusted to have spring tension. Personal
injury may occur if tension is not released prior to removing clamp and
separating cover from cylinder.
(2) Release spring tension on brake chamber assembly (2) by backing spring release bolt (15) out of
brake chamber cylinder (19) to a minimum length of 3.08 in. (78 mm) from back of chamber body to
top of bolt head.
(3) Match mark cover (20) to brake chamber cylinder (19), remove nuts (16), capscrews (17), clamp
halves (18), and separate brake chamber cylinder (19) and cover (20).
(6) Remove snap ring (23) and guide (24) from cover (20).
(8) Remove snap ring (26), bushing (27), and collar (28) from cover (20).
2-4-27
TM 5-3810-307-24-1-1
(2) Position collar (28) and bushing (27) in cover (20), and secure with snap ring (26).
(3) Install o-ring (25) on guide (24), position guide (24) in cover (20), and secure with snap ring (23).
(4) Install piston (22) in cover (20) so that shaft of piston passes through guide (24) and contacts collar
(28).
(5) Install diaphragm (21) in brake chamber cylinder (19), carefully position cover (20) on brake
chamber cylinder (19) as marked during removal, and secure together with clamp halves (18),
capscrews (17), and nuts (16).
(6) Install hose (14) on brake chamber cylinder (19) and cover (20), and secure both ends with clamps
(13).
c. Disassemble brake chamber assembly (4, Figure 2-4-7) as necessary to replace damaged, worn, and
defective components.
WARNING
Brake chamber assembly is assembled with spring tension. Maintain
pressure on cover and cylinder, and slowly release spring tension when
removing clamp and separating cover from cylinder. Failure to observe
this warning could result in personal injury.
(1) Match mark cover (34) to brake chamber cylinder (33), hold cover (34) and cylinder (33) together,
remove nuts (30), capscrews (31), clamp halves (32), and slowly separate brake chamber cylinder
(33) and cover (34).
(3) Remove piston (35) and spring (36) from cover (34).
(4) Remove snap ring (38) and guide (39) from cover (34).
(6) Remove snap ring (41), bushing (42), and collar (43) from cover (34).
(2) Position collar (43) and bushing (42) in cover (34), and secure with snap ring (41).
(3) Install o-ring (40) on guide (39), position guide (39) in cover (34), and secure with snap ring (38).
(4) Position spring (36) and piston (35) in cover (34) so that shaft of piston passes through guide (39).
2-4-28
TM 5-3810-307-24-1-1
(5) Install diaphragm (37) in brake chamber cylinder (33), carefully position brake chamber cylinder (33)
on piston (35), press brake chamber cylinder (33) and cover (34) together while aligning match
marks, and secure together with clamp halves (32), capscrews (31), and nuts (30).
Installation
a. If removed, install new o-ring (12, Figure 2-4-7), washer (11), adapter (10), and tee (9) in brake chamber
assembly (4).
b. If removed, screw counter nut (3) onto brake chamber assembly (4) with castellations toward brake
chamber body. Screw nut on as far as it will go.
c. Apply LOCTITE 565 to threads of brake chamber assembly (4). Then screw brake chamber assembly (4)
into brake expander housing until it bottoms
d. Back out brake chamber assembly (4) no more than 1 turn to correctly orient air connections as shown in
Figure 2-4-7.
e. Screw counter nut (3) down to brake expander housing and torque nut to 105-135 lbs-ft (142-183 Nm).
f. If removed, install new o-rings (8), washers (7), adapters (6), and connectors (5) in brake chamber
assembly (2).
g. If necessary, cage parking brake spring on brake chamber assembly (2) by backing spring brake release
bolt (15) out of brake chamber cylinder (19) to a minimum length of 3.08 in. (78 mm) as measured from back of
chamber body to top of bolt head.
h. If removed, screw counter nut (1) onto brake chamber assembly (2) with castellations toward brake
chamber body. Screw nut on as far as it will go.
i. Apply LOCTITE 565 to threads of brake chamber assembly (2). The screw brake chamber assembly (2)
into brake expander housing until it bottoms.
j. Back out brake chamber assembly (2) no more than 1 turn to correctly orient air connections as shown in
Figure 2-4-7.
k. Screw counter nut (1) down to brake expander housing and torque nut to 105-135 lbs-ft (142-183 Nm).
l. Tension spring (to set parking brake) in brake chamber assembly (2) by turning spring release bolt (15)
into brake chamber cylinder (19) to a maximum dimension of 1.02 in. (26 mm) from back of chamber body to top
of bolt head.
m. Connect air lines to connectors (5) and tee (9). Remove tags.
2-4-29
TM 5-3810-307-24-1-1
LEGEND
2-4-30
TM 5-3810-307-24-1-1
2-4-31
TM 5-3810-307-24-1-1
2-4-32
TM 5-3810-307-24-1-1
Removal
a. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.
b. Tag and disconnect air lines from connectors (3, Figure 2-4-8).
c. Back off counter nut (1) and unscrew brake chamber assembly (2) from wheel.
d. If necessary, remove connectors (3), adapters (4), washers (5), o-rings (6), and counter nut (1) from brake
chamber assembly (2).
Repair
a. Disassemble brake chamber assembly (2, Figure 2-4-8) as necessary to replace damaged, worn, and
defective components.
(1) Loosen clamps (7), and remove hose (8) and clamps (7) from elbow (24) and brake chamber
cylinder (13).
WARNING
Brake chamber assembly is adjusted to have spring tension. Personal
injury may occur if tension is not released prior to removing clamp and
separating cover from cylinder.
(2) Release spring tension on brake chamber assembly (2) by backing spring release bolt (9) out of
brake chamber cylinder (13) to a minimum length of 3.08 in. (78 mm) from back of chamber body to
top of bolt head.
(3) Match mark cover (14) to brake chamber cylinder (13), remove nuts (10), capscrews (11), clamp
halves (12), and separate brake chamber cylinder (13) and cover (14).
(6) Remove snap ring (17) and guide (18) from cover (14).
(8) Remove snap ring (20), bushing (21), and collar (22) from cover (14).
2-4-33
TM 5-3810-307-24-1-1
(3) Position collar (22) and bushing (21) in cover (14), and secure with snap ring (20).
(4) Install o-ring (19) on guide (18), position guide (18) in cover (14), and secure with snap ring (17).
(5) Install piston (16) in cover (14) so that shaft of piston passes through guide (18) and contacts collar
(22).
(6) Install diaphragm (15) in brake chamber cylinder (13), carefully position cover (14) on brake
chamber cylinder (13) as marked during removal, and secure together with clamp halves (12),
capscrews (11), and nuts (10).
(7) Install hose (8) on brake chamber cylinder (13) and elbow (24), ensuring hose passes through hole
in cylinder flange, and secure both ends with clamps (7).
Installation
a. If removed, install new o-rings (6, Figure 2-4-8), washers (5), adapters (4), and connectors (3) in brake
chamber assembly (2).
b. If necessary, cage parking brake spring on brake chamber assembly (2) by backing spring brake release
bolt (9) out of brake chamber cylinder (13) to a minimum length of 3.08 in. (78 mm) as measured from back of
chamber body to top of bolt head.
c. If removed, screw counter nut (1) onto brake chamber assembly (2) with castellations toward brake
chamber body. Screw nut on as far as it will go.
d. Apply LOCTITE 565 to threads of brake chamber assembly (2). The screw brake chamber assembly (2)
into brake expander housing until it bottoms.
e. Back out brake chamber assembly (2) no more than 1 turn to correctly orient air connections as shown in
Figure 2-4-8.
f. Screw counter nut (1) down to brake expander housing and torque nut to 105-135 lbs-ft (142-183 Nm).
g. Tension spring (to set parking brake) in brake chamber assembly (2) by turning spring release bolt (9) into
brake chamber cylinder (13) to a maximum dimension of 1.02 in. (26 mm) from back of chamber body to top of
bolt head.
2-4-34
TM 5-3810-307-24-1-1
LEGEND
AIR VALVES
DESCRIPTION
The air valves used in the brake system are the control valve. These valves control the application
brake valves, park brake valves, service brake relay and release of the service brakes and parking
valves, park brake relay valve, and the spring brake brakes and are all a part of the cranes air system.
NOTE
For more detailed information concerning the air valves used in the
crane's brake system refer to Section 7 - AIR SYSTEM.
2-4-36
TM 5-3810-307-24-1-1
SECTION 5
STEERING SYSTEM
TABLE OF CONTENTS
Page
2-5-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
2-5-2 C-1
TM 5-3810-307-24-1-1
STEERING SYSTEMS
DESCRIPTION
The crane is equipped with four steering systems, FRONT AXLE STEERING FROM THE SUPER-
one for steering the front axle from the carrier, one STRUCTURE.
for steering the rear axle from the carrier, one for
steering the front axle from the superstructure, and The system for steering the front axle from the
one for steering the rear axle from the superstructure consists of the third section of the
superstructure. hydraulic pump, the integrated outrigger valve,
double selector valve, and front steer cylinders. This
FRONT AXLE STEERING FROM THE CARRIER. system is primarily used for maneuvering the crane
into tight areas on the job site and is operated by the
The system for steering the front axle from the carrier FRONT AXLE STEERING control switch on the front
consists of the steering pump, single selector valve, console.
double selector valve, miter gear, front steering gear,
and front steer cylinders. This system is primarily The steering mode control handle must be pulled out
used for roading the crane and is operated by the to steer the front axle from the superstructure.
steering wheel in the carrier cab.
REAR AXLE STEERING FROM THE SUPER-
The steering pump is driven by the engine. The STRUCTURE.
single selector valve and the double selector valve
are mechanically linked and operate together. The The system for steering the rear axle from the
two valves are controlled by the steering mode superstructure consists of the steering pump, single
control handle. The handle must be pushed in to selector valve, steering control valve, steer reversing
steer the front axle from the carrier. The miter gear solenoid, steer selector valve, and the rear steer
transmits the mechanical force from the steering cylinders. This system is used for job site travel and
column in the cab at a 90 degree angle to the is operated by the steering wheel in the
steering gear which is connected to the wheels superstructure cab.
through the drag link and tie rod. The steering gear
also directs hydraulic flow to the applicable side of The steering pump feeds the system through the
the front steer cylinders which provides the power single selector valve. The steering mode control
assistance for steering. handle must be pulled out to steer the rear axle from
the superstructure.
REAR AXLE STEERING FROM THE CARRIER.
The steer reversing solenoid is located on the
The system for steering the rear axle from the carrier electrical swivel and the steer selector valve is
consists of the steering pump, single selector valve, located in the turntable center section. The purpose
steering selector valve, steer control valve, and the of these components is to reverse the direction of the
rear steer cylinders. The system is used only at low hydraulic flow to the steer cylinders in accordance
speed to provide the additional maneuverability with the position of the superstructure. This means
needed when steering the crane into a tight area for that the crane will turn in the direction the steering
parking or when near a job site. The function is wheel is turned whether the superstructure is facing
operated by the REAR AXLE STEERING control the front or rear of the carrier.
switch on the front console.
THEORY OF OPERATION
front steering gear. The mechanical input to the valve to the appropriate ends of the front axle steer-
steering gear shifts the internal valving within the ing cylinders.
gear which routes hydraulic flow from the steering
gear through the double selector valve to the REAR AXLE STEERING FROM THE SUPER-
applicable ends of the front steer cylinders as STRUCTURE.
determined by the positioning of the steering wheel
in the cab. For rear axle steering from the superstructure the
steering mode control handle must be pulled out.
REAR AXLE STEERING FROM THE CARRIER.
Hydraulic flow for steering is provided by the steering
The steering mode selector must be in the CARRIER pump. Flow from the pump is routed through the
position (handle pushed in) to enable steering single selector valve, through the swivel to the steer-
control. ing control valve. The steering control valve routes
flow through the steer selector valve, through the
Hydraulic flow for steering is provided by the steering swivel to the appropriate ends of the steer cylinders
pump. Flow from the pump is routed through the as selected by the steering wheel in the cab.
single selector valve to the steer control valve, and
steering selector valve to the appropriate ends of the The steer selector valve is actuated by the steer
steer cylinders as selected by the REAR AXLE reversing switch. With the superstructure over the
STEERING control switch on the console. As the rear of the crane carrier the valve is de-energized.
switch is positioned to the left or right, the Turning the steering wheel to the right will turn the
appropriate solenoid on the steer control valve is wheels to the right and turning the wheel to the left
energized to actuate steering in the same direction. will turn the wheels to the left. This causes the crane
A gauge on the console indicates the positioning of to turn in the direction the steering wheel is turned.
the wheels. Rotating the superstructure over the front of the
carrier actuates the steer reversing solenoid, which
FRONT AXLE STEERING FROM THE SUPER- in turn energizes the solenoid in the steer selector
STRUCTURE. valve and shifts the valve spool. This reverses the
flow of oil to the steer cylinders on the rear axle thus
For front axle steering from the superstructure the turning the steering wheel to the right will turn the
steering mode control handle must be pulled out. wheels to the left and turning the steering wheel to
the left will turn the wheels to the right. This allows
Hydraulic flow is provided by the third section of the the crane to turn in the direction the steering wheel is
hydraulic pump. Flow from the pump is routed to the turned whether the superstructure is facing the front
integrated outrigger valve. As the control switch in or the rear of the carrier.
the cab is positioned to the left or right, the
applicable solenoid on the integrated outrigger valve
is energized and hydraulic oil is routed through the
double selector
MAINTENANCE
2-5-4
TM 5-3810-307-24-1-1
2-5-5
TM 5-3810-307-24-1-1
STEERING GEAR
DESCRIPTION
The Z.F. Steering Gear is a semi-integral power against axial thrust by means of two anti-friction
steering unit that directs the steering fluid to the steer bearings. The control valve is installed across in the
cylinders in response to the movement of the piston. The valve is composed of a valve spool and
steering wheel. The steering housing contains the two fixed reaction pistons. One finger of the steering
control valve, a complete mechanical steering gear, nut fits snugly into the bore of the valve spool. The
and it is at the same time the operating cylinder of piston and the sector shaft are positively connected
the piston. The worm and the steering nut are by a gearing. Due to a special tooth shape on the
connected by an endless chain of balls. The balls sector shaft, their axial adjustment is possible. This
are returned via a recirculating tube. The steering ensures clearance free operation in the straight
nut is maintained clearance free ahead travel range.
THEORY OF OPERATION
In the neutral position of the valve, the oil pressure in Consequently the oil pressure is now supplied to
the right and the left cylinder chambers is balanced. only one of the two cylinder chambers. The piston
By moving the valve spool from the neutral position, assists the worm rotation. A compression spring
a pressure difference is produced between the left arranged in the steering nut causes the return of the
and the right cylinder chambers. The piston will steering nut, and also the valve spools, to neutral
receive more oil pressure on one side, and the position. The return to neutral, is also assisted by a
hydraulic power assistance is operative. The valve design function called hydraulic reaction. Two
is actuated by a rotation of the steering wheel, or by hydraulic pistons are mounted to float in bores of the
the forces which coming from the road wheels, act valve spool, and secured against axial movement by
through the sector shaft and piston on the steering locking plates. The outside faces of the two reaction
nut and worm. Any rotation of the worm means an pistons are permanently pressurized in the operating
axial movement of the piston, and a radial movement position of the valve. Likewise only one of the two
of the output shaft. This operation causes the valve faces in the bores of the valve spool are pressurized
spools to be moved by the finger on the steering nut. with oil. This causes a hydraulic reaction force which
is trying to return the valve spool to the neutral
position.
MAINTENANCE
2-5-6
TM 5-3810-307-24-1-1
NOTE
2-5-7
TM 5-3810-307-24-1-1
2-5-8
TM 5-3810-307-24-1-1
2-5-9
TM 5-3810-307-24-1-1
MITER GEAR
DESCRIPTION
The miter gear is located at the front of the carrier. It steering column at a 90 degree angle to the steering
is connected to the carrier steering column and the gear. The miter gear is necessary because the
steering gear by relay shafts. The miter gear is used distance and angles between the steering column
to transmit mechanical turning power from the and the steering gear make a direct link impossible.
MAINTENANCE
NOTE
REMOVAL. INSTALLATION.
1. Remove the bolt, nut, and washer securing the 1. Position the miter gear on the mounting
steering column relay shaft to the miter gear and bracket and secure in place with the bolts, nuts, and
disconnect the shaft. washers. Torque the bolts to 75 pounds-foot (102
Nm).
2. Remove the bolt, nut, and washer securing the
steering gear relay shaft to the miter gear and 2. Connect the relay shafts to the miter gear and
disconnect the shaft. secure in place with the bolts, nuts, and washers.
Refer to RELAY SHAFT ALIGNMENT. Torque the
3. Remove the bolt, nuts, and washers securing bolts to 35 pounds-foot (47 Nm).
the miter gear to the mounting bracket and remove
the miter gear.
2-5-10
TM 5-3810-307-24-1-1
2-5-11
TM 5-3810-307-24-1-1
SELECTOR VALVES
DESCRIPTION
The single selector valve and the double selector actuated when the valve linkage is in the
valve are located on the inner rail near the center of superstructure steering mode. The switch
the carrier frame. The two valves are mechanically illuminates an indicator light in the carrier cab to
connected and are used to select the mode of signify that the control handle is in the superstructure
steering (carrier or superstructure). The mechanical mode and the crane cannot be steered from the
linkage is connected to a control cable which is carrier.
operated by a handle mounted beside the hydraulic
reservoir. For more detailed information concerning the valves,
refer to VALVES in Section 8 - HYDRAULIC
Incorporated in the linkage is a switch that is SYSTEM.
MAINTENANCE
CABLE ADJUSTMENT. 2. Remove the bolt from the rod end of the cable
at the steering valve mechanism. Position the
1. Position the steering selector valve to the mechanism so the upper and lower steering valve
carrier position by pushing in on the control handle. spools are bottomed out against the snap rings.
Turn the handle to the horizontal position to lock the
cable and engage the mechanical lock. 3. Adjust the cable rod end so the attach bolt will
just fit. Lengthen the rod end by one full turn and
tighten the jam nut.
NOTE
4. Adjust the switch so the steering disconnected
Ensure the cable jam nut is adjusted so light in the carrier cab is out when the valves are in
the control handle is in the horizontal the carrier steering mode and the light illuminates
position when locked. when moved from the carrier steering position.
2-5-12
TM 5-3810-307-24-1-1
2-5-13
TM 5-3810-307-24-1-1
STEERING PUMP
DESCRIPTION
The steering pump is mounted on the torque system, and the parking brake. The pump is a gear
converter and driven by the engine. It provides the type pump and provides a priority flow of
hydraulic flow necessary to power the front steer approximately 8 gpm. (30.2 lpm) at 2500 psi
cylinders, the brake system, the axle lockout (17237.5 kPa).
MAINTENANCE
NOTE
REMOVAL. INSTALLATION.
1. Thoroughly clean the area around the steering 1. Install the drive gear, lockwasher, and nut onto
pump. the pump. Torque the nut 121 to 147 pounds-foot
(164 to 199 Nm).
2. Disconnect both hoses from the pump. Cap
the hoses and pump connections. 2. Place the pump and drive gear onto the
mounting pad. Ensure the steel spacer is between
3. Remove the two bolts and lockwashers the two gaskets. Secure the pump in place with the
securing the pump. two bolts and washers. Torque the bolts 70 to 84
pounds-foot (95 to 114 Nm).
4. Remove the pump and drive gear. Cover the
mounting pad. 3. Connect the hydraulic lines to the pump as
tagged during REMOVAL.
5. Remove the nut, lockwasher, and drive gear
from the pump. 4. Function test the pump and check for proper
operation and any leakage.
2-5-14
TM 5-3810-307-24-1-1
2-5-15
TM 5-3810-307-24-1-1
DESCRIPTION
The front axle steering from the superstructure circuit control switch in the superstructure cab.
utilizes a working section of the integrated outrigger
valve as a control valve. The valve section is con- For more information on the valve refer to VALVES
trolled electrically by the FRONT AXLE STEERING in Section 8 - HYDRAULIC SYSTEM.
2-5-16
TM 5-3810-307-24-1-1
STEER CYLINDERS
DESCRIPTION
Four steer cylinders are utilized on the crane, two on Each set of steering cylinders are connected hydrau-
the front axle and two on the rear axle. The steer lically so the rod end of one cylinder is connected to
cylinders have a 2.76-inch (7.0 cm) cylinder bore the barrel end of the other thus providing dual
with an extended length of 28.35 inches (72.0 cm) cylinder action for steering the axle in either
and a retracted length of 18.5 inches (47.0 cm). direction.
MAINTENANCE
NOTE
REMOVAL. INSTALLATION.
1. Tag and disconnect the hydraulic hoses from 1. Position the steer cylinder (Figure 2-5-7) onto
the steer cylinder ports (Figure 2-5-7). Cap or plug the axle and secure in place with the cotter pins and
all openings. castle nuts.
NOTE
2. Connect the hydraulic hoses to the cylinders
Wheel and axle alignment will be easier as tagged during removal.
if the tie rod ends are not unscrewed
from the steer cylinder. 3. Function the cylinders and check for proper
operation and any leakage.
2. Remove the cotter pins and castle nuts
securing the steer cylinders to the axles. Remove
the cylinders.
2-5-17
TM 5-3810-307-24-1-1
2-5-18
TM 5-3810-307-24-1-1
DESCRIPTION
The steering system incorporates a ground driven valve which normally returns the oil to the hydraulic
emergency (standby) steering pump which is reservoir. The standby valve is spooled so that in
mounted on the rear of the transmission. As long as the event of an engine failure or main steering pump
the transmission is turning (crane moving), the failure, the hydraulic oil flow produced by the
emergency steering pump will pump hydraulic oil. emergency steering pump is directed to the front
The hydraulic flow is controlled by the standby axle steering circuit which will allow the operator to
safely steer the crane while the crane is moving.
MAINTENANCE
Removal
(1) Tag and disconnect electrical leads from emergency steering valve (4, Figure 2-5-8).
(2) Place a suitable drain pan under emergency steering valve (4) to catch residual oil.
(3) Tag and disconnect hydraulic lines from fittings on emergency steering valve (4). Cover open ends
of lines and fittings.
(4) Remove capscrews (1), washers (2), lockwashers (3), and nuts (5) securing emergency steering
valve (4).
(5) If necessary, remove elbows (6, 8, and 10) and o-rings (7, 9, and 11) from connectors (12, 13, and
14).
(6) If necessary, remove connectors (12, 13, 14, and 15), washers (16, 18, and 19), crush washer (17),
and o-rings (20, 21, and 22) from emergency steering valve (4).
(1) Drain oil from hydraulic tank and place suitable drain pan under emergency steering pump (29,
Figure 2-5-8) to catch residual oil.
(2) Remove capscrews (23), flange halves (24), hydraulic hose (25), and o-ring (26) from emergency
steering pump (29).
(3) Tag and disconnect remaining hydraulic hoses from elbows (38 and 40) and adapter (39). Cover
open ends of lines and fittings.
(4) Remove capscrews (27), washers (28), pump (29), and gasket (30) from spacer (32).
(5) Remove splined adapter (41) from shaft of pump (29) or transmission if it did not come out with
pump.
2-5-19
TM 5-3810-307-24-1-1
(6) If necessary, remove socket head screws (31), spacer (32), and gasket (33) from transmission.
(5) If necessary, remove capscrews (34), washers (35), relief valve (36), and flow regulator (37) from
pump (29).
(6) If necessary, remove elbow (38) from relief valve (36), adapter (39) from flow regulator (37), and
elbow (40) from pump (29).
Installation
(1) If removed, install new o-rings (20, 21, and 22, Figure 2-5-8), washers (16, 18, and 19), new crush
washer (17), and connectors (12, 13, 14, and 15), on emergency steering valve (4).
(2) If removed, install new o-rings (7, 9, and 11) and elbows (6, 8, and 10) on connectors (12, 13, and
14).
(3) Position emergency steering valve (4) near mount and start hydraulic line, as tagged, on connector
(15). Do not tighten hydraulic line at this time.
(4) Secure emergency steering valve (4) on frame mount with capscrews (1), washers (2), lockwashers
(3), and nuts (5).
(5) Remove covers, connect, and tighten hydraulic lines to fittings on emergency steering valve (4) and
remove tags.
(6) Connect electrical leads to emergency steering valve (4) and remove tags.
(1) If removed, install elbow (40, Figure 2-5-8) in emergency steering pump (29), adapter (39) in flow
regulator (37), and elbow (38) in relief valve (36).
(2) If removed, install flow regulator (37) and relief valve (36) on pump (29) with washers (35) and
capscrews (34).
(3) If removed, apply LOCTITE 518 to gasket (33), and install gasket (33) and spacer (32) on
transmission with socket head screws (31).
(4) Install splined adapter (41) on shaft of pump (29), apply LOCTITE 518 to gasket (30) and install
gasket (30) and pump (29) on spacer (32) with washers (28) and capscrews (27).
(5) Position o-ring (26) and hydraulic hose (25) on pump (29) and secure in place with flange halves
(24) and capscrews (23).
(6) Connect hydraulic hoses to elbows (38 and 40) and adapter (39). Remove tags.
2-5-20
TM 5-3810-307-24-1-1
LEGEND
2-5-21
TM 5-3810-307-24-1-1
2-5-22
TM 5-3810-307-24-1-1
Removal
a. Install new check valve (3, Figure 2-5-9) on straight adapter (4).
b. Install adapter (2) and manifold (1).
c. Connect four hydraulic lines to manifold (1) as tagged. Remove tags.
d. Remove tie wraps securing hydraulic hoses out of the way.
4 3 2
SECTION 6
AXLE OSCILLATION SYSTEM
TABLE OF CONTENTS
Page
LIST OF FIGURES
Number Title Page
2-6-1/(2-6-2 Blank)
TM 5-3810-307-24-1-1
DESCRIPTION
The axle oscillation system allows both the front and electrical swivel and the micro switch is mounted on
rear axles to oscillate under certain conditions. The the boom rest.
system consists of four oscillation lockout cylinders,
two double solenoid valves, an area definition switch, The two double solenoid valves control hydraulic oil
and a micro switch. An oscillation lockout cylinder is flow between the oscillation lockout cylinders. One
mounted at each end of both axles. The double valve controls flow between the two front cylinders and
solenoid valves are located at the center of the carrier the other valve controls flow between the two rear
frame, one forward of the swivel and one to the rear of cylinders. The double solenoid valves are controlled
the swivel. The area definition switch is located on the by the area definition switch and the micro switch.
THEORY OF OPERATION
With the superstructure facing the front and the boom With the superstructure facing directly over the rear,
in the boom rest, the micro switch on the boom rest is the area definition switch on the electrical swivel
closed. When closed, the micro switch activates both activates the double solenoid valve that controls the
double solenoid valves allowing the front and rear front oscillation lockout cylinders allowing the front axle
axles to oscillate. As soon as the boom is raised from to oscillate. As soon as the superstructure rotates
the boom rest, the contacts on the micro switch open, more than 6 degrees in either direction from directly
thus deactivating the solenoid valves and locking both over the rear, the area definition switch deactivates the
axles. double solenoid valve and causes the front axle to
lock.
2-6-3
TM 5-3810-307-24-1-1
LOCKOUT CYLINDERS
DESCRIPTION
Two 3.5-inch (8.9-cm) hydraulic lockout cylinders are each side of the axle. The lockout cylinders are
installed on each axle, one left and one right. The connected hydraulically so that hydraulic oil flows from
base end of each cylinder is attached to each side of the left cylinder to the right cylinder and from the right
the carrier frame and the rod ends are attached to cylinder to the left cylinder.
MAINTENANCE
NOTE nut, lockwasher, and cotter pin securing the barrel end
to the fitting on the frame.
Refer to CYLINDERS in Section 8 for
disassembly and assembly procedures. 8. Tap out the retaining pin and remove the
cylinder.
REMOVAL.
INSTALLATION.
1. Raise the crane up on outriggers.
1. Position the barrel end of the cylinder in the
2. Raise the boom enough to deactivate the micro frame attach fitting and tap in the shaft (Figure 2-6-1).
switch on the boom rest and lock out the oscillation
cylinders. 2. Install the cotter pin, nut, bolt, and lockwasher.
Torque the bolt to 75 pounds-foot (102 Nm).
3. Remove the wheel.
3. Align the rod end of the cylinder in the fitting on
4. Tag and disconnect both hydraulic hoses from the axle and tap in the shaft.
the ports on the cylinder (Figure 2-6-1). Cap both
hoses and the ports on the cylinder. 4. Install the cotter pin, lockwasher, bolt, and nut.
Torque the bolt to 75 pounds-foot (102 Nm).
5. At the rod end of the cylinder, remove the bolt,
nut, lockwasher, and cotter pin securing the retaining 5. Connect the two hydraulic hoses to the
pin to the fitting on the axle. appropriate ports on the cylinder, and bleed cylinder.
Refer to Section 4 - AXLES.
6. Tap out the retaining pin, freeing the rod end
from the cradle fitting. 6. Install the wheel and follow the proper tightening
sequence. Refer to Section 4 - AXLES.
7. At the barrel end of the cylinder, remove the bolt,
7. Grease both ends of the cylinder using the
fittings provided.
2-6-4
TM 5-3810-307-24-1-1
2-6-5
TM 5-3810-307-24-1-1
DESCRIPTION
The double solenoid valves are located to the front and an area definition switch. For more detailed
rear of the swing bearing on the center of the carrier information on the double solenoid valve, refer to
frame. The valves are actuated by a micro switch and VALVES in Section 8.
MAINTENANCE
REMOVAL. INSTALLATION.
1. Tag and disconnect the hydraulic hoses from the 1. Position the valve on the mounting bracket and
ports on the solenoid valve (Figure 2-6-2). Cap or plug secure with bolts, lockwashers, and nuts (Figure 2-6-
all openings. 2).
2. Remove the two nuts, lockwashers, and bolts 2. Connect the hydraulic hoses to the appropriate
securing the valve to the mounting bracket and remove ports on the valve.
the valve.
SECTION 7
AIR SYSTEM
TABLE OF CONTENTS
Page
2-7-1 C-1
TM 5-3810-307-24-1-1
2-7-2 C-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
LIST OF TABLES
Title Page
2-7-3 C-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-7-5
Before removing or disconnecting any component or line of the air
system, ensure that all air pressure in both systems has been depleted.
WARNING 2-7-5
Before attempting to remove any components for leak repair, ensure that
all air pressure in both air systems has been depleted.
WARNING 2-7-11
Before removing any air lines for component maintenance, bleed the air
from the primary and secondary systems.
2-7-17
WARNING
Disconnect the batteries prior to loosening the front console screws.
WARNING
There may be residual pressure in air lines after air reservoirs are 2-7-34
drained. Wear eye protection when disconnecting air lines or components 2-7-36
to prevent injury.
2-7-4 C-1
TM 5-3810-307-24-1-1
AIR SYSTEM
DESCRIPTION
The air system provides the air supply to operate the and the primary supply reservoir. When the
service brakes, the differential locks, the engine governor is on an unload cycle, the air dryer
throttle, and the rear steering lock. The air system functions to remove water and oil vapor from the air.
also provides air to the trailer air couplings, the rear
air supply coupling, and the tire inflation couplings. An alcohol evaporator is installed below the primary
supply reservoir and connected between the
The air system is pressurized by an air compressor secondary and auxiliary air reservoirs. As
mounted on the engine. The air pressure generated compressed air from the secondary air reservoir
by the compressor is stored in three air reservoirs passes through the evaporator, alcohol is evaporated
mounted to the carrier frame. From these reservoirs, into the air to act as antifreeze to keep any moisture
air is provided for operation of the above mentioned in the air from freezing and causing air actuated
components. components in auxiliary air circuit from locking up.
A dual air pressure gauge is provided in each cab to The air system is a split system wherein the primary
monitor air pressure in the system. The red arrow and secondary systems are isolated from each other
indicates primary air pressure (primary supply under normal operation. Therefore, in the event of
reservoir), while the green arrow indicates secondary the failure of one system, air is retained in the other
pressure (secondary and auxiliary air reservoirs). and, by means of the pressure protection valves, and
check valves, a reserve of air pressure remains to
An air dryer is installed beside the primary supply operate the brakes through normal use of the brake
reservoir, and is connected between the compressor pedal. Any unusual loss of pressure should be
investigated immediately and corrected, so as to
restore the full back-up capability of the system.
MAINTENANCE
All connecting lines of the air system are either tubing LEAK DETECTION.
or flexible hoses. All tubing in the system is nylon,
except that from the compressor to the air dryer. If a leak is suspected in the air system, shut down
the engine and record the pressure readings of the
green and red arrow in the air pressure gauge on the
front console. A loss of 6 psi (41.37 kPa) or less
WARNING within a 30 minute time interval is usually considered
Before removing or disconnecting any acceptable.
component or line of the air system,
If a leak is detected and not obvious, the leaking
ensure that all air pressure in both
valve, fitting, or reservoir may be isolated by wetting
systems has been depleted.
the suspected area with a concentrated liquid soap
CAUTION solution and observing for bubbles.
2-7-5
TM 5-3810-307-24-1-1
NOTE 10. Warning buzzer and light will operate until both
pressure gauge needles show 60 - 70 psi.
Perform the AIR SYSTEM TEST
PROCEDURE as the final step of ANY 11. Release park brakes.
maintenance action. Ensure all
functions are restored to full operational 12. Continue charging air system until air dryer
capability before returning the crane to cycles and compressor shuts off, all system gauges
service. should read 120 10 psi.
2. Raise crane on outriggers. 18. Check that brakes are applied on all wheels,
3. Turn off engine. 19. Release the service brake and check that
existing reservoir pressure is maintained.
4. Drain entire system by opening drain cocks on
the air reservoirs. 20. Start engine and recharge air system.
5. If not already on, park brakes will automatically 21. With engine running, simulate a full air leak in
apply with air pressure drop. the secondary air system by opening the drain cock
on the secondary air reservoir.
6. Check that brakes are applied on all wheels.
22. The low air pressure light and warning buzzer
7. Close drain cocks and start engine. should come on when the air pressure in the
secondary system drops below 70 5 psi.
8. Low Air Pressure light and warning buzzer
should operate immediately. 23. Air pressure in the primary system should not
drop below 85 5 psi.
9. Air will fill the main supply reservoir first,
consequently, the red needle on the dual air gauge 24. Drain secondary air system pressure to 0 psi.
will rise first, pressure will increase to approximately
85 psi, at which time the pressure protection valve 25. With park brakes released, check that all
will open, allowing air to flow into the secondary air wheels can turn.
reservoir and the green needle will then begin to rise.
26. Apply service brakes and hold.
NOTE
27. Front service brakes and rear spring brakes
If required, the pressure protection valve should apply.
pressure setting can be adjusted by
turning the cap; Clockwise to raise the 28. Assure brake lights on rear of machine come
pressure - Counterclockwise to lower the on when service brakes are applied.
pressure.
29. Release service brakes.
2-7-6
TM 5-3810-307-24-1-1
30. Close drain cock on the secondary reservoir 36. Service brakes on rear axles only should
and recharge the air system. apply.
31. Simulate a full air leak in the primary air 37. Assure brake lights on rear of crane come on
system by depressing needle in center of automatic when service brakes are applied.
drain valve on the main supply reservoir.
38. Release service brakes.
32. Low Air Pressure light and warning buzzer will
come on when primary system air pressure drops 39. Check that all wheels can turn freely.
below 70 5 psi. Keep needle on automatic drain
valve depressed. 40. Release needle on automatic drain valve and
recharge primary air system.
33. Secondary system air pressure should not
drop below 85 5 psi. 41. Retract and stow outriggers.
34. Check that all wheels can turn freely. This completes the Air System Test, if all test results
are acceptable, the crane may be returned to
35. Apply service brakes. service.
2-7-7
TM 5-3810-307-24-1-1
DESCRIPTION
NOTE
All air system components will be removed and installed in this Section.
NOTE
Double Check Valve Six places; see diagram; right turntable side plate
Three-way Air Valve, Pilot Left side inner frame near rear
Spring Brake Control Valve Center of frame rail forward of rear axle
Air Pressure Reducing Valve (47 psi) Left inner frame rail at the rear
Air Pressure Reducing Valve (110 psi) Center of frame rail behind front axle
2-7-8
TM 5-3810-307-24-1-1
Low Pressure Switch Mounted to foot brake valves and park brake relay valve
2-7-9
TM 5-3810-307-24-1-1
2-7-10
TM 5-3810-307-24-1-1
MAINTENANCE
AIR GOVERNOR
WARNING
Before removing any air lines for Description
component maintenance, bleed the air
from the primary and secondary The governor, operating in conjunction with the
systems. compressor unloading mechanism, automatically
controls the air pressure in the system between the
NOTE desired, predetermined maximum and minimum
pressures. The compressor runs continually while
Perform the AIR SYSTEM TEST PRO- the engine runs, but the actual compression of air is
CEDURE as the final step of ANY controlled by the governor which stops or starts
maintenance action. Ensure all compression when the maximum or minimum
functions are restored to full operational reservoir pressures are reached. The governor has
capability before returning the crane to a piston upon which air pressure acts to overcome
service. the pressure setting spring and control the inlet and
exhaust valve to either admit or exhaust air to or
from the compressor unloading mechanism.
AIR COMPRESSOR
Removal
NOTE
1. Chock the wheels.
For more detailed information refer to the
applicable SM package. 2. Deplete all pressure in both systems.
5. Tag and disconnect all air, water, and oil lines Service Checks
going to and from the compressor.
Operating Test
6. Remove the two mounting nuts and remove
the compressor from the engine. 1. Start the vehicle engine and build up air
pressure in the system. Check the pressure
Installation registered by the dash gauge or a test gauge at the
time the governor cuts-out, stopping the
1. Position the compressor on the engine and compression of air by the compressor.
secure it with the two mounting bolts.
2-7-11 C-1
TM 5-3810-307-24-1-1
2. With the engine still running, perform a series The air dryer consists of a desiccant cartridge and
of brake applications to reduce the air pressure and a die cast aluminum end cover secured to a
observe the pressure when the governor cuts-in the cylindrical steel outer shell with eight capscrews
compressor. The cut-in pressure is 105 psi (7239 and nuts. The end cover contains a check valve
kPa) Never adjust the governor pressure settings assembly, a safety valve, three threaded air
connections and the purge valve housing
unless they are checked with a gauge that is known
assembly. The removable purge valve housing
to be accurate If it has been determined that the assembly incorporates a purge valve mechanism
pressure settings of the governor must be changed, and a turbo charger cutoff feature that is designed
the procedure is as follows: to prevent loss of engine turbo boost pressure
during the purge cycle of the air dryer. For ease of
a. Unscrew the cover at the top of the serviceability, the desiccant cartridge and
governor. discharge check valve assembly are screw-in type.
The purge valve housing assembly, which includes
b. Loosen the adjusting screw locknut. the heater and thermostat assembly, and the
discharge check valve assembly, is serviceable
from the exterior of the air dryer, while servicing the
c. Turn the adjusting screw counter-
screw-in desiccant cartridge requires removal of
clockwise to raise the pressure settings and the air dryer assembly from the crane.
clockwise to lower the pressure setting.
Removal
d. Tighten the adjusting screw locknut to
lock the adjustment. 1. Chock the wheels.
3. Repeat Step 2 as necessary. 2. Deplete the pressure in both air systems.
Leakage Test 3. Ensure the ignition switch is in the OFF
position.
1. Leakage checks on the governor are made at
its exhaust port in both the cut-in and cut-out 4. Tag and disconnect the air lines from the
positions. In the cut-in position, check the exhaust dryer.
port for inlet valve leakage by applying a soap
solution at the port. Leakage could also be through 5. Disconnect the electrical lead from the bottom
the bottom piston grommet. In the cut-out position, of the dryer.
check the exhaust port to determine leakage at the
exhaust valve seat or stem grommet. In this 6. Remove four bolts, lockwashers, and nuts
position, leakage could also be through the upper attaching the dryer to the chassis frame and remove
piston grommet. the dryer.
2 If the governor does not function as described, 7. If the dryer is to be replaced with a new one,
or if leakage is excessive, it is recommended that it remove the fittings from the dryer ports.
be repaired or replaced. Refer to the Parts Manual.
NOTE
AIR DRYER The dryer does not have to be removed
to disassemble it.
Description
Installation
The function of the air dryer is to collect and
remove air system contaminates in solid, liquid, and 1. Install the fittings in the dryer ports.
vapor form before they enter the brake system. It
provides clean, dry air to the components of the 2. Position the air dryer on the mounting bracket
brake system which increases the life of the system and secure it with the four bolts, lockwashers, and
and reduces maintenance costs. nuts.
2-7-12 C-1
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2-7-13
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2-7-14
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2-7-15
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2-7-16
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NOTE Installation
For more detailed information refer to the 1. Screw the switch into the fitting on the dual
applicable SM package. brake valve. Using a wrench on the hex portion of
the switch, tighten the switch securely.
Removal
2. Connect the electrical lead to the switch.
1. Chock the vehicle wheels.
Service Checks
2. Deplete all pressure in both air systems.
Operating Test
3. Disconnect the electrical lead from the
indicator switch. 1. Install an accurate air gauge in the service
brake line.
4. Unscrew the indicator switch from the fitting.
2. Depress brake pedal and observe that stop
Installation lights illuminate at 6 psi (41 kPa) or less.
1. Screw the indicator switch into the appropriate 3. Release the brake valve and observe that the
valve fitting. stop lights go out.
Operating and Leakage Checks 1. With pressure applied, coat the switch with a
soap solution. No leakage is permitted.
1. With the engine shut down and the ignition
switch ON, slowly reduce pressure in the system. If the switch does not function as described or if
leakage is found, replace the switch with a new one.
2. The switch should actuate at approximately 75 Refer to the Parts Manual.
psi (517 kPa) as indicated by sounding of the buzzer
and illumination of the LOW AIR indicator. This AIR PRESSURE GAUGE
pressure may be read on the dual pressure gauge in
the cab. Removal
3. With air pressure present at the port, coat the 1. Chock the vehicle wheels.
indicator switch with a soap solution. No leakage is
permitted. 2. Deplete all air pressure in both air systems.
WARNING
Disconnect the batteries prior to
loosening the front console screws.
2-7-17
TM 5-3810-307-24-1-1
3. Using the wrench flat, closest to the reservoir, 3. Install the drain valve in the bottom port of the
unscrew the valve from the fitting on the reservoir. reservoir and tighten.
2-7-18 C-1
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2-7-19
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2-7-20
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5. Under no conditions should the valve be 1. Position the valve, and if used, install the
installed without a filter installed in the adapter. mounting bolts.
Service Checks 2. Connect the two air lines to the proper ports of
the valve.
Operating Test
3. Perform the procedures under Operating and
With the air system pressurized, make several foot Leakage Checks.
valve applications and note that each time an
application is made an exhaust of air occurs at the Service Checks
exhaust port of the drain valve. If no air comes out,
push the wire stem. If no air comes out, the filter is Operating Test
plugged and the valve should be removed and
cleaned.
NOTE
NOTE If the pressure protection valve does not
operate as described or leakage is
Because the automatic drain valve
excessive, it is recommended that it be
functions as reservoir pressure is
replaced.
reduced, excessive leakage in the
system could cause constant exhausting
1. Provide a pressure gauge and drain valve at
of the valve.
the supply side and delivery side of the pressure
protection valve being checked.
Leakage Test
2. Build up the air system to full pressure and
With the system pressurized and pressure stabilized
shut off the engine.
in the system, there should be no leaks at the drain
valve exhaust. A constant slight exhaust of air at the
3. While watching the gauges on the supply and
drain valve exhaust could be caused by excessive
delivery sides of the valve, slowly begin to exhaust
leakage in the air system.
pressure from the delivery side. Note that both
gauges will show pressure loss until the closing
If the valve does not function as described or if
pressure of the pressure protection valve is reached.
leakage is excessive, it is recommended that the
The pressure protection valve should close at
valve be replaced or rebuilt. Refer to the Parts
approximately 85 5 psi (586 344 kPa). The gauge
Manual.
on the delivery side of the valve should continue to
show loss of pressure while the gauge on the supply
side should stop at the same pressure as the setting
PRESSURE PROTECTION VALVES of the valve.
NOTE
2-7-22
TM 5-3810-307-24-1-1
1. Build up the air system to full pressure and The leakage check should be performed at the inlet
shut off the engine. ports of the valve in the following manner.
2. Apply a soap solution around the cap of the 1. Disconnect the line from the inlet port.
pressure protection valve. A 1 in. (254 cm) bubble in
three seconds or longer is acceptable. 2. Apply air to the other inlet port and coat the
opposite inlet port with a soap solution. Permissible
3. Drain the air pressure from the delivery side leakage is a 1 in. (254 cm) bubble in five seconds.
of the pressure protection valve and disconnect air
line to it. 3. Repeat step b. applying air to the other inlet
port while checking the opposite inlet port for
4. Apply a soap solution to the delivery port. A 1 leakage. If the double check valve does not function
in. (254 cm) bubble in five seconds or more is as described or if leakage is excessive, it is
acceptable. recommended that the valve be replaced.
1. Install an accurate test gauge in the outlet port 4. Remove the bolt, lockwashers, and nuts that
or in a line from the outlet port. secure the valve and remove the valve.
2-7-24
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2-7-25
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3. Connect the air lines to the proper port on the The circuits in the dual brake valve are identified as
valve in accordance with identification marks made follows. The No. 1 circuit portion is that portion of
during removal. the valve between the spring seat which contacts
the plunger and the relay piston. The No. 2 circuit
4. Perform the procedures under Operating and portion is that portion between the relay piston and
Leakage Checks. the exhaust cavity.
2-7-26 C-1
TM 5-3810-307-24-1-1
2. Coat the exhaust port and body of the brake 3. Lift the rubber material on the pedal, position
valve with a soap solution. the throttle bracket on the pedal and secure it with
the two screws, lockwashers, and nuts.
3. Leakage of a 1 in. (2.54 cm) bubble in three
seconds is permitted. 4. Connect the air lines to the foot throttle valve.
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2-7-28
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2-7-29
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Removal Description
1. Chock the wheels. The function of the spring brake control valve is to
supply a specific, limited hold-off pressure to the
2. Deplete all pressure in both air systems. spring brakes, and in the event of loss of service
pressure, to modulate the spring brakes through
3. Identify, mark, and disconnect the air lines the use of the dual brake valve.
from the three-way air solenoid valve.
The valve has four air connection ports and a
4. Tag and disconnect the electrical leads to the diaphragm protected exhaust port. Each air
solenoid. connection port is labeled with embossed letters to
identify the ports.
5. Remove the bolts, lockwashers, and nuts
securing the valve to the mounting bracket and NOTE
remove the valve.
For proper internal drainage, the spring
6. If a new valve is to be installed, remove the brake control valve should be mounted
mufflers from the two exhaust ports and remove all with the exhaust port down.
fittings.
Removal
Installation
1. Chock the wheels.
1. If a new valve is being installed, install fittings
in the ports and a muffler on each exhaust port. 2. Deplete all pressures in both air systems.
2. Position the valve on the mounting bracket and 3. Tag and disconnect all air lines from the valve.
secure with the bolts, lockwashers, and nuts.
4. Remove the two nuts and lockwashers
3. Connect the electrical leads as tagged at attaching the valve and remove the valve.
removal.
Installation
4. Connect the air lines to the appropriate ports
on the valve in accordance with the identification 1. Position the spring brake control valve on the
marks made during removal. mounting studs and secure it with the nuts and
lockwashers.
2-7-30 C-1
TM 5-3810-307-24-1-1
Operating and Leakage Checks 7. With the air system fully charged and the
parking control valve in the release position, coat the
1. Chock the vehicle wheels. exhaust port and the area around the valve corner
with a soap solution. Slight leakage is permitted.
2. Charge the air systems to the governor cut-out
pressure. 8. If the spring brake control valve does not
function as described above, or leakage is
3. Place the parking control valve in the park excessive, it is recommended that it be repaired or
position. Observe the spring brake actuators apply replaced Refer to the Parts Manual for repair parts.
promptly. In the delivery port of the valve, install a
test gauge known to be accurate. Place the parking PRESSURE REDUCING VALVES
control valve in the release position. Observe the
spring brake actuators release fully. Removal
4. With the parking control valve in the release 1. Chock the wheels.
position, note the gauge pressure reading. It should
be approximately 45 psi (310 kPa). If the pressure 2. Deplete the pressure in both air systems.
reading is incorrect, the valve must be repaired or
replaced. 3. Disconnect and tag the air lines from the valve
and remove the valve.
5. Place the parking control valve in the park
position The gauge reading should drop to zero Installation
promptly A slow release of pressure could indicate
faulty operation of the single check valve (within the 1. Install the fittings and air lines to the valve as
modulating valve). tagged during removal.
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2-7-32 C-1
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Description
The four-way air solenoid valve installed in the air system allows the operator to engage or release the parking
brake from either cab regardless of the position of the PARK BRAKE control in the other cab. The air valve has
two solenoids, one connected into the circuitry of each cab to activate the valve. This means that only one
solenoid is powered at a time depending on which cab has electrical control (ignition switch on), thus giving that
cab and only that cab control of the parking brake.
Removal
b. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
c. Disconnect electrical connector for four-way air solenoid valve (8, Figure 2-7-14).
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.
d. Loosen clamps (1), tag, and disconnect air hoses (2) from air fittings on four-way air solenoid valve (8).
f. Remove nuts (5), lockwashers (6), washers (7), and four-way air solenoid valve (8) from mounting studs.
Note that ground wires are installed under one nut (5).
g. If necessary, note position of 45 elbows (11 and 13) and remove elbows (9 thru 13) from valve.
Installation
a. If removed, install elbows (9 thru 13, Figure 2-7-14) in four-way air solenoid valve (8). Ensure 45 elbows
(11 and 13) are installed in ports noted during removal.
b. Position four-way air solenoid valve (8) on mounting studs and secure with washers (7), lockwashers (6),
and nuts (5). Secure ground wires on right side mounting stud under one nut (5) as removed.
d. Install air hoses (2) on valve air fittings and tighten clamps (1). Remove tags.
2-7-34 C-1
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LEGEND
2-7-35 C-1
TM 5-3810-307-24-1-1
Removal
(1) Relieve system air pressure by draining supply (depress pin in center of automatic drain valve),
secondary, and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines or
components to prevent injury.
(3) If necessary, remove air line (2) from elbow (3), and elbow (3) from connector (6).
(4) If necessary, remove nut (4), lockwasher (5), and connector (6) from vehicle frame.
(2) Tag and disconnect air lines (8 and 9, Figure 2-7-15) from elbows (16 and 17).
(3) Tag and disconnect air lines (10 and 11) from elbows (18 and 19).
(4) Remove nuts (12), lockwashers (13), tractor protection valve (14), and washers (15) from mounting
studs.
(5) If necessary, remove elbows (16, 17, 18, and 19) from valve (14).
Installation
(1) If removed, install elbows (16, 17, 18, and 19, Figure 2-7-15) on tractor protection valve (14).
(2) Position washers (15) on mounting studs, and install tractor protection valve (14) on studs with
lockwashers (13) and nuts (12).
(3) Connect air lines (10 and 11) to elbows (18 and 19).
(2) If removed, install connector (6) in vehicle frame with lockwasher (5) and nut (4).
(3) If removed, install elbow (3) in connector (6) and connect air line (2) to elbow (3).
2-7-36 C-1
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LEGEND
SECTION 8
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Page
2-8-1 C-1
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2-8-2
TM 5-3810-307-24-1-1
2-8-3
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2-8-4
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
LIST OF TABLES
Title Page
2-8-5
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-8-12
Extreme care must be used when removing any plugs or restrictions from
a hydraulic system suspected to have entrapped air that may be
pressurized.
WARNING 2-8-13
WARNING 2-8-17
Ensure that all hydraulic systems are shut down and the pressure is
relieved.
WARNING 2-8-27
Do not attempt to loosen fittings in pressurized lines or while the hydraulic
pumps are in operation.
WARNING 2-8-57
2-8-64
Do not use air pressure to remove the cylinder rod assembly. Use only a 2-8-68
source of controlled hydraulic oil pressure if the rod assembly is hard to 2-8-72
remove. 2-8-75
2-8-6
TM 5-3810-307-24-1-1
2-8-60
WARNING
2-8-62
Do not use air pressure to cycle or pressurize the cylinder. Use only a 2-8-67
source of controlled hydraulic pressure. 2-8-71
2-8-74
2-8-78
2-8-7/(2-8-8 Blank)
TM 5-3810-307-24-1-1
HYDRAULIC SYSTEM
DESCRIPTION
This Section describes the supply pressure and refer to Figure 2-8-1. The test panel contains five
return hydraulic circuit, pumps, and disconnect, all fittings. By removing the fittings and connecting a
hydraulic valves, and all hydraulic cylinders. pressure gauge, the pressure setting of the relief
Description and operation of individual hydraulic valves can be checked.
circuits are discussed in their individual Sections.
A complete hydraulic system schematic showing all
A hydraulic test panel for checking relief valve options is at the back of this Manual and an A.N.S.I.
settings is located at the rear left side of the Graphical Symbols chart is provided in this Section,
turntable, refer to Figure 2-8-2.
MAINTENANCE
HYDRAULIC OIL RECOMMENDATIONS. 8. Connect the outrigger return line and retract
the outrigger. Replenish the reservoir oil level as
For the hydraulic oil specifications, refer to Chapter necessary.
1, Section 4 - LUBRICATION.
9. Repeats steps 7 and 8 for the remaining
DRAINING AND FLUSHING. outriggers.
4. Remove the reservoir drain plug and drain the 13. Disconnect the return line from the telescope
reservoir. Clean and install the drain plug and fill the cylinder and fully extend the boom.
reservoir with clean oil.
14. Connect the return line and retract the boom.
CAUTION Replenish the reservoir oil level as necessary.
Oil supply lines must be connected to 15. Disconnect the return lines from both front
the cylinders when flushing the system. steer cylinders and turn the front wheels to the
extreme right.
NOTE
16. Connect the return lines and turn the front
Draining the various components will be wheels to the extreme left and then back to center.
facilitated by connecting a drain line in Replenish the reservoir oil level as necessary.
place of the disconnected return line.
17. Repeat steps 15 and 16 for the rear steering
5. Disconnect the return line from the lift cylinder cylinders.
and raise the boom to maximum elevation.
CAUTION
6. Connect the cylinder return line and lower the
boom to its stowed position. Replenish the reservoir When oils are changed or added, ensure
oil level as required. that oils of different manufacturers are of
the same specifications. However, dis-
7. Disconnect the return line from an outrigger coloration (milkiness) may occur.
extension cylinder and fully extend the outrigger.
2-8-11
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2-8-12
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Inspect the control valves for visible damage, binding Some of the most common causes for stiff spool
spools, and evidence of leakage. If excessive movement or jammed spool action are; system
internal leakage is suspected during operation with a overheating, excessive pressure, contaminated or
spool in its center position, it is possible that the area deteriorated oil, or warped mountings. When
between the spool and working section bore of the scorched or deteriorated oil or contamination is the
valve body is worn beyond serviceable limits. If this cause, flushing the system and replenishing with
condition exists, the spool and body must be clean oil may solve the problem. If the spool bores
replaced as an assembly. are badly scored or galled, the valve must be
removed for servicing.
Valve Leakage.
Warping occurs when mounting plates are not level
Dripping oil indicates some type of external leakage. or they become distorted from machine damage. As
The machine should be removed from service for mentioned previously, the valve can be shimmed
immediate repairs. External leaks sometimes level.
develop at fittings and seals. Spool seals are
susceptible since they are subject to wear. Seals Also check the valve for rust. Rust or dirt collecting
may be damaged by temperatures that are too high, on the linkages can prevent free movement of the
or by dirt or paint accumulation on the spool. spool, and keep it from the true center position.
Damaged seals must be replaced. Excessive system pressure can create both internal
and external leaks in valves that are otherwise
A component functioning at reduced efficiency may sound. Therefore, it is extremely important that relief
indicate that the control valve for that component is valves be adjusted only by qualified personnel using
leaking internally. Assuming preliminary check-out the proper equipment.
2-8-13
TM 5-3810-307-24-1-1
DESCRIPTION
The supply pressure and return circuit is made up of directed through an external filter located inboard of
three (3) separate circuits which route oil from the the hydraulic reservoir. Both filters incorporate a
hydraulic pumps to the directional control valves for bypass feature allowing oil to bypass the filter when
the individual operating circuits. The supply the element is clogged and back pressure exceeds
pressure and return circuit consists of the reservoir, 25 psi (172.3 kPa). Gauges on the front of the filter
a three section hydraulic pump, pump disconnect, oil heads show the amount of filter restriction present.
cooler, two oil filters, and a 15 port hydraulic swivel.
The operating circuits description and components OIL COOLER.
begin with the circuits directional control valve.
An air cooled hydraulic oil cooler is mounted on the
HYDRAULIC RESERVOIR AND FILTER. right side of the superstructure. The oil cooler
consists of a hydraulic radiator, and fan-mounted on
The hydraulic reservoir is mounted on the left side of an electric motor. The fan draws cool air through the
the carrier frame and is held in place by two retaining cooling fins on the radiator.
straps, refer to Figure 2-8-3. The reservoir is all-
steel and has an internally-mounted full-flow filter A temperature switch installed in the return manifold
and an integral baffle that helps cool the oil and controls the operation of the fan motor. When the
prevent foaming. The reservoir has a capacity of temperature of the oil reaches 120F (48.8C) the
approximately 73 gal. (276 l) total; 64.4 gal. (244 l) to switch's contacts close and energize the fan motor
the full level, with a low level of 60 gal. (227 l). relay to actuate the fan motor.
Oil flows through the two individual tubes at the back PUMP DISTRIBUTION.
of the reservoir to the hydraulic pump. The majority
of the return flow enters directly into the return filter. Section One.
A drain plug located in the bottom of the reservoir is Section One of the hydraulic pump supplies the main
magnetized to collect metal particles from the oil, hoist circuit. Oil flowing from the valve bank returns
should the oil become contaminated. to the return manifold.
2-8-14
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2-8-15
TM 5-3810-307-24-1-1
Figure 2-8-4. Reservoir Connection Legend
TM 5-3810-307-24-1-1
MAINTENANCE
HYDRAULIC FILTER. 5. Remove the filter bowl from the filter head and
remove the element.
Removal and Disassembly.
6. Discard the used element.
WARNING Assembly and Installation.
Ensure that all hydraulic systems are
shut down and the pressure is relieved. 1. Install a new element into the filter bowl and
install the filter bowl into the filter head, refer to
1. Shut down all hydraulic systems. Figure 2-8-5.
2. Thoroughly clean the area around the filter. 2. Using a new gasket, install the filter and gasket
Wipe any dirt from the filter housing and filter head. onto the hydraulic reservoir.
3. Disconnect the hydraulic line from the filter 3. Secure the filter in place with the mounting
head, refer to Figure 2-8-5. bolts.
4. Remove the four bolts securing the filter to the 4. Connect the hydraulic line to the filter head.
reservoir and remove the filter and gasket.
5. Operate the system and check for any
leakage.
2-8-17
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2-8-18
TM 5-3810-307-24-1-1
8. Use a suitable lifting device to remove the 12. If coolant heater installed, refill engine
reservoir from its mounting bracket (7). coolant.
13. Place battery disconnect switch in the ON
9. If replacing the reservoir, remove the
position.
hydraulic oil sampling valve hose connection
(10) and pressure gauge. 14. Start the diesel engine, bleed air from system,
and check all hydraulic functions. Inspect the
10. If replacing the reservoir, remove the return hydraulic reservoir hose connections for
filter (9), window gauge (4), and the breather evidence of leaks. Refill engine coolant as
(1). necessary.
11. If replacing the reservoir, remove hydraliner 15. Remove air trapped in the hydraulic system.
heater elements, if installed.
HYDRAULIC PUMP
DESCRIPTION
The hydraulic pump is mounted on a drive pad of the The hydraulic pump is a positive displacement, gear-
torque converter. The purpose of the pump is to type pump and consists of three separate sections.
convert the mechanical energy of the torque The first section of the pump, the one on the
converter into fluid energy for the operation of the mounting flange end, has an output of 39 gpm (148
crane's hydraulic components. lpm). The second (middle) section has an output of
39 gpm (148 lpm). The third section has an output of
16 gpm (61 lpm).
MAINTENANCE
NOTE
The hydraulic pump and the disconnect 2. Operate the pump for at least two minutes at
are attached to the torque converter with zero pressure and moderate speed (not over 1,500
the same hardware. rpm). If the pump appears to be operating
satisfactorily, increase the rpm intermittently, until the
4. Remove the four nuts and washers attaching governed rpm has been attained. Continue this
the pump to the torque converter drive pad. Remove procedure for approximately five minutes while
the pump. checking for proper operation and leakage.
2-8-19
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2-8-20
TM 5-3810-307-24-1-1
DESCRIPTION
The hydraulic pump disconnect is mounted between actuates the movable collar within the housing which
the hydraulic pump and the drive pad on the torque in turn sides the splined sleeve on the splined pump
converter. shaft to engage the sleeve with the splined shaft of
the torque converter drive. The disconnect housing
The disconnect assembly is provided for cold is initially filled with one pint of transmission fluid and
weather starting and consists of a housing, lever, during operation, the torque converter will spray
movable collar, and a sliding splined sleeve. The transmission fluid into the housing to lubricate the
housing and pump are bolted to the torque converter disconnect.
drive pad with the same hardware. The lever
extends up through the cover plate. Moving the lever
MAINTENANCE
(Text Deleted)
2. Remove the hydraulic pump. Refer to 5. Cover the disconnect mount opening to
HYDRAULIC PUMP - REMOVAL in this Section. prevent dirt from entering the drive unit.
NOTE INSTALLATION.
The hydraulic pump and the disconnect 1. Using a new gasket, position the pump
are attached to the torque converter with disconnect to the torque converter drive pad, refer to
the same hardware. Figure 2-8-7.
3. Remove the pump disconnect from the torque 2. Refer to HYDRAULIC PUMP - INSTALLATION
converter drive pad, refer to Figure 2-8-7. and install the hydraulic pump.
2-8-21 C-1
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2-8-22
TM 5-3810-307-24-1-1
VALVES
GENERAL
This sub-section provides descriptive information for The description of the valves given here is for the
all the hydraulic valves used on this crane. For a valve itself. For information on how the valve
listing of all valves, the circuit they are used in, and functions in the individual circuits, refer to the
their physical location, refer to the Valve Usage Description and Operation of that circuit.
Table and Figures 2-8-8 and 2-8-9.
2-8-23
2-8-24
TM 5-3810-307-24-1-1
Figure 2-8-8. Valve Locations (Carrier)
TM 5-3810-307-24-1-1
1. Solenoid Valve, Steer Reversal 5. Solenoid Valve, LMI Lockout 9. Solenoid Valve, Swing Brake
2. Manifold Assembly, Return 6. Directional Valve, Controls 10. Pressure Reducing Valve
3. Directional Valve, Swing 7. Selector Valve, Tele/Clamshell 11. Shuttle Valve, Swing-A/C
4. Solenoid Valve, A/C Idle Boost 8. Pressure Switch, A/C 12. Pressure Switch, Swing Brake Light
13. Solenoid Valve, Controller Lockout
2-8-25
TM 5-3810-307-24-1-1
Relief Valves
DESCRIPTION
Relief valves are used to protect a component, a valves, but some are located in the line between
circuit, or a system from over pressurization. Most of components (e.g., double cross-over relief valve),
the relief valves are located in the directional control while others are part of a component.
MAINTENANCE
GENERAL. The following test tables list Main and Circuit Relief
Valve Settings. If the pressure setting of any relief
Relief valves are checked and adjusted by causing a valve is not 100 psi ( 689.5 kPa) of that listed in
given circuit to reach its prescribed pressure limit the tables, adjustment is necessary.
(stall). At this point, the relief valve opens, returning
oil to the reservoir. Hydraulic motor circuits may be CAUTION
stalled by preventing rotation of the motor shaft prior
to actuating the control valve. Cylinder circuits may Do not overtighten the adjustment screw
be stalled by extending or retracting a cylinder to its or locknut.
limit of travel.
CAUTION
By placing a pressure gauge in the proper line or
port, a pressure reading will indicate the point at Do not hold the relief valve open for
which the relief valve opens. The needle on the more than one minute at a time.
meter face will climb until it reaches the relief valve
setting. At that point the needle will stop climbing NOTE
and fluctuate, indicating the relief valve is open and
returning oil to the reservoir. To adjust a relief valve, turn the
adjustment screw (in to increase or out
Correct relief valve adjustment is mandatory if any to decrease) until the proper setting is
hydraulic circuit is to function properly. Settings must reached.
be within specified tolerances. Therefore, after the
need for adjustment has been established, it should MAIN RELIEF SETTINGS TABLE
be performed only by qualified technicians using the
correct equipment. Valve Bank Setting - psi (kPa)
The hydraulic system utilizes two valve banks. A One Section (Swing) . . . . . . . . . . . 1,500 (10,342)
single section valve bank directs oil flow for operation Five Section . . . . . . . . . . . . . . . . 3,500 (24,132)
of the Swing Circuit. The five section valve bank
directs flow for operation of the Telescope, Lift, NOTE
Auxiliary Hoist, Main Hoist, and Clamshell/
Attachments Circuits. Release the control lever after taking
each reading and while making
Each valve bank has one main relief valve limiting adjustments.
maximum operating pressure of the component(s) in
that circuit. In addition, circuit relief valves further
limit operating pressures as required by circuit
design.
2-8-26
TM 5-3810-307-24-1-1
Valve Bank Circuit Relief - psi (kPa) Main Relief - psi (kPa)
1. Start and warm up the engine until the 3. Fully extend the boom lift cylinder and hold
hydraulic oil temperature reaches a minimum of 70F momentarily. Note the maximum reading on the
(21C). pressure gauge. If the reading is not 100 psi (
689.5 kPa) of that listed in the Main Relief Settings
WARNING Table, adjust the pressure setting as necessary.
Do not attempt to loosen fittings in
pressurized lines or while the hydraulic 4. Shut down the engine. Remove the pressure
pumps are in operation. gauge and install the plug.
Single Section Valve Bank. (Swing Circuit) 1. Disconnect a retract line from any one of the
outrigger jack cylinders and install the pressure
1. Remove the pipe plug from the SWING gauge in this line.
pressure test port on the Hydraulic Test Panel and
install the pressure gauge. 2. Set the throttle to 2,800 rpm.
2. Set the throttle to 2,800 rpm. 3. On the front console position, the outrigger
extension/retraction toggle switch to RETRACT.
2-8-27
TM 5-3810-307-24-1-1
Note the maximum reading on the pressure gauge. 1. Remove the plug from the pressure test port
If the reading is not 100 psi ( 689.5 kPa) of that on the Hydraulic Test Panel and install the pressure
listed in the Circuit Relief Setting Table, adjust the gauge.
pressure setting as necessary.
2. Set the throttle to 1,000 rpm.
4. Shut down the engine. Remove the pressure
gauge and reconnect the line to the jack cylinder. 3. Move the boom control lever to down and hold
momentarily. Note the maximum reading on the
Telescope - Retract. pressure gauge. If the reading is not 100 psi (
689.5 kPa) of that listed in the Circuit Relief Setting
NOTE Table, adjust the pressure setting as necessary.
Telescope extend uses the valve bank 4. Shut down the engine. Remove the pressure
main relief valve. gauge and install the pipe plug.
1. Remove the plug from the pressure test port Front or Rear Steer.
on the Hydraulic Test Panel and install the pressure
gauge. 1. Disconnect one hose from the applicable steer
cylinder. Install the pressure gauge in this hose.
2. Set the throttle to 1,000 rpm.
2. Set the throttle to 1,200 rpm.
3. Move the TELESCOPE control lever to IN and
hold momentarily. Note the maximum reading on the 3. Turn the steering wheel in the direction that will
pressure gauge. If the reading is not 100 psi ( pressurize this hose. Continue turning to the end of
689.5 kPa) of that listed in the Circuit Relief Setting its travel and hold it momentarily. Note the maximum
table, adjust the pressure setting as necessary. reading on the pressure gauge. If the reading is not
100 psi ( 689.5 kPa) of that listed in the Circuit
4. Shut down the engine. Remove the pressure Relief Setting Table, adjust the pressure setting as
gauge and install the plug. necessary.
2-8-28
TM 5-3810-307-24-1-1
1. Remove the plug from the pressure test port 1. Remove the plug from the pressure test port
on the Hydraulic Test Panel and install the pressure on the Hydraulic Test Panel and install the pressure
gauge. gauge.
2. Set the throttle to 2,800 rpm. 2. Set the throttle to 2,800 rpm.
3. Engage the swing brake and mechanical 3. Lift the armrests in the cab to disable the
swing lock. controllers.
4. If the reading is not 10 psi (68.9 kPa) of that 4. If the reading is not 10 psi (68.9 kPa) of that
listed in the Circuit Relief Settings Table, adjust the listed in the Circuit Relief Settings Table, adjust the
pressure setting as necessary. pressure as necessary.
2-8-29
TM 5-3810-307-24-1-1
DESCRIPTION
The directional control valves are pilot-operated, the opposite end of the valve spool. This flow
four-way, three-position valves with either an open or pattern is applicable in either direction the valve may
closed spool. Whether a valve has an open or be positioned. If it is necessary to open more than
closed spool is determined by whether, with the one directional control valve in the same valve bank,
spool in the neutral position, the work ports are open it may be required to partially close or feather the
to the reservoir return passage. If the work ports are valves that are located in the bank first, in reference
open to the reservoir return passage, the valve is to flow from the pump, in order to provide sufficient
classified as an open spool-type; if they are not, the flow to the valves located last in the bank.
valve is a closed spool-type. (Refer to the Valve
Usage Table for circuit applicability by valve type.) The closed spool directional control valve functions
Additionally, the valve spool is spring-loaded to the basically the same way as the open spool directional
neutral position. control valve, in that the through passage of the
valve must be blocked off by the valves' spool to
The open spool directional control valve is divert flow to the dead end parallel passage. With
constructed with a through passage to allow flow to flow diverted to the parallel passage, pressure than
pass to the next valve(s) in the bank and on to the must unseat the load check valve to allow the flow to
reservoir, when the valve spool is in the neutral reach the open work port. The load check valve is
position. By positioning the valve spool to a work provided to prevent back sliding of components
position, the through passage is blocked and flow is which support heavy loads as is evidenced by the
diverted o the dead end parallel passage. This circuits this valve is used in. Return flow from the
causes flow to be directed to the component's open component is through the return work port to the
supply work port. Return flow is routed from the reservoir return passage.
return work port to the reservoir return passage by
MAINTENANCE
(Text Deleted)
REMOVAL. INSTALLATION.
1. Remove the valve cover, if applicable. 1. Position the valve bank onto the turntable and
secure it in place with the bolts and nuts, Refer to
2. Tag and disconnect the hydraulic lines running Figure 2-8-10.
to the directional control valve bank, refer to Figure
2-8-10. Cap or plug all openings. 2. Connect the electrical leads to the valve bank
as tagged during removal.
3. Tag and disconnect any electrical leads from
the valve bank. 3. Connect the hydraulic lines to the valve bank
as tagged during removal.
4. Remove the bolts and nuts securing the valve
bank and remove the valve bank.
2-8-30 C-1
TM 5-3810-307-24-1-1
1. Start the engine with the pump disconnect 3. Operate the control lever(s) of the affected
disengaged and check the operation at high and low circuit(s). Check for smooth operation of cylinders
idle speed with no load applied. and motors. Check the valve bank(s) and lines for
leakage.
2. Engage the hydraulic pump and set the
2-8-31
TM 5-3810-307-24-1-1
DESCRIPTION
There are three hydraulic remote control valves armrest controls the main hoist and boom lift.
utilized in the crane cab. One is a pedal operated Moving the control lever straight forward or back
dual function valve located under the cab. This valve operates the main hoist function. Pushing the
is used for control of the telescope cylinder or the control lever to either side operates boom lift.
clamshell/grapple cylinder depending on the position Positioning the lever in a diagonal direction operates
selected on the TELE/CLAMSHELL selector switch both functions simultaneously. The valve in the left
on the right armrest. armrest controls the auxiliary hoist and swing.
Pushing the control lever straight forward or back
The other two hydraulic remote control valves are controls the auxiliary hoist function. Pushing the
dual-function joystick-type valves. One valve is control lever to either side operates swing.
located in each armrest. The valve in the right Positioning the lever diagonally operates both
functions simultaneously.
MAINTENANCE
(Text Deleted)
Removal
b. Remove screws (1, Figure 2-8-11), lift top cover (2), and slide bottom cover (3) from arm rest.
d. Tag and disconnect hydraulic lines from fittings on joystick assembly (6).
e. Remove screws (4), threaded plates (5), and joystick assembly (6) with mount (10) from top cover (2) of
arm rest.
f. If necessary, remove locknut (7), washers (8), screws (9), and mount (10) from joystick assembly (6).
g. If necessary, remove tubes (11) and o-rings (12) from ports A2, B1, B2, and T, elbow (13) from port A1,
and tube (14), o-ring (15), and adapter (16) from port P of joystick assembly (6).
h. If replacing joystick, remove screws and nuts and retain joystick instruction plate.
Installation
a. If removed, install adapter (16, Figure 2-8-11), tube (14), and new o-ring (15) in port P, elbow (13) in port
A1, and o-rings (12) and tubes (11) in ports A2, B1, B2, and T of joystick assembly (6).
2-8-32 C-1
TM 5-3810-307-24-1-1
b. If removed, install mount (10) on joystick assembly (6) with screws (9), washers (8), and locknuts (7).
c. Install joystick assembly (6) with mount (10) in top cover (2) of arm rest with screws (4) and threaded
plates (5).
d. Connect hydraulic lines to fittings of joystick assembly (6) and remove tags.
e. Connect electrical leads for joystick assembly (6) and remove tags.
f. Slide bottom cover (3) onto arm rest and secure top cover (2) to bottom cover (3) with screws (1).
g. If removed, install joystick instruction plate and secure with screws and nuts.
Functional Check
With engine running at governed rpm, operate both functions controlled by the control valve. Check the valve for
proper operation and leaks.
2-8-33
TM 5-3810-307-24-1-1
LEGEND
2-8-34
TM 5-3810-307-24-1-1
2. Tag and disconnect the hydraulic lines from 1. With the engine running at governed rpm,
the control valve. telescope the boom the whole way out and then the
whole way back in. Check valve for proper operation
3. Remove the bolts, nuts, and washers securing and any leakage.
the control valve to the mounting bracket and
remove the valve. 2. Place TELE/CLAMSHELL selector switch in
CLAMSHELL position, operate pedal in both
Installation. directions, and check for leaks.
2-8-35
TM 5-3810-307-24-1-1
2-8-36
TM 5-3810-307-24-1-1
DESCRIPTION
The hoist control valve is designed to provide an operated poppet off its seat. This allows flow to the
even flow of oil to the hoist motor in both directions. return reservoir through the directional control valve.
To drive the hoist motor in the raise direction, An orifice plug is installed in the pilot pressure port to
hydraulic oil flows through the in port and pushes the restrict back flow when the directional control valve is
free flow poppet off its seat. The oil then flows to the closed. The restriction prevents the pilot-operated
out port and on to the hoist drive motor. poppet from chattering on its seat.
When driving the hoist motor in the lower direction, A vent is provided that vents the area between the
oil from the directional control valve enters the out pilot piston seal and the free flow poppet and pilot-
port. The pilot-operated poppet is held shut by the operated poppet seals to prevent a hydraulic lock
adjustment spring until pilot pressure of sufficient should weepage around the seals occur.
force is sensed at the pilot pressure port to move the
pilot-
MAINTENANCE
(Text Deleted)
2-8-37 C-1
TM 5-3810-307-24-1-1
2-8-38
TM 5-3810-307-24-1-1
DESCRIPTION
There is one pressure reducing valve used on the Hydraulic circuits served by the pressure reducing
crane. The purpose of the valve is to take input flow valve include the remote controllers, swing brake
from the supply pressure and return circuit, divide it, and the swing directional control valve bank.
and maintain a regulated flow to two or more
separate circuits. Excess oil returns to the reservoir
via a vent port in the valve.
MAINTENANCE
NOTE
REMOVAL. INSTALLATION.
1. Remove the hoses and fittings from the valve, 1. Position the valve and secure in place with the
refer to Figure 2-8-14. nuts and lockwashers, refer to Figure 2-8-14.
2. Remove the nuts and lockwashers which 2. Install the fittings and attach the hoses.
secure the valve.
FUNCTIONAL CHECK.
3. Remove the valve and plug the ports.
With the engine running at governed rpm, activate
the remote controllers and swing brake several
times. Check for proper operation and check the
valve for any leakage.
2-8-39
TM 5-3810-307-24-1-1
2-8-40
TM 5-3810-307-24-1-1
Solenoid Valve
DESCRIPTION
The valve is held in a normally closed position or Single solenoid valves are used in the control
normally open position by a spring. When the lockout, swing brake release, LMI lockout manifold,
solenoid is energized, the plunger assembly forces A/C (idle boost), steer reversal, front axle steering,
the spool to shift, causing the valve to open or close. rear axle steering, axle disconnect, and rear steer
De-energizing the solenoid allows spring pressure to lockout circuits. Double solenoid valves are used in
shift the spool back to its normal position. the axle oscillation lockout circuit.
MAINTENANCE
NOTE
2-8-41
TM 5-3810-307-24-1-1
2-8-42
TM 5-3810-307-24-1-1
DESCRIPTION
A manually-operated, two-position double selector A solenoid operated double check valve is located
valve is located in the carrier frame center section. on the turntable left side plate. The solenoid,
The valve is connected by a control cable to the controlled by the TELE/CLAMSHELL selector switch
steering mode selector handle located at the rear of positions the valve to direct hydraulic pilot pressure
the hydraulic reservoir. The selector valve so that the telescope/clamshell control pedal
determines if the front steer cylinders are to be operates the boom telescope cylinder or the
operated from the carrier cab or from the clamshell/grapple cylinder. With the selector switch
superstructure cab. The hydraulic circuit which is to in the TELE position, ports T and C4, and ports P
be operated should be selected before pressure is and C1 are connected together directing pilot
applied. The valve spool is of the open crossover- pressure to the telescope directional control valve
type. As the spool is moved and one set of outlet which in turn directs hydraulic flow to operate the
ports start to close, the other set of outlet ports start telescope cylinder. With the selector switch in the
to open. With the spool pulled out of the housing CLAMSHELL position, ports T and C3, and ports P
(viewed from the handle end), ports A and D are and C2 are connected together directing pilot
connected to each other, and ports B and C are pressure to the clamshell directional control valve to
connected to each other. With the spool pushed into operate the clamshell/grapple cylinder.
the housing (viewed from the handle end), ports A
and E are connected to each other, and ports B and
F are connected to each other.
MAINTENANCE
(Text Deleted)
REMOVAL. INSTALLATION.
1. Tag and disconnect the six hydraulic hoses 1. Position the selector valve onto the mounting
from the ports on the selector valve, refer to Figure bracket and secure it with bolts and lockwashers,
2-8-16. Cap or plug all openings. refer to Figure 2-8-16.
2. Disconnect the handle linkage or electrical 2. Connect the handle linkage or electrical
connector as applicable. connector onto the valve as applicable.
3. Remove the bolts and lockwashers securing 3. Connect the six hydraulic hoses to the selector
the selector valve to the mounting bracket. Move the valve as tagged prior to removal.
valve to a clean work area.
FUNCTIONAL CHECK.
2-8-43 C-1
TM 5-3810-307-24-1-1
2-8-44
TM 5-3810-307-24-1-1
DESCRIPTION
The single selector valve is a manually-operated, two superstructure steering control. Both the single and
position valve located in the carrier frame center double selector valves are operated by a single
section. The selector valve is mechanically control located at the rear of the hydraulic reservoir.
connected to the double selector valve and Positioning the control will, by cable, move the
determines if hydraulic flow for steering control is to mechanical linkage which shifts the selector valve's
be routed to the carrier steering control or to the valve spool.
MAINTENANCE
REMOVAL. INSTALLATION.
1. Tag and disconnect the hydraulic hoses from 1. Position the selector valve onto the mounting
the ports on the selector valve, refer to Figure 2-8- bracket and secure it with bolts and lockwashers,
17. Cap or plug all openings. refer to Figure 2-8-17.
3. Remove the bolts and lockwashers securing 3. Connect the hydraulic hoses to the selector
the selector valve to the mounting bracket. Move the valve as tagged prior to removal.
valve to a clean work area.
FUNCTIONAL CHECK.
2-8-45
TM 5-3810-307-24-1-1
2-8-46
TM 5-3810-307-24-1-1
Holding Valves
DESCRIPTION
Two different holding valves are utilized on the is used for positioning the main poppet valve which
crane, one in the lift cylinder and one in the is being held against its seat by heavy springs. The
telescope cylinder. Both valves are installed in the pilot pressure is sensed from the lowering side of
port block of their respective cylinder. the hydraulic circuit. As the directional control valve
is opened to the lower position, pressure is applied
The holding valve is ported to allow hydraulic flow to the pilot piston. The pilot piston moves against
in two directions. To raise a load, the oil must the pilot release poppet until it unseats the pilot
unseat the free flow poppet valve. In this case, oil release poppet valve which ports oil to the return
pressure must overcome the main poppet spring. side of the directional control valve.
To do this, the oil flows through the oil ports of the
pilot release poppet valve which applies pressure The free flow check valve is provided for venting
to the inside face of the free flow poppet. When the the pressure side of the pilot piston.
main poppet unseats, the oil flows past the main
poppet seat to the component to be worked. A vent is provided for venting the area between the
pilot piston 0-rings should weepage occur. A
When a load is to be lowered, as in retracting the second vent is provided at the adjustment end of
boom, better control is necessary because of the the pilot release poppet valve should weepage
weight of the load. For this reason a pilot occur past the 0-ring seal into the spring area.
pressure
MAINTENANCE
REMOVAL. CAUTION
Do not damage the O-rings during
1. To remove the holding valve, unscrew it from
installation of the holding valve. If the
the port block, refer to Figure 2-8-18.
holding valve turns freely then gets hard
to turn, then easy to turn; remove the
INSTALLATION.
holding valve and check the O-rings.
They have probably been damaged by a
1. Check the inside of the port block for any
sharp edge of a port.
sharp edges or burrs and remove as necessary with
emery cloth.
NOTE
2. Install new O-rings onto the holding valve, refer The holding valve should turn by hand
to Figure 2-8-18. until compression of the O-rings begins.
3. Lubricate the holding valve and O-rings with 4. Carefully install the holding valve into the port
clean hydraulic oil. block until fully seated.
2-8-47 C-1
TM 5-3810-307-24-1-1
2-8-48
TM 5-3810-307-24-1-1
DESCRIPTION
The integrated outrigger valve is mounted near the The solenoid valves are normally closed and are
center of the carrier frame and is used for the control energized by 24 volts. They are used to control a
of the outrigger circuit and the rear steer circuit from pilot pressure that positions the spool within the
the superstructure cab. The valve consists of five working section. When the solenoid valves are de-
subassemblies; two solenoid valves, and inlet energized, the springs maintain the spool in a
section, an outlet section, and two working sections. centered position, permitting oil to flow to the
pressure beyond circuit.
MAINTENANCE
NOTE
3. Remove the nuts and lockwashers securing 3. Observe the beam for adequate speed of
the selector valve; remove the valve. extension and retraction and smooth operation.
2-8-49
TM 5-3810-307-24-1-1
2-8-50
TM 5-3810-307-24-1-1
DESCRIPTION
There are two outrigger solenoid valve stacks utilized Each valve stack consists of four solenoid valve
on the crane, one to control each outrigger box assemblies, two for each outrigger beam.
assembly.
MAINTENANCE
NOTE
REMOVAL. INSTALLATION.
1. Tag and disconnect the hydraulic lines to the 1. Position the valve assembly on the mounting
solenoid valve bank, refer to Figure 2-8-20. Cap all bolts; secure with the nuts and lockwashers, refer to
lines and openings. Figure 2-8-20.
2. Disconnect the electrical leads; tape the lead 2. Connect the electrical leads to the solenoid.
ends.
3. Connect the hydraulic lines as marked prior to
3. Remove the nuts and lockwashers securing removal.
the valve bank assembly to the frame; remove the
assembly. FUNCTIONAL CHECK.
2-8-51
TM 5-3810-307-24-1-1
2-8-52
TM 5-3810-307-24-1-1
DESCRIPTION
There are three types of pilot-operated check valves purpose of the valve is to prevent reverse flow from
utilized on the crane, two being used in the outrigger the piston side of the outrigger cylinders.
circuit, and one in the superstructure cab steering Incorporated within the valve cartridge is a thermal
circuit. relief valve set to open at 4,000 psi (27,580 kPa).
MAINTENANCE
(Text Deleted)
2. Install new O-rings onto the check valve, refer 4. Carefully install the check valve into the port
to Figure 2-8-21. block until fully seated.
2-8-53 C-1
TM 5-3810-307-24-1-1
Removal. Installation.
1. Remove the hoses and fittings from the valve, 1. Position the valve onto the frame and secure in
refer to Figure 2-8-21. place with two nuts and lockwashers, refer to Figure
2-8-21.
2. Remove the two nuts and lockwashers which
secure the valve to the frame. 2. Install the fittings and attach the hoses.
2-8-54
TM 5-3810-307-24-1-1
2-8-55
TM 5-3810-307-24-1-1
CYLINDERS
GENERAL
This sub-section provides descriptive information for For information on how the cylinder functions in
all the hydraulic cylinders used on this crane. The individual circuits, refer to the Description and
description of the cylinder given here is for the Operation of that circuit.
cylinder itself.
MAINTENANCE
2-8-56
TM 5-3810-307-24-1-1
Lift Cylinder
DESCRIPTION
The lift cylinder is the double-acting-type with a cylinder. The backup rings protect the O-ring from
cylinder bore of 7.5 in. (19.1 cm). The retracted damage and prevent movement of the O-ring seal
length of the cylinder from the center of the barrel during rod retraction and extension. The O-ring seal
bushing to the center of the rod bushing is 102.6 in. between the rod side and the piston prevents internal
(260.6 cm). The extended length of the cylinder from leakage.
the center of the barrel bushing to the center of the
rod bushing is 184.6 in. (468.9 cm). Foreign matter The cylinder weighs approximately 685 lbs (310.7
is prevented from entering the cylinder by a wiper kg) dry and 713 lbs (323.4 kg) wet.
seal. An O-ring seal prevents oil leakage from the
MAINTENANCE
NOTE
DISASSEMBLY. CAUTION
Exercise extreme care when handling or
NOTE
setting down the cylinder rod. Do not
Any maintenance requiring disassembly damage the chrome surface.
of the cylinder should include replace-
ment of all cylinder seals and O-rings. 2. Remove the cylinder rod assembly from the
cylinder barrel and cover the barrel to avoid
NOTE contamination.
It may be necessary to heat cylinder in
CAUTION
setscrew area to break cylinder head
loose from cylinder. When removing seals and rings, avoid
scratching grooved and gland surfaces.
1. Remove the setscrew securing the cylinder
head and using a spanner wrench, unscrew the NOTE
cylinder head, refer to Figure 2-8-22.
Aligning discarded seals and rings in the
order of disassembly will facilitate
WARNING installation of new items.
Do not use air pressure to remove the 3. Remove the hydrolock piston seal to gain
cylinder rod assembly. Use only a access to the setscrew securing the piston to the
source of controlled hydraulic oil rod.
pressure, if the rod is hard to remove.
4. Remove the setscrew and unscrew the piston
from the cylinder rod.
2-8-57
2-8-58
TM 5-3810-307-24-1-1
Figure 2-8-22. Lift Cylinder
TM 5-3810-307-24-1-1
8. If necessary, remove the holding valve from The holding valve should turn by hand
the port block. until compression of the O-rings begins.
ASSEMBLY.
NOTE
2-8-59
TM 5-3810-307-24-1-1
9. Install the rod spacer. Install the O-ring and 12. Clean all oil from the threads of the head and
backup rings inside the piston and install the piston coat the threads with NEVER-SEEZ (paste-type)
onto the rod. Secure the piston in place with the lubricant.
setscrew.
13. Using a spanner wrench, tighten the head
securely.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
2-8-60
TM 5-3810-307-24-1-1
Steer Cylinder
DESCRIPTION
The 2.76 in. (7.01 cm) bore steer cylinder is the prevent internal and external leakage. A wiper ring is
double-acting-type and has a usable stroke of 7.48 mounted to the front of the cylinder to wipe dirt from
in. (19.00 cm). O-rings are used within the cylinder the rod as it is being retracted.
to
MAINTENANCE
NOTE
Any maintenance requiring disassembly 4. Remove the seal and wear ring from the
of the cylinder should include outside of the piston on the cylinder rod.
replacement of all cylinder seals and O-
rings. 5. Remove the caps and o-rings from the cylinder
barrel.
1. Unscrew the cylinder head from the cylinder
barrel, refer to Figure 2-8-25. CLEANING AND INSPECTION.
2-8-61 C-1
TM 5-3810-307-24-1-1
1. Install the caps and o-rings on the cylinder 5. Install the cylinder rod with piston into the
barrel, refer to Figure 2-8-25. cylinder barrel with a slight twisting motion.
2. Install the seal and wear ring onto the outside 6. Install the cylinder head onto the cylinder
of the piston on the cylinder rod. barrel.
2-8-62 C-1
TM 5-3810-307-24-1-1
1. Cylinder Barrel
2. O-ring
3. Cap
4. Seal
5. Wear Ring
6. Cylinder Rod and Piston
7. Wiper Ring
8. Deep Z Rod Seal
9. Backup Ring
10. Cylinder Head
11. Wear Ring
12. Low Temperature O-ring
2-8-63 C-1
TM 5-3810-307-24-1-1
Telescope Cylinder
DESCRIPTION
The boom telescope cylinder has a 5.5 in. (13.9 cm) fittings is 24 ft (7.3 m). The cylinder has a stroke of
bore. The cylinder is internally ported (rod ported). 21.6 ft (6.5 m) which gives the cylinder an overall
Oil from the telescope control valve is routed to the extended length of 45.6 ft (13.9 m) from the end of
cylinder by external lines. Foreign material is the cylinder barrel to the center of the attachment
prevented from entering the cylinder during rod fittings on the cylinder rod.
retraction by a wiper seal in the head. O-ring seals
prevent internal and external leakage. The cylinder weights approximately 1,305 lbs (591.9
kg) dry and 1,380 lbs (625.9 kg) wet.
The retracted length of the telescope cylinder from
the end of the barrel to the center of the attachment
MAINTENANCE
NOTE
DISASSEMBLY. CAUTION
2-8-64
TM 5-3810-307-24-1-1
Before installing new seals and rings, 4. Carefully install the holding valve into the port
clean all surfaces and carefully remove block until fully seated.
burrs and nicks. Parts displaying
excessive wear or damage should be CAUTION
replaced.
When installing new seals and rings,
2. Stone out minor blemishes and polish with a avoid stretching seals or scratching the
fine crocus cloth. grooved or gland surfaces.
ASSEMBLY. NOTE
2-8-65
2-8-66
TM 5-3810-307-24-1-1
Figure 2-8-26. Telescope Cylinder
TM 5-3810-307-24-1-1
CAUTION
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
2-8-67
TM 5-3810-307-24-1-1
DESCRIPTION
The oscillation lockout cylinders have 3.5 in. (8.9 cm) The retracted length is 19.5 in. (49.5 cm) measured
diameter bores and are the double-acting-type. The from the center of the rod bushing to the center of
cylinders are mounted to the frame and the axles. the barrel bushing. The extended length from the
center of the rod bushing to the center of the cylinder
O-rings are used within the cylinders to prevent bushing is 25.7 in. (65.4 cm).
internal and external leakage. A wiper ring is
mounted to the front of the cylinder barrels to wipe Each cylinder weighs approximately 46 lbs (20.8 kg)
dirt from the rod as it is retracted. dry and 47.5 lbs (21.5 kg) wet.
MAINTENANCE
NOTE
2-8-68
TM 5-3810-307-24-1-1
2-8-69
INSPECTION.
CAUTION
2. Stone out minor blemishes and polish with a Figure 2-8-30. Cylinder Head Seal Installation
fine crocus cloth.
5. Install the cylinder head onto the rod.
3. Clean with solvent and dry with compressed
air any parts that have been stoned and polished. 6. Install the O-ring and backup rings inside the
piston and install the piston onto the rod. Secure
4. Inspect the barrel carefully for scoring. the piston in place with the setscrew.
Lubricate new seals and rings with 8. Lubricate the cylinder rod assembly with
clean hydraulic oil. clean hydraulic oil and install the rod assembly into
the cylinder with a slight twisting motion.
1. Install the wiper ring into the head retaining
ring and install the retaining ring onto the rod, refer
to Figure 2-8-29.
CAUTION
2-8-70
TM 5-3810-307-24-1-1
2-8-71
TM 5-3810-307-24-1-1
DESCRIPTION
The four extension cylinders have 1.5 in. (6.35 cm) front of the extension cylinder barrel to wipe dirt from
diameter bores. The cylinders are the double-acting- the rod as it is retracted. Each cylinder has a
type and are mounted to the outrigger beams. O- retracted length of 84 in. (213.4 cm) from the center
rings are used within the cylinders to prevent internal of the rod bushing to the center of the cylinder
and external leakage. A wiper ring is mounted to the bushing. The extended length is 149.6 in. (379.9
cm).
MAINTENANCE
NOTE
Exercise extreme care when handling or 5. Remove the two piston seals from the piston
setting down the cylinder rod. Damage and the O-ring from the rod.
to the rod surface may cause
unnecessary maintenance and expense. 6. Remove the spacer.
2-8-72
TM 5-3810-307-24-1-1
2-8-73
1. Clean all parts with solvent and dry with 3. Install the O-ring onto the rod and the piston
compressed air. Inspect all parts for serviceability. seals onto the piston.
Before installing new seals and rings, 5. Install the piston locknut. Torque the locknut
clean all surfaces and carefully remove 99 to 121 lbs-ft (134.2 to 164.0 Nm).
burrs and nicks. Parts displaying
excessive wear or damage should be CAUTION
replaced.
Avoid scratching or damaging the
2. Stone out minor blemishes and polish with a grooved or gland surfaces of the rings
fine crocus cloth. and seals.
1. Install the wiper seal and rod seal into the head 8. Pressurize and cycle the cylinder. Check for
and the gland seal onto the head. Install the head proper operation and any leakage.
onto the rod, refer to Figure 2-8-32.
2-8-74
TM 5-3810-307-24-1-1
DESCRIPTION
The stabilizer cylinders have a 3.5 in. (8.9 cm) mounted on the front of the stabilizer cylinder barrel
diameter cylinder bore and are the double-acting- to wipe the rod as it is retracted into the barrel. The
type. The cylinders are pinned into tubes welded cylinder is approximately 42.5 in. (107.9 cm) long
onto the end of the outrigger beams. A port block is retracted and 63 in. (160 cm) long fully extended.
welded to the end of the cylinder rod and a pilot-
operated check valve is threaded into the port block. The cylinder weighs approximately 109 lbs (49.4 kg)
O-rings are used within the cylinder to prevent dry and 114 lbs (51.7 kg) wet.
internal and external leakage. A wiper ring is
MAINTENANCE
NOTE
DISASSEMBLY.
CAUTION
NOTE
When removing seals and rings, avoid
Any maintenance requiring disassembly scratching grooved and gland surfaces.
of the cylinder should include
replacement of all cylinder seals and O- NOTE
rings.
Aligning discarded seals and rings in the
1. Remove the setscrew securing the cylinder order of disassembly will facilitate
head and using a spanner wrench, unscrew the installation of new items.
cylinder head, refer to Figure 2-8-33.
3. Remove the hydrolock piston seal to gain
access to the setscrew securing the piston tot he
WARNING rod.
Do not use air pressure to cycle or
pressurize the cylinder. Use only a 4. Remove the setscrew and unscrew the piston
source of controlled hydraulic oil from the cylinder rod.
pressure, if the rod is hard to remove.
5. Remove the remaining hydrolock seal and
CAUTION guide lock ring from the outside of the piston and the
O-ring and two backup rings from the inside of the
Exercise extreme care when handling or piston.
setting down the cylinder rod. Do not
damage the chrome surface. 6. Remove the spacer from the rod.
2. Remove the cylinder rod assembly from the 7. Remove the cylinder head from the rod.
cylinder barrel and cover the barrel to avoid
contamination.
2-8-75
TM 5-3810-307-24-1-1
2-8-76
TM 5-3810-307-24-1-1
Before installing new seals and rings, 4. Carefully install the check valve into the port
clean all surfaces and carefully remove block until fully seated.
burrs and nicks. Parts displaying
excessive wear or damage should be CAUTION
replaced.
When installing new seals and rings,
2. Stone out minor blemishes and polish with a avoid stretching the seals or scratching
fine crocus cloth. the grooved and gland surfaces.
ASSEMBLY. NOTE
2-8-77
TM 5-3810-307-24-1-1
CAUTION 11. Install the hydrolock seals and guide lock ring
onto the piston, refer to Figure 2-8-35 for proper seal
Improper installation of seals could orientation.
cause faulty cylinder operation.
CAUTION
6. Install the buffer seal, deep Z seal, and wiper
ring inside the head ensuring the seals are Avoid scratching or damaging the
assembled properly and installed in the correct grooved or gland surfaces or the rings
direction, refer to Figure 2-8-34. and seals.
7. Install the wear ring, O-ring, and backup ring 12. Lubricate the cylinder rod assembly with clean
onto the outside of the head. hydraulic oil and install the rod assembly into the
cylinder with a slight twisting motion.
8. Install the cylinder head onto the rod.
13. Clean all oil from the threads of the head and
9. Install the spacer onto the rod. coat the threads with NEVER-SEEZ (paste-type)
lubricant.
10. Install the O-ring and backup rings inside the
piston and install the piston onto the rod. Secure the 14. Using a spanner wrench, tighten the head
piston in place with the setscrew. securely.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
2-8-78
TM 5-3810-307-24-1-1
SECTION 9
SWING SYSTEM
TABLE OF CONTENTS
Page
2-9-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
2-9-2
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-9-6
WARNING 2-9-6
Eye contact with these silicone RTV materials may cause irritation. If eye
contact takes place, flush the eyes with water for 15 minutes and have the
eyes examined by a doctor.
WARNING 2-9-11
2-9-11
WARNING
It is mandatory that bearing attaching bolts be inspected for lack of torque
and retorqued, as required, after the first 300 hours of machine operation.
The bolts may loosen in service due to vibration, shock-loads, and
temperature changes, therefore, periodic inspection should be
accomplished every 500 hours thereafter, ensuring the bolts are properly
torqued.
2-9-3
TM 5-3810-307-24-1-1
WARNING 2-9-15
Ensure the lifting device is capable of fully supporting the weight of the
superstructure. Ensure the superstructure will not tilt or slide during lifting
and moving. Failure to do so may result in death of injury to personnel
and damage to equipment.
WARNING 2-9-15
2-9-15
WARNING
Ensure that any blocking material used is capable of fully supporting the
weight of the superstructure and will not allow it to tilt or shift. Failure to
do so may result in death of injury to personnel.
2-9-17
WARNING
Anytime a grade 8 turntable bolt has been removed, it must be replaced
with a new grade 8 bolt and nut.
2-9-4
TM 5-3810-307-24-1-1
SWING SYSTEM
DESCRIPTION
The superstructure has full 360 degrees rotation in disengaged from the cab. A brake pedal and swing
both directions and is equipped with free swing. A brake control are used to stop rotation.
positive swing lock and a pin-type swing lock are
both provided to lock the superstructure in position. The swing system consists of the hydraulic remote
The positive swing lock consists of teeth that mesh control valve, control valve, pressure reducing valve,
with the swing gear teeth at any point along the 360 brake pedal and power brake valve, two position
degrees of rotation. The pin-type swing lock consists selector valve, swing drive, and the swing brake
of a round pin and a retainer weldment which locks assembly.
the turntable with the boom straight over the front or
rear. Both turntable locks are engaged and
THEORY OF OPERATION
The system is supplied by the 16 gpm (60.5 lpm) 5 gpm (18.9 lpm) flow at 250 psi (1723.7 kPa) to the
pump section. The oil flows from the pump to the swing brake control and the swing brake valve for
outrigger control valve. Bypass flow from the application or release of the swing brake. Pilot
outrigger control valve. Bypass flow from the pressure signals from the hydraulic remote control
outrigger control valve supplies the swing circuit. valve in the cab shift the spool in the control valve. If
The bypass oil flows through swivel port 11 to the the swing brake control is in the disengage position,
pressure reducing valve. The pressure reducing the superstructure will rotate in the direction selected
valve provides a constant flow to the control valve by the hydraulic remote control. Shifting the control
bank containing the swing control valve. The lever to neutral and depressing the brake pedal will
pressure reducing valve also provides a constant stop swing.
2-9-5
TM 5-3810-307-24-1-1
SWING MOTOR
DESCRIPTION
The swing motor is mounted on top of the swing gearbox in the center of the turntable. After the
brake which is located on the top of the swing brake releases, the motor drives the gearbox through
the brake.
MAINTENANCE
(Text Deleted)
2. Clean the port area around the motor. Tag a. Remove dirt, grease, or moisture from
and disconnect the hydraulic hoses from the motor the surface of the carrier and housing.
assembly (Figure 2-9-1). Cap or plug all openings.
b. Dry the surface.
CAUTION
c. Apply a thin bead, maximum 0.125 in.
Pull straight up on the motor assembly to (3.175 mm) diameter, completely around one
avoid damaging the splined shaft. mating surface and all fasteners holes to
ensure complete seal and prevent leaks.
3. Remove the bolt and washers securing the
motor and lift the swing motor free. d. Assemble the components immediately
to permit silicone RTV gasket material to
INSTALLATION. spread evenly.
CAUTION
2-9-6 C-1
TM 5-3810-307-24-1-1
2-9-7
TM 5-3810-307-24-1-1
DESCRIPTION
MAINTENANCE
NOTE
NOTE
4. Remove the bolts and washers securing the 2. Place a new, lubricated O-ring on the top of the
brake to the gear housing cover. Remove the brake. gear reducer.
5. Remove and discard the O-ring between the 3. Insert the brake shaft into the gear reducer.
motor and the brake.
2-9-8
TM 5-3810-307-24-1-1
1. Ensure the turntable lock pin is installed. 3. Using an adequate lifting device, lift and
position the assembly onto the superstructure.
2. Disconnect and tag the hydraulic lines from the
swing motor and swing brake. 4. Apply medium strength thread locking
adhesive to threads of bolts and install the nine
NOTE grade 5 bolts securing the swing gearbox to the
mounting plate on the superstructure base plate.
The swing motor and swing brake may Torque the bolts to 110 lbs-ft (149.1 Nm).
or may not be removed at this time. If
not removing at this time, proceed to 5. Connect the hydraulic lines to the swing motor
step 6. and brake as tagged during removal.
2-9-9
TM 5-3810-307-24-1-1
2-9-10
TM 5-3810-307-24-1-1
SWING BEARING
DESCRIPTION
The swing bearing is an anti-friction roller bearing race contains two grease fittings for lubrication of the
that mates the superstructure to the carrier. The bearing. The outer race incorporates 156 gear teeth
bearing inner race is bolted to the superstructure and that mesh with the pinion gear of the swing gearbox
the outer race is bolted to the carrier. The inner to provide rotation.
MAINTENANCE
General WARNING
It is mandatory that bearing attaching
WARNING bolts be inspected for lack of torque, and
retorqued, as required, after the first 300
Failure to maintain proper torque of the hours of crane operation. The bolts may
turntable bearing attaching bolts will loosen in service due to vibration, shock-
result in damage to the crane and loads, and temperature changes, there-
possible injury to personnel. fore, periodic inspection should be
accomplished every 500 hours
Maintaining proper torque value for bolts is extremely thereafter, ensuring the bolts are
important for structural strength, performance, and properly torqued.
reliability of the crane. Variations in torque can
cause distortion, binding, or complete separation of KNOW YOUR TORQUE WRENCH! Flexible beam-
the superstructure from the carrier. type wrenches, even though they might have a pre-
set feature, must be pulled at right angles and the
CAUTION force must be applied at the center of the handle.
Force value readings must be made while the tool is
Repeated retorquing may cause bolts to in motion. Rigid handle-type, with torque limiting
stretch. If bolts keep working loose, they devices that can be pre-set to required values,
must be replaced with new bolts of the eliminate dial readings and provide more reliable,
proper grade and size. less variable readings.
2-9-11
TM 5-3810-307-24-1-1
2-9-12
TM 5-3810-307-24-1-1
If multipliers and/or special tools are Torque all turntable bolts to 370 lbs-ft (501.6 Nm).
used to reach hard to get at areas,
ensure torque readings are accurate. Tools Required.
Torque wrenches are precision instruments and Figure 2-9-4 illustrates and lists the complete set of
must be handled with care. To ensure accuracy, special tools required to torque the turntable bolts.
calibrations must be made on a scheduled basis.
Whenever there is a possibility that a torque wrench Inner Race Torquing.
may have been either over-stressed or damaged, it
should immediately be removed from service until 1. Fully extend and set the outriggers.
recalibrated. When using a torque wrench, any
erratic or jerking motion can result in the application 2. Torque bolts 1, 20, 11, 30, 6, 25, 35, and 16, in
of excessive or improper torque. ALWAYS use a that order, to 296 lbs-ft (401.3 Nm), refer to Figure 2-
slow, even movement and STOP when the 9-3.
predetermined value has been reached.
3. Return to bolt 1 and torque each bolt
It is reported by the crane operator or suspected that sequentially in a clockwise direction to 370 lbs-ft
the crane has been overloaded beyond the (501.6 Nm).
capacities specified above the bold line on the
cranes' capacity chart, then all turntable bolts must Outer Race Torquing.
be inspected for looseness and retorqued to
specifications. 1. Fully extend and set the outriggers.
Turntable bolts should be torqued diametrically 2. Torque bolts 1, 19, 10, 28, 5, 23, 14, and 32, in
opposed, working in sequence from one side of the that order, to 296 lbs-ft (401.3 Nm), refer to Figure 2-
circle to the opposite side, rather than tightening 9-3.
adjacent bolts successively. Torque first to 50%,
then to the final torque value. 3. Return to bolt 1 and torque each bolt
sequentially in a clockwise direction to 370 lbs-ft
When using step wrenches, calculated wrench (501.6 Nm).
settings are valid only when the following conditions
are met. REMOVAL.
1. Torque wrenches must be those specified and 1. Fully extend and set the outrigger enough to
forces must be applied at the handle grip. The use take up the slack in the pads.
of handle extensions will change applied torque to
the bolt. NOTE
2. All handles must be parallel to the step wrench Do not raise the crane on the outriggers.
during final tightening. Multiplier reaction bars may
be misaligned no more than 30 degrees without 2. Ensure the boom is in the travel position and
causing serious error in torque. the swing lock is engaged.
3. Multiplier bar handles must be propped or 3. Elevate the boom slightly and shut down the
supported within the outer of the handle length, or engine.
serious under- or over-tightening will occur.
4. Remove the boom following the procedures
The inner race of the bearing is secured to the outlined in Section 10, BOOM.
turntable by 39 in. Grade 8 bolts. The outer race
of the bearing is secured to the carrier frame by 36 5. Tag and disconnect the battery cable from the
in. Grade 8 bolts. battery.
2-9-13
TM 5-3810-307-24-1-1
Quantity
Item Description Grove Part Number Required
1 1-1/8 in. Socket in. Drive 9-999-100142 1
2 in. Drive Torque Wrench 9-999-100159 1
3 10 in. Extension in. Drive 9-999-100138 1
4 13 in. Extension in. Drive 9-999-100137 1
5 Tool Box (Optional) Not Shown 9-999-100146 1
2-9-14
TM 5-3810-307-24-1-1
2-9-15
TM 5-3810-307-24-1-1
2-9-16
TM 5-3810-307-24-1-1
NOTE
2-9-17
TM 5-3810-307-24-1-1
5. Install the swing gearbox (refer to SWING 11. Connect the two pin lock-type electrical
GEARBOX - Installation in this Section) with the connectors.
pinion aligning the high point (maximum eccentricity)
on the turntable bearing. Using a 0.005 in. (0.127 12. Install the electrical swivel cover.
mm) thick shim, check that backlash is 0.010 in.
(0.254 mm) [0.005 in. (0.152 mm) between adjacent 13. Install the boom following the procedures
teeth of pinion and bearing on both sides], refer to outlined in Section 10, BOOM.
Figure 2-9-6. If the pinion must be moved to achieve
proper backlash, contact your local Service 14. Connect the battery.
Representative or Manitowoc Crane CARE, PO Box
21, Shady Grove, PA. 17256-0021 TESTING.
6. Connect the swivel links to the superstructure. Activate the crane and check for proper function.
8. Remove the hardware attaching the electrical If the superstructure does not turn freely
swivel cover and remove the cover. after bearing and pinion replacement,
contact your local Service Representative
9. Connect the two power lock connectors and or Manitowoc Crane CARE, PO Box 21,
route the wires through the electrical swivel base Shady Grove, PA. 17256-0021.
plate.
2-9-18 C-1
TM 5-3810-307-24-1-1
SECTION 10
BOOM
TABLE OF CONTENTS
Page
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-10
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
BOOM EXTENSION AND RETRACTION CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
TELESCOPE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
LIFT CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
HOOK BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
BOOM HOSE REEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Boom Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-20
Tagline Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
2-10-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
2-10-2
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-10-6
Wear gloves when handling wire rope.
2-10-6
WARNING
2-10-10
Ensure all blocking and lifting devices are capable of supporting boom
assembly.
2-10-6
WARNING
Ensure the boom lift cylinder is properly supported before disconnecting it
from the boom.
2-10-6
WARNING
Shut down the crane before proceeding.
WARNING 2-10-10
Block the boom before doing any work under the boom.
WARNING 2-10-10
Failure to properly support the boom lift cylinder may result in death or
injury to personnel.
2-10-3
TM 5-3810-307-24-1-1
Page
WARNING 2-10-10
WARNING 2-10-12
WARNING 2-10-16
WARNING 2-10-16
WARNING 2-10-19
2-10-22
Hose reel is installed with a spring preload. Hold on to hoses when
disconnecting so reel does not spin freely causing possible damage to
equipment or personal injury.
WARNING
2-10-11
Boom/structural repairs and/or modifications must be approved by the
manufacturer. Repair requests should be submitted to Manitowoc
Crane CARE, P.O. Box 21, Shady Grove, PA 17256-0021, USA. Any
unauthorized repairs and/or modification could void any remaining
crane warranty and/or result in serious injury and equipment damage.
2-10-4 C-1
TM 5-3810-307-24-1-1
BOOM
DESCRIPTION
The boom is a three section 27 to 70 ft (8.2 to 21.3 the sections. The boom nose consists of five
m) cable extended boom. sheaves (two upper and three lower), mounted on
heavy duty tapered roller bearings and utilizes pin-
The boom is trapezoidal in design and utilizes one type guards to allow easy reeving.
heavy duty 5.5 in. (13.9 cm) telescope cylinder. The
telescoping sections are supported on graphite Boom assembly lift is provided by one heavy duty
impregnated nylatron wear pads. Adjustable side 7.5 in. (18.9 cm) diameter bore lift cylinder. Boom
wear pads prevent metal-to-metal contact between elevation is from -3 to 78 degrees.
THEORY OF OPERATION
2-10-5
TM 5-3810-307-24-1-1
MAINTENANCE
2. Remove the hook block and wind all the wire 13. Raise the boom clear of the crane and lower to
rope onto the hoist drum. ground level for service.
4. Attach a lifting device to provide equal weight 2. Place the boom in a horizontal position.
distribution and place the boom safety block in
position. Rest the boom on the safety block. 3. Completely retract the boom.
5. Disconnect any electrical wiring from the 4. Tag and disconnect the hydraulic lines to the
boom. telescope cylinder. Remove the telescope cylinder
holding valve. Cap all lines and openings.
6. Tag and disconnect the hydraulic lines to the
telescope cylinder. Cap the lines and openings.
WARNING
Ensure the boom lift cylinder is properly
supported before disconnecting it from
the boom.
2-10-6
TM 5-3810-307-24-1-1
2-10-7
5. Remove the bolt, washer, and plate securing 17. Remove the bolt, washer, and plate securing
the telescope cylinder retaining pin and remove the the retraction cable retainer pin to the fly section.
pin. Remove the retainer pin and the retraction cable.
6. Remove the nuts, jam nuts, and washers 18. Withdraw the telescope cylinder from the fly
securing the extension cables to the base section. section.
7. Remove the nut, jam nut, and washer securing 19. If the telescope cylinder is to be replaced,
the retraction cable to the front of the base section. remove the foot plate, sheave mounting assembly,
and sheaves from the telescope cylinder.
8. Back off the setscrews on the adjustable wear
pads to provide additional clearance and withdraw the 20. Refer to BOOM EXTENSION AND
mid and fly sections from the base section. RETRACTION CABLE MAINTENANCE in this
section for cable inspection.
9. Remove the adjustable wear pads from the
inside of the base section. ASSEMBLY.
10. Remove the lower wear pad from the outside of 1. If removed, install the foot plate, sheave
the mid section and the upper wear pads and spring mounting assembly, and sheaves from the telescope
assembly from the upper rear of the mid section. cylinder. Torque the bolts to 250 lbs-ft (338.9 Nm).
11. Remove the bolts, washers, mounting plate, 2. Route the extension cables through the cover
and retaining pin securing the retraction sheave to assembly, around the telescope cylinder sheaves,
the mid section and remove the retraction sheave. and through the foot plate. To aid in assembly,
secure the cables to the cylinder by wrapping tape
CAUTION around the cylinder in several places.
Do not let the telescope cylinder fall. 3. Position the telescope cylinder into the fly
section. Place blocking under the rear of the
12. Place blocking beneath the telescope cylinder telescope cylinder to aid in assembly. Install the
in the fly section. Remove the bolts and washers mounting plates on the telescope cylinder.
securing the telescope cylinder barrel to the mid
section. 4. Secure the cover assembly to the fly section
with the bolts and washers. Torque the bolts to 31
CAUTION lbs-ft (42.0 Nm).
Use care when removing the fly section 5. Install the retraction cable and retaining pin
from the mid section. The telescope and secure the pin with the bolt, washer, and plate.
cylinder is not firmly attached and can
slide. 6. Install the lower wear pads and upper wear
pads and spring assembly onto the fly section.
13. Back off the setscrews on the adjustable wear
pads to provide additional clearance and withdraw 7. Install the adjustable wear pads into the mid
the fly section and telescope cylinder from the mid section.
section.
CAUTION
14. Remove the adjustable wear pads from the
mid section. Use care when installing the fly section
into the mid section. The telescope cyl-
15. Remove the lower wear pads from the outside inder is not firmly attached and can slide.
of the fly section and the upper wear pads and spring
assembly from the upper rear of the fly section. 8. Install the fly section and telescope cylinder
into the mid section.
16. Remove the bolts securing the cover assembly
to the fly section. Remove the extension cables.
2-10-8
TM 5-3810-307-24-1-1
2-10-9
TM 5-3810-307-24-1-1
9. Position the cylinder barrel in place and secure 3. Lubricate and install the boom pivot shaft.
with the bolts and washers. Torque the bolts to 250 Secure in place with the retaining pin, clip pin, and
lbs-ft (338.9 Nm). Remove the blocking under the plate.
telescope cylinder.
11. Install the lower wear pads and the upper wear 5. Attach a suitable lifting device to the lift
pads and spring assembly to the mid section. cylinder.
14. Secure the retraction cable to the front of the 6. Anchor a ratchet device to the boom and raise
base section with the nut, jam nut, and washer. the lift cylinder into place. Block the lift cylinder in
position.
15. Secure the extension cables to the rear of the
base section with the nuts, jam nuts, and washers. WARNING
Torque the jam nut to 20 lbs-ft (27.1 Nm), then
tighten the nut. If the hydraulic system must be activated
to extend or retract the lift cylinder,
16. Install the telescope cylinder retaining pin and ensure the rod end is properly aligned
secure in place with the bolt, washer, and plate. with the lift cylinder attach fitting.
Torque the bolt to 31 lbs-ft (42.0 Nm). Install the
telescope cylinder holding valve. 7. Lubricate and install the upper lift cylinder
shaft. Secure in place with the bolts, washers, and
17. Connect the hydraulic lines to the telescope retaining plate. Torque the bolts to 75 lbs-ft (101.6
cylinder as tagged during disassembly. Nm).
1. Attach an adequate lifting device to the boom 12. Refer to BOOM EXTENSION AND
and suspend the boom over the machine. RETRACTION CABLE ADJUSTMENT in this section
for cable adjustments.
2. Lower the boom into position and align the
boom pivot shaft mounting holes for installation of
the pivot shaft.
2-10-10
TM 5-3810-307-24-1-1
1. Activate the hydraulic system and check for Visually inspect telescoping sections for adequate
proper operation and any leaks. lubrication of all wear surfaces. Observe extended
sections for evidence of cracks, warping, or other
2. Ensure the boom will extend and retract damage. Periodically check security of boom wear
properly. pads. Check boom nose sheaves for security and
freedom of movement.
3. Ensure the lift cylinder will not allow the boom
to drift down until the operator lowers it. WARNING
Boom/structural repairs and/or
4. Ensure all electrical components disconnected modifications must be approved by the
during removal are operating properly. manufacturer. Repair requests should be
submitted to Manitowoc Crane CARE,
P.O. Box 21, Shady Grove, PA 17256-
0021, USA. Any unauthorized repairs
and/or modification could void any
remaining crane warranty and/or result in
serious injury and equipment damage.
2-10-11 C-1
TM 5-3810-307-24-1-1
MAINTENANCE
INSPECTION. ADJUSTMENT.
WARNING NOTE
Never handle wire rope with bare hands.
The retraction cable must be adjusted
The following information is taken from a National before the extension cables.
Consensus standard as referenced by Federal
Government Agencies. 1. Extend and set the outriggers, ensuring the
crane is level.
All wire rope will eventually deteriorate to a point
where it is no longer usable. Wire rope shall be taken 2. Ensure the boom is over the front and at a
out of service when any of the following conditions horizontal position (boom angle elevation 0 degrees).
exist.
3. Extend the boom sections approximately one
1. In running ropes, six randomly distributed foot (20.5 cm).
broken wires in one lay or three broken wires in one
strand in one lay. 4. Loosen the extension cables by loosening the
jam nuts and locknuts. Do not remove the nuts.
2. Wear of the original diameter of outside
individual wires. Kinking, crushing, bird caging, or 5. Retract the boom sections slowly until the mid
any other damage resulting in distortion of the rope and fly sections bottom out and note the point at
structure. which the mid and fly sections bottom out. The stop
block on the bottom of the fly section bottom plate
3. Evidence of any heat damage from any cause. should make contact with the mid section bottom
plate approximately 0.125 to 0.375 in. (0.31 to 0.95
4. Reductions from nominal diameter of more cm) before the stop block or the bottom of the mid
than: section contacts the base section bottom plate.
2-10-12
TM 5-3810-307-24-1-1
8. Remove the locknuts from the extension extension cables until no slap is present during
cables. Tighten all four jam nuts until the cable ends extension or retraction.
extend approximately 2.75 to 3 in. (6.9 to 7.6 cm)
from the mounting plate on the boom base section. 11. After the cables are adjusted to eliminate all
cable slap, check the cable tension through the
9. Check the cable tension through the access access hole in the side of the boom. All cables
hole in the side of the boom. The cables should should have equal tension. Readjust if necessary.
have an equal amount of slack and not be resting Install the locknuts.
upon the telescope cylinder. Readjust the cables if
necessary. 12. Fully extend the boom and then fully retract it
again. Recheck the retraction cable adjustment and
10. Fully extend and retract the boom several readjust if necessary.
times. If any cable slap is present, readjust the
2-10-13
TM 5-3810-307-24-1-1
TELESCOPE CIRCUIT
DESCRIPTION
The boom telescope circuit consists of a Foreign material is prevented from entering the
telescope/clamshell foot pedal actuated remote cylinder by a wiper seal during rod retraction. O-ring
control valve, telescope/clamshell directional control seals prevent internal an external leakage. Refer to
valve, holding valve, and the telescope cylinder. CYLINDERS in Section 8 for a complete description
of the telescope cylinder.
The telescope/clamshell directional control valve is
described under VALVES in Section 8. The holding valve is threaded into the rod end of the
telescope cylinder. The holding valve functions
Refer to VALVES in Section 8 for a complete during the retraction, extension, or holding operation.
description of the telescope/clamshell remote control When holding the boom section at a given length, oil
valve. The boom telescope cylinder has a 5.5 in. is trapped in the cylinder by the holding valve. Refer
(13.9 cm) bore. to VALVES in Section 8 for a complete description of
the holding valve.
THEORY OF OPERATION
The valve bank housing the telescope directional the poppet (check) valve in the holding valve when
control valve is supplied by flow from the 39 gpm pressure is 6 4 psi (41.4 27.6 kPa). This oil is
(147.6 lpm) middle pump section. Flow from the routed to the piston side of the cylinder which forces
pump travels through port 13 of the swivel to the the rod out of the cylinder, causing the boom section
telescope directional control valve. When the foot to extend.
pedal for telescope functions is moved from neutral,
it sends a pilot pressure signal to the directional During retraction, oil enters the retract port and flows
control valve, which shifts the spool in the directional to the rod side of the cylinder. When pilot pressure
control valve. This shift aligns the appropriate reaches a pre-determined value, the main poppet
passages in the control valve to route oil to the unseats, and oil flows from the piston side of the
telescope cylinder holding valve. The holding valve, cylinder to the reservoir causing the boom section to
with its' internal makeup of valves and springs, retract. All return flow from the directional control
passes oil to and from the telescope cylinder. During valve goes through the swivel to the reservoir.
extension, oil unseats
MAINTENANCE
Removal and installation of the telescope cylinder Disassembly and assembly procedures of the
from the boom is described under disassembly and telescope cylinder and control valve are provided in
assembly of the boom. Refer to BOOM Section 8 under CYLINDERS and VALVES
MAINTENANCE in this Section. respectively.
2-10-14
TM 5-3810-307-24-1-1
LIFT CIRCUIT
DESCRIPTION
The boom lift circuit consists of the lift hydraulic The lift cylinder has a 7.5 in. (19.1 cm) bore and is
remote controller, lift directional control valve, holding the double acting-type. Dirt and other foreign
valve, and the lift cylinder. These components material are prevented from entering the cylinder and
enable the boom to be raised or lowered to various causing internal damage by a wiper seal during rod
degrees of elevation ranging from -3 to 78 degrees retraction. Oil seals on both the piston and cylinder
from horizontal. head prevent internal and external hydraulic oil
leakage. Refer to CYLINDERS in Section 8 for a
The lift directional control valve is the closed spool- complete description of the lift cylinder.
type and is described under VALVES in Section 8 -
HYDRAULIC SYSTEM. The holding valve is a balanced poppet-type
hydraulic valve. It is threaded into the port block
Refer to VALVES in Section 8 for a complete which is an integral portion of the lift cylinder barrel.
description of the hydraulic remote controller. The holding valve functions when booming up
(cylinder rod extended), booming down (cylinder rod
retracted), or holding (cylinder rod stationary).
THEORY OF OPERATION
The directional control valve bank housing the lift When booming down, oil enters the retract port of
control valve is supplied by flow from the 39 gpm the port block and flows to the cylinder rod side.
(147.6 lpm) middle section of the hydraulic pump. When pilot pressure reaches a pre-determined
Flow from the pump travels through port 13 of the valve, the main poppet unseats and oil flows from
swivel to the lift directional control valve. the piston side of the cylinder to the reservoir.
When booming up, oil unseats the poppet (check) All return flow from the control valve goes through
valve in the holding valve, letting oil flow to the piston the swivel to the reservoir.
side of the cylinder. Pressure is applied to the
piston, forcing the rod to extend, raising the boom.
2-10-15
TM 5-3810-307-24-1-1
MAINTENANCE
3. Ensure the boom is fully supported by placing 2. Lower the lift cylinder into the attach fittings on
blocking or cribbing under the boom. Rest the boom the turntable and align the lift cylinder bushing with
on the blocking or cribbing. the attach fitting holes.
4. Remove the bolt, washer, and plate securing 3. Install the lift cylinder lower pivot shaft and
the lift cylinder upper pivot shaft to the boom. secure with the bolts and nuts. Torque the bolt to
250 lbs-ft (338.9 Nm).
5. Remove the bolts and nuts securing the lift
cylinder lower pivot shaft to the turntable. 4. Connect the extend and retract hoses to the lift
cylinder.
2-10-16
TM 5-3810-307-24-1-1
2-10-17
TM 5-3810-307-24-1-1
HOOK BLOCK
DESCRIPTION
The crane is equipped with a three sheave hook is equipped with a safety latch. Grease fittings are
block rated at 22 tons (19.9 metric tons). The hook provided to ensure lubrication of all moving parts.
block utilizes a one-piece pivot block and the hook
2-10-18
TM 5-3810-307-24-1-1
DESCRIPTION
A hydraulic hose reel, with two hydraulic hoses, is allowing the hoses to extend as the attachment is
installed on the right side of the boom base section lowered, and reels in the hoses as the attachment is
to direct hydraulic oil for operation of the crane's raised.
hydraulically operated attachments.
A tagline assembly installed on the hoses should be
The reel incorporates four quick disconnects. Two connected to the attachment so that there is slack in
connect the hose reel to the crane hydraulic system the hoses between the tagline clamp and attachment
and the other two (at the ends of the hoses on the connection points. This will relieve the stress of the
reel) connect to the attachment. The reel is installed hoses pulling on the connection points.
with spring tension which is
overcome
MAINTENANCE
Removal
WARNING
Hose reel is installed with a spring preload. Hold on to hoses when
disconnecting so reel does not spin freely causing possible damage to
equipment or personal injury.
a. If hose reel hoses (7, Figure 2-10-6) and taglines are connected to an attachment, disconnect hoses and
taglines from attachment and allow hose reel assembly (6) to slowly rotate counterclockwise until spring preload
is released. Cap ends of hoses and attachment ports.
b. Position boom over an elevated platform and lower boom until hose reel assembly (6) rests on platform.
c. Disconnect hydraulic hoses (1) at connectors (2) (one on each side of boom). Cap ends of hydraulic
hoses and connectors on boom.
d. Remove nuts (3), lockwashers (4), capscrews (5), and hose reel assembly (6) from boom mounting
bracket.
NOTE
There may be shim washer(s) between hose reel and boom mounting
bracket for alignment. Mark position and number of shim(s).
e. If necessary, remove hoses (1 and 7) from hose reel assembly (6). Cap ends of hydraulic hoses and
connectors on hose reel assembly.
f. If necessary, remove tagline assembly from hydraulic hoses (7), refer to TAGLINE ASSEMBLY Removal
procedures.
2-10-19
TM 5-3810-307-24-1-1
Installation
a. If removed, install tagline assembly on hydraulic hoses (7, Figure 2-10-6), refer to TAGLINE ASSEMBLY
Installation procedures.
b. If removed, remove caps and install hydraulic hoses (1 and 7) on hose reel assembly (6).
c. With hose reel assembly (6) on an elevated platform, lower boom to align hose reel assembly mounting
holes with boom mounting bracket.
NOTE
d. Secure hose reel assembly (6) to boom with capscrews (5), lockwashers (4), and nuts (3).
f. Preload hose reel spring by rotating hose reel assembly (6) clockwise seven turns, then maintain tension
by attaching tagline clips to stowage link on boom.
2-10-20
TM 5-3810-307-24-1-1
LEGEND
2-10-21
TM 5-3810-307-24-1-1
TAGLINE ASSEMBLY
Removal
a. Mark position of tagline retainer (12, Figure 2-10-6) on hose reel hydraulic hoses (7) for installation
purposes.
WARNING
Hose reel is installed with a spring preload. Maintain tension on hoses
when disconnecting taglines so reel does not spin freely causing possible
damage to equipment or personal injury.
b. Ensure hydraulic hoses (7) are secured to maintain tension on hose reel spring, and disconnect clips of
taglines (13) from stowage link on boom or attachment as applicable.
c. Remove locknuts (8 and 10), capscrews (9 and 11), tagline retainer (12), and taglines (13) from hydraulic
hoses (7).
Installation
b. Position tagline retainer (12) on hydraulic hoses (7) as marked during removal. If position is lost, install
retainer so that hydraulic hoses (7) have a small amount of slack when attachment is raised to highest working
position, but without excessive slack when attachment is lowered.
c. Secure tagline retainer (12) on hoses (7) with capscrews (9 and 11) and locknuts (8 and 10).
2-10-22
TM 5-3810-307-24-1-1
SECTION 11
HOISTS
TABLE OF CONTENTS
Page
HOISTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Main and Auxiliary Hoist Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Adjustment of the Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
VANE TYPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
CABLE IDLER DRUM AND FOLLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-11
HOIST TO BOOM ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
HOIST DRUM ROTATION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Main and Auxiliary Hoist Rotation Indicator Controller Unit . . . . . . . . . . . . . . . . . . . . . 2-11-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-15
LIST OF FIGURES
Number Title Page
2-11-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-11-14
2-11-2
TM 5-3810-307-24-1-1
HOISTS
DESCRIPTION
One hoist type is available, the Grove HO-15C. The Each hoist uses a vane motor to drive the reduction
hoist is a single speed unit and is fitted with a 16 inch unit within the hoists. An overrunning clutch will
(28 cm) drum. The main hoist is mounted on the allow the hoist to be raised without releasing the
counterweight. The auxiliary hoist is mounted brake while holding the load until there is sufficient
forward of the main hoist. pressure to release the brake when hoisting down.
THEORY OF OPERATION
The first section of the hydraulic pump supplies oil When the remote control lever is placed in a working
through swivel port 12 to the hoist directional control position, it sends a pilot pressure signal to shift the
valve. Movement of the directional control valve valve spool in the directional control valve, thus
spool is controlled by pilot pressure signals received routing pressure and flow to drive the hoist.
from the remote control levers in the cab.
MAINTENANCE
NOTE
Removal
NOTE
a. Disconnect hoist cable from hook block, and remove cable from hoist by unwinding cable from hoist drum
onto a spare cable reel.
c. Remove rotation indicator controller unit with mounting bracket, refer to MAIN AND AUXILIARY HOIST
ROTATION INDICATOR CONTROLLER UNIT Removal procedures.
e. Remove nuts (1, Figure 2-11-1) and washers (2) securing hoist to turntable counterweight.
f. Attach suitable lifting device to hoist (4) and lift hoist from turntable counterweight.
2-11-3
TM 5-3810-307-24-1-1
NOTE
Tag shims for mounting pad from which removed, to ease installation
leveling procedures.
g. Remove capscrews (3) from hoist (4) and shims (5) from turntable mounting pads.
Installation
a. Position shims (5, Figure 2-11-1), as marked during removal, on turntable mounting pads for hoist (4).
CAUTION
Ensure rear mounting capscrews (3) for main hoist (6) only, are installed
from bottom of counterweight assembly. Failure to follow this caution will
cause damage to roof-mounted air conditioner on carrier cab when
swinging superstructure.
c. Using suitable lifting device, lift hoist into position on turntable counterweight while ensuring capscrews
align and pass through shims (5) and mounting pad holes.
NOTE
d. Check that hoist is level by placing a level across the top of the hoist. Insert or remove shims (5) to
mounting pads as necessary to level hoist.
e. Secure hoist (4) to turntable counterweight with washers (2) and nuts (1). Torque nuts to 385 lbs-ft (522
Nm).
f. Remove caps and tags, and connect three hydraulic lines to hoist.
g. Install rotation indicator controller unit with mounting bracket, refer to MAIN AND AUXILIARY HOIST
ROTATION INDICATOR CONTROLLER UNIT Installation procedures.
Functional Check
1. Attach a weight to the hook and raise and lower the load several times.
2. Check the hoist for smooth operation of the hoist motor and brake system.
3. Ensure the hydraulic connections are secure and free from leaks.
Servicing.
2. Rotate the hoist drum until one drain plug is at the highest point.
2-11-4
TM 5-3810-307-24-1-1
LEGEND
2-11-5
TM 5-3810-307-24-1-1
4. Fill the drum with lubricant until oil begins to flow from the horizontally positioned opening. Refer to
Chapter One, Section 4, LUBRICATION for proper lubricant.
If adjustment of the motor control valve is necessary, contact Grove Product Support in Shady Grove, PA for
proper procedures.
2-11-6
TM 5-3810-307-24-1-1
DESCRIPTION
The vane type motor is a fixed displacement, rotary plate assembly consisting of the port plate with a
balanced motor that converts hydraulic oil flow into built-in check valve, a cam ring assembly containing
rotary mechanical motion. The motor consists of the rotor, vanes, vane springs and cam ring, and the
four basic subassemblies; a body or housing and end cap assembly consisting of the end cap and
shaft with a permanently lubricated bearing, a front needle bearing.
port
MAINTENANCE
NOTE
REMOVAL. INSTALLATION.
1. Drain the oil from the drum by removing the 1. Using a new gasket, position the motor and
plugs. gasket to the left end cover. Secure the motor and
gasket in place with the bolts and washers.
2. Tag and disconnect the hydraulic lines from
the motor and the hoist motor control valve. Cap or 2. Connect the hydraulic line as tagged during
plug all lines and openings. removal.
3. Remove the hex head bolts and washers 3. Fill the drum with oil. Refer to Chapter One,
securing the motor to the left end cover; remove the Section 4 - LUBRICATION in this manual.
motor; discard the motor gasket.
2-11-7
TM 5-3810-307-24-1-1
2-11-8
TM 5-3810-307-24-1-1
DESCRIPTION
The main and auxiliary hoists are equipped with an The cable follower is mounted on the forward side of
idler drum on the forward side of the hoist. The idler its respective hoist. The cable follower applies a
drum on the main hoist is used to keep the hoist downward spring pressure against the cable onto the
cable from coming in contact with the auxiliary hoist, hoist drum, to ensure that the cable will be uniformly
while the idler drum on the auxiliary hoist is used to wound onto the hoist drum, and also prevent cable
keep the hoist cable from coming in contact with the jumping under abnormal line conditions.
boom.
MAINTENANCE
1. Remove the hex head bolt, lockwasher, and 1. Install the inner shaft bearings into the roller
end cap securing the idler shaft to the side plate. assembly.
2. Remove and lay the side plate aside. 2. Install one shim washer on the inner shaft.
3. Remove the idler shaft from the drum 3. Install the roller assembly on the inner shaft
assembly. and install a shim washer on the end.
4. Remove the remaining side plate and lay 4. Ensure the roller assembly and bearings are
aside. fully seated and install the angle iron on the end of
the inner shaft.
5. Remove the bearings from the drum assembly.
2-11-9
TM 5-3810-307-24-1-1
2-11-10
TM 5-3810-307-24-1-1
5. Install the two hex head bolts and washers weldment of the cable follower, if provided, and
securing the angle to the roller assembly and install the lever weldment with the hardware
completely fill the roller assembly with grease provided.
through the grease fitting on the end of the shaft.
11. Install the end of the idler shaft through the
6. Install the two bearings in the idler drum and hole provided in the top of the side plate.
ensure they are fully seated.
12. Install the end cap, bolt, and lockwasher
7. Install the left hand side plate over the arm securing the idler shaft to the side plate.
weldment of the cable follower, if provided, and
install the lever weldment with the hardware Installation.
provided.
1. Using a suitable lifting device, align the holes
8. Install the idler shaft through the hole provided in the side plates with those provided on the hoist
at the top of the side plate. and secure with the existing hardware.
9. Install the idler drum assembly over the shaft 2. Install the tension springs and adjust the
and completely fill the drum assembly with grease springs to provide equal tension across the roller
through the grease fitting on the end of the shaft. assembly.
10. Install the right hand side plate over the arm 3. Refer to Chapter One, Section 4 -
LUBRICATION and lubricate the cable idler drum
and follower as specified.
2-11-11
TM 5-3810-307-24-1-1
2. Find a line on top of the hoist drum which is 3. Find the midpoint of the lines drawn across the
parallel to the drum axis as follows. top of the base boom section, perpendicular to its
length, at both ends of the boom section. (Figure
a. Use a Miracle Point Gauge and find a points A and B).
zero degree dial point next to each flange on
top of the drum. 4. Check as follows to see if the hoist is aligned
perpendicularly to the boom.
NOTE
a. String a chalk line from point A, (outer
If this special equipment is not available, boom centerline) across the base section
sufficient accuracy in locating a center- centerline and the hoist drum midpoint.
line may be obtained by using a steel
square against the machined inner b. Pull the line taunt, aligning it directly over
surfaces of both flanges. It is advisable the top of point B.
to avoid using any cast surfaces in this
procedure unless a check from both c. With a protractor, measure the angle be-
flanges indicates that the resultant line is tween the chalk line and the cross line drawn
straight. on the hoist. If the measurement of the angle
exceeds 90 degrees degree, realignment
will be necessary.
2-11-12
TM 5-3810-307-24-1-1
2-11-13
TM 5-3810-307-24-1-1
DESCRIPTION
The hoist drum rotation indictor is an electrically the hoist motor to sense rotation of the motor shaft
operated system (one for each hoist) that provides and thus indirectly the hoist drum. The sensor is
the operator with a touch indication of drum rotation connected by electrical wiring to the controller unit
so he will know if and at what speed the drum is that acts as a pulse generator and sends a pulsating
rotating, even under the most distracting conditions. signal (proportional to rotation speed) to the indicator
unit. The indicator unit is located in the control lever
The indictor assembly consists of three main parts - handle and pulsates in time with the signal from the
the magnetic sensor, the controller unit, and the controller unit.
indicator unit. The magnetic sensor is installed in
MAINTENANCE
2-11-14
TM 5-3810-307-24-1-1
Removal
c. Disconnect electrical connector for controller unit (7, Figure 2-11-6) from superstructure electrical harness.
d. Remove screws (1) and cover (2) from controller unit (7).
e. Remove nut (3), lockwasher (4), washer (5), capscrew (6), and controller unit (7) from mounting bracket
(11).
f. If necessary, remove nut (8), lockwashers (9), washers (10), and mounting bracket (11) from
counterweight.
Installation
a. If removed, install mounting bracket (11, Figure 2-11-6) on counterweight with washers (10), lockwashers
(9), and nuts (8).
b. Install hoist rotation indicator controller unit (7) on mounting bracket (11) with capscrew (6), washer (5),
lockwasher (4), and nut (3).
d. Connect electrical connectors for controller unit (7) to superstructure electrical harness and magnetic
sensor at hoist motor.
2-11-15
TM 5-3810-307-24-1-1
LEGEND
Figure 2-11-6. Main and Auxiliary Hoist Rotation Indicator Controller Unit
2-11-16
TM 5-3810-307-24-1-1
SECTION 12
OUTRIGGERS
TABLE OF CONTENTS
Page
OUTRIGGER CIRCUIT
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
OUTRIGGER BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-7
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
STABILIZER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
INTEGRATED OUTRIGGER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
SOLENOID VALVE STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-13
PILOT OPERATED CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Cylinder Mounted Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Frame Mounted Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
LIST OF FIGURES
Number Title Page
2-12-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-12-5
Ensure any blocking material used is capable of supporting the weight of
the outrigger beam. Do not allow it to tilt or slide. Failure to do so may
result in death or injury to personnel.
2-12-2
TM 5-3810-307-24-1-1
OUTRIGGER CIRCUIT
DESCRIPTION
The outrigger circuit consists of four extension of frame to the rear of the swivel. The extension and
cylinders, four stabilizer cylinders, an integrated stabilizer solenoid valves are bolted to the frame at
outrigger valve, extension and stabilizer solenoid the outrigger beams.
valves, and (pilot operated) check valves. The front
two extension cylinders are mounted in the front The OUTRIGGER SELECTOR controls are located
outrigger beams and the rear two extension cylinders in the superstructure cab on the front console. Both
are mounted in the rear outrigger beams. The front the selector valve and the solenoid valves are
and rear stabilizer cylinders are mounted on their electrically actuated from the control panel. The
respective stabilizer boxes; in turn the stabilizer solenoid switches must be held depressed to actuate
boxes are mounted on the end of each outrigger the solenoid valve. The selector valve switch is
beam. Each stabilizer cylinder has a port block spring loaded to the OFF position. The control panel
incorporated into the cylinder rod. A fifth check is placarded with switch positions.
valve, mounted to the frame, is positioned inline
between the integrated outrigger valve and the A sight bubble level is mounted on the front console
outrigger circuit to prevent reverse flow from the in the superstructure cab. The sight bubble level
piston side of the outrigger cylinders. The integrated provides the operator with a visual indication of
outrigger valve is located on the left side crane level attitude.
THEORY OF OPERATION
The appropriate OUTRIGGER SELECTOR switch valve is directed to the rod side of the cylinder. The
and OUTRIGGER EXTEND/RETRACT switch must oil in the piston side flows through the open solenoid
both be held in position. Flow from the 16 gpm (60.5 back to the integrated outrigger valve. If a stabilizer
lpm) pump section supplies the outrigger circuit. cylinder is to be retracted, then pilot pressure from
Depressing one of the OUTRIGGER SELECTOR the pressurized retract line unseats the cylinder
switches causes that solenoid valve to open. As the check valve allowing oil to flow from the piston side
EXTEND/RETRACT switch is moved, the integrated through the open solenoid valve to the integrated
outrigger valve shifts allowing flow to either the outrigger valve. The integrated outrigger valve
extend or retract line as applicable. If the directs the flow to the reservoir.
EXTEND/RETRACT switch is in the EXTEND
position, the flow continues through the open The integrated outrigger valve has two internal relief
solenoid valve to the piston side of the cylinder. If valves. A 300 psi (2068.5 kPa) thermal relief is in
the stabilizer(s) is/are to be extended, the flow first the retract circuit and a 2000 psi (13,790 kPa) relief
unseats the cylinder check valve then extends the protects the extend circuit.
cylinder. The oil from the rod end flows through the
integrated outrigger valve, and then to the reservoir. The frame mounted pilot operated check valve has a
thermal relief set to open at 4000 psi (27,580 kPa).
When the EXTEND/RETRACT switch is in the
RETRACT position, the flow through the selector
2-12-3
2-12-4
TM 5-3810-307-24-1-1
Figure 2-12-1. Outrigger Assembly
TM 5-3810-307-24-1-1
DESCRIPTION
The outrigger box assembly consists of an outrigger 2.5-inch (6.35 cm) extension cylinder, and the
beam, a 3.5-inch (10.4 cm) stabilizer cylinder, a required hoses and mounting hardware.
THEORY OF OPERATION
When the outrigger extension is activated, it extends the outrigger beam vertically. This sequence of
or retracts the outrigger beam within the outrigger events provides for lifting and stabilizing the crane for
box. The jack cylinder is mounted to the end of the operation.
beam. The jack cylinder applies force to
MAINTENANCE
REMOVAL.
2-12-5
2-12-6
TM 5-3810-307-24-1-1
Figure 2-12-2. Outrigger Beam Removal
TM 5-3810-307-24-1-1
2-12-7
TM 5-3810-307-24-1-1
EXTENSION CYLINDER
DESCRIPTION
Two outrigger extension cylinders are utilized within The extended length of the cylinders from the center
each outrigger box assembly. The extension of the rod bushing to the center of the barrel bushing
cylinders provide the force for the outrigger beam's is 149.6 inches (380.0 cm). It is attached to the
horizontal movement. The cylinders have a 2.5 inch outrigger box by means of a pin through a clevis on
(6.35 cm) diameter bore and are the double acting the barrel end of the cylinder. Attachment of the rod
type. Each cylinder has a retracted length of 84 end to the outrigger beam is by means of a pin
inches (213.4 cm) measured from the center of the through a bushing. The cylinder weighs
barrel bushing to the center of the rod bushing. approximately 81 lbs (36.7 kg).
MAINTENANCE
NOTE INSTALLATION.
Refer to CYLINDERS in Section 8 for 1. If removed, install the clamp assembly onto the
Disassembly and Assembly of the cylinder.
cylinder.
2. Tilt the cylinder so the clamp assembly will
clear the access hole and place the cylinder in the
REMOVAL. beam.
1. Remove the outrigger beam, refer to OUTRIG- 3. Position the extension cylinder so the hydraulic
GER BEAM - REMOVAL in this Section. port on the rod end of the cylinder can be accessed.
Connect the hydraulic hoses to the ports as tagged
2. Remove the cotter pin and clevis pin securing during removal.
the rod end of the extension cylinder to the outrigger
beam. 4. Push the cylinder into the outrigger beam.
Align the cylinder rod with the clevis in the beam and
3. Pull the extension cylinder from the outrigger secure in place with the clevis pin and cotter pin.
beam until the hydraulic hoses on the rod end of the
cylinder can be accessed. Tag and disconnect the 5. Install the outrigger beam, refer to
hoses from the rod end of the cylinder. OUTRIGGER BEAM - INSTALLATION in this
Section.
4. Pull the cylinder to the end of the beam. Tilt it
so the clamp assembly will clear the access hole in FUNCTIONAL CHECK.
the beam and remove the cylinder.
1. Activate the hydraulic system; extend and
5. If necessary, remove the clamp assembly from retract the outrigger.
the cylinder.
2. Observe the operation of the outrigger beam.
2-12-8
TM 5-3810-307-24-1-1
2-12-9
TM 5-3810-307-24-1-1
STABILIZER CYLINDER
DESCRIPTION
Four stabilizer cylinders are used on the crane, one inches (107.9 cm) measured from the end of the
at the end of each outrigger beam. The stabilizer cylinder barrel to the end of the cylinder rod. The
cylinders provide the force for the outrigger beam's extended length of the cylinder from the end of the
vertical movement. The cylinders have a 3.5 inch cylinder barrel to the end of the cylinder rod is 63.5
(8.9 cm) diameter bore and are the double acting inches (161.3 cm). The stabilizer cylinder weighs
type. Each cylinder has a retracted length of 42.5 approximately 114 lbs (51.7 kg).
MAINTENANCE
3. Remove the cylinder cap. 2. Remove the retaining pin and cotter pins from
the cylinder.
4. Place a jack capable of supporting the weight
of the stabilizer cylinder at the base of the cylinder 3. Lower the jack until the holes in the cylinder
barrel. Jack up the cylinder just enough to relieve rod align with the holes in the outrigger beam.
any pressure on the cylinder retaining pin. Secure the cylinder in place with the retaining pin
and cotter pins.
5. Remove the cotter pins securing the cylinder
retaining pin and remove the cylinder retaining pin. FUNCTIONAL CHECK.
6. Jack the stabilizer cylinder up just enough to 1. Activate the hydraulic system.
insert the retaining pin back into the cylinder. Insert
the retaining pin into the lugs on the cylinder and 2. Extend and retract the stabilizer cylinder.
secure in place with the cotter pins.
3. Check for smooth operation of the cylinder.
CAUTION
4. Check all hydraulic connections and hoses for
Use a nylon strap to remove the cylinder. evidence of leakage.
This will ensure the retaining pin is not
damaged.
2-12-10
TM 5-3810-307-24-1-1
2-12-11
TM 5-3810-307-24-1-1
DESCRIPTION
The integrated outrigger valve consists of five sub- on the left side of the frame to the rear of the swivel
assemblies; two solenoid valves, an inlet section, an assembly.
outlet section, and a working section. It is located
NOTE
2-12-12
TM 5-3810-307-24-1-1
DESCRIPTION
Each solenoid valve stack assembly consists of four an assembly kit. The solenoid valve stacks are
valve sections, four 24-volt solenoid assemblies, located on the outrigger boxes.
and
NOTE
2-12-13
TM 5-3810-307-24-1-1
DESCRIPTION
NOTE
2-12-14
TM 5-3810-307-24-1-1
SECTION 13
SWIVELS
TABLE OF CONTENTS
Page
SWIVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
14 PORT AIR/HYDRAULIC SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-6
ELECTRICAL SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-10
LIST OF FIGURES
2-13-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-13-9
2-13-2
TM 5-3810-307-24-1-1
SWIVELS
DESCRIPTION
The main swivel installation is a two part assembly The center of the electrical swivel, or collector core
consisting of a 14 port air/hydraulic swivel, and an assembly, is secured by setscrews to a center post
electric swivel. Solid connections cannot be used to which is bolted to the spool of the air/hydraulic swivel.
transfer oil, or electricity between the carrier and This holds the collector core assembly stationary with
superstructure due to the continuous 360 degree reference to the carrier.
swing. The use of swivels efficiently accomplishes this
function. The outer portion of the swivel, consists of brush
assemblies mounted on studs threaded into the swivel
The barrel portion of the air/hydraulic swivel is attached base plate/mounting bracket, enclosed in a protective
to the superstructure by four bolts which connect to cover. This assembly is attached to a bracket on the
mounting lugs on the barrel. The spool portion of the turntable bearing plate which rotates with the air/
swivel rides upon a thrust ring at the top of the swivel hydraulic swivel barrel and superstructure.
barrel. A retainer arm bolted to the bottom of the
spool, keeps the spool aligned with the carrier. The The electrical swivel also includes cam plates which
other end of the retainer is keyed to a lug on the carrier actuate micro switches to provide area definition
frame, which allows the retainer to float, so that the switching needed for steering, axle oscillation lockout
swivel does not bind, as the barrel rotates with the functions.
superstructure.
2-13-3
TM 5-3810-307-24-1-1
2-13-4
TM 5-3810-307-24-1-1
DESCRIPTION
Each of the ports on the spool and barrel of the swivel PORT TEST PRESSURE FUNCTION
is stamped with the port number. The function and test NUMBER
pressure of each port is described below. 7 500 psi (3447.5 kPa) Return
1 150 psi (1034 kPa) Throttle (Air) 10 3500 psi (24132.5 kPa) Supply-Steer
2 150 psi (1034 kPa) Park Brake (Air) 11 3500 psi (24132.5 kPa) Supply-O/R & Swing/AC
3 150 psi (1034 kPa) Secondary Supply (Air) 12 3500 psi (24132.5 kPa) Supply-Main/Aux Hoist
4 150 psi (1034 kPa) Primary Supply (Air) 13 3500 psi (24132.5 kPa) Supply-Lift/Tele/Clamshell
5 150 psi (1034 kPa) Delivery 1-Front (Air) 14 500 psi (3447.5 kPa) Return
THEORY OF OPERATION
The hydraulic swivel allows oil to flow from the main channel corresponds with a mating port on the barrel
pump and steer pump, to the various crane functions of the swivel. Each channel is separated by a series
on the superstructure. All oil is routed into the spool of Teflon and O-ring seals that prevents transfer of oil
portion of the swivel where, through a series of and pressure. Return oil flow from the crane functions
internally drilled passages, oil is transferred to a is accomplished in the same manner through another
circumferential channel on the spool exterior. This set of ports.
MAINTENANCE
NOTE
REMOVAL. and the turntable side plate. Shut down the engine.
1. Extend and set the outriggers. Ensure the crane 3. Measure the distance from the top of the lift
is level. cylinder to the base of the boom section where the lift
cylinder attaches. Cut a piece of 4 x 4-inch (10.16 x
2. Elevate the boom and note at what boom angle 10.16 cm) oak to fit.
you have the most clearance between the lift cylinder
2-13-5
TM 5-3810-307-24-1-1
5. Remove the electrical swivel, refer to The hydraulic swivel weighs approximately
ELECTRICAL SWIVEL - REMOVAL in this Section. 203 lbs (92 kg).
6. Bleed air pressure from the air system at the air 11. Position an adequate supporting device beneath
system reservoirs. the swivel.
7. Tag and disconnect six air lines at the air/hydra- 12. Remove the bolts, and washers securing the
ulic swivel, ports 1 thru 6. Install plugs, couplers, and swivel to the superstructure and lower the swivel to the
fittings in each of the disconnected air lines except for ground.
those connected to port nos. 5 and 6. Bundle the
disconnected air lines in plastic wrap and tie wraps. INSTALLATION.
Then tie wrap them to the carrier, up and out of the
way. Cover/plug the six air line openings in the 1. Raise the swivel into position.
air/hydraulic swivel.
2. Secure the swivel to the turntable with the
NOTE bushings, bolts, and washers. Torque the bolts to 250
Use suitable drip pan to catch hydraulic oil. lbs-ft (338.9 Nm).
Remove the split flange hydraulic return 3. Install the electrical swivel, refer to ELECTRICAL
line hose connected to air/hydraulic swivel SWIVEL - INSTALLATION in this Section.
port no. 14 last.
4. Install the hydraulic lines to the spool as tagged
8. Tag and disconnect seven hydraulic hoses on during removal.
the bottom of the air/hydraulic swivel, ports 7 thru 13.
Install plugs in the hydraulic hoses and caps on the 5. Remove protective covers on both ends of
air/hydraulic swivel ports. Cover all loose hydraulic hydraulic return line hose. Remove flange plugs in
hoses with plastic wrap/bag and tape or tie wrap. Then hydraulic tank and in air/hydraulic swivel port no. 14.
tie wrap them to the carrier, up and out of the way. Retain split flanges and attaching hardware. Install
hydraulic return line hose between port no. 14 and
NOTE hydraulic tank. Secure with bolts and split flanges.
There will be considerable hydraulic oil 6. Cut tie wraps; remove plastic wrap/bags, plugs,
draining from the hydraulic drain line hose. and caps; and connect seven hydraulic hoses on the
bottom of the air/hydraulic swivel, ports 7 thru 13 as
tagged. Remove all tags.
2-13-6
TM 5-3810-307-24-1-1
2-13-7
TM 5-3810-307-24-1-1
7. Cut tie wraps; remove plastic wrap/bags; and 9. Service the hydraulic tank with oil, MIL-L-2104.
connect three multi-pin electrical connectors at the
electrical slip ring as tagged. Secure cable clamps to 10. Remove the blocking material from the lift
frame with two bolts. Be sure to capture the slip ring cylinders.
ground wire in one of the two clamp bolts. Remove all
tags. 11. Activate all systems; cycle all functions and
observe for proper operation and any leakage.
8. Cut tie wraps and remove plugs, covers,
couplers, and fittings in each of the disconnected air
lines. Connect all six air lines to the air/hydraulic
swivel, ports 1 thru 6, as tagged. Remove all tags.
2-13-8
TM 5-3810-307-24-1-1
ELECTRICAL SWIVEL
DESCRIPTION
The electrical swivel consists of brushes, collector each ring) stacked alternately on two brush holding
rings, and a cover assembly. The swivel uses 46 sets studs which are threaded into the swivel mounting
of brushes and collector rings. plate. The stack is completed by a nylon plate
attached across both studs. It acts as a bearing for the
Each collector ring and lead assembly is mounted on a outer end of the collector core, and holds the brush
nylon bushing/insulator. These are stacked together to arms firmly on the studs, in proper alignment with the
form the collector core. The core assembly extends rings. Leads from the brush sets are formed into four
though the swivel mounting plate and is attached to connectors, attached to the mounting plate, which
the center post with set screws. Collector ring leads mate with connectors on the superstructure wiring
are formed into one harness which is routed downward harness.
through the center post, and the center of the hydraulic
swivel. Extending from the base of the hydraulic The electrical swivel also incorporates a cam plate and
swivel, the harness is separated and routed into four area definition switches. These switches control
connectors which mate with receptacles from the functions in the load moment indicating system,
carrier wiring harness. superstructure steering, and the axle oscillation
system.
Brushes with leads, are mounted in pairs, on holder
arms, to match each ring. Tension springs on the The swivel is protected by a sealed cover which is
holder arms assure contact between brushes and the attached by two bolts to the base plate/mounting
collector rings. The brush arm assemblies (one for bracket.
MAINTENANCE
NOTE
REMOVAL. NOTE
1 Perform steps 1 through 4 of 14 PORT AIR/- Do not disconnect the collector ring wires
HYDRAULIC SWIVEL - REMOVAL in this Section. crimped at the top of the swivel assembly.
2. Position battery disconnect switch to OFF. 5. Tag the round connectors and their receptacles
with numbers 1 and 2. Disconnect both connectors
from the chassis wiring receptacles.
2-13-9
TM 5-3810-307-24-1-1
The round connectors are too large to go 14. Remove the rectangular connectors and wires
through the center of the hydraulic swivel. (part of the superstructure wiring harness) and secure
They must be removed. them and the round connector receptacles to the
turntable side plates.
6. Tag each wire on connector 1. Using pin
removal tools listed in Section 14 - ELECTRICAL 15. Remove the bolt securing the swivel base to the
SYSTEM, remove the pins, with wires still attached, mounting bracket.
and mark each wire with the pin socket number in the
connector. Collect the wires and secure into one 16. Remove three setscrews securing the swivel
bundle. Mark the bundle with the connector number. core assembly to the center post.
8. Secure the rectangular connectors, and the When withdrawing the wiring harness
wires from the connectors 1 and 2, so the harness can through the center of the swivel, ensure
be withdrawn through the center of the swivel. the rectangular connectors do not get
caught and damaged.
9. Remove the attachment screws and remove the
swivel cover and seal. 17. Remove the swivel and wiring harness from the
crane.
10. Tag and disconnect the two rectangular
connectors.
INSTALLATION.
11. Tag and disconnect the two round connectors
from the receptacles on the mounting plate. 1. Route the collector core wiring harness through
the center of the hydraulic swivel, and insert the center
post into the base of the core assembly
NOTE
Figure 2-13-3. Connector Receptacle 5. Tighten the bolt securing the swivel to the
bracket.
12. Remove the screws securing the round
connector receptacles to the mounting plate. 6. Install the rectangular connectors and wires into
the connector receptacle cutout on the mounting plate.
2-13-10
TM 5-3810-307-24-1-1
2-13-11
TM 5-3810-307-24-1-1
7. Install the round connector receptacles into the 10. Connect each of the wires from connector one
mounting plate and secure with the screws. into connector one.
8. Connect the round connectors and the 11. Connect each of the wires from connector two
rectangular connectors as tagged. into connector two.
9. Install the swivel cover, gasket, and screws. 12. Plug the round and rectangular connectors into
the chassis wiring receptacles.
NOTE
13. Connect the batteries.
Steps 10 and 11 are performed on the
collector ring harness after it has been 14. Activate all systems; cycle all functions and
routed down through the hydraulic and air observe for proper operation.
swivel.
2-13-12
TM 5-3810-307-24-1-1
SECTION 14
ELECTRICAL SYSTEM
TABLE OF CONTENTS
Page
2-14-1
TM 5-3810-307-24-1-1
LIST OF FIGURES
Number Title Page
LIST OF TABLES
Name Title Page
2-14-2
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-14-14
If it should become necessary to perform electrical maintenance on live or hot
circuits, remove all rings, watches, and other jewelry before performing
maintenance as serious burns result from accidental grounding or shorting
circuits.
WARNING 2-14-14
Ensure the batteries are disconnected before performing any maintenance on
an electrical circuit.
2-14-3/(2-14-4 Blank)
TM 5-3810-307-24-1-1
ELECTRICAL SYSTEM
DESCRIPTION
The electrical system is 24-volt operation with 24-volt output terminals. When the engine is running, the 24-
starting, consisting of an alternator, and four 12-volt volt terminal supplies power to the machine electrical
lead-acid batteries, series-parallel connected. The circuits and the voltage to recharge the batteries and
system is a single wire ground return type, utilizing the maintain them at a full state of charge.
machine's structure as ground.
BATTERIES.
Electrical power is transferred to and from the carrier
and superstructure through the electrical swivel. For The four 12-volt batteries are located in a box on the
more detailed information on the electrical swivel, refer right side of the carrier in front of the fuel tank. The
to Section 13 - SWIVELS. cover is secured with an adjustable draw latch and
hinges downward to open. A two-position battery
Electrical schematics and wiring diagrams are located disconnect switch is located below the battery box.
at the back of this manual. Refer to Figure 2-14-1 for The switch completes or interrupts the battery circuit by
locations of major electrical components. connecting or disconnecting the circuit to ground.
2-14-5
TM 5-3810-307-24-1-1
CARRIER CAB
2-14-6
TM 5-3810-307-24-1-1
SUPERSTRUCTURE CAB
2-14-7
2-14-8
TM 5-3810-307-24-1-1
CARRIER FRAME
TM 5-3810-307-24-1-1
2-14-9
TM 5-3810-307-24-1-1
SUPERSTRUCTURE
TM 5-3810-307-24-1-1
CONNECTOR 29. BATTERY JUNCTION BOX 46. MAIN JUNCTION BOX 65. WINDSHIELD WASHER
11. WINDSHIELD WIPER MOTOR 30. BATTERY DISCONNECT 47. BOOM REST SWITCH BOTTLE
12. CIRCULATING FAN SWITCH 48. FULE LINE HEATER 66. FUEL LINE HEATER &
13. WORK LIGHT 31. BATTERY BOX 49. FUEL TEMP. SWITCH THERMOSTAT
14. STEERING COLUMN 32. FUEL LEVEL SENDER 50. 2WD SELECT SWITCH 67. SWING BRAKE SOLENOID
CONNECTOR 33. REAR STEER PINNED 51. FUEL HEATER RELAY 68. LOW AIR PRESS. SWITCHES
15. BOOST SWITCH SENSOR 52. STEER REVERSING SOLENOID 69. A/C CONDENSER
16. HEATER SWITCH 34. REAR DIFF. LOCK SWITCH 53. HYD. OIL COOLER TEMP.
2-14-11
SWITCH
CIRCUIT BREAKERS
CB6 10 WIPER/WASHER
CB12 10 HORN
2-14-12
TM 5-3810-307-24-1-1
CIRCUIT BREAKERS
CB7 15 OUTRIGGERS
2-14-13
TM 5-3810-307-24-1-1
MAINTENANCE
2-14-14
TM 5-3810-307-24-1-1
2-14-15
TM 5-3810-307-24-1-1
2-14-16
TM 5-3810-307-24-1-1
Removal
b. Remove capscrew (1, Figure 2-14-5), lockwasher (2), and negative battery cable (3) from NATO slave
receptacle (11).
c. Remove capscrew (4), lockwasher (5), and positive battery cable (6) from NATO slave receptacle (11).
d. Remove nuts (7), lockwashers (8), washers (9), screws (10), and NATO slave receptacle (11) from vehicle.
Installation
CAUTION
a. Install NATO slave receptacle (11, Figure 2-14-5) on vehicle with screws (10), washers (9), lockwashers (8),
and nuts (7).
b. Connect positive battery cable (6) to "+" side of NATO slave receptacle (11) with lockwasher (5) and capscrew
(4).
c. Connect negative battery cable (3) to "-" side of NATO slave receptacle (11) with lockwasher (2) and capscrew
(1).
2-14-17
TM 5-3810-307-24-1-1
LEGEND
1. Capscrew 7. Nut
2. Lockwasher 8. Lockwasher
3. Negative battery cable 9. Washer
4. Capscrew 10. Screw
5. Lockwasher 11. NATO slave receptacle
6. Positive battery cable
INSTRUMENTS. Installation.
2. Remove the hardware securing the gauge to the Start the engine and observe for proper functioning of
dash panel; then remove the gauge. the repaired indicator. (Refer to Operator's Manual).
Troubleshoot further as necessary any system
3. Tag and disconnect the electrical leads to the malfunction not corrected by repair or replacement of
gauge; then tape the lead ends. the indicator or associated wiring.
Check gauge terminals and mounting studs for Procedures are typical for all switches
damage. except AIR CONDITIONER and PANEL
DIM switches in superstructure cab, and
IGNITION and WIPER/WASHER switches
in both cabs.
Removal.
Inspection.
2-14-19
TM 5-3810-307-24-1-1
Functional Check.
2-14-20
TM 5-3810-307-24-1-1
IGNITION SWITCH
Removal
b. Remove retaining ring (1, Figure 2-14-8) and ignition switch (2) from dash panel.
Installation
b. Install ignition switch (2, Figure 2-14-8) in dash panel with retaining ring (1).
LEGEND
1. Retaining ring
2. Ignition switch
2-14-21
TM 5-3810-307-24-1-1
Removal
b. Disconnect electrical connector for windshield wiper/washer switch (4, Figure 2-14-9).
c. Loosen set screw and remove knob (1) from switch (4).
d. Remove nut (2), washer (3), and windshield wiper/washer switch (4) from dash panel.
Installation
a. Position windshield wiper/washer switch (4, Figure 2-14-9) in dash panel, and secure with washer (3) and nut
(2).
b. Install knob (1) on windshield wiper/washer switch (4) and tighten set screw.
LEGEND
2-14-22
TM 5-3810-307-24-1-1
Removal
b. Tag and disconnect electrical leads from rheostat (4, Figure 2-14-10).
c. Loosen screw (part of knob). Then remove knob (1), nut (2), washer (3), and rheostat (4) from dash panel.
Installation
a. Position rheostat (4, Figure 2-14-10) in dash panel and secure with washer (3) and nut (2).
b. Install knob (1) on stem of rheostat (4). Tighten screw (part of knob).
LEGEND
1. Knob
2. Nut
3. Washer
4. Rheostat
2-14-23
TM 5-3810-307-24-1-1
Removal
(2) Tag and disconnect electrical leads from LED clusters (21, Figure 2-14-11).
(3) Remove nuts (1), lockwashers (2), washers (3), screws (4), light strip (5), and panel (6) from dash panel.
(1) Remove nuts (7, Figure 2-14-11), lockwashers (8), washers (9), screws (10), light strip (11), and panel
(12) from dash panel.
(2) Tag and disconnect electrical leads from LED clusters (21).
(2) Tag and disconnect electrical leads from LED cluster (17, Figure 2-14-11).
(3) Remove nuts (13), lockwashers (14), washers (15), screws (16), LED cluster (17), gasket (18), and
panel (19).
NOTE
(1) Remove capscrews (20) securing each LED cluster to light strip (5 or 11) as applicable.
(2) Remove LED cluster (21) and gasket (22) from light strip.
Installation
(1) Position gasket (22, Figure 2-14-11) and LED cluster (21) on light strip (5 or 11) as applicable. Ensure
arrow on diode is pointing up.
(2) Secure LED cluster (21) and gasket (22) with capscrews (20).
2-14-24
TM 5-3810-307-24-1-1
(1) Position panel (19, Figure 2-14-11), gasket (18), and LED cluster (17) in dash panel. Ensure arrow on
diode is pointing up.
(2) Secure panel (19), gasket (18), and LED cluster (17) with screws (16), washers (15), lockwashers (14),
and nuts (13).
(3) Connect electrical leads, remove tags, and install access panel on top of dash panel.
(1) Position light strip (11, Figure 2-14-11) near dash panel, connect electrical leads, and remove tags.
(2) Position panel (12) and light strip (11) in dash panel and secure with screws (10), washers (9),
lockwashers (8), and nuts (7).
(1) Position panel (6, Figure 2-14-11) and light strip (5) in dash panel and secure with screws (4), washers
(3), lockwashers (2), and nuts (1).
(2) Connect electrical leads, remove tags, and install access panel on top of dash panel.
2-14-25
TM 5-3810-307-24-1-1
LEGEND
2-14-26
TM 5-3810-307-24-1-1
Removal
b. Unscrew knobs and move LMI display console aside. Then remove access panel from top of dash panel.
NOTE
d. Pinch locking tabs (Figure 2-14-12) on sides of light and remove light from dash panel.
Installation
a. Push light (Figure 2-14-12) into dash panel until locking tabs on sides of light pop out.
c. Install access panel on top of dash panel. Install LMI display console.
2-14-27
TM 5-3810-307-24-1-1
Removal
b. Disconnect backup alarm (6, Figure 2-14-13) electrical connector from carrier electrical harness.
c. Remove nuts (1), lockwashers (2), washers (3), capscrews (4), washers (5), and backup alarm (6) from carrier
frame.
Installation
a. Insert capscrews (4, Figure 2-14-13) with washers (5) through holes in carrier frame.
b. Position backup alarm (6) over capscrews (4) and install ground wire on capscrew (4) on terminal side of
backup alarm.
c. Secure backup alarm (6) to carrier frame with washers (3), lockwashers (2), and nuts (1).
LEGEND
2-14-28
TM 5-3810-307-24-1-1
Removal
b. Tag electrical leads and disconnect superstructure electrical harness lead from backup alarm (4, Figure 2-14-
14).
c. Remove nuts (1), lockwashers (2), washers (3), ground wires, backup alarm (4), and washers (5) from
superstructure frame.
Installation
a. Position washers (5, Figure 2-14-14) and backup alarm (4) on studs on superstructure frame.
b. Place ground wires from backup alarm (4) and superstructure electrical harness on stud at terminal side of
backup alarm.
c. Secure backup alarm (4) to carrier frame with washers (3), lockwashers (2), and nuts (1).
LEGEND
2-14-29/(2-14-30 Blank)
TM 5-3810-307-24-1-1
SECTION 15
EMERGENCY STOWAGE SYSTEM
TABLE OF CONTENTS
Page
LIST OF FIGURES
Number Title Page
2-15-1
TM 5-3810-307-24-1-1
WARNING SUMMARY
Page
WARNING 2-15-4
2-15-6
Do not attempt to loosen fittings in pressurized lines or while hydraulic
pumps are in operation.
2-15-4
WARNING
2-15-6
Ensure that all hydraulic systems are shut down and the pressure is
relieved.
2-15-8
WARNING
If it should become necessary to perform electrical maintenance on live or
hot circuits, remove all rings, watches, and other jewelry before
performing maintenance as serious burns result from accidental
grounding or shorting circuits.
WARNING 2-15-8
2-15-2
TM 5-3810-307-24-1-1
DESCRIPTION
2-15-3
TM 5-3810-307-24-1-1
DESCRIPTION
The 3-way valve assembly is a manually operated hydraulic flow of the emergency stowage pump, all
ball valve used to direct flow to either the crane hoist craning functions can not be supplied at the same
functions or telescope and lift functions during time. It is therefore necessary to reposition the valve
emergency stowage operations. Due to the limited control lever to operate the different functions.
MAINTENANCE
2-15-4
TM 5-3810-307-24-1-1
LEGEND
2-15-5
TM 5-3810-307-24-1-1
Pump/Motor Assembly
DESCRIPTION
The emergency stowage system pump/motor The electric motor, operates on power received
assembly is comprised of a 24 VDC electric motor through the electrical control box to drive the
and a positive displacement, gear-type, single hydraulic pump which provides the hydraulic flow
section hydraulic pump with an output of 2 gpm (7.6 required for emergency stowage operations.
lpm).
MAINTENANCE
2-15-6
TM 5-3810-307-24-1-1
LEGEND
2-15-7
TM 5-3810-307-24-1-1
DESCRIPTION
The emergency stowage system electrical control batteries through the NATO slave receptacle. When
box assembly is comprised of an ON/OFF control the switch is moved to ON, power is sent to the
switch, a 400 amp power relay, two 44 joules metal power relay which closes and transfers battery
oxide varistor (MOV) assemblies, and a wiring power to operate the electric motor to drive the
harness to connect the control switch to the relay. hydraulic pump. The switch can also be powered by
an external 24 VDC source connected to the NATO
The control switch receives power from the vehicle's slave receptacle.
MAINTENANCE
REMOVAL. REPAIR.
WARNING 1. Disassemble electrical control box (4, Figure 2-
If it should become necessary to perform 15-3) as necessary to replace worn, damaged, or
electrical maintenance on live or hot cir- defective components:
cuits, remove all rings, watches, and other
jewelry before performing maintenance as a. Remove nuts (5 and 6), then tag and
serious burns result from accidental remove MOV assemblies (7) and
grounding or shorting circuits. electrical wires from power relay (11).
2-15-8
TM 5-3810-307-24-1-1
LEGEND
1. Install control box (4, Figure 2-15-3) on vehicle Operate emergency stowage system. Check system
mounting plate with capscrews (3), washers (2), and for proper operation.
new locknuts (1).
2-15-10
TM 5-3810-307-24-1-1
SECTION 16
PREPARATION FOR STORAGE OR SHIPMENT
TABLE OF CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-1
PRESERVATION, PACKAGING, PACKING, MARKING, AND SHIPPING REQUIREMENT . . . . . . . . . . 2-16-1
SHORT TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-1
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-2
PREPARATION FOR SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-2
INTRODUCTION
Before storing the crane for long periods or shipping it to a distant location, certain preparations must be made to
ensure operational readiness when the crane is placed in service again.
General
These instructions provide minimum preservation and interim storage requirements for the crane. Components
not to be painted will be coated with a preservative, whose application, removal, or use will not damage the
mechanism, structure, or function of the component or end item.
The crane should be stored in an "operation-ready" status wherein all fluid levels and lubrication points are
maintained in an operational status.
Diesel Engine
Refer to TM 5-3810-307-24-2-2, page 14-23 for short term diesel engine storage instructions.
Fuel Tank
Draining of fuel tanks is not required. If fuel tank is empty, no preservation is required.
Sealing of Openings
Openings that will permit direct entry of water will be sealed with pressure-sensitive tape conforming to PPP-T-60,
Type IV. Large openings will be bridged with waterproof barrier material conforming to PPP-B-1055, and the
edges of the barrier material secured to adjacent surfaces with tape.
Lubricating System
Lubricate the equipment in accordance with the lubrication chart. Check lubricant for level and condition.
Operate the engine until it reaches normal operating temperature to ensure complete lubrication of bearings,
gears, etc. The oil will remain in the crankcase.
2-16-1 C-1
TM 5-3810-307-24-1-1
NOTE
Once the crane is stored, periodically cycle the crane through all of its crane
functions.
In long term storage where periodic cycling of crane functions is not feasible, preserve the crane in accordance
with the procedures contained in MIL-STD-162E, Preparation for Shipment, Storage, Cycle Maintenance (of)
Material Handling Equipment (Level A).
Diesel Engine
Refer to TM 5-3810-307-24-2-2, page 14-25 for long term diesel engine storage instructions.
Batteries filled and fully charged will be secured in the battery compartment. The cable terminals will be
disconnected and secured to the battery support with tape to prevent grounding.
Packaging
Loose components on the crane should be secured with rope or tape to prevent damage. The cab door should
be secured in the closed position with strapping.
Marking
Waterproof shipping tags will be affixed to the crane. The tags may be white or manila colored cloth or paper.
The information required should be printed in waterproof ink or type; and the tag waterproofed with shellac, spar
varnish, laminated plastic or other suitable transparent waterproofing compound.
1. Remove the hook block and anti-two block weight. Stow both of these in a shipping container.
2. Start the diesel engine and take up wire rope onto hoist drum. Secure wire rope end.
3. Engage the superstructure locking pin and lower the boom until it rests on the boom cradle.
5. Retract and raise the outriggers, if necessary. Remove and stow the outrigger stabilizer pads on the rear of
the crane.
(a) Cushion and tape the LMI console, defroster fan, and load chart.
2-16-2 C-1
TM 5-3810-307-24-1-1
7. Prepare the boom for shipment by taping the boom hose reel hoses to the lower boom nose sheave shaft.
(d) Fold mirrors (on cab and on carrier right side) in toward crane.
12. Preserve the crane in accordance with MIL-STD-162, Preparation for Shipment, Storage Cyclic
Maintenance of Material Handling Equipment (Level A).
2-16-3/(2-16-4 Blank)
TM 5-3810-307-24-1-1
APPENDIX A
Section I. INTRODUCTION
a. This introduction (section I) provides a general explanation of all maintenance and repair
functions authorized at various maintenance levels under the standard Army Two-Level
Maintenance System concept.
b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and
responsibility for the performance of maintenance functions on the identified end item or
component. The application of maintenance functions to the end item or component will be
consistent with the capacities and capabilities of the designated maintenance levels, which are
shown on the MAC in column (4) as:
c. Section III lists the tools and test equipment (both special tools and common tool sets) required
for each maintenance function as referenced from section II.
b. Test. To verify serviceability and to detect incipient failure by measuring the mechanical or
electrical characteristics of an item and comparing those characteristics with prescribed
standards.
A-1 C-1
TM 5-3810-307-24-1-1
c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to
clean (decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical,
or gases.
d. Adjust. To maintain, within prescribed limits, by bringing into proper or exact position, or by
setting the operating characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired
performance.
g. Remove/Install. To remove and install the same item when required to perform service or
other maintenance functions. Install may be the act of emplacing, seating, or fixing into
position a spare, repair part, or module (component or assembly) in a manner to allow the
proper functioning of an equipment or system.
h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.
i. Repair. The application of maintenance services (inspect, test, service, adjust, align, calibrate,
replace) or other maintenance actions (welding, grinding, riveting, straightening, facing,
remachining, or resurfacing) to restore serviceability to an item by correcting specific damage,
fault, malfunction, or failure in a part, subassembly, module (component or assembly) end item,
or system.
a. Column (1) - Group Number. Column 1 lists functional group code numbers, the purpose of
which is to identify components, assemblies, subassemblies, and modules within the next
higher assembly.
A-2 C-1
TM 5-3810-307-24-1-1
c. Column (3) - Maintenance Function. Column 3 lists the functions to be performed on the
item listed in column 2.
d. Column (4) - Maintenance Level. Column 4 specifies, by the listing of a work time figure in
the appropriate subcolumn(s), the lowest level of maintenance authorized to perform the
function listed in column 3. This figure represents the active time required to perform that
maintenance function at the indicated level of maintenance. If the number or complexity of
tasks within the listed maintenance function vary at different maintenance levels, appropriate
work time figures will be shown for each level. The work time figure represents the average
time required to restore an item (assembly, subassembly, component, module, end item, or
system) to a serviceable condition and typical field operating conditions. This time includes
preparation time, (including necessary disassembly/assembly time), troubleshooting/fault
location time, and quality assurance/quality control time in addition to the time required to
perform the specific tasks identified for the maintenance function authorized in the
maintenance allocation chart. The symbol designations for the various maintenance levels are
as follows:
e. Column (5) - Tools and Equipment. Column 5 specifies by code, those common tool sets,
(not individual tools) and special tools, TMDE, and support equipment required to perform the
designated function.
a. Column (1) - Reference Code. The tool and test equipment reference code correlates with a
code used in the MAC, Section II, column 5.
b. Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool
or test equipment.
c. Column (3) - Nomenclature. This column lists the name and nomenclature of the tools and
test equipment required to perform the maintenance function.
d. Column (4) - National/NATO Stock Number. This column lists the National/NATO stock
number of the specific tool or test equipment.
e. Column (5) - Tool Number. This column lists the manufacturer's part number of the tool
followed by the Contractor and Government Entity (CAGE) code (five digits) in parenthesis.
A-3 C-1
TM 5-3810-307-24-1-1
a. Column (1) - Reference Code. This code refers to the appropriate item in Section II, Column
6 of the MAC.
b. Column (2) - Remarks. This column provides the required explanatory information necessary
to clarify items appearing in Section II of the MAC.
A-4 C-1
TM 5-3810-307-24-1-1
C O F H D
A-5 C-1
TM 5-3810-307-24-1-1
C O F H D
A-6 C-1
TM 5-3810-307-24-1-1
C O F H D
C O F H D
A-8 C-1
TM 5-3810-307-24-1-1
C O F H D
A-9 C-1
TM 5-3810-307-24-1-1
C O F H D
09 PROPELLER &
PROPELLER SHAFTS:
DRIVE LINE INSPECT 0.2
ASSEMBLIES SERVICE 0.1 7
REPLACE 1.5 6,7
REPAIR 1.0 6,7,11
10 FRONT AXLE:
1000 FRONT AXLE ASSY: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7,11
REPLACE 4.0 6,7,11
REPAIR 8.0 6,7,11
1002 DIFFERENTIAL: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7,11
REPLACE 4.0 6,7,11
REPAIR 3.0 6.0 6,7,11 P
1003 PLANETARY DRIVE: INSPECT 0.1 0.1 1
SERVICE 0.3 1,7,11
REPLACE 4.0 6,7,11
REPAIR 4.0 6,7,11
11 REAR AXLE:
1100 REAR AXLE ASSY: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7
REPLACE 4.0 6,7,11,14
REPAIR 8.0 6,7,9,11,14
1102 DIFFERENTIAL: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7
REPLACE 4.0 6,7,11,14
REPAIR 3.0 6.0 6,7,9,11,14 P
1103 PLANETARY DRIVE: INSPECT 0.1 0.1 1
SERVICE 0.3 1,7
REPLACE 4.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
A-10 C-1
TM 5-3810-307-24-1-1
C O F H D
12 BRAKES:
1202 SERVICE BRAKE SHOES INSPECT 0.5 0.5 1,7
AND RELATED PARTS: ADJUST 0.2 0.2 1,7
REPLACE 4.0 1,7,9,14
REPAIR 2.0 1,7,9,14 M
1208 AIR BRAKE SYSTEM:
BRAKE CHAMBER INSPECT 0.1 0.1
REPLACE 1.0 6,7,14
REPAIR 1.0 6,7,14 N
AIR RESERVOIRS INSPECT 0.1 0.1 0.1
REPLACE 1.0 6,7
AIR DRYER INSPECT 0.1 0.1
TEST 0.2 1,7
SERVICE 0.1 0.5 1,7 E
REPLACE 1.0 1,7,14
AUTOMATIC DRAIN INSPECT 0.1 0.1
VALVE TEST 0.5 1,7,14
SERVICE 0.1 0.5 1,7 E
REPLACE 1.0 1,7,14
SERVICE AND PARK INSPECT 0.1 0.1
BRAKE RELAY VALVES TEST 0.2 0.5 1,6,7
SERVICE 0.1 0.5 1,6 E
REPLACE 1.0 1,6,7,14
CARRIER AND INSPECT 0.1 0.1
SUPERSTRUCTURE CAB TEST 0.5 6
BRAKE VALVES SERVICE 0.1 0.5 1,6,7 E
REPLACE 1.5 6,7
SPRING BRAKE INSPECT 0.1 0.1
CONTROL VALVE TEST 0.5 6
SERVICE 0.1 0.5 1,6,7,11 E
REPLACE 1.0 6,7,11
LINES, HOSES, INSPECT 0.1 0.1
FITTINGS REPLACE 0.4 1,2,7,11
1209 AIR COMPRESSOR INSPECT 0.1 0.1
ASSY: SERVICE 0.1 0.5 1,6,7 E
REPLACE 1.5 6,7,11,14
REPAIR 4.0 6,7,11,14
A-11 C-1
TM 5-3810-307-24-1-1
C O F H D
A-12 C-1
TM 5-3810-307-24-1-1
C O F H D
A-13 C-1
TM 5-3810-307-24-1-1
C O F H D
A-14 C-1
TM 5-3810-307-24-1-1
C O F H D
A-15 C-1
TM 5-3810-307-24-1-1
C O F H D
74 CRANES, SHOVELS,
AND EARTH MOVING
EQUIPMENT
7411 CRANE OR CLAMSHELL
COMPONENTS:
BOOM ASSEMBLY INSPECT 0.1 0.1 0.2 1,6,7,11
SERVICE 0.3 1,7,11
REPLACE 10.0 6,7,11,14
REPAIR 6.5 6,7,11,14
BOOM SHEAVES INSPECT 0.1 0.1 0.1
SERVICE 0.1 1,7,11
REPLACE 0.5 1,7,11
REPAIR 0.5 6,7,11,14
HOOK BLOCK INSPECT 0.1 0.1 0.1
SERVICE 0.1 1,7,11
REPLACE 1.0 1
REPAIR 2.0 1,7,11,18
WIRE ROPE INSPECT 0.1 0.1
SERVICE 0.3 1,7,11
REPLACE 1.0 1,18
CLAMSHELL ASSEMBLY INSPECT 0.1 0.1 0.1
REPLACE 1.0 1
REPAIR 1.5 6,7,11,18
GRAPPLE ASSEMBLY INSPECT 0.1 0.1 0.1
REPLACE 1.0 1
REPAIR 1.5 6,7,11,18
7413 PILE DRIVER INSPECT 0.1 0.1
ATTACHMENT REPLACE 1.0 1,18
SHIPPING/STORAGE INSPECT 0.1
CONTAINER SERVICE 0.1
REPAIR 0.2 0.5 1,6,20
LEAD TOWER INSPECT 0.2
ASSEMBLY SERVICE 0.3
REPAIR 0.2 1.0 1,2,6
REPLACE 1.0
SPOTTER ASSEMBLY INSPECT 0.1
SERVICE 0.2
REPAIR 0.5 1.0 1,2,6,20
A-16 C-1
TM 5-3810-307-24-1-1
C O F H D
REPLACE
1.0
IMPACT HAMMER INSPECT 0.2
SERVICE 0.8
REPAIR 1.5 1,2
REPLACE 1.0
FUEL SYSTEM INSPECT 0.3
SERVICE 0.5 1.0 1,2
REPAIR 1.5 1,2
REPLACE 2.0 1,2
HAMMER TRIP SYSTEM INSPECT 0.3
SERVICE 0.2
REPAIR 1.5 1,2
REPLACE 2.0 1,2
LUBE OIL SYSTEM INSPECT 0.5
SERVICE 1.0 1,2
REPAIR 1.0 1,2
REPLACE 2.5 1,2
7417 HOISTS:
MAIN HOIST INSPECT 0.1 0.1 0.1
ADJUST 0.5 1,7,11
SERVICE 0.5 1,7,11
REPLACE 2.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
MAIN HOIST MOTOR INSPECT 0.1 0.1 0.1
REPLACE 1.0 6,7,11,12,14
REPAIR 2.0 6,7,11,12,14
AUXILIARY INSPECT 0.1 0.1 0.1
HOIST ADJUST 0.5 1,7,11
SERVICE 0.5 1,7,11
REPLACE 2.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
AUX HOIST MOTOR INSPECT 0.1 0.1 0.1
REPLACE 1.0 6,7,11,12,14
REPAIR 2.0 6,7,11,12,14
HOIST ROTATION INSPECT 0.1
INDICATOR REPLACE 0.5 1,3,6,7,13
A-17 C-1
TM 5-3810-307-24-1-1
C O F H D
7419 TURNTABLE:
SWING BEARING INSPECT 0.1 0.1 0.1
SERVICE 0.3 1,6,7,11
REPLACE 8.0 6,7,11,12,13,
14,18
PLANETARY DRIVE INSPECT 0.1 0.1
AND GEAR REDUCER SERVICE 0.2 1,7,11
REPLACE 4.0 6,7,11,14
REPAIR 4.0 6,7,9,11
SWING MOTOR INSPECT 0.1 0.1
REPLACE 1.5 6,7,11,14
AIR/HYDRAULIC INSPECT 0.1 0.1
SWIVEL TEST 1.0 6,7,11,14
REPLACE 6.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
ELECTRICAL SWIVEL INSPECT 0.1 0.1
REPLACE 4.0 6,7,11,13,14
REPAIR 2.0 2.0 6,7,9,11,13,14 Q
A-18 C-1
TM 5-3810-307-24-1
TOOL OR TEST
EQUIPMENT MAINTENANCE NATIONAL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER TOOL NUMBER
1 O TOOL KIT, GENERAL 5180-00-177-7033 SC5180-90-CL-N26
MECHANIC'S
AUTOMOTIVE
2 O SHOP EQUIPMENT, 4910-00-754-0654 SC4910-95-CL-A74
AUTOMOTIVE MAINT
AND REPAIR, ORG LEVEL
COMMON NO. 1
3 O MULTIMETER, DIGITAL 6625-01-139-2512 N60449
4 F SHOP EQUIPMENT, 4940-00-209-6239 SC4940-95-CL-A63
CANVAS AND GLASS
SHOP, SHELTER MTD
5 F TEST STAND, AUTO 4910-00-767-0218 MIL T4544
GENERATOR AND
STARTER, FLOOR
MTD
6 F,H TOOL KIT, MASTER 5180-00-699-5273 SC5180-90-CL-N05
MECHANIC'S
7 F,H SHOP EQUIPMENT, 4910-00-754-0705 SC4940-95-CL-A31
AUTOMOTIVE MAINT
AND REPAIR, FIELD,
BASIC, LESS POWER
8 F,H SHOP EQUIPMENT, 4940-01-150-3113 SC4940-95-CL-B05
ELECTRICAL REPAIR,
SEMITRAILER MTD
9 F,H SHOP EQUIPMENT, 3470-00-754-0708 SC3470-95-CL-A02
MACHINE SHOP,
FM BASIC
10 F,H SHOP EQUIPMENT, 4940-00-357-7268 SC4940-95-CL-A08
WELDING, FIELD
MAINTENANCE
11 F,H SHOP EQUIPMENT, 4910-00-754-0706 SC4910-95-CL-A62
AUTO MAINTENANCE AND
REPAIR, FM SUPPL NO. 1
12 F,H TOOL OUTFIT, HYD 4940-01-036-5784 SC4940-95-CL-B07
SYSTEM TEST AND
REPAIR, 3/4 TON
TRAILER MTD
A-19 C-1
TM 5-3810-307-24-1
A-20 C-1
TM 5-3810-307-24-1
REMARKS
CODE REMARKS
ALPHABETICAL INDEX
Index-1 C-1
TM 5-3810-307-24-1-1
A - Continued
Index-2 C-1
TM 5-3810-307-24-1-1
A - Continued
Index-3 C-1
TM 5-3810-307-24-1-1
B - Continued
Index-4 C-1
TM 5-3810-307-24-1-1
Index-5 C-1
TM 5-3810-307-24-1-1
D - Continued
Index-6 C-1
TM 5-3810-307-24-1-1
F,G
Index-7 C-1
TM 5-3810-307-24-1-1
H - Continued
Index-8 C-1
TM 5-3810-307-24-1-1
H - Continued
Index-9 C-1
TM 5-3810-307-24-1-1
Index-10 C-1
TM 5-3810-307-24-1-1
Index-11 C-1
TM 5-3810-307-24-1-1
N,O
P,Q
Index-12 C-1
TM 5-3810-307-24-1-1
P,Q - Continued
Index-13 C-1
TM 5-3810-307-24-1-1
R - Continued
Index-14 C-1
TM 5-3810-307-24-1-1
S - Continued
Index-15 C-1
TM 5-3810-307-24-1-1
Index-16 C-1
TM 5-3810-307-24-1-1
S - Continued
Index-17 C-1
TM 5-3810-307-24-1-1
T,U
Index-18 C-1
TM 5-3810-307-24-1-1
T,U - Continued
W,X,Y,Z
Index-19 C-1
TM 5-3810-307-24-1-1
W,X,Y,Z - Continued
Index-20 C-1
TM 5-3810-307-24-1-1
6
(48) 3(R) 6 BRN LEFT S/S POWER 5
(45) 2(W) 873 BLK 901 FRONT STEER 901 RELAY 51 112 TO POWER TO POWER
51 K 5
BLU INDICATOR SWITCHES
601 FUSE FU51 FUSE FU52 105
BRN
(SEE PAGE 4) (SEE PAGE 4)
(46) 2(X) 874 BLK 112 112
51 BLU 52 52
CENTER 901 901 901 TO ANTI-RESTART
(40) 3(T) 112 2 TO FUEL 151
RELAY TO START RELAY, HEATER RELAY
(42) 3(W) 52 (SEE PAGE 4)
ELECTRIC SHIFTER REV FORWARD FUEL SOLENOID, & (SEE PAGE 4)
(41) 3(V) 901 1 2 3 N 6 5 4 3 2 1
BLK 2 810 OIL COOLER RELAY
(43) 3(X) 644 NEUTRAL 606 606 RED 3
20 19
810 (SEE PAGE 4)
(21) 1(R) 936 597 367 RELAY 367 YEL 4
16 15 1
(23) 1(S) 937 598 368 GRN 5
8 7
(27) 1(U) 938 609 644 2 843 BLU 6 CB20 IGNITION SWITCH
(29) 1(V) 943 789 51 PARK 372 BRN 7
2 1
52 709 2
K RELAY 370
10 9
WHT 1 901 601 15A 601 I B
810
606 ORN 9
18 17
(25) 1(T) 940 788 403 K B/O 35 4 POS
14 13
782 419 VIO 10 112 RELAY 3
22 21
840 718 718 712 712
TRANSMISSION
SOLS GRN TURBINE SPEED 583 51
BLK 1 ST 597 597 1086 RED K
F G J E L A G 418
718 B
1087 BLK 712 712
BLK FWD LO GRN 788 788 B ENGINE RPM 718 718 810 810
A
149 RED
G ACC
BLK FWD HI GRN 789 789 K
148 BLK CONVERTER 804 RELAY
B
LOCK UP SOL K 35 35 51
BLK 2 ND GRN 598 598 APC100 448 448 51 104 51 K
H TRANSMISSION Q 101
CONTROL UNIT THROTTLE POSITION POWER
BLK REV GRN 609 609 916 44
D SEE SHEET 3 T SELECT MODE SOLS
718 51
W ENG IDLE RELAY PARK BRAKE
839 448 51 A(CARR)
712
840 718 A 918 918 44 K TORQUE 718 51 105 105
U
367 371 C 401 CONV
TRANS CLUTCH PRESS B(S/S)
STEER LOW K 935 O 920 44 44 UNLOCKED 901 51 180
S
UNPINNED SPEED 103 914 P X R
CLUTCH PRESS LOW 740 A 51 CB1
RELAY RELAY 51 /TRANS O/S 810 810 810 105
221 BACKUP RELAY 905 905 A 51 L/U LIGHT 15A
CB4
K 371 609 8 8 8 RELAY 151 A 40
404 621 843 51 516 516 51 BACKUP 10A
DIFF LOCKED
(26) 2(N) 477 782 FRONT REAR
542 641 641 ENGAGED
(18) 2(J) 476 DIFF LOCK SWS 836 621 546 144 51 OPTIONAL WIRING
(14) 2(G) 10 10 941 31 31 ENGINE BUZZER EXISTING WIRING
PARK BRAKE
221 641 40
TACH SENDER 32 32 I 40 A R
FURNISHED WIRING,
R R
10 51 554 51 40 40 40
R R
40 R
40 40 BUT NOT USED
G FUEL TRANS
479 LEVEL 51 CONNECTED WIRES
OIL TEMP STOP LTS
25 25 t VOLTMETER 583 583 B/O DRIVE LTS
549 R A 40 V 51 582 A B/O MARKER LTS NON-CONNECTED WIRES
ENG OIL CB8
OUTRIGGERS 478 PRESS 51 40 40 41 PANEL BRIGHT F 587 105
OFF FUSIBLE LINK WIRE
(9) 1(J) 79 EXT 4 4 OP 40 GAUGE LIGHTS CB19 PANEL DIM 20A 20A
(11) 1(K) 80 RET 362 SPEEDOMETER 54 54 582 582
30
OFF SERVICE STOP LTS
51 ENG W/HI BEAM IND 5A
477 TEMP 53 53 B PARK SERVICE DRIVE LTS
(1) 1(A) 75 RFE 3 3 t U 132 583 B/O SIDE/TAIL LTS
W W W W W W W W E
(5) 1(F) 77 RRE 355 40 140
51 I
476 141 730 J SERVICE LTS
10 10 51 53
76 LFE I 221 W 53
(3) 1(C) 51
(7) 1(H) 78 LRE 51 51 44 TACH/ 51 585 D
BLACKOUT HEADLT 12 12 12
K K SPEEDO PANEL BLACKOUT 786 H SIDE & MARK LTS
HOUR HEADLIGHT MS 51113-1
(13) 1(L) 81 RFS 409 411 SENDER LTS 51 W 53 PANEL BRIGHT
(17) 1(N) 83 RRS 51 51 44 585 PANEL DIM LIGHT SW 51 51
K G W A A A R A A A R
K 11 M HEAD LTS OFF
(15) 1(M) 82 LFS 410 412 730 730 PARK 51
L FRONT TRIPLE RIGHT LEFT
(19) 1(P) 84 LRS 44 44 44 44 584 N B/O STOP LTS FRONT REAR
134 CB13 123 ID LIGHTS LEFT RIGHT RIGHT
718 HEADLIGHTS
LO-BLK
840 10A 586 C TURN SW STOP SIGNAL REAR FRONT MID CLEARANCE
FRONT/REAR RT STEER REAR STEER SOL 841 LEFT RIGHT LO-BLK 133
CB14
SIDE MARKER LIGHTS LIGHTS
3(Y) 792 RT 792 51 841 840 51 GRN 10A 41 K STOP LT SW
(33) 51 GRN W W
841 REAR HI-RED 131 CB15 730 730
3(Z) 793 LT 793 792 RT 792 10A 586 786
(35) STEER CB16
840 2WD HI-RED 132 122 11 51 786
FRONT/REAR LT STEER LT 793 RELAY 132 10A 123 COLUMN SWITCHES 12 12 CB17 K LIGHTS
51 935 122 TURN TURN BEAMS
10A 105 RELAY
LOCK STEER CB18
721 721 B K 584 584 13 731 731 105
HEAD FLASH
(16) 2(H) R L R L R HI-LO
STEER 721 LOCK SW 416
L W LOCK 583 583 10A
(20) 2(K) 722 UNLOCK 722 R L 840 914 786 786 13 13 13
SOL
HAZARD
722 17 16
875 875 584 583 786 584 583 786 786 583 15 786 583
A 718 718 15 14
REAR STEER 221 632 23 24 21 22 23 24 21 22 491 483 460 491 483 460 51 A 51 A 51 R
REAR STEER R R R A R
PINNED SOL REAR STEER INDICATOR SWITCHES W R R R W R R R W W A A W W A A
PINNED 221
385 WR
51 875 221 BRN
12 GB
15 RY
13 RB
RIGHT
511 G
LEFT LEFT
3 GW
2 WU
LEFT RIGHT
9 GO
REAR TRIPLE
5 OU
196 O
872
44 U
51 BLK 840 B/O B/O SERV
SERV
B/O B/O SERV SERV SERV B/O SERV 51 SERV B/O SERV 51 FRONT MID REAR FRONT REAR
K BRN K 51 BLU STOP TAIL TAIL
STOP/
STOP TAIL TAIL STOP/ PARK PARK TURN PARK PARK TURN
ID LIGHTS
CENTER TURN SIDE MARKER LIGHTS CLEARANCE
907 413 867 BLK 221 CENTER 414 TURN
L FRONT TURN
SIDE SIDE
LIGHTS
SENSOR L REAR R REAR 51 51 R FRONT TURN 36 38 CB10
51 BLU PINNED 51 866 17 16 38 730
SENSOR
G 840 840 DIFF 930 931 586 10A
51 869 REAR DIFF LOCK LOCK 932 933 11 11 95 CB11
A 51 870 868 BRN 51 631 631 15 15 123 123 10A
RIGHT A 51 871 840 14 14 122 122 FLASHER 98 98 CB12
BLK
LEFT K 51 BLU 51 831 831 36 36 L 38 K 10A
415 LEFT RIGHT G LEFT 106 HORN SW
SENSOR G 931 931 X 97 YEL
(36) 2(S) 930 FRONT DIFF LOCK DOME LT TURN TURN 933 P
WHT 95 SIGNAL SIGNAL
SH
(37) 2(T) 932 51 51 15 99
W IND
AUX1_SHT_UA
(38) 2(U) 15 CAB DOOR SW IND 14 14 51 HORN
(39) 2(V) 14 BLK 45 95 95 95 95 HORN
(24) 2(M) 831 831 712 RELAY 712
BOOM REST 630 CB5 180
(22) 2(L) 942 939 939 630 CAB CIRC FAN W/SW
10A
WINDSHEILD
SWITCH M 558 RES RES 559
LO
15A
FO-1. Electrical Schematic (Sheet 1 of 4)
FRONT AXLE OSCILL SOLS REAR AXLE OSCILL SOLS WIPER 1 1
FO-1/FO-2 Blank
6 SWIVEL - 49 SLIP RINGS
TM 5-3810-307-24-1-1
112 47 30A
IGNITION SW 6 48 60A
2 52
112 B I 601 CAB STRAP 23 49 60A 23
4 POS
35 3 HEATER FUEL 601 901
ACC K LINE HEATER 112
RELAY 101 51 948 51
S/S D6 40 7.5A
102 IGNITION K 650 901
RELAY 103 D5 52 42 7.5A
6 30 DEG 51 650 52
ELECTRIC SHIFTER
180 REV FWD 901 41 7.5A
27 MAGNETIC SENSOR 3 2 1 N 1 2 3
CB1 15A
51 CONTROLLER 2
52 RED 3
14 13
BLK 2 644 644 43 7.5A
948 MAIN G GRD +10V R 1.37K 9 10
YEL 4 597
WHT 27 27 27 W +BAT IN W 1 4 3 4
GRN 5 598 597 21 7.5A
CB2 15A
BLK 508 508 B OUT COM B 3 901 WHT 1
7 8
BLU 6 372
661 /8 /4 G 1 2
BRN 7 609 598 23 7.5A
HOIST ROT INDICATORS 15 16
ORN 9 789
CB3 5A MAGNETIC SENSOR 372 25 7.5A
27 27 51 CONTROLLER 372
2 S/S 951 951 609 609
AUX G GRD +10V R 1.37K BACKUP 27 7.5A
WHT 27 27 27 W +BAT IN W 1 4 51 S/S
509 509 ALARM 70 789
BLK B OUT COM B 3 BACKUP 29 7.5A
/8 /4 G ALARM K
RELAY 104 805 619 2 7.5A
BUZZER
CB4 5A D2 169
40 40 40 40 40 40 40 641 169 6 7.5A
D1 D3 619 440
VOLTMETER 10 7.5A
661 40 V 51 40 LO AIR
R R SWING BRAKE R A R R R
PRESS D7 31 8 7.5A
180 143 539 ON 159 STEER PUMP FAILED
619
STEER PINNED 619 221 12 7.5A
WIPER/WASHER 51 169 ENG/TRANS DISTRESS
WASHER I t OP t I 440
51 51 51 51 51 51
DIFF LOCKED 10 14 7.5A
51 TIME 31
M 67 68
WASH BRN RED PARK BRAKE ON
DELAY 221 3 18 7.5A
64 HI WHT WIPER/ BLK 10 TACH
51 65 LO YEL WASHER 3 ENG TEMP 4 26 7.5A
M SWITCH
66 PARK BLU 51 4 OIL PRESS
25 TRANS OIL TEMP 25 30 7.5A
WIPER
WINDSHIELD CAB CIRC
FAN W/SW 32 FUEL LEVEL 32 34 7.5A
CB5 10A
113 YEL BLK 51 133 32 7.5A
M
CB6 10A
159 4 7.5A
68
OUTRIGGERS 79 EXT 79
CB7 15A 9 7.5A
46 46
CB8 10A
80 RET 80 11 7.5A
44 44
75 RFE 75 1 7.5A
46
DOME LT SWING BRAKE 77 RRE
CB13 10A L R L R HI LO
50 51
77 5 7.5A
6 95 95 44
W
76 LFE 76 3 7.5A
TURN
46
WORK LT CLAMSHELL
HAZARD
78 LRE
CB14 10A
56 51 FLASHER 51
78 7 7.5A
55 W G 81 RFS
CB15 10A
X
P 81 13 7.5A
38 38 44 342 51 46
L 83 RRS 83 17 7.5A
WR 385
511
44
12
15
13
133 274 51
GW 3
GO 9
OU 5
WU 2
15 G
82 LFS 82 15 7.5A
RB
GB
RY
U
O
G
14 TELE 46
36 932 84 LRS 84
DRIVE/PANEL LEFT G RIGHT G 19 7.5A
CB16 10A 133 TURN TURN 930 TRANS SELECT
30 IND 15 44 148 2 WHEEL 934 934 7.5A
D4 51 IND 51 14 4 WHEEL 630
31
54 54 FRONT STEER 792 792 7.5A
R 33
44
L 793 793 7.5A
53 53 W W 35
W W W W W W W 932 7.5A
PANEL 51 51 37
180 LTS DIMMER GAUGE LTS TACH 930 7.5A
LT PANEL LTS 36
CRANE FUNCT SEAT TAPE LEFT RIGHT L/O SOL 15 7.5A
CB9 10A 38
794 794 799 800 706 707 51 STEER LOCK
10A LOCK 721 14 7.5A
CB10 ARM REST L/O SWS 720 39
720
113 UNLOCK 722 721
CB11 15A 16 7.5A
71
OIL COOLER FAN TEMP SW CONSOLE 722 7.5A
CB12 5A
71 71 DIFF LOCK 20
522 530 51 DEFROST FAN
K HYD OIL COOLER 630 831 831
485 51 24 7.5A
FAN 201 ORN YEL
HI
RELAY FAN MTR 113 M BLK AREA DEFIN
120 DEG
CB17 15A LO
486 RED BLU 71 #2 (SWIVEL)
6 520 521 521 RED M BLK 51 805 51 28 7.5A
DIESEL HEATER
HEATER HTR STEER 7.5A
CB18 20A
37 37 FUEL PUMP REVERSING SOL 44
59 A2B
HTR M M AREA DEFIN
CB19 10A 58 #3 (SWIVEL)
98 99 99 SW FRONT AXLE OSCILL 7.5A
HORN LMI 22
51 CPU
K 873 873 7.5A
98 102 97 97 AREA DEFIN FRONT STEER 45
#1 (SWIVEL) INDICATION K
HORN RELAY STER WHEEL 105
A
98 HORN
99 AIRCOND RELAY BOX 874 LEFT
SWING 51 K 870
88 88 88 88 106 A
HORN RIGHT
AIRCOND CONDENSER 807 B 869
92 51 540 51 51 51 BINARY A
K1 K2 K3 K4 PRESS SW
720 868 CENTER
88 B(1) W N 89 AUX HOIST AUX UP 866 866
661 87 91 73A 780 51 G
661 X(1)
88 B(2) U B AUX
661 K5
SWING PRESS SW 874 874
UNLOCK 46 7.5A
AUX DN
R A(B) 88 51 51 51 51 B(3) B 44 197 51 SOLS
B A(A) 540 540 540 540
87 87 B(4) O O O B 73B
M
BRN A(C) 91 91 91
UNLOCK SOLS
FANS RLY 73B
IDLE BOOST P/SW O B 51 51 MAIN UP
180 M C
92 663 663 991 991
Y(1)
CONDENSOR FANS 73C 51 LIFT DN
51 E(6) B COMPRESSOR
CB20 20A
60 91 E(5) U IDLE BOOST SOL CLUTCH 73D 51 TELE OUT
92 E(4)
92 W 991 51
THERMOSTAT
LO 61 E(1) Y Y-LO
60 MED 62 E(2)
E(3)
R R-MED
M
B AIRCOND
EVAPORATOR
FO-1. Electrical Schematic (Sheet 2 of 4)
B HI 63 O O-HI
A/C SW EVAP FAN
FO-3/FO-4 Blank
TM 5-3810-307-24-1-1
7 7
LEGEND
8 8
BATTERY CABLES
23 23
OPTIONAL CABLES
26 26 STANDARD WIRING
51 51 OPTIONAL WIRING
EXISTING WIRING
FURNISHED WIRING,
BUT NOT USED
CONNECTED WIRES
NON-CONNECTED WIRES
FUSIBLE LINK WIRE
ENGINE A EN1 28
RPM IN B EN2 29
30
CARRIER CAB TURBINE A
RPM IN B
TR1
TR2 31
TO ACC
105
RELAY
(SEE PAGE 1)
TO SUPER 100 A
5 5
POWER RELAY FU51
(SEE PAGE 1)
100 A
105 FU52
OIL
1
K COOLER
RELAY TRANS OIL
835 301
COOLER FAN
833 RED M BLK 57
200 F FU53
100 A
834 834 796
14 PASS SWIVEL
3.50" DIA BORE B
LOCKOUT CYLINDERS PORTS 1 THRU 6
FRONT AXLE (REF) ARE AIR
7
(4) P.O. CHECK VALVE CARTRIDGE
8
A 9
B AXLE 10 SUPERSTRUCTURE
LH RH LOCKOUT VALVE CONTINUED ON SHEET 2
11
LF EXT LF STAB RF STAB RF EXT
12
SOL SOL SOL SOL
C 13
14 14
PO CHECK
VALVE
14 13 12 11 10 9 8 7
A
B
V C
LR EXT LR STAB RR STAB RR EXT
3.50" DIA BORE C VALVE STACKS
LOCKOUT CYLINDERS SOL SOL SOL SOL
REAR AXLE (REF)
P 4000
A
B AXLE
LH RH LOCKOUT VALVE
A
(4) STABILIZER CYLINDER
3.50" DIA BORE
CHECK VALVE
7 PSI CRACK
SELECTOR
VALVE
P
2500 PSI
4 3
M
STAND-BY 0.603
VALVE & FLOW IN 3/REV VALVE SPOOLS
SWITCH SHOWN 'PULLED'
(SUPERSTRUCTURE
STEERING MODE)
P1 P2 EMERGENCY STOWAGE PUMP E
LH RH
SINGLE (FRONT AXLE)
SELECTOR F A LH RH
FRONT STEER (2) 2.76" (70MM) DIA BORE
VALVE B
REAR STEER S/S
D
C
FRONT STEER CARRIER (REAR AXLE)
3 4
DOUBLE (2) 2.76" (70MM) DIA BORE
FRONT STEER S/S
SELECTOR VALVE REAR STEER CARRIER
MAIN STEER PUMP C V B T
A P
MAIN STEER PUMP
FLOW SWITCH AXLE 2175
C V CARRIER REAR
DISCONNECT PRIORITY FLOW PSI STEER VALVE
VALVE 8 GPM + 1 1 2 P.O. CHECK
- 0.5 GPM VALVE
PR
RELIEF FEED
2300
2300 PSI +50/-0 CHECK VALVE
CRACK INTEGRATED O/R VALVE
65 PSI
APPROX
2500 PSI AT P
IN .062 DIA ORIFICE
GROUND-DRIVEN FULL FLOW 250
2500 A B A B
STEERING PUMP 10.6 ENGINE RPM
GPM
AXLE DISCONNECT 24.3 GAGE
B1-ROTATIONAL 2500 RPM 22.3
1.68 IN 3/REV GPM SAMPLING
THEORETICAL TRANSMISSION VALVE
300
25 25
2500 2000
.06 DIA
ORIFICE
STEER O/R
7 PSI TANK
CRACK
CARRIER
HYD RESERVOIR 63 GAL CAPACITY FILTER ISOLATION VALVES FO-2. Hydraulic Schematic (Sheet 1 of 2)
FO-9/FO-10 Blank