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TM 10-3950-672-24-1 for

1. 5 153 Fuel gt ERU Eu cago 5 83 Fuel System Components and Flow Description 5 67 Fuel System Description tee tiere ee 3 25 Fuel System Replacement 5 83 Fuel System 21 5 68 Fuel System 22 01 00 e eee 5 69 Fuel Tank Installation ae a A A A 3 26 Fuel Removal e eds 3 26 Fuel Water Separator Filter Unit Troubleshooting 5 71 Fuse and Relay Panel 3 220 Fuse and Relay Panel 3 220 G Gaskets General Maintenance 02 0 100000 1 6 Gauges Overfueling and Loading Coolant System 5 58 Gear Gover Installation EE C 5 1 38 TM 10 3950 672 24 1 AL
2. Disassembly 6 3519 rejt e Jo E 162 162 E 5 E 6 blank TM10 3950 672 24 1 AIR INTAKE SYSTEM DESCRIPTION The engine air intake system consists of an air cleaner and associated piping for channeling the air from the atmosphere to the engine intake manifold The intake pipe also provides the necessary connections for a restriction indicator to indicate a dirty air cleaner The air cleaner is the dry type with a replaceable element MAINTENANCE TROUBLESHOOTING Dust passing the air cleaner even through small holes can cause rapid engine wear Ensure all connections between the air cleaner and the engine are tight and sealed If these connections are all well sealed and there is still evidence of dust leakage check the following places for possible trouble NOTE Dust that gets by the air cleaner system can often be detected by looking for dust streaks on the air transfer tubing or just inside the intake manifold inlet 1 Inspect the air cleaner outlet tube for damage 2 Ensure the element gasket washer is not damaged and the washer s rubber face seals against the element 3 Inspect the element gasket for damage 4 Check for structural failures Any damaged parts must be replaced 5 Inspect the restriction indicator tap for leaks
3. 3 60 Park Brake 3 59 Park Brake 3 59 Park Brake 7 3 59 Pilot Operated Check Valve 0000 103 Pilot Operated Check Valve Cleaning and nnns E 103 Pilot Operated Check Valve E 103 Pilot Operated Check Valve Description and 3 114 Pilot Operated Check Valve Disassembly E 103 Pilot Operated Check Valve 103 Pintle Hook 00 cee eee eee nearer eee aaa 3 199 Pintle HOOK Removal REM 3 199 Pintle HOOK Repa PERDE M 3 199 Piston and Rod Assemblies Operation and Description 04040400 5 165 Piston and Rod Assembly Installation In Chassis 5 239 Piston and Rod Assembly
4. 5 79 High Pressure Lines 5 89 Hoist Description Replacement and 3 183 Hoist Maintenance ARMEN 3 183 Hoist Motor Control Valve E 102 Hoist Motor Control Valve Cleaning and E 102 Hoist Motor Control Valve E 100 Hoist Motor Control Valve Description and 3 117 Hoist Motor Control Valve E 102 Hoist Motor Control Valve 2 102 Hoist to Boom 0 000 0 66 60 nennen rines isis ss 3 190 Holding Valve Assembly 0 2 ee E 105 Holding Valve Assembly 0 te ee eee isis ss sse trn neni sss E 107 Holding Valve Cleaning and E 105 Holding Valve Description RE E 105 Holding Valve Descript
5. bet a 3 11 Accelerator Pedal Disassembly D dE 3 11 Accelerator Pedal Installation 2 3 12 Accelerator Pedal 3 11 Adjustment of Motor Control Valve 1 3 185 Administrative Storage eee 1 2 Air Flow Restriction Results in Excess Smoke and Low Power Troubleshooting 2 2 5 111 Air in the Fuel System Troubleshooting 2 5 70 Air Intake and Exhaust System Description 000 3 30 Air Intake and Exhaust System 2 3 30 Air Intake System Description eee eee E 7 Air Intake System Element 0 8 9 8 Air Intake System Filter Element Replacement sse nennen nnn nemen isse nnn nn nnn E 8 Air Intake System E 10 Air Intake System E 7 Air Intake System Troubleshooting 2 ieee eee
6. ER Planetary Gear MEM needa 8 DiSASSEMDIY eee Cleaning and MEME Grove Model 12 Hoist 132 Description 3 E 132 Theory of RIIV E 132 e RRRR E 133 Troubleshooting RR E 133 RR E 137 Cleaning and Inspection eene nnns eae eee E 141 Assembly 141 Vane Type Motor 147 Description 147 Theory Of Operation needa E 147
7. 3 235 Back up Alarm Removal nien 3 235 Base Engine Components Operation and Description 5 161 Base Engine Components Replacement Procedures sse nennen nennen nsns 5 190 Base Engine Components Specifications 5 185 Battery Gables Installation EUR EU Ui otros etta 3 219 Battery Cables Removal i ton eo euo 3 219 Battery Installation n o as 3 217 Battery Removal US Sk 3 217 Index 1 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page B continued Batteries General Maintenance 1 6 Bearings General Maintenance 1 5 Belt Tensioner Replacement 5 59 Bleeding the Brake System 9 3 74 Bleeding the Fuel System 1 eee eae 5 83 BOWE Mc 5 313 Boom Alignment and 3 154 Boom Assembly enndem t n ee ea a eden Cae Ares ewer 3 152 DISASSEMDIY RE 3 152 Boom Functional Check dae wale re i t eel in eee eva ea Senn ee deve
8. 5 16 Swing Bearing Description Replacement and nnne nnn 3 143 Swing Motor ele scant dE E 123 Swing Motor Cleaning and Inspection nennen sss n nnn nnn E 123 Swing Motor Descriptio Mi sinreriiieii diini E 119 Swing Motor Description and 3 141 Swing Motor Disassembly oet e RERUM LARA A ERR E a E e n sed E 119 Index 13 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page S continued Swing Motor 119 Swing System Description and Troubleshooting 3 136 Swing System Maintenance 3 136 Swivels Maintenance R 3 176 T 5 5 A E E 5 186 Telescope Circuit Replacement and Troubleshooting 0 000000000000000000000 90 199000950000 24 3 159 Telescope Cylinder Description Replacement and Repair 3 124 Temperature Sensor 5 158 Thermostat a o tolto a RR 5 63 Thermostat Replacement EMEN 5 6
9. 5 320 Engine Testing Service 5 316 Engine Will Not Crank Or Cranks Slowly 1 5 10 Engine Will Not Shut Off Troubleshooting 0 00 00 cece 5 44 Excessive Engine Noises Troubleshooting 5 47 Excessive Exhaust Smoke Troubleshooting eae unntatt ttnn aaaee sees eed 5 27 Excessive Fuel Consumption 5 43 Excessive Vibration 0 00 000001 5 45 Exhaust Manifold 5 114 Exhaust Manifold 5 114 Expansion and Pipe Plug nnns 5 288 Expendable Durable Supplies and Material 6 C 1 External Engine Components Location 5 4 External Pump Leaks Repair nner sss n iss nn rnn iners 5 101 F Fan Elub Replacemient 5 5 60 Fan Pulley
10. 5 360 Valve Seais Grinding oL E 5 251 Valve Seats eee 5 359 Valve Springs a s 0 1011 0 6 RM 5 255 Valve Springs nnne needed 5 359 Valve Train and Head Assembly Troubleshooting ssssssssssssssssssseseeeeeneeeeeee nennen nnne nsns nnns 5 169 VETE TTIESTe Leti ez lioe RR 5 185 ValvesUsage Table RC 3 106 Valves General SCREEN 3 106 Valves Grinding che eA MATAR TAA AE AE 5 250 Vane Type Motor E 150 Vane Type Motor Cleaning and E 148 Vane Type Motor cette ee E 145 Vane Type Motor Description and 3 189 Vane Type Motor 2 0 ended eee E 146 Vane Type Motor 0 ee eee eee ane E 145 Vane Type Motor Theory of E 145 Vane Type Motor trn niens isis nnn nnns sss nnn E 145 Vent Fitting Sealing Washer
11. E 7 Air Restriction Indicator Replacement 22 211 5 115 Air System Flow Description 11 5 111 Air System Replacement Procedures 0 110 tree eee aaa eee eee 5 112 Alternator Not Charging Or Insufficient Charging 5 48 Alternator Removal Repair Installation ae 13 212 Alternator Troubleshooting eee 5 150 Antitwo Block System Cable Reel Installation 2 3 172 Antitwo Block System Cable Reel Removal 3 172 Antitwo Block System Console nnne nnn nnn nennen nnn 3 174 Antitwo Block System Console Removal 3 174 Antitwo Block System Switch Installation 8 3 170 Antitwo Block System Switch 7 3 170 Automatic Transmission C 6 Description Replacement and Repair 2 3 44 Axles and Brakes Maintenance 1 a eee te te e e e ee demie aeri eed dae inira raa Pee tate seek rains 3 64 B Back Leakage Valve Replacement Inspection injection PUMP 5 265 Back up Alarm
12. 2 00000 5 177 Piston and Rod Disassembly In Chassis 5 231 Piston and Rod Removal In Chassis 5 222 Piston Pin Specifications RR 5 357 Piston Ring Gap Check SER 5 357 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page P Q continued Piston Rings 5 358 Piston 5 356 Piston to Connecting Rod Installation 5 235 Planetary Gear Reducer 130 Planetary Gear Reducer Cleaning and eene nnne nennen nennen nnne E 128 Planetary Gear Reducer E 128 Planetary Gear Reducer Description and 3 142 Planetary Gear Reducer 128 Planetary Gear Reducer 128 Power Steering Pump 3 83
13. 5 99 M N Main Bearing Preliminary Inspection In Chassis 5 221 Main Bearing Replacement In Chassis 5 227 Maintenance 21486 n B 1 Maintenance Forms Records and Reports 1 1 Mairitenarice Generali CCE enn ev ee MAT MEET RN E 1 3 Mirror Assembly Left Side 3 207 Mirror Assembly Left Side Removal i tite ate eens Aenean ees 3 207 Mirror Assembly Right Side 1 1 3 205 Mirror Assembly Right Side senis nnns 3 205 Mourting W heelAssembll6S 22 yee etic tne ht nt ava DM DU DV aa eV Y D LU D UL dE E 3 79 Mutfler and Exhaust Pipe Installation rere re eer aeter p eren nete et peres ae 3 32 Murfler and Exhaust Pipe Removal 2t ie we ves EXER RYE ea eee 3 32 Index 10 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page Oil Cooler Element and or Gasket 5 129 OI Goolers dette LE LE EE E 5 118 Oil Dilution Troubleshooting 5 123 Oil Filter Bypass
14. 3 108 Removal and Installation General ccccccccsccccceeecceceeeeeecaeseceeceeeceeeaeeeeeeeecaeeeeeeaeseeeeaenseeecaeaeceeauedeeeeaueeeecaeseeeeaaeasss 1 4 Repair Parts Special Tools TMDE and Support 2 1 Reporting Equipment Improvement Recommendations EIRS ssssssssesssseeeeeeeeeee enne 1 2 Reporting of Item and Packaging 1 1 Reports of Maintenance and Unsatisfactory 1 1 Rocker Lever Valve Stem Push Rod Tappet and Camshaft 5 176 Rocker Levers and Pedestals Specifications nnne nne 5 361 Rocker Levers and Push Rods 5 190 Rough Idle Irregularly Firing Or Engine Shaking Troubleshooting sssssssssene nennen 5 17 S Sately Instr ctioris Generalo et rer re eee e 4 4 foh we P DEN F 1 Index 12 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page S continued E MU 1 1 Sealants aa At E EU EU UU UU 5 369 Seat Assembly Installation
15. E 14 Electric Fuel Shut Off Valve Electrical System 5 157 Electric Fuel Shut Off Valve Replacement eee nnnm sse 5 97 Electric Swivel Assembly E 160 Electric Swivel Cleaning and E 159 Electric Swivel 000 159 Electric Swivel 159 Electric Swivel EIC UO EE E 159 Electric Swivel Theory of Operation 159 El ctrical 1 Electrical Switches Functional 3 224 Electrical Switches 3 223 Electrical Switches 3 224 Electrical Switches 3 223 Electrical Swivel Description Replacement and ennemis 3 180 Electrical System Description Operation
16. EE Iesum Troubleshooting Removal and Installation Disassembly and Assembly Eisen E p 3 62 Description Troubleshooting Removal Disassembly and Assembly Installation Hook SR 3 63 Description Disassembly Inspection Assembly Periodic Maintenance Wire 0 00000 0 General Environmental Conditions Dynamic Shock Loads Lubrication Precautions and Recommendations During Inspection or Replacement Wire Rope Inspection Running Ropes and Pendant Cables Wire Rope Replacement All Wire Rope Boom Nose Sheave Installation Antitwo Block System Switch Antitwo Block System Cable Reel 0 22 4444 220080 1 3 67 ECHTE n n nnnm nnn nnn n nnn nnn nnn nnn nnn nnns Antitwo Block System REMOVAL Installation 3 149 10 3950 672 24 1 ov 3 151 3 152 3 152 R id id alo ex 3 162 3 164 3 60 BOOM TM 10 3950 672 24 1 The boom is a 14 to 24 ft 4 2 to 7 3 m two section full power boom and is trapezoidal in design It consists of a telescope cylinder a base section and a telescope The telescope cylinder is used to extend and retract the telescope section Boom assembl
17. 5 143 Electrical System Maintenance 0 1 erence eee eee etna eee eee aan eee 3 208 Engine Assembly 5 350 Engine Component Torque 5 366 Engine Coolant Temperature Sender Description and 3 24 Engine Coolant Temperature Switch Description and 3 22 Engine Cooling Fan 3 40 Engine Cooling Fan 3 40 Engine Cranks But Will Not Start No Smoke From Exhaust 5 11 Engine Dataplate veer CRM 5 2 Engine Description and 3 17 aree aBIF To i r 5 8 525 Eu 5 349 Engine DynamometerTest Engine nennen nennen nnn 5 321 Engine Dynamometer Test for Engine 0000 100 5 327 Engine Dynamometer Test Performance Check 5 332 Engine Electrical System Replacement Procedures 000 0 000 5 155 Engine Hard To Start Or Will Not Start Smoke From Exhaust 0
18. l 8 la lalii lisli FUSE amp RELAY PANEL ASSY 3 7 100 12 14 15 14 i i3 12 LM A g B 716 Le 4 stt FRONT CONSOLE PANEL ASSY pe 3 62 372 70 73 11 715 Figure 1 Electrical Schematic Sheet 2 of 3 FP 3 FP 4 blank TM 10 3950 672 24 1 169 136 R FRONT Qe sis MARKER LT 22 7 FUEL LEVEL HYD OIL COOLER SENDER TEMP Sw v D RD uL lt 13 137 0 136 _ ax R REAR E MARKER LT STOP TURN TAIL eS 25 BACK UP m AUTO TRANS NEUTRAL AND BACK UP SWS 99 eu 73 uo desee GROUND sete es 4 size amp 52 N 25 e 4 O 6 EYELET les EYELET eto EET 1 4 EYELET HYD OIL COOLER Fe kii FAN MOTOR 3 8 EYELET 4 7 16 EYELET 1 2 EYELET 38 1 4 FASTON 3 16 FASTON 5 16 FASTON o PIGTAIL 32 CD 156 Pos vereri COLEN NE sone 18 O 17 GJ mte orarmer r we Es 14 SLIP RINGS PIN GRIP RAE lt 5 2 e pu M P Ee 3 e 0y e c clc 4 e 8 s ducet ONT ERON 5 cw uzfgpajAg celezsesame amp m 1 7 0 ys 800M s e 9
19. 2 5 118 ouis 5 118 Oil aks Tro bleshoOtlKig cooe cute e eee te e utet e e b 5 127 Oil Pan Operation and Description 5 169 Oil Pan Suction Tube and or Gaskets 5 131 Oil Pressure Regulating Valve 5 121 Oil Pressure Regulator Valve and or Spring 5 128 Oil Pressure Switch and Temperature Sensor Troubleshooting 5 153 Oil Pressure Switch and Temperature Sensors Description Operation 5 145 Oil Pressure Switch Replacement 0 021 1000000 5 157 Oil Pump System Replacement 5 133 Outrigger Selector Valve Description Replacement and 3 115 Outrigger Stabilizer Cylinder Description and 3 196 Outriggers DESCH Pt OM sce AL EM 3 192 OULOGErS INSPECUON bee EE 3 195 EE 3 195 Outiggers Removals LEE 3 193 Outriggers Theory of Operation cece eee eee eee ener eee eae eee eee aden 3 193 P Q Park Brake
20. M metalation es natant Seat Belt Removal 5 ir ERA a Seat Belt Install At OM REA Gab Fan Assembly teet D PN E REMOVA Irun e Windshield Wiper and Washer Assembly REMOVAI M Iac uuo Door and Latch 3 9 RR Installation Door Glass Replacement 0 000000000 Accelerator Pedal Assembly 00220000 400 11 Blea Disassembly 4 4 0 0 Assembly RM Installation 2 3 1 Cab Heater Defroster 3 6 3 1 Description ee er 3 6 1 Theory of Operation 3 6 2 2 3 6 3 Inspection eee ee 3 6 4 Installation re 3 6 5 TM10 3950 672 24 1 3 1 SEAT ASSEMBLY 3 1 1 Removal a Pull release handle 1 Figure 3 1 and slide seat 2 forward off rails 3 b Remove seat assembly 2 from cab 3 1 2 Installation a Position seat assembly 2 Figure 3 1 in cab with rear of seat slide on rail 3 b Slide seat assembly 2 rearward until release handle 1 locks in desired slot 3 1 3 Seat Belt Remov
21. Removal 3 93 1 no erbe ee a 3 93 2 Ege cesset M mM E M 3 94 Removal acte tache Be o t d e E UG cu cin unb chua i Fea UU Cava UE eaa a 3 94 2 3 231 3 208 TM 10 3950 672 24 1 Headlight Backup Removal 3 95 1 2222 3 95 2 Tail Brake and Turn Signal Light 3 96 REMOVAl 3 96 1 Jar E IOTER TTD MAAAAMMVD 3 96 Backup Alarm c ccccccscsssssesscssessessesscsscsessscssesscsscsscssssessessassassussessessessassusassaseaeeaes Removal Installation 8 3 97 2 Chassis Wiring Harness cccccccsccssssecseesseeseecseeseccsesseecaesseecseessecaeesseesesestsaaeeaeens Removal 00 0000 0 Starter RR 3 99 ne Bench 0000000 0 0 sereni erri 3 99 2 Disassembly Inspect Measure and 3 99 4 ec err
22. yv Wu AW Y yy E PES TM 10 3950 672 24 1 HYDRAULIC PUMP DESCRIPTION The hydraulic pump is a two section gear type pump mounted on and driven by the engine through an adapter and or coupler on the crankshaft MAINTENANCE DISASSEMBLY NOTE Any maintenance requiring disassembly of the pump should include replacement of seals and plates 1 Clean the outside of the pump thoroughly and disassemble in a clean work area 2 Scribe a line the entire length of the outside of the pump to aid in assembly 3 Clamp the pump in a vise with the shaft down 4 Remove the bolts 18 and washers 17 from the cover 16 Remove the cover 16 5 Remove the gasket 11 and dowel pins 12 from the cover 16 6 Remove the thrust plate 10 7 Remove the drive gear 14 and driven gear 1 5 and keep them together as a set 8 Remove the wear plate 7 spacer 6 and seal 5 9 Remove the bolts 1 and washers 2 from the front housing 4 10 Remove the rear housing 13 11 Remove the dowel pins 12 and gasket 11 from the housing 13 12 Remove the thrust plate 10 E 109 13 Remove the drive gear 8 and driven gear 9 and keep them together as a set 14 Remove the shaft seal 3 15 Remove the wear plate 7 spacer 6 and seal 5 INSPECTION 1 Inspect the components for sharp edges roughness nicks and burrs lf any areas are
23. 3 2 Seat Assembly Removal RRE m 3 2 Service Maintenance Packages E 1 Service Tools Engine 5 316 Service Upon Receipt te teretes 2 1 Shiims General Maintenance of ecco net t see E 1 4 Short Term Storage Engine tpe pertes decus pe eese ate e tua 5 338 Shutdown Lever Spring Replacement Injection 5 271 Shutdown Solenoid Replacement Injection 5 266 solenoid Valve Assembly EU lee bu Lu cuu Rund E 114 Solenoid Valve Description er a inns E 114 Solenoid Valve Description and n nennt nennen 3 116 Solenoid Valve 5 5 aa aaaee isst iiis nri ines E 114 Solenoid Valve Maintenance RM E 114 Special Tools Repair Parts TMDE and Support 2 1 Installato a 3 227 SPOUIGHTREMOV mea ana 3 227 Stabilizer Outrigger Cylinder Description Replacement and 3 131 Starting 3
24. END DR P atten Cleaning INSPECHOMAMG E 73 BE Front Steering Control Valve 79 Description 79 Theory Of Operation RR E 79 Maintenance 79 Prior to Disassembly ee eee eee E 79 Disassembly 0 nn Eee eee E 81 Assembly ere eee eee E 83 Steer PUMP AEE Eee E 88 Description 0 2 nn eee E 88 Maintenance RRR m E 88 Troubleshooting ERR E 88 Disassembly 0 nnn 89 REM 90 90 Assembly REM E 90 Brake Master Cylinder ms E 92 Description 20 2 rn eee E 92 Theory Of Operation RR E 92 94 Troubleshooting Rockwell FSH Hydraulic Brakes Description DiSASSEMDIY REM Cleanin
25. 2 1 0 nnne trn 3 92 Hydraulic Oil 3 92 Hydraulic Purmp Assembly ree oet cone e uon odo uico oet rusos E 109 Hydraulic Pump Descriptlon ette te ret nce bio cete eio Boo a Page CCo e a Peste ec ieee totus oed E 109 Hydraulic Pump Description and 3 105 Hydraulic Pump 109 Hydraulic Pump a aaa aaaea nnne trn nennen E 1 09 Hydraulic Pump inns 109 gi je e tees tea qiue Aerie 7 Hydraulic Swivel 6 port Description and 3 178 Hydraulic Swivel Assembly maien nananana nananana naaa aa ana ak aha naaa aaka naha naaa aka aah tana aiaiai aa E 155 Hydraulic Swivel Cleaning and E 155 Hydraulic Swivel Description 0000 155 Hydraulic Swivel 155 Hydraulic Swivel 2 155 Hydraulic Swive
26. 2 7 147 TrOUDICSHOOTING ccccescsecsssecsesacsessessssessssessesassessssassessssassssassessssassesassassesassesassassesassessesasaesassacaesacsecaesacseeaesaeas EU DiSASSOMDIY RR E 148 Cleaning and Inspection eee 150 Assembly 2 004004 0 00 eee eee E 152 Hydraulic eee eee eee E 155 eae eee E 155 Theory Of Operation ccccccccsscssesscscssessessessessessessesscsscsscsscsassssssssacssssssssssassassasssssessassassassessasseesacsussussasueeasenees Maintenance RRRRRRRR E 155 RR E 155 Cleaning and Inspection ee eee E 155 155 A 158 4 TM10 3950 672 24 1 TABLE OF CONTENTS continued eue M m Bite REM Theory of Operation Maintenance LC M tbat eee Cleaning and Inspection RR REIP PIENE DIR M IE A nce Cab Heater Defroster Hot Water 9 Been m Of 0 duc d
27. 3 236 Checking and Unpacking 2 2 ATE TR HR Ts 2152 MESE DOCTR DE ORE 1 4 Clearance Light Installation aan sss sed nnn nns 3 225 Clearance Light Removal ssssssssssssssessseesseseeneenene nennen aaa e teen eee eects 3 225 Cold Start Installation pe nr aerae diat e derat d e deat aea dad a e Reda 3 28 Cold Start Removal ctr te tte ee Den ad n e eat d ner ex rat P 3 28 Common Tools and 2 1 Compression Knocks Troubleshooting 5 42 Connecting Rod nnns 5 188 GOntaMinated COOlaN 5 39 Contaminated Lube Oil nnne 5 40 Control Lever Replacement Injection 5 270 COOlaNt O 5 60 Coolant Loss Troubleshooting 5 32 Coolant System Components and Flow Description 0 nennen nnn nnne 5 50 Coolant System Malfunctions rnnt essen 5 51
28. 3 85 2 Er RE du td d 3 218 REMOVAL Iristallati Fh Fuse and Relay Panel 3 87 1 Installation en itd ae d ie 3 87 2 Instr migribs casse 373 nth eb e ce eo see cbe so rb e ce este bela d d tiu a 3 88 1 ed deed Installation 3 88 3 Functional Check ccceccesseseccescescescescessescesceseescesserseaceseessesseasersersersersessesserserseres Electrical Switches 3 89 1 pae QoS In a Installation 3 89 3 Functional Check 0 0 Clearance 3 90 o LEE Y 3 90 1 Installation 2 2 2 a 2 2 220 900 tee TT EEUU 3 91 RemoVal itte e ete Rebel EE ete LER eL IristallaliOfi seco RR du e e Ra a aa 3 91 2 PING MR T T T 3 92 Removal oce eu Ld ud a elie ae na i etu he Installation nmrn stresses stress r erre rns sets 3 92 2 T ri Signal Light ase sha
29. Installation 40 TM 10 3950 672 24 1 3 7 ENGINE 3 7 1 Description This Service Manual does not include detailed information on the engine itself A separate manual as prepared in detail by the engine manufacturer is supplied with this Service Manual However a short description and maintenance of certain components of the fuel system is provided in this section Refer td Appendix E for detailed information on the air intake system and water cooling system Engine speed is controlled by a foot throttle pedal in the cab The throttle is connected to a cable to the governor speed control shaft through linkage on the diesel engine To aid in starting the diesel engine in cold weather a starting aid injection system is provided The system consists of a quick start switch located on the lower right side of the front console an atomizer valve assembly and associated tubing 3 7 2 Removal a Ensure the crane is on flat level ground and set the outriggers Disconnect battery negative leads from battery negative post Disconnect the air filter tubing at the engine refer to paragraph 3 17 Disconnect the muffler exhaust piping at the engine refer to paragraph 3 18 Drain the engine coolant system refer td paragraph 3 20 Drain the engine lubrication system refer to TM 10 3950 672 24 2 Drain the transmission torque converter oil system refer to paragraph 3 cO 000U0 CAU
30. 5 13 Engine icr PERMET 5 310 Engine M ESTA Y ACC Lo CRM 3 16 Engine Oil Pressure Sender Description and 3 21 Engine Oil Pressure Switch Description and 3 20 Engine RM RM CPC CNN RM 5 337 Engine Replacement REM 5 308 Engine RPM Will Not Reach Rated Speed Troubleshooting 1 5 21 Engine Run In and Test in the 5 314 Engine Run In Procedure In Chassis Off Highway 5 336 Engine Runs Rough Or Misfiring 5 19 Engine ViCWS REM 5 318 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page E continued Engine Melo Tejli e7 0 0 RM 5 6 Engine Starts But Will Not Keep Running 22 5 15 Engine Storage Long 2 5 341 Engine Storage Short 5 338 Engine Test Procedures Chassis 2 2 5 334 Engine Testing cack stave 5 312 Engine Testing General Information 2
31. B 1 EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST TORQUE VALUE 2 SERVICE MAINTENANCE PACKAGES E 1 SCHEMATIC S e rr a uu Raus F 1 ALPHABETICAL INDEX INDEX 1 HOW TO USE THIS MANUAL This manual is designed 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 and CAUTIONS as they contain information that will prevent injury to personnel or damage to equipment Use the alphabetical index at the back of the manual to find a topic not listed in the table of contents TM 10 3950 672 24 1 WARRANTY THERE ARE NO WARRANTIES EXPRESS OR IMPLIED MADE BY EITHER THE DISTRIBUTOR OR THE MANUFACTURER ON NEW GROVE EQUIPMENT EXCEPT THE MANUFACTURER S WARRANTY AGAINST DEFECTS MATERIAL AND WORKMANSHIP SET OUT BELOW NEW EQUIPMENT WARRANTY The Manufacturer warrants each new product made by the Manufacturer to be free from defects in material and workmanship its obligation and liability under this warranty being limited to replacing free of charge at its factory any part proving defective under normal use and service for a period of fifteen 15
32. Nipple Bolt Lockwasher Strap Rubber Strip Shock Mount Nut Lockwasher Clamp TM 10 3950 672 24 1 Support radiator 12 and remove two nuts 27 and two lockwashers 28 securing sides of radiator to vehicle Then lift radiator 12 with shroud 29 out of vehicle If necessary remove ten bolts 30 ten lockwashers 31 and shroud 29 from radiator Then remove eight screws 32 eight lockwashers 33 upper shroud 34 and baffle 35 from shroud 29 If replacing radiator 12 remove drain valve 2 elbow 36 nipple 37 and two fittings 24 from radiator If replacing radiator 12 remove two bolts 38 two lockwashers 39 and two straps 40 from radiator If damaged remove rubber molding 41 and two shock mounts 42 3 20 2 Installation ococm If removed install nipple 37 Figure 3 10 elbow 36 drain valve 2 and two fittings 24 in radiator 12 If removed cut and install two new strips of rubber molding 41 on radiator 12 where shroud mounts Install upper shroud 34 and baffle 35 on shroud 29 with eight screws 32 and eight lockwashers 33 Install shroud 29 on radiator 12 with ten screws 30 and ten lockwashers 31 If removed secure two straps 40 to radiator 12 with two bolts 38 and two lockwashers 39 WARNING The radiator assembly weighs 72 165 To prevent personal injury use a suitable lifting device to install radiator assembly
33. Torque the outer race hex socket head capscrews to 395 Ib ft 536 Nem Torque the inner race bolts to 370 Ib ft 502 Nem Using the 4 to 1 multiplier and no step wrench set the torque wrench for 106 Ib ft 144 Nem Using the 4 to multiplier and six Inch step wrench set the torque wrench for 78 Ib ft 106 Nem Tools Required The figure titled Special Turntable Bolt Torquing Tools illustrates and lists the complete set of special tools required to torque the turntable bolts Outer Race Torquing 1 Extend and set the outriggers if equipped Fully elevate the boom 2 Torque the corner bolts 3 8 18 and 18 using the hex nut adapter and step wrench 3 Torque all other bolts in a diametrically opposed sequence using the hex nut adapter 4 to 1 multiplier and step wrench 4 First torque all bolts to 185 Ib ft 251 N m and then to a final torque of 370 Ib ft 502 Nem Inner Race Torquing 1 Extend and set the outriggers 2 An access hole is available on the turntable top plate for inner race bolt torquing First torque all bolts to 185 Ib ft 251 N m and then to a final torque of 370 Ib ft b02 N m 3 Torque the bolts in a clockwise motion using a Socket extension 4 to 1 multiplier and torque wrench 4 Swing the turntable until the next series of bolts are exposed within the access area TM 10 3950 672 24 1 WILLIAMS DESCRIPTION TOOL NO 1 Backlash Adapter ST 50ABR 2 3 4 Drive Torque
34. WARNING ENSURE THE LIFTING DEVICE IS CAPABLE OF FULLY SUPPORTING THE WEIGHT OF THE SUPERSTRUCTURE ENSURETHE SUPERSTRUCTURE WILL NOT TILT OR SLIDE DURING LIFTING AND MOVING CAUTION USE SPARE PIVOT SHAFTS OR OTHER MATERIAL CAPABLE OF SUPPORTING THE WEIGHT OF THE SUPERSTRUCTURE DO NOT DAMAGE THE PIVOT SHAFT BUSHINGS NOTE If a lifting device capable of lifting the entire superstructure is not available superstructure weight may be reduced by removing the hoist 9 Install spare pivot shafts or other suitable material through the lower lift cylinder pivot bushings and through the boom pivot bushings 10 Attach a suitable lifting device to the spare pivot shafts and take in cable or chain to remove slack Do not pull up on the superstructure 3 147 TM 10 3950 672 24 1 WARNING ENSURE THE SUPERSTRUCTURE IS FULLY SUPPORTED BEFORE PROCEEDING NOTE If the same bearing is to be used again mark the pinion and bearing where the teeth mesh point of maximum eccentricity This will facilitate installation and checking the gear backlash 11 Remove the bolts and washers attaching the turntable bearing to the superstructure WARNING ENSURETHATANY BLOCKING MATERIAL USED IS CAPABLE OF FULLY SUPPORTING THE WEIGHT OFTHE SUPERSTRUCTURE AND WILL NOT ALLOW IT TO TILT OR SHIFT 12 Carefully lift the superstructure guiding it over the swivel and set it on blocking that will not allow the superstructure to t
35. system clogged with rust or scale b Grille or bug screen clogged c Radiator core fins damaged d Thermostat damaged stuck closed e Water pump leaking air into system f Radiator hose collapsed or rotting in wardly Clear obstructions Straighten fins Replace thermostat Repair or replace water pump Replace radiator hoses TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 1 Engine overheating continued g Radiator pressure cap damaged h Cylinder head loose causing ex haust gas leakage into cooling system i Water pump impeller corroded or loose on shaft j Antifreeze protection inadequate causing partial freeze up After Boil a Improper installation of thermostat b Damaged thermostat c High temperature thermostat used with alcohol type antifreeze antifreeze d Excessive sediment in cooling sys tem a Excessive sediment in cooling sys tem b Air or exhaust leak into cooling sys tem Radiator Air Flow Obstructed a Leaves dirt and foreign material b Bent fan blades c Improper valve timing or sticking valves d Clogged muffler or pipe e Dragging brakes f Low engine oil level g Replace cap h Check and tighten i Repair or replace water pump j Check and add antifreeze as re quired a Check and correct b Replace thermostat c Use thermostat of proper operat ing range use ethylene glycol type
36. 3 154 Boom Installation x t rte n ee e t ne e YR us 3 151 Boom Maintenance ictor Ether Rate ex ete ra n dn e ee n a n ved add en deir 3 150 Boom Nose Sheave Installation 3 168 Boom Nose Sheave Removal 3 168 Removal Sosi DI DII bathe tated coy OO OO 3 150 Brake Master Cylinder Description E 92 Brake Master Cylinder Description Replacement and 2 enne 3 76 Brake Master Cylinder E 94 Brake Master Cylinder Theory of Operation 2 E 92 Brake Master Cylinder Troubleshooting 22 00242 2 E 94 Brake Shoe Adjustment Rm 3 75 C 6 Automatic Transmission Description Replacement and Repair 3 44 Gab Fanilnstall ation zorro heartened 3 4 ab Fah bremoVal ccm temen mu mL DIA LIUM DNI TIAM Saas 3 4 Cab Heater Defroster Assembly Description and Replacement 2 3 14 Cab Heater Defroster Hot Water Assembly 22 000000 nnns E 162 Cab Heater Defroster Hot Water Descript
37. Entrapped air may be removed from cylinders having wet rods by cycling On certain cylinders a plugged port is provided on the rod end to bleed off entrapped air WARNING DO NOT ATTEMPT TO LOOSEN FITTINGS IN PRESSURIZED LINES OR WHILE THE HYDRAULIC PUMP IS IN OPERATION In the event that air entrapment should persist bleeding of air by loosening various clamp and screw type fittings may become necessary CONTROL VALVES The control valves that control the crane functions are installed under the dash in the cab Access to the control valves is gained by removing the cover in front of the cab Mechanical linkage extends from the base of the control levers under the cab to the respective control valves Inspection Inspect the control valves for visible damage binding spools and evidence of leakage If excessive internal leakage is suspected during operation with a spool in its center position it is possible that the area between the spool and working section bore of the valve body is worn beyond serviceable limits lf this condition exists the spool and body must be replaced as an assembly Valve Leakage Dripping oil indicates some type of external leakage The machine should be removed from service for immediate repairs External leaks sometimes develop at fittings and seals Spool seals are susceptible since they are subject to wear Seals may be damaged by temperatures that are too high or by dirt or paint acc
38. Improper band or clutch appli cation or oil pressure control System Polished glazed band or drum Dirty or sticking valve body Governor valve stuck Linkage out of adjustment Improper band or clutch appli cation or oil pressure control system Intermediate servo piston seals cut leaking Dirty or sticking valve body body Kickdown linkage out of adjust ment Damaged internal kickdown linkage Improper clutch or band appli cation or oil pressure control System Dirty or sticking governor Dirty or sticking valve body body Misadjusted neutral start switch Misadjusted linkage Defective neutral start switch 3 55 Adjust band Perform air pressure test Ser vice front servo and or internal leaks Perform control pressure test Service or replace band or drum Clean service or replace valve body Perform governor test Service as required Service or adjust linkage Perform control pressure test Replace seals Check for leaks Clean service or replace valve Service or adjust linkage Service internal kickdown link age Perform control pressure test Perform governor test Service or replace governor clean screen Clean service or replace valve Adjust neutral start switch Adjust linkage Replace neutral switch REMOVAL 1 Refer to Section 2 ENGINES and remove the engine and transmission as
39. Section One Section one of the hydraulic pump supplies the 3 valve bank housing the outrigger tow winch lift and main hoist directional control valve Section Two Section two of the hydraulic pump supplies the 2 valve bank housing the swing and telescope directional control valve TM 10 3950 672 24 1 Temperature Switch Pipe Plug Reservolr Cover Assembiy Grommet Bowi O ring Window Geuge Breather Return F liter Diverter Handle Head 5 gt 5 Lockwasher Screw Indicator Bow Element Diverter Hydraulic Reservoir and Filter 3 102 TROUBLESHOOTING MAINTENANCE TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 1 No oil flows in systems b 2 Excessive pressure buildup 3 Pump noise Accompanied by oil foaming in reservoir a Low oil level Pump coupling or shaft sheared or disengaged c Reservoir to pump supply line broken or restricted Air entering at suction lines Pump not priming d Internal contamination a System relief valve set too high b Restricted pump to control valve supply line a Air entering at suction lines Low oil level b Excessive engine rpm 3 103 a Fill reservoir b Properly engage the pump drive If drive or coupling is damaged or sheared remove and repair or replace as necessary c Clean repair or replace line as necessary Check all lines for sec urity suction lines for cracks and pr
40. Tag and disconnect wire 14 from right front turn signal light Tag and disconnect wire 12A from left headlight Tag and disconnect wire 12B from left front side marker light Tag and disconnect wire 15 from left front turn signal light Tag and disconnect wire 99 from horn NOTE All wires numbered 51 various suffixes are common ground Tag and disconnect wires 137 and 51 H from oil cooler fan motor Tag and disconnect wire 715 from alternator discharging light Tag and disconnect wires 38 and 41 from brake switch Tag and disconnect wires 73 70 67 52A 41 5 38A 32 25A 18 17 16 15 14 130 12D 10 9 7A 372A 1 3 4 99 371 169A and 136 from crane relay panel Tag and disconnect wires 51 L 73A 51 M 73B 51N and 73C from two block override solenoid Tag and disconnect wires 156 157 and 2A from starter relay Tag and disconnect wire 1 96A from battery connector Tag and disconnect wires 137 and 136 from oil cooler temperature switch Tag and disconnect connector from gearshift solenoid 3 236 TM 10 3950 672 24 1 2 274 am 27 r ce a a e ru rjr rir r r r r r a rjr a 2 2 DD co OD DD ro op os of coc ce OD OZ PAM BATTERY w LIE rit gt Y mae it 3 NT 3 EIE al i 1 T a eps R b CONTINUED ON SHEET 2 ay 4 DEL RI CU Gal Lae a
41. c Adjust the engine idle speed to the specified rom If the engine idle speed cannot be brought within limits check the throttle and downshift linkage for a binding condition If linkage is satisfactory check for vacuum leaks in the transmission diaphragm unit and its connecting tubes and hoses 2 To perform the control pressure test using the vacuum pump method perform the following a Disconnect and temporarily plug the vacuum line at the vacuum diaphragm unit b Attach a vacuum pump to the vacuum diaphragm Apply both the parking and service brakes Start the engine and vacuum pump c Set the vacuum at 15 inches and read and record the control pressure in all the selector positions Run the engine up to 1000 rpm and reduce the vacuum to 10 inches Read and record the control pressure D 2 and 1 Keep the engine rpm at 1000 and reduce the vacuum to 1 inch Read and record the control pressure in D 1 2 and R VACUUM SUPPLY TEST Check the vacuum supply to the vacuum diaphragm unit and the diaphragm itself To check the supply disconnect the vacuum line at the diaphragm unit and connect it to vacuum gauge With the engine idling the gauge must have a steady acceptable vacuum reading for the altitude at which the test is being performed If the vacuum reading is low check for a vacuum leak or poor engine vacuum f the vacuum reading is OK rapidly accelerate the engine momentarily The vacuum reading must drop
42. f Remove two bolts 9 two lockwashers 10 and disconnect suction hose 11 steering pump hose 12 and return tube 13 from back of reservoir g Remove locknut 14 washer 15 hold down 15 and hydraulic tank 1 from crane frame h Remove six bolts 17 six lockwashers 18 return filter assembly 19 and gasket 20 from hydraulic tank 1 Discard gasket 20 i Remove clamp 21 cover 22 and o ring 23 from hydraulic tank 1 Discard o ring 23 j Remove breather cap 24 oil level gauge 25 and temperature switch 26 from hydraulic tank 1 3 38 2 Installation a Install temperature switch 26 Figure 3 1 6 oil level gauge 25 and breather cap 24 in hydraulic tank 1 b Install new gasket 20 and return filter assembly 19 in hydraulic tank 1 with six lockwashers 18 and six bolts 17 c Install hydraulic tank 1 on crane frame with hold down 16 washer 15 nut 14 two bolts 8 two washers 7 and two nuts 6 Torque nuts 6 and 14 to 75 Ib ft 102 Nem d Connect return tube 13 steering pump hose 12 and suction hose 11 with two washers 10 and two bolts 9 to back of reservoir e Connect two electrical leads to temperature switch 26 and remove tags 3 98 10 3950 672 24 1 Hydraulic Tank Drain Plug Bolt Lockwasher Return Line Nut Washer Bolt Bolt 10 11 12 13 15 16 18 LEGEND
43. h Replace return hose i Replace all cylinder seals j Hone or replace barrel k Repair or replace pump section l Replace piston rod and all cy linder seals Replenish hydraulic oil to pro Repair or replace relief valve Reduce load as required d Adjust linkage to obtain full spool travel e Repair or replace pump sec tion Replace pump shaft and seals Replace drive coupling Replace control a Replenish hydraulic oil to pro per level b Repair or replace relief valve TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 6 Boom will not lower C continued valve linkage d Worn or damaged hydraulic pump section Improperly adjusted control e Broken pump shaft f Broken pump drive coupling g Broken control valve spool NOTE Refer to Section 6 for lift cylinder Disassembly and Assembly procedures Maintenance requiring removal of the cylinder barrels such as packing may be performed without removing the cylinders from the turntable However all disassembly and assembly should be conducted in a clean dust free area REMOVAL 1 Extend and set the outriggers 2 Elevate the boom so that the lift cylinder is extended approximately one foot 0 3 m WARNING ENSURE ANY BLOCKING OR CRIBBING USED IS CAPABLE OF SUPPORTING THE BOOM 3 Ensure the boom is fully supported by placing blocking or cribbing under the boom Rest the boom on th
44. 102 0 cm long from the center of the barrel to the center of the rod bushing and has a stroke of 29 0 inches 73 6 cm The barrel end of the cylinder is attached to the frame by means of a pin capscrew lockwasher flatwasher and cotter pin The rod end of the cylinder is attached by means of a plate pin bolt and washer to the outrigger beam There are four stabilizer cylinders on the crane and each cylinder weighs 80 pounds 36 2 kg dry and 82 5 pounds 37 4 kg wet MAINTENANCE NOTE Refer to CYLINDERS in Section 6 for Disassembly and Assembly of the cylinder REMOVAL 1 Remove the outrigger beam RIGGERS Removal in this Section 2 Remove the plate pin bolt and washer securing the rod end of the cylinder to the outrigger beam 3 Remove the cylinder Refer to OUT INSTALLATION 1 Install the cylinder into the outrigger beam 2 Apply anti seize compound to the pin and install the plate pin washer and bolt securing the rod end of the cylinder to the outrigger beam 3 Install the outrigger beam OUTRIGGERS Installation in this Section FUNCTIONAL CHECK Refer to 1 Activate the hydraulic system using the outrigger control lever and outrigger selector Extend and retract the outrigger 2 Observe the operation of the outrigger beam 3 Check the hydraulic connections for any evidence of leakage 3 196 TM 10 3950 672 24 1 3 77 OUTRIGGER SELECTOR VALVE DESCRIPTION The OUTRIG
45. 3 16 COLD START ASSEMBLY 3 16 1 Removal a b Disconnect negative battery cable and two electrical leads from negative battery post Open engine access door Tag and disconnect two electrical connectors for starting fluid valve 3 Figure 3 7 from electrical harness CAUTION Cover opening to prevent dirt from falling into valve 3 Dirt could prevent starting fluid cylinder 2 from sealing properly 7Q gt D Open clamp 1 unscrew starting fluid cylinder 2 from starting fluid valve 3 and remove starting fluid cylinder 2 from clamp 1 Remove plastic tubing 4 between atomizer 5 and elbow 6 Cut wire ties as needed Remove atomizer 5 from engine intake manifold Remove two nuts 7 two lockwashers 8 and starting fluid valve 3 from studs on crane frame Remove elbow 6 from starting fluid valve 3 3 16 2 Installation Install elbow 6 Figure 3 7 on starting fluid valve 3 Install starting fluid valve 3 on studs on crane frame with two lockwashers 8 and two nuts 7 Install atomizer 5 in engine intake manifold Install plastic tubing 4 between atomizer 5 and elbow 6 Install new wire ties as needed Connect two electrical connectors for starting fluid valve 3 to electrical harness and remove tags Insert starting fluid cylinder 2 through clamp 1 and screw cylinder tightly into starting fluid valve 3 Connect negative battery cable and two electrical
46. Continued FOR CRANE WAREHOUSE M469 5 4 MAINTENANCE LEVEL Direct General Tools and Component Maint Support Support Depot Equipment Remarks Assembly Function ERN Ref Code Code Water Pump Inspect Replace Fan Assembly Fan Inspect Replace Belt Drive Inspect Replace ELECTRICAL SYSTEM Alternator Starting Motor Starter Solenoid Assembly Repair Instrument or Engine Control Panel Inspect Switches Circuit Replace Breakers amp Instruments TM10 3950 672 24 1 Section 11 MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component i Support RUN 5 Equipment Remarks Assembly Function ejoj F Ref Code Code Miscellaneous Items Light Switches Inspect 21 23 24 Fuse and Relay Panel Inspect Replace Lights Vehicle Head Tail Inspect Stop Back up Spot Replace t 21 23 24 Flood amp Clearance Lights Gages Sending Units amp Warning Switches Oil Temperature Oil Inspect Pressure Coolant Replace Temperature amp Test Transmission Temperature Gage Fuel Quantity Sending Unit Low Oil Pressure High Engine Temperature Switches Horn amp Back up Inspect Alarm Replace TM10 3950 672 24 1 Section MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component i Supp
47. The low pressure bore has a diameter of 1 75 inch 4 4 cm and the high pressure bore has a diameter of 1 inch 2 5 cm The stroke of the cylinder is 1 50 inches 3 8 cm MAINTENANCE For more detailed information refer to Appendix TROUBLESHOOTING SYMPTOM PROBABLE CAUSE 1 Slow pedal return sticking Poor quality or incorrect brake fluid Runout O D and I D of low pressure pistons Binding pedal linkage or heavy pedal 2 Brake drag or pressure build up Incorrect fluid or oil in the fluid causing cups to swell and stick Fluid return ports of the relief piston valve may have become plugged through entrance of foreign matter No push rod end clearance SOLUTION Remove relief valve and wash in alcohol Clean the return ports by hand using a 0 0625 inch 1 58 mm drill Disassemble cylinder and wash all parts in alcohol then lubricate service cylinder Replace defective component Free up linkage pivots Adjust the push rod to maintain the 0 0312 inch i0 792 mm maxi mum clearance to the secondary piston contact when pedal is fully retracted Disassembly cylinder and re build replacing all gaskets TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 3 Pedal loss pedal too low be fore braking action starts Too much clearance between push rod and piston pedal loss at the start of the stroke means loss at the end of the stroke where it is
48. Washer Suction Hose Steering Pump Hose Return Tube Nut Washer Hold Down Bolt Lockwasher Figure 3 16 Hydraulic Tank 3 99 Return Filter Gasket Clamp Cover O ring Breather Cap Sight Glass Temp Switch TM 10 3950 672 24 1 Connect hydraulic line 5 to return filter assembly 19 with two lockwashers 4 and two bolts 3 Install drain plug 2 in hydraulic tank 1 and service reservoir with new hydraulic oil Refer to Operator s Manual TM10 3950 672 10 for proper hydraulic oil Install new o ring 23 cover 22 and clamp 21 on hydraulic tank 1 WARNING Hydraulic fluid under pressure can penetrate skin or damage eyes Fluid leaks under pressure may not be visible Use a piece of cardboard or wood to find leaks but do not use bare hand Wear safety goggles for protection If fluid enters skin or eye get immediate medical attention Start up hydraulic system and check for leaks Connect negative battery cable and two electrical leads to negative battery post 3 100 3 39 SUPPLY PRESSURE AND RETURN CIRCUIT TM 10 3950 672 24 1 DESCRIPTION The supply pressure end return circuit routes hydraulic oil from the pump to the directional control valves for the individual operating circuits The supply pressure and return circuit consists of the reservoir pump oil filter hydraulic swivel and oil cooler The operating circuit s description and components begin with
49. are oil soaked or worn to one half of their original length These must be replaced 2 Check the spring tension of each brush Any that are damaged or weak must be replaced Spring tension should be sufficient to firmly hold the brushes against the collector ring 3 Inspect the collector ring conductors for arcing pitting and corrosion Under some conditions the ring will have a tendency to collect fine silt and in a salt atmosphere corrosion will occur If this happens rotate the collector core several times This should clean the ring If it does not it might be necessary to clean the core after disassembly 4 Check the continuity between each of the collector core rings surfaces and the electrical leads any conductors are defective they must be replaced After Disassembly 1 If the collector rings are corroded it may be necessary to use a standard non residue solvent to clean them Then lightly sand the brushes with double ought 2 0 nonabrasive material Blow out any dust with compressed air 2 Any brush sets that are oil soaked cannot be cleaned They must be replaced 3 If the nylon bearing is worn replace it ASSEMBLY 1 Install the nylon bearing in the mounting bracket E 160 TM 10 3950 672 24 1 2 Install the collector core in the mounting bracket and tighten one setscrew to secure the core to the center post This setscrew will be loosened later CAUTION ENSURE THE BRUSH AND ARM ASSE
50. avo T aie u ic ze satt uu Ot E 16 LINE PHESS COASTING REGULATOR Ji uuu mme SEHVO CUPBACE ta HAN ALOR gt 544 Di Pa Mi ES C amp VALVE ISTATOH SUPPORT 2 2 REAR LUBE s ti BEN i mes uu i a OHAIN BACK istaron AN Hee od d cov In surroh iC pow GENEEN H A pis HN i Hydraulic Control System E 22 TM 10 3950 672 24 1 1 2 l2 THRU 156 2THRU4 31 r 31 THRU 34 Transmission Assembly Exploded View Sheet 1 of 6 E 23 TM 10 3950 672 24 1 Transmission Assembly Exploded View Sheet 3 of 6 E 25 110 111 112 Transmission Assembly Exploded View Sheet 4 of 6 E 26 TM 10 3950 672 24 1 TM 10 3950 672 24 1 120 124 127 Peer P ga 131 Transmission Assembly Exploded View Sheet 5 of 6 E 27 TM 10 3950 672 24 1 143 144 150 151 THRU 156 Transmission Assembly Exploded View Sheet 6 of 6 E 28 CONOR Wh TRANSMISSION AUTO HOUSING SEAL OUTPUT SHAFT BUSHING BOLT CLIP BOLT GASKET SHAFT OUTPUT PILOT SCREW BODY ASSEMBLY COLLECTOR OIL SEAL GOVERNOR HOUSING RING RETAINING SLEEVE OIL DISTRIBUTION BOLT TUBE OUTLET TUBE INLET SCREW CLIP CLIP DIAPHRAGM ROD VALVE GASKET BOLT PAN OIL PLUG CONVERTER ASSEMBLY
51. contacted flush eyes with large amounts of water for at least fifteen minutes and GET IMMEDIATE MEDICAL ATTENTION SAFT 1 TM10 3950 672 24 1 SAFETY SUMMARY Continued WARNING Dry cleaning solvent P D 680 is TOXIC and flammable Wear protective goggles and gloves and use only in well ventilated areas Avoid contact with skin eyes and clothes Do not breathe vapors Keep away from heat and flame Never smoke when using solvent the flashpoint of type solvent is 100 F 38 C and for type 138 F 50 Failure to do so may result in injury or DEATH to personnel If a person becomes dizzy while using cleaning solvent immediately get fresh air and medical help If solvent contacts skin or clothes flush with cold water If solvent contacts eyes flush eyes with cold water and get immediate medical attention WARNING EXHAUST GASES CAN KILL Ensure that the area is properly ventilated Brain damage or DEATH can result from heavy exposure to exhaust gases Precautions must be followed to ensure personnel safety when operating the diesel engine 1 Do not operate the engine in an enclosed area 2 Do not idle the engine with the cab windows closed 3 Be alert for exhaust gases 4 Be alert for headaches dizziness sleepiness loss of muscular control 5 If you see another person with exhaust poisoning remove that person from the area and expose to open air Then keep the person warm and do not allow physical exercise Administer
52. d Determine cause of condition Service as required e Determine cause of condition Service as required f Determine cause of condition Service as required g Determine cause of condition Service as required h Service as required a Service or replace one way clutch Adjust intermediate band Perform control pressure test Perform air pressure test Clean service or replace valve Replace or service as required Perform control pressure test b Perform governor check Re place or service governor clean Screen c Tighten valve d Clean service or replace valve e Service or replace valve body and or case as required TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 13 All upshifts harsh delayed or no upshifts 14 Mushy early all upshifts pile up upshifts 15 No 1 2 upshift a Improper fluid level b Manual linkage misadjusted or damaged c Governor sticking as required d Main control pressure too high as required e Valve body bolts loose or too tight f Valve body dirty or sticking valves g Vacuum leak to diaphragm unit a Low main control pressure suits b Valve body bolts loose or too tight c Valve body valve or throttle control valve sticking d Governor valve sticking as required a Improper fluid level b Manual linkage misadjusted damaged c Governor valve sticking Inter mediate band out of a
53. e Free linkage TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 7 Sticking spool in the control valve continued 8 Leaking seals 9 Unable to move spool in or lout 10 Load drops when spool moved from neutral 11 Poor hydraulic system per formance or failure Spacer bent Return spring damaged Spring or valve cap binding Oil not thoroughly warmed Paint on or under seal Dirt under seal Scored spool Loose seal plates Cut or scored seal Dirt in valve Spool cap full of oil Bind in linkage Dirt in check valve b Scored check valve poppet or seat c Motor control valve out of adjustment Damaged pump Dirt in relief valve Relief valve damaged Worn hoist motor E 136 f Replace valve g Replace faulty parts h Loosen cap recenter and re tighten Allow time for system warm up a Remove and clean as neces sary b Remove and clean as neces sary Replace valve Clean and tighten plates Replace faulty parts a Clean and flush out valve assembly b Replace seals c Free linkage a Disassemble and clean check valve b Replace poppet or lap poppet to seat c Refer to Adjustment of the Motor Control Valve in this Section and adjust the valve a Check pressure and repair or replace pump b Disassemble and clean relief valve c Replace relief valve d Repair or replace damaged components DISASSEM
54. 107 DiSASSEMDIY REM 107 REM 107 biydraulic Pump Description 00 eee nr naan Maintenance RRR Disassembly RRRRRRRRRRRRRREEEEMEMMM 555751101 MM Crossover Relief Valve eee Maintenance E 112 Disassembly 8 Cleaning Inspection 6 Ace ee eee Solenoid Maintenance DiSASSEMDIY eee eee Directional aa Description RM Maintenance RR Disassembly TM10 3950 672 24 1 TABLE OF CONTENTS continued Subject SWING MOON a Disassembly
55. 19 and press the bearing 20 from the shaft Remove the other snap ring 19 18 Remove the felt wiper 23 and shaft seal 22 from the body CLEANING AND INSPECTION 1 Wash all metal parts in cleaning solvent Stoddard Solvent or equal and dry thoroughly 0 0625 0 1588 x 45 BOTH ENDS G 2 043 5 189 2 045 5 194 6 to 8 15 24 to 20 32 DRIVER 0 031 0 079 R 0 876 2 225 0 937 2 381 DIA 0 886 2 250 D THIMBLE 4 0 252 mE TM 10 3950 672 24 1 0 031 0 079 RECESS AS SHOWN IN CUTAWAY 0 125 0 318 0 995 2 527 p A 0 998 2 535 NS 1 490 3 785 Dia 1 489 3 782 BLEND IN 2 PLACES RADIUS NO SHARP CORNERS 9 375 0 953 POLISH FINISH L o e25 1 588 NOTE ALL DIMENSIONS IN INCHES CM 0 040 A Vane Motor Special Tools 2 Inspect the seals for wear breaks cuts and brittleness Check closely the shaft seal for scratches and cracks Discard and replace all defective seals 3 Inspect all springs for wear on the OD for cracks or permanent set Replace all defective springs 4 Inspect the bearings for wear or flat spots If the bearings are rough or loose they must be replaced 5 Inspect the cam ring for excessive wear ripples or washboard marks on the contour Replace a badly worn or defective cam ring 6 Inspect the rotor for scored marred or scratched faces and vane slots surfaces Replace a defective
56. 2 Inspect for hydraulic leaks and repair as necessary each TM 10 3950 672 24 1 DESCRIPTION The planetary gear reducer is bolted to the turntable frame The gear reducer pinion meshes with the turntable bearing to rotate the turntable The gear reducer has an integral brake mounted to it and the swing motor is mounted on the brake The crossover relief valve is mounted on the swing motor The swing motor drives the gear reducer through the brake assembly The gear reducer has a ratio of 27 98 1 and has an air vent to allow air to escape when the reducer is being filled with oil MAINTENANCE REMOVAL 1 Extend and set the outriggers 2 Tag disconnect and cap all hydraulic lines from the swing motor and reducer 3 Remove the nuts spring washers and flatwashers securing the pinion guard and remove the guard 4 Remove the slotted flat screws securing the pinion end cap and remove the end cap and pinion 5 The gear reducer must be supported before the mounting bolts are removed It can be supported from the top by installing an eye bolt in the hole where the pinion cap is normally installed Use an adequate lifting device to lower the gear reducer to the ground after the mounting bolts and washers have been removed The gear reducer can be supported from the underside using an automatic transmission jack or equivalent Lower the gear reducer after removing the bolts and washers and move to a clean work area
57. 2 Slide the inner downshift lever assembly out from the inside of the case 3 Remove the two bolts securing the neutral start Switch 4 Remove the C ring securing the parking pawl actuating rod to the manual lever Remove the rod from the case E 48 TM 10 3950 672 24 1 5 Remove the nut securing the inner manual lever to the shaft Remove the inner lever from the shaft Slide the outer lever and shaft from the case 6 Remove the seal from the case with tools T59L1 00 B and T58L101 A hammer and puller or equiva lent Assembly of the Downshift and Manual Linkage 1 Dip the new seal in transmission fluid and install it in the case using seal replacer tool 77288 or equivalent 2 Slide the outer manual lever and shaft In the transmission case Install the Inner lever on the shaft ensuring the leaf spring roller is positioned In the Inner manual lever detent Install the attaching nut and torque 30 to 40 Ib ft 41 to 54 Nom 3 Install the parking pawl actuating rod and secure it to the inner manual lever with the C ring 4 Slide the neutral start switch on the outer lever shaft and install the bolts in the case 5 With the transmission manual lever in neutral rotate the switch and install the gauge pin No 43 drill shank end into the gauge pin holes of the switch The gauge pin must be installed a full 0 4844 inches 12 303 mm into the three holes of the switch 6 Torque the attaching bolts 55 to 75 pou
58. 3 162 4 Install the hook in position in the hook block weldment 5 Install the washer and slotted nut on the hook NOTE Position the nut and cotter pin to provide free rotation of hook with minimum clearance 6 Install the cotter pin in the nut PERIODIC MAINTENANCE It is recommended that the hook block be inspected every 50 hours A complete disassembly inspection should be conducted every quarter or 500 hours in the area of the hook hex nut and threaded areas for corrosion and proper fit After assembly of the hook a liberal coating of multipurpose grease should be applied to the nut and threaded areas by brush or hand to prevent corrosion Grease containing molybdenum disulfide should not be used For hook blocks and other load handling devices not manufactured by Grove Manufacturing Company follow the Manufacturer s inspection and testing recommendations to assure an adequate preventative maintenance program is established TM 10 3950 672 24 1 Sheave Assembly Bolt Shaft Rivet Eye Bolt Cotter Pin A Heavy Duty Flapper Latch Hook Link Thrust Bearing Washer Slotted Nut Cotter Pin Shaft Washer ROND 5 6 7 8 9 10 8 5 Ton Single Sheave Hook Block Assembly 3 64 WIRE ROPE GENERAL The following information is a compendium of information from various wire rope manufacturers and includes inspection replacement and maintenance guidelines for wire rope as established by ANSI A
59. 3 212 10 3950 672 24 1 Nut Washer Screw Voltage Reg Screw Brush Assy Screw 8 Rear Housing 9 Retainer Stator Bearing Rotor Assy Retainer Bearing LEGEND Frt Housing Spacer Fan Nut Lockwasher Pulley Nut Figure 3 26 Alternator Assembly 3 213 Washer Pivot Hex Flange Screw Support Bracket Screw Screw Cap Alternator Brace TM 10 3950 672 24 1 NOTE To remove nut 18 place rotor assembly 12 in a soft jawed vise e Remove nut 18 lockwasher 19 pulley 20 fan 17 and spacer 16 from rotor assembly 12 shaft Using arbor press remove rotor assembly 12 from front housing 15 g Remove bearing retainer 1 3 and press bearing 14 from front housing 15 3 84 3 Inspection a Inspect brushes for cracks grooves on sides being oil soaked and that they are at least 0 1875 inch 4 7625 mm long Inspect rear housing for cracked or broken casting stripped threads and severe wear of rear bearing bore Inspect fan for cracked or broken fins and for worn mounting hole Inspect front housing for cracked or broken casting stripped threads and bore of mounting foot for elongation Inspect other components for damage such as broken terminals or insulation discoloration stripped threads and other obvious damage Replace damaged components as necessary ooo FLAT TIP SCREWDRIV
60. 4 Remove and oil seal assembly the bearing cover CAUTION THE USE OF A PINCH BAR WILL DAMAGE THE SHIMS DRIVING THE PINION FROM THE INNER END WITH A DRIFT WILL DAMAGE THE BEARING LOCK RING GROOVE 5 Remove the bearing cage The original may have pulled holes 6 Wire the shim pack together to facilitate adjustment on assembling Disassembly of the Pinion and Cage Assembly 1 Tap the shaft out of the cage with a soft mallet or press the shaft from the cage 2 Remove the outer bearing from the cage 3 Remove the spacer or spacer combination from the pinion shaft E 64 TM 10 3950 672 24 1 4 If it is necessary to replace the rear thrust bearing or radial bearing remove them with a suitable puller 5 Remove the oil seal assembly from the bearing cover ASSEMBLY OF THE DRIVE UNIT Silicone RTV Gasket Application CAUTION FAILURE TO USE THE APPROPRIATE GASKET MATERIAL WILL CAUSE THE AXLE TO LEAK NOTE Where silicone RTV gasket material is used Dow Siliastic No RTV 732 Black and General Electric No RTV 1473 Black meet the requirements However silicone RTV is also available in bulk under Rockwell part number 1199 Q 2981 in 10 oz tubes part number 1250 X 388 or in 3 oz tubes part number 1199 T3842 Removal of all gaskets including silicone RTV is accomplished by peeling or scraping the used gasket off the carrier to housing surfaces WARNING MINOR CONCENTRATIONS OF ACETIC ACID V
61. 42 4 E 52 0 021 0 046 0 533 1 168 0 022 0 036 0 558 0 914 CLUTCH PLATE SELECTIVE SNAP RINGS Snap Ring Thickness oom o om 0 056 0 060 0 064 0 069 0 074 0 078 0 083 0 087 0 092 0 096 0 110 0 114 0 218 0 132 7 After all clutch plates have been installed install the pressure plate in the clutch drum Install the pressure plate selective snap ring 8 With a feeler gauge check the clearance between the pressure plate and snap ring while the pressure plate is held downward The clearance should be 0 022 to 0 036 inches 0 558 to 0 914 mm If the clearance is not within specifications refer to the Clutch Plate Selective Snap Rings chart for the correct size snap ring Install the correct size snap ring and re check the clearance Disassembly of the Forward Clutch 1 Remove the clutch pressure plate snap ring 2 Remove the rear pressure plate the drive and driven plates wave plate and the forward pressure plate from the clutch hub 3 Remove the snap ring that secures the disc spring in the clutch cylinder Using tool T65L 77515A or equivalent remove the disc spring 4 Using an air nozzle tool 7000 DE or equivalent apply air pressure to the clutch cylinder to remove the piston 5 Remove the seal from the piston and the seal from the clutch hub Assembly of the Forward Clutch 1 Dip the two new seals in transmission fluid Install the smaller seal on the clutch hub and the lip seal on t
62. 5 Unit of Measure U M Indicates the measure used in performing the actual maintenance function This measure is expressed by a two character alphabetical abbreviation e g EA IN PR If the unit of measure differs from the unit of issue requisition the lowest unit of issue that will satisfy your requirements C 1 TM10 3950 672 24 1 Section Il EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST 1 3 4 ITEM NATIONAL STOCK DESCRIPTION NUMBER NUMBER TM10 3950 672 24 1 APPENDIX D TORQUE VALUE CHARTS D 1 TM10 3950 672 24 1 Ec Ec NCC CHC MATERIAL TORQUE POUNDS FOOT TENSILE STRENGTH MINIMUM FINE OR COURSE THREAD FASTENER GRADE DESIGNATION Medium Carbon Stee or Low Alloy Heat Treated Low Alloy or Med Carb Quenched Tempered ASTM A 354 BC STEEL SA E 6 STEEL 133 000 69 5 1 SAE 7 S TEEC APS S A E 8 150 000 STEEL PS S SOCKET HEAD Alloy Quenched Tempered Roll Threaded Carbon Alloy Quenched CAPSCREW High Carbon SOCKET ALSO N A S Alloy CAPSCREW AIRCRAFT STD Quenched Tempered N A S 144 AIRCRAFT STD 520000 MIL STD N A S 624 High Carbon NATIONAL Alloy AIRCRAFT Quenched CAPSCREW STANDARD Tempered STEEL Torque values as shown are for nut bolt combinations that have not been plated and have not had s
63. 5 8 inch 45 Final pressure should be held for approximately one minute to ensure the rivet has filled the hole Differential case and gear bolts are also available for service replacement of rivets The use of bolts greatly facilitates servicing these units in the field and eliminates the need for special equipment necessary to cold upset rivets correctly 2 Lubricate the differential case inner walls and all component parts with axle lubricant 3 Position the thrust washer and the side gear in the gear case half 4 Place the spider with pinions and thrust washers in position E 68 TM 10 3950 672 24 1 5 Install the second side gear and the thrust washer NOTE The case bolts must be treated with adhesive before installing using either new Dri Loc bolts or applying Loctite No 277 New Dri Loc bolts have adhesive on the threads but it is usable only once When the same bolt is reused Loctite No 277 must be used as in step 7 6 Wipe excess oil residue from the threaded holes in the case NOTE Do not apply liquid Loctite No 277 or any other type of fastener retainer material sealant or adhesive on new Dri Loc bolts or in the threaded holes 7 If new Dri Loc bolts are to be used proceed to step 8 Otherwise adhere to the following a Wipe excess oil residue from the bolts NOTE Do not apply Loctite to the bolt since trapped air in the hole will create back pressure and blow out the Locti
64. 57 Nem 1 Remove the cartridge solenoid valve s from the valve body 3 If the jam nut on the solenoid was loosened torque the jam nut 120 to 140 Ib in 14 to 16 Nem 2 Remove and discard the O rings from the valve Body O Ring Coil O Ring Cartridge Backup Ring Nut Nut Gasket 2 Way Solenoid Valve Exploded View E 114 TM 10 3950 672 24 1 DIRECTIONAL CONTROL VALVE DESCRIPTION The directional control valves are four way three position valves with either an open or closed spool Whether a valve has an open or closed spool is determined by whether with the spool in the neutral position the work ports are open to the reservoir return passage f the work ports are open to the reservoir return passage the valve is classified as an open spool type if they are not the valve is a closed spool type Additionally the valve spool is spring loaded to the neutral position The open spool directional control valve is constructed with a through passage to allow flow to pass to the next valve s in the bank and on to the reservoir when the valve spool is in the neutral position By positioning the valve spool to a work position the through passage is blocked and flow is diverted to the dead end parallel passage This causes flow to be directed to the component s open supply work port Return flow is routed from the return work port to the reservoir return passage by the opposite end of the valve spool This flo
65. Breathers vented shift units and all other openings should be tightly covered or closed to prevent the possibility of water entering the assembly DRYING Parts should be thoroughly dried immediately after cleaning Use soft clean lintless absorbent paper towels or wiping rags free of abrasive material such as lapping compound metal filings or contaminated oil Bearings should never be dried by spinning with compressed air CORROSION PREVENTION Parts that have been cleaned dried inspected and are to be immediately assembled should be coated with light oil to prevent corrosion If these parts are to be stored for any length of time they should be treated with a good RUST PREVENTIVE and wrapped in special paper or other material designed to prevent corrosion Inspection It is impossible to overstress the importance of careful and thorough inspection of drive unit components prior to assembly Thorough visual inspection for indications of wear or stress and the replacement of such parts as are necessary will eliminate costly and avoidable difficulties INSPECTION OF THE DRIVE UNITS 1 Inspect all bearings cups and cones including those not removed from parts of the drive unit and replace if rollers or cups are worn pitted or damaged in any way Remove parts needing replacement with a suitable puller or in a press with sleeves Avoid the use of drifts and hammers They may easily mutilate or distort comp
66. Coolant System Replacement Procedures 6 5 59 Coolant System 0 5 51 Coolant Temperature Above Normal 5 28 Coolant Temperature Below Normal 5 31 Crankshaft and Main Bearings Operation and Description 5 167 Crankshaft and Main Bearings Troubleshooting 5 179 Grankshatt Cleaning Pec E E Mw 5 293 Crankshaft Gear 5 295 Crankshaft Inspection 122 5 294 Crankshaft 5 189 Crossover Relief Valve Assembly 112 Crossover Relief Valve Cleaning and Inspection E 112 Crossover Relief Valve Description 2 E 112 Crossover Relief Valve Description and Replacement 3 118 Crossover Relief Valve E 112 Crossover Relief Valve Maintenance E
67. DISPLACEMENT REVERSIBLE VALVES CAPABLE OF INFINITE POSITIONING HORIZONTAL BARS INDICATE INFINITE POSITIONING ABILITY TM 10 3950 672 24 1 METHODS OF OPERATION MISCELLANEOUS MANUAL ENCLOSURE PUSH BUTTON PUSHPULL LEVER ROTATING SHAFT RESERVOIR VENTED PRESSURIZED PEDAL OR TREADLE MECHANICAL PRESSURE COMPENSATED PRESSURE GAUGE ELECTRIC MOTOR ACCUMULATOR SPRING LOADED ACCUMULATOR GAS CHARGED COOLER TEMPERATURE CONTROLLER SOLENOID SINGLE WINDING REVERSING MOTOR PILOT PRESSURE REMOTE SUPPLY FILTER STRAINER INTERNAL SUPPLY 3 94 such leaks Seal all normal openings in the hydraulic system and the reservoir Using a positive means to control the pressure i e a regulator pressurize the hydraulic system to 2 to 4 psi 13 79 to 27 6 0 1379 to 0 276 bar and inspect all joints and fittings for evidence of leaks A soap solution applied to the fittings and joints may also prove helpful in detecting minute leaks while the system is pressurized Remove the pressure repair any leaks found and reopen any openings vents etc closed for inspection Refill the reservoir after completing any repairs or service Operate all hydraulic circuits several times in both directions This action should return any entrapped air to the reservoir where it can be removed from the oil by th
68. Flow Control Reilef Vaive Back Cover Thrust Plate Steer Pump Exploded View E 89 7 Mark the front cover island next to the pressure vent hole in the heat shield 9 gasket 8 and V seal 6 to act as a guide in assembly The location of this vent hole determines pump rotation 8 Use a small diameter wire a paper clip will do to remove the phenolic heat shield 9 the paper compound gasket 8 and the rubber V seal 6 Discard these parts and replace when the pump is assembled 9 Remove both O rings 11 and discard 10 Do not remove the shaft seal 1 in the front cover 5 unless it is damaged or leaking If the seal is to be replaced use great care not to damage the seal recess or bearing Heating the cover in an oven to 250 degrees F 121 degrees C will reduce the press fit 11 If the flow control is defective replace it as a cartridge 12 If the relief valve is defective replace it as a complete relief valve unit INSPECTION Drive and Driven Gear Assemblies 1 Inspect the shafts for roughness in the bearing and sealing areas Measure for wear The minimum acceptable diameter is 0 7492 inch 19 03 mm 2 Inspect the splines for damage or excessive wear 3 Inspect the gear end faces outside diameter and teeth for roughness and score marks Minimum gear width is 1 3840 inches 35 154 mm 4 Ensure the snap rings are secure break any sharp edges on the si
69. INSTALLATION 1 Install an eye bolt in the hole where the pinion cap is normally installed and attach an adequate lifting device 3 142 2 Carefully raise the gear reduction assembly into place While holding in place with the lifting device apply Loctite 271 to the threads of the mounting bolts and install the bolts and washers securing the gear reduction assembly to the frame weld Torque the bolts to 99 Ib ft 134 Nom 3 Remove the lifting device and eye bolt Apply never seeze compound to the splines of the pinion shaft Install the pinion and pinion end cap Apply Loctite 271 to the screws Install the slotted flat screws and secure the end cap 4 Install the pinion guard and secure with the nuts spring washers and flat washers 5 Connect the hydraulic lines to the swing motor and gear reducer as tagged during removal 6 Service the assembly as indicated in Section 13 LUBRICATION TEST 1 Test the swing of the superstructure in each direction Start and stop swing several times 2 Inspect for hydraulic leaks and repair as necessary TM 10 3950 672 24 1 3 59 SWING BEARING DESCRIPTION The swing bearing mates the superstructure to the The inner race contains one grease fitting for lubrication carrier The bearing outer race is bolted to the of the bearing The outer race incorporates 94 gear superstructure and the inner race is bolted to the carrier teeth that mesh with the pinion gear of the gear reduce
70. Install the telescope cylinder into the telescope section and secure with the stop blocks washers and capscrews Torque the capscrews to 203 Ib ft 275 Nem 3 152 TM 10 3950 672 24 1 e 3 2 9 E 2 o 2 tb Two Section Boom 3 153 TM 10 3950 672 24 1 Install the telescope section into the base section Install the lower base section wear pads and secure with the plates washers and capscrews Torque the capscrews to 1 5 Ib ft 20 Nem Install the upper front base section plate and secure with the screws Install the screws in the base section adjustable wear pads Secure the telescope cylinder to the base section with the pins plates washers and bolts Torque the bolts 10 to 1 2 Ib ft 14 to 16 Nem Refer to paragraph 3 60 2 for installation procedures 3 60 5 Functional Check d Activate the hydraulic system Elevate the boom and hold it in the extended position The boom should stay in position until retracted by the operator Extend and retract the boom several times at various elevations Check for smooth operation of the telescope cylinder Check operation of all electrical electronic components affected by boom removal 3 60 6 Alignment and Inspection Visually inspect the telescoping sections for adequate lubrication of bottom plates Observe extended sections for evidence of cracks warping or other damage Periodically check security of boom wear pads Check boom nose
71. POSSIBLE TRANSMISSION FAILURE COULD RESULT b Firmly apply the parking brake and start the engine c Adjust the engine idle speed to the specified rom If the engine idle speed cannot be brought within limits check the throttle and downshift linkage for a binding condition If linkage is satisfactory check for vacuum leaks in the transmission diaphragm unit and its connecting tubes and hoses 2 To perform the control pressure test using the vacuum pump method perform the following a Disconnect and temporarily plug the vacuum line at the vacuum diaphragm unit b Attach a vacuum pump to the vacuum diaphragm Apply both the parking and service brakes Start the engine and vacuum pump c Set the vacuum at 15 inches and read and record the control pressure in all the selector positions Run the engine up to 1000 rpm and reduce the vacuum to 10 inches Read and record the control pressure in D 2 and 1 Keep the engine rpm at 1 000 and reduce the vacuum to 1 inch Read and record the control pressure in D 1 2 and R VACUUM SUPPLY TEST Check the vacuum supply to the vacuum diaphragm unit and the diaphragm itself To check the supply disconnect the vacuum line at the diaphragm unit and connect it to vacuum gauge With the engine idling the gauge must have a steady acceptable vacuum reading for the altitude at which the test is being performed If the vacuum reading is low check for a vacuum leak or poor engine vacuu
72. Power Steering Pump 1 1 3 84 Power Steering Pump Removal 1 00 0 3 84 Power Steering Pump nnn 3 84 Preliminary Servicing and tnnt nsns sensn 2 2 Pressing Parts General 1 5 Pressure Regulator Valve 5 129 Preventive Maintenance Checks and Services Organizational 2 3 R Radiator Fans and Shutters Troubleshooting seen nennen nennen 5 55 Radiator Install ation ERR 3 38 Radiator REMOVAl PRIM 3 36 Rear Access Cover 3 203 Rear Access Cover Removal 3 203 Rear Crankshaft Seal Operation and Description 5 169 Rear Steer Axle 02222 100 Ee 3 67 Hefer nces c AAA MR MAAN LUE 1 Relief Valve AdjUStMeM cece en nn Eee eee isis 3 77 Relief Valves Description Preparation and
73. Press the bushing in 0 060 to 0 080 inches 1 52 2 03 mm below the front face of the bushing bore Use bushing replacer tool T66L 7003 C2 or equivalent and a handle to seat the bushing properly Ensure the half moon slot is in past the lube hole to provide proper lubrication TM 10 3950 672 24 1 FRONT PUMP SUPPORT THRUST WASHER SELECTION IDENTIFICATION THICKNESS COLOR INCH Blue Natural White Red Assembly of the Front Pump NOTE Each drive and driven gear has either an identification mark or chamfered teeth or one face The identification mark on the chamfered surface on each gear must be installed toward the front of the pump housing 0 056 0 060 0 073 0 077 0 088 0 092 1 42 1 52 1 85 1 95 2 23 2 33 Stator to Impeller Interference Check 1 Install the front pump assembly a bench with the spline end of the stator shaft pointing up 2 Mount a converter on the pump with the splines on the one way clutch inner race engaging the mating splines of the stator support The converter hub will then engage the pump drive gear 1 Install the drive and driven gears in the pump 3 Hold the pump stationary and try to rotate the housing converter counterclockwise The converter should rotate freely without any signs of interference or 2 Install the stator support in the pump housing scraping within the converter assembly and secure with the five attaching bolts Torque the i bolts 12 to 16 I
74. TM 10 3950 672 24 1 LEGEND 10 Nut 6 Screw 1 Cover o Xn d 2 x 255 O0 23022 QNO wem c yum 03 M 0925 z c oO JOE Noo D 5 zo Os 5 Noz No lt 5 Lockwasher Figure 3 23 Access Covers Rear 3 202 TM 10 3950 672 24 1 3 80 REAR ACCESS COVERS 3 80 1 Removal Open cover 1 and slide cover off crane deck hinges Remove two self tapping screws 2 and cover plate 3 from crane deck Remove two nuts 4 two lockwashers 5 two screws 6 lower spring 7 and cover 8 from hinge 9 Remove two nuts 10 two lockwashers 11 two screws 12 upper spring 13 and hinge 9 from crane frame 3 80 2 Installation a Install hinge 9 Figure 3 23 upper spring 13 crane frame with two screws 12 two lockwashers 11 and two nuts 10 Install cover 8 and lower spring 7 on hinge 9 with two screws 6 two lockwashers 5 and two nuts 4 Install cover plate 3 on crane deck with two self tapping screws 2 d Slide cover 1 into crane deck hinges and close cover Bop 3 203 TM 10 3950 672 24 1 11 14 18 15 17 16 1 Locknut 6 Washer 11 Bracket 16 Nut 2 Screw 7 Screw 12 Nut 17 Lockwasher 3 Cushion Washer 8 Locking Plate 13 Lockwasher 18 Mirror 4 Nut 9 Star Washer 14 Carriage Bolt 19 Jam Nut 5 Lock
75. Tag and disconnect wire 51X from engine oil pressure switch ee Tag and disconnect wire 1 from fuel solenoid ff Tag and disconnect wires 157 and 156 from starter 99 hh Tag and disconnect connector and wires 1 96B 5 and 1 96A from alternator Tag and disconnect wires 3 and 1 69C from engine water temperature sensor ii Tag and disconnect wire 32 from fuel level switch jj Tag and disconnect wires 18 51Y from quick start solenoid kk Tag and disconnect wire 25C from transmission oil temperature switch 1 Tag and disconnect wires 1 and 16 from right tail stoplight mm Tag and disconnect wire 1 3G from right rear side marker light nn oo Tag and disconnect wires 8A 5127 from backup alarm Tag and disconnect wires 17 and 1 2G from left tail stoplight Tag and disconnect wire 8C from backup light 3 239 TM 10 3950 672 24 1 qq Tag and disconnect wire 1 2F from left rear side marker light rr Remove wire ties and or clamps securing harness to crane and remove chassis harness 3 98 2 Installation NOTE To aid installation refer to electrical schematic in Appendix F Position chassis harness in crane Connect wire 1 2F to left rear side marker light and remove tag Connect wire 8C to backup light and remove tag Connect wires 17 and 12G to left tail stoplight and remove tag Connect wires 8A and 51Z to backup alarm and rem
76. The swing motor is a hydraulic gerotor type with low and the gerotor star The motor has two ports for speed and high torque characteristics It has only connection to the hydraulic system three moving parts the commutator valve the drive MAINTENANCE NOTE SEALWASHER CA The swing motor shown is typical of all swing motors however splined output shaft is used instead of a keyed output shaft CAPSCREW NOTE The swing motor shown is typical of all swing motors however a drive spacer may or may not be installed END CAP DISASSEMBLY NOTE 2187 2 It is recommended that the motor be 2 Remove the capscrews and sealwashers kept in a vise during disassembly 3 Remove the end cap 4 Remove the seal from the end cap 2187 1 1 Place the motor in a vise and clamp across the edge of the flange with the output shaft down When clamping use a protective device on the vise such as special soft jaws or pieces of hard rubber or board DRIVE SPACER 2187 3 5 Remove the gerotor 6 Remove the seal from the gerotor E 119 TM 10 3950 672 24 1 CAPSC REW SEALWASHER WEAR PLATE DRIVE SPACER SPLINED DRIVE HOUSING BEARING RACE SEAL OUTPUT SHAFT NEEDLE THRUST BEARING PRESSURE SEAL MOUNTING FLANGE Swing Motor Exploded View E 120 7 Remove the drive spacer WEAR PLATE SPLINED DRIVE 2387 4 8 Remove the splined drive 9 Remove the wear plate 10
77. Using an ohmmeter check for continuity between the switch terminals with switch in ON or activated position 2 Position switch to OFF Ohmmeter should register zero no continuity Electrical Switch Removal and Installation 3 223 TM 10 3950 672 24 1 3 89 3 Installation a Connect the electrical leads as marked prior to removal b Position the switch on the panel and secure it with the attaching hardware c Install the cab front console cover d Connect negative leads to battery negative post 3 89 4 Functional Check Operate the switch as described in the operators manual TM 10 3950 672 10 Observe it for proper functioning in the applicable circuit Continue troubleshooting as necessary any system or circuit malfunction not corrected by repair or replacement of the switch or associated wiring 3 224 TM 10 3950 672 24 1 3 90 CLEARANCE LIGHT 3 90 1 3 90 2 Removal Disconnect negative battery cable and two electrical leads from battery Disconnect light assembly 1 Figure 3 32 electrical connector from crane electrical harness Unsnap lens 2 and remove two nuts 3 two lockwashers 4 two screws 5 and light assembly 1 from crane frame Remove two bulbs 6 from light assembly 1 Installation Install two bulbs 6 Figure 3 32 in light assembly 1 Install light assembly 1 in crane frame with two screws 5 two lockwashers 4 and two nuts 3
78. capscrews and secure the motor to the brake housing Torque the capscrews to 109 Ib ft 148 Nom 32 Install the relief valve to the motor with the capscrews and washers TM 10 3950 672 24 1 GROVE MODEL HO 12 HOIST DESCRIPTION The Grove Model HO 12 hoist is a single speed hoist consisting of a hoist control valve a vane type motor the brake cable drum clutch assembly and the motor and brake end housings The following is a list of specifications for the model HO 12 hoist Drum dimensions are 9 625 inches 24 4 cm diameter with 9 0 inches 22 8 cm length Drum Dimensions Cable Capacity Cable capacity for the 9 0 inch 22 8cm drum with 9 16 inch cable is 135 feet 41 1 m Refer to the Line Pulls and Reeving Info Chart in the cab Permissible Line Pull THEORY OF OPERATION The first section of the hydraulic pump supplies oil to the hoist directional control valve The control valve supplies oil through swivel port 4 to the hoist motor control valve The control valve is actuated by the main hoist control lever Hydraulic oil from the hoist returns to the reservoir through hydraulic swivel port 3 The hoist drum rotates on anti friction bearings located in the drum ends A shaft splined to the drive motor transmits the drive motor rotation to the primary carrier assembly A second shaft transmits this rotation from the secondary carrier assembly to the clutch assembly Brake discs and plates mounted on
79. converter housing 5 Fluid leakage from the converter drain plugs will appear at the outside diameter of the converter SYMPTOM PROBABLE CAUSE SOLUTION 1 Slow initial engagement a Improper fluid level b Damaged or improperly adjust ed linkage c Contaminated fluid d Improper clutch and band ap Perform fluid level check Service or adjust linkage Perform fluid condition check Perform control pressure test plication or low main control pressure TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 2 Rough initial engagement in either forward or reverse 3 Harsh engagements warm engine 4 No delayed forward engage ment reverse OK a Improper fluid level b High engine idle c Looseness in the driveshaft U joints or engine mounts d Improper clutch or band appli cation or oil control pressure e Sticking or dirty valve body body a Improper fluid level b Throttle valve linkage misad justed long disconnected stick ing damaged return spring discon nected c Valve body bolts loose or too tight d Valve body dirty or sticking valves a Improper fluid level b Manual linkage misadjusted damaged c Low main control pressure Leakage Forward Clutch stator support seal rings leaking 3 4 d Forward clutch assembly burnt Damaged leaking check ball in cylinder Leaking piston seal rings e Valve body bolts loose or to
80. months CONUS or eighteen 18 months OCONUS beginning with Government acceptance of the crane This warranty is in lieu of all other warranties express or implied and the obligation and liability of the Manufacturer under this warranty shall not include any transportation or other charges or the cost of installation or any liability for direct indirect or consequential damages or delay resulting from the defect Any operation beyond rated capacity or the improper use or application of the product or the substitution upon it of parts not approved by the Manufacturer shall void this warranty This warranty covers only the products of Grove Manufacturing Company The products of other Manufacturers are covered only by such warranties as are made by their Manufacturers THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND OF ANY OTHER OBLIGATIONS OR LIABILITY ON THE PART OF THE MANUFACTURER AND GROVE MANUFACTURING COMPANY NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY INCONNECTION WITH SUCH EQUIPMENT NOTE The Cummins diesel engine is covered by a separate warranty as described in TM 10 3950 672 24 2 There is a decal in the cab of the crane near the main control panel which has the warranty expiration date TM10 3950 672 24 1 Warehouse Crane M469 1 0 TM10 3950 672 24 1 C
81. obstructions COMPONENT INSPECTION Radiator 1 Top and Bottom Tank Look for leaks particularly where the tank is soldered to the core Vibration and pulsation from pressure can fatigue soldered seams 2 Filler Neck The sealing seat must be smooth and clean Cams on filler neck must not be bent or worn so as to allow a loose fitting cap Ensure the overflow tube is not plugged 3 Radiator Cap This is the pressure setting type Its purpose is to hold the cooling system under a slight pressure increasing the boiling point of the cooling solution and preventing loss of solution due to evaporation and overflow The cap has a spring loaded valve the seat of which is below the overflow pipe in the filler neck This prevents the escape of air or liquid while the cap is in position When the cooling system pressure reaches a predetermined point the cap valve opens and will again close when the pressure falls below the predetermined point When removing the pressure type cap from the radiator perform the operation in two steps Loosening the cap to its first notch raises the valve from the gasket and releases the pressure through the overflow pipe In the first stage position of the cap it should be possible to depress the cap approximately 0 125 inch 3 175 mm The prongs on the cap can be bent to adjust this condition Care must be taken that the cap is not too loose as this would prevent proper sealing WARNING WHEN REMOVIN
82. 10 Install the collector and tubes in place on the rear of the case and secure with the attaching bolts Torque the bolts 12 to 16 Ib ft 16 to 22 N m 11 Install the output shaft and governor as an assembly 12 Clean the mounting surface on the transmission case and extension housing Install a new gasket on the transmission case Install the extension housing on the case and secure with the attaching bolts Torque the bolts 25 to 35 Ib ft 34 to 48 Nem 13 Mount the transmission case in the holding fixture 14 Coat a new gasket with petroleum jelly and install on the servo cover 15 Install the servo spring on the piston rod 16 Install the servo piston rod in the case Install the servo cover and secure with the attaching bolts taking care to back off the band adjusting screw as the cover bolts are tightened Torque the bolts 14 to 20 Ib ft 19 to 27 Nem 17 Align the low reverse clutch hub and one way clutch with the inner race at the rear of the case Rotate the low reverse clutch hub clockwise while applying pressure to seat it on the inner race 18 Install the low reverse clutch plates starting with the wave plate next to the piston and following alternately with steel and friction plates Retain them with petroleum jelly If new composition plates are being used soak them in clean transmission fluid for fifteen minutes before installation Install the pressure plate and the snap ring Test the operation of
83. 10 3950 672 24 1 3 51 CYLINDERS GENERAL This sub section provides descriptive information for all For information on how the cylinder functions in the the hydraulic cylinders used on this crane individual circuits refer to the Description and Operation description of the cylinder given here is for the cylinder of that circuit itself MAINTENANCE GENERAL There must be a gap between the ends of each wear ring when it is installed onto the piston or head In component The resulting value is the number of addition each wear ring gap is to be located as follows degrees each wear ring gap is to be located with respect Divide 360 degrees by the number of wear rings on the to each other The approximate wear ring gaps are as follows PISTON WEAR RING GAP m ms 1 to 4 75 25 4 to 120 66 0 125 3 175 5 50 to 10 0 139 70 to 254 00 0 187 4 750 greater than 10 0 greater than 254 0 0 250 6 350 HEAD WEAR RING GAP 1 to 4 75 25 40 to 120 65 5 to 10 0 127 00 to 254 00 greater than 10 0 greater than 254 00 3 119 3 52 LIFT CYLINDER TM 10 3950 672 24 1 DESCRIPTION The lift cylinder is the double acting type with a cylinder bore of 7 0 inches 17 7 cm The retracted length of the cylinder from the center of the rod bushing to the center of the barrel bushing is 37 inches 93 9 cm and the extended length of the cylinder is 59 06 inches 150 0 cm Foreign matter
84. 2 with new cotter pin 5 Installation Insert pintle hook assembly 4 Figure 3 21 through crane frame and secure with washer 3 and slotted nut 2 Tighten slotted nut 2 back off nut until pintle hook assembly 4 will rotate and hole in shaft of hook body 9 aligns with slotted nut 2 Secure slotted nut 2 with new cotter pin 1 Install radiator refer to paragraph 3 20 2 3 199 TM 10 3950 672 24 1 LEGEND 1 Battery Compartment 6 Hinge 2 Screw 7 Screw 3 Lockwasher 8 Transmission Oil Cooler Access 4 Washer 9 Screw Self tapping 5 1 Tool Box Compartment O Cover Plate Figure 3 22 Access Covers Front 3 200 TM 10 3950 672 24 1 3 79 FRONT ACCESS COVERS 3 79 1 oaoop 3 79 2 oaoop Removal Open cover 1 Figure 3 22 and slide cover off crane deck hinges Remove four screws 2 four lockwashers 3 four washers 4 and cover 5 from crane deck Remove two hinges 6 from cover 5 Remove four screws 7 and cover 8 from crane deck Remove four self tapping screws 9 and cover plate 10 from crane frame Installation Install cover plate 10 Figure 3 24 on crane frame with four self tapping screws 9 Install cover 8 on crane deck with four screws 7 Slide two hinges 6 onto pins of cover 5 Install cover 5 on crane deck with four screws 2 four lockwashers 3 and four washers 4 Slide cover 1 into crane deck hinges and close cover 3 201
85. 3 186 3 189 LA 3 74 3 190 3 71 HOIST TM 10 3950 672 24 1 DESCRIPTION One hoist is available the Grove HO 12 The hoist is a single speed assembly consisting of a hoist control valve a vane type motor the brake cable drum clutch assembly and the motor and brake end housings The hoist is installed at the rear of the turntable Hoist usage is controlled by a hoist control lever If the optional cable follower assembly is provided it is installed on the rear side of the hoist The following is a list of specifications for the model HO 12 hoist Drum dimensions are 9 625 inches 24 4 cm di ameter with 9 0 inches 22 8 cm length Drum Dimensions Cable Capacity Cable capacity for the 9 0 inch 22 8 cm drum with 9 16 inch cable is 135 feet 41 1 m Refer to the Line Pulls and Reeving Info Chart in the cab Permissible Line Pull NOTE For more detailed information refer to THEORY OF OPERATION The first section of the hydraulic pump supplies oil to the hoist directional control valve The control valve supplies oil through swivel port 4 to the hoist motor control valve The control valve is actuated by the main hoist control lever Hydraulic oil from the hoist returns to the reservoir through hydraulic swivel port 3 MAINTENANCE REMOVAL 1 Remove the cable and cable follower Refer to CABLE FOLLOWER REMOVAL in this Section 2 Attach a suitable lifting s
86. 305183 12 to 8 gauge wire P N 91019 3 FOR IN LINE CONNECTORS AMP 4 to 9 circuit P N 453300 1 15 circuit PIN 458944 1 Extraction Deutsche 12 gauge wire P N 114010 16 gauge wire P N 0411 204 1605 8 to 10 gauge wire P N 114008 4 to 6 gauge wire P N 114009 Crimping Amp Tool Die 14 to 12 gauge wire P N 69710 1 P N 90145 1 10 to 8 gauge wire P N 69710 1 P N 90140 1 4 to 9 circuit in line connectors P N 69710 1 P N 90306 1 15 circuit in line connectors P N 90299 1 Crimping Deutsche 12 gauge wire P N HDT 12 00 16 gauge wire P N HDT 16 00 8 to 10 gauge wire P N HDT 08 00 4 to 6 gauge wire P N HDT 04 00 Because the pins are crimped to the wires it is not possible to remove the pin Using the proper extraction tool remove the pin s from the plug or receptacle Cut the wire as close to the pin as possible After cutting the pin off the wire will most likely be too short Using a wire that is too short will allow pressure to be applied to the pin and wire where they are crimped when the pin is inserted in the plug or receptacle Add a short length of the same size wire to the short wire by crimp splice or solder Use heat shrinkable tubing or other suitable material to insulate the splice 3 211 TM 10 3950 672 24 1 3 84 ALTERNATOR 3 84 1 Removal 3 84 2 Open the engine compartment Disconnect battery negative leads from battery negative post Remove the drive belt See D
87. 6 PARKER C HYD RESERVOIR 40 GALLON CAPACITY EMERGENCY STEER PUMP amp PRESSURE CHECK PANEL HYD LOCKOUT SOLENOID VALVE REQUIRED FOR CE CONFORMITY TEER PUMP HYO RESERVOIR 40 GALLON CAPACITY PARKER FLUID POWER Figure FO 2 Hydraulic Schematic FP 7 FP 8 blank By Order of the Secretary of the Army 7 MAIL Administrative Assistant to the Secretary of the Army DENNIS J REIMER Uniad Stalas Army Chief af Staff RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL pa ao SENT IET ao IN THIS SPACE TELL WHAT IS WRONG I AND WHAT SHOULD BE DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE DA Pd ro 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS Linear Measure 1 centimeter 10 millimeters 39 inch 1 decimeter 10 centimeters 3 94 inches 1 meter 10 decimeters 39 37 inches 1 dekameter 10 meters 32 8 feet 1 hectometer 10 dekameters 328 08 feet 1 kilometer 10 hectometers 3 280 8 feet Weights 1 centigram 10 milligrams 15 grain 1 decigram 10 centigrams 1 54 grains 1 gram 10 decigram 0
88. 6 and star washer 7 disconnect two electrical leads and remove sealed beam 8 with retaining ring 9 from light assembly 1 Remove four retainers 10 and separate retaining ring 9 from sealed beam 8 Installation NOTE Align tabs on retaining ring 9 Figure 3 37 with boss on sealed beam 8 Install retaining ring 9 on sealed beam 8 and secure with four retainers 10 Position sealed beam 8 with retaining ring 9 to light assembly 1 connect two electrical leads and secure with screw 6 and star washer 7 Install light assembly 1 in crane frame with four bolts 5 four washers 4 four lockwashers 3 and four nuts 2 Connect light assembly 1 electrical connector to crane electrical harness Connect negative battery cable and two electrical leads to battery 3 233 TM 10 3950 672 24 1 3 96 TAIL BRAKE AND TURN SIGNAL LIGHT 3 96 1 Removal Disconnect negative leads from negative battery post Disconnect two electrical connectors for light assembly 1 Figure 3 38 from crane electrical harness Remove three nuts 2 three lockwashers 3 three washers 4 three bolts 5 and light assembly 1 from crane frame Remove retaining ring 6 lens 7 gasket 8 and bulb 9 from light assembly 1 Installation Install bulb 9 Figure 3 38 gasket 8 lens 7 and retaining ring 6 in light assembly 1 Install light assembly 1 in crane frame with three bolts 5 three was
89. 60 minutes to dry and apply Loctite 290 adhesive Install the spacer 28 in the right hand drum end 3 E 142 TM 10 3950 672 24 1 6 Apply a thin even film of silicone adhesive sealant RTV silicon rubber to the cable drum 2 and right hand drum end 3 surfaces Install the right hand drum end into the housing 2 8 Ensure the thread surface of the capscrews 33 are free of dirt and oil Apply high strength thread locking adhesive sealant and primer to the threads of the capscrews 33 Install the capscrews 33 and washers 34 and secure the right hand drum end 3 to the cable drum 2 TM 10 3950 672 24 1 9 12 Install the brake end housing cover 5 to the right hand drum end 3 securing with the washers 32 and capscrews 31 Torque the capscrews to 31 Ib ft 42 Nom 10 Install the seals 26 in the brake end housing 5 13 Install the input shaft 14 into the motor end housing 4 11 Install the O ring 24 on the brake end housing cover 5 E 143 TM 10 3950 672 24 1 DEFLECTOR ELEVATION AT mr COLLAR amp vATION AT 70 COLLAR L H SIDE VIEW R H SIDE VIEW Deflector and Collar Location E 144 14 Install the motor end housing cover 4 to the drum with the washers 38 and capscrews 37 Torque the capscrews to 31 Ib ft 42 N m 15 Install the hoist housing collars 48 and deflector 44 Refer to figure titled Deflector and Col
90. AS SODIUM HYDROXIDE ORTHOSILICATES OR PHOSPHATES E 73 TM 10 3950 672 24 1 Steam cleaning is not recommended for assembled drive units after they have been removed from the housing When this method of cleaning is used water is trapped in the cored passage of the castings and in the close clearances between parts as well as on the parts This can lead to corrosion rust of critical parts of the assembly and the possibility of circulating rust particles in the lubricant Premature failure of bearings gears and other parts can be caused by this practice Assembled drive units cannot be properly cleaned by steam cleaning dipping or slushing Complete drive unit disassembly is necessary for a thorough cleaning ROUGH PARTS WARNING EXERCISE CARE TO AVOID SKIN RASHES OF VAPORS WHEN USING ALKALI CLEANERS Rough parts such as differential carrier castings cast brackets and some brake parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts are not ground or polished The parts should remain in the tank long enough to be thoroughly cleaned and heated through This will aid the evaporation of the rinse water The parts should be thoroughly rinsed after cleaning to remove all traces of alkali COMPLETE ASSEMBLIES Completely assembled axles may be steam cleaned on the outside only to facilitate initial removal and disassembly providing all openings closed
91. Air Cleaner Installation 3 31 3 18 TM 10 3950 672 24 1 MUFFLER AND EXHAUST PIPES 3 18 1 Removal 3 18 2 a Set rear outriggers refer to Operator s Manual TM 10 3950 672 10 b Turn steering wheel all the way left to position left rear wheel to gain access to muffler WARNING Exhaust components can be hot causing burns to exposed skin Allow exhaust components to cool before proceeding Loosen three pipe clamps 1 2 and 3 Figure 3 9 Disconnect and remove tube 4 and elbow 5 Slide three pipe clamps 1 2 and 3 off of tube and elbow Remove four bolts 7 and four lockwashers 8 securing flange 6 to engine exhaust manifold Remove flange 6 and cover opening in exhaust manifold Loosen two pipe clamps 9 and 10 and remove tailpipe 11 and exhaust tube 12 Remove two bolts 14 and two nuts 15 securing muffler clamp 13 Remove muffler 16 with clamp 13 Then separate muffler 16 and clamp 13 If damaged remove muffler bracket 17 Remove two nuts 18 and two lockwashers 19 securing muffler bracket 1 7 to vehicle frame Installation If removed install new muffler bracket 17 Figure 3 9 and secure with two nuts 18 and two lockwashers 19 Slide muffler clamp 13 over muffler 16 Then install muffler 16 and secure with two bolts 14 and two nuts 15 Slide two pipe clamps 9 and 10 over tailpipe 11 and exhaust tube 12 Then install exhaust tube 12 on muffler 16 an
92. CAUTION WATER PRESSURE FROM A HOSE OR TAP SHOULD NOT EXCEED 40 PSI 276 KPA 2 76 BAR 6 Rinse the element with clean water until the water coming through the element is clean Air dry the element thoroughly before using CAUTION HEATED AIR MAXIMUM TEMPERATURE 160 DEGREES F 71 DEGREES MUST HAVE CIRCULATION DO NOT USE LIGHT BULBS FOR DRYING ELEMENTS 7 Mechanized drying methods can be used E 10 TM 10 3950 672 24 1 INSPECTION Element 0282 4 CAUTION DO NOT TOUCH THE INSIDE OF THE FILTER WITH A BARE LIGHT BULB After cleaning the filter element inspect the element for damage Look for dust on the clean air side the slightest rupture or damaged gaskets A good method to use to detect ruptures in the element is to place a light inside the element and look toward the light from the outside Any hole in the element even the smallest will pass dust to the engine and cause unnecessary engine wear Element replacement is recommended if such holes are evident Air Cleaner Body Before installing the filter element remove any foreign material leaves lint or other foreign matter that may have collected inside the air cleaner body Inspect the inside of the body for dents or other damage that would interfere with air flow or with the fins on the element or inside the body Repair any body dents being careful not to damage the sealing surfaces Vacuator Valve Vacuator valves are designed to ex
93. CL A08 TM10 3950 672 24 1 Section TOOL AND TEST EQUIPMENT REQUIREMENTS Continued FOR CRANE WAREHOUSE M469 Tool or Test Equipment Maintenance National NATO Ref Code Level Nomenclature Stock Number Shop Equipment 4910 00 754 0705 SC4910 95 Auto Maintenance CL A31 and Repair FM Basic Shop Equipment 4910 00 754 0706 5 4910 95 Auto Maintenance CL A62 and Repair FM Suppl No 1 Shop Equipment 4910 00 754 0707 SC4910 95 Auto Maintenance and CL A63 Repair FM Suppl No 2 Tool Outfit Hydraulic 4940 01 036 5784 13221E6850 Sys Test and Repair 3 4 Ton Trailer Mtd 5 4940 95 07 Shop Equipment 4940 00 754 0714 5 4910 95 Fuel and Electric 01 System Engine FM Basic Stand Maintenance 4910 00 241 3329 150 AX Auto Axle Wheel Mtd Front and Rear Axle Unit Test Set Diesel 4910 00 317 8265 5910359 Injector Test Stand Auto 4910 00 767 0218 MIL T4544 Generator and Starter Floor Mtd 500 AMP Tool Kit Auto 5180 00 754 0655 5 5180 95 Fuel and Electric CL B08 System Repair Shop Equipment Auto 4910 00 754 0654 C4910 95 Maintenance and Repair CL A74 Common No 1 B 23 TM10 3950 672 24 1 Section TOOL AND TEST EQUIPMENT REQUIREMENTS Continued FOR CRANE WAREHOUSE M469 Tool or Test Equipment Maintenance Ref Code Level National NATO Tool Nomenclature Stock Number Number Shop Equipment Auto Maintenance and Repair Common No 2 Shop Equipment Auto Maintenance and
94. Check Valve Stabilizer Outrigger Cylinder 3 132 8 If necessary remove the pilot operated check valve from the port block CLEANING AND INSPECTION 1 Clean all parts with solvent and dry with compressed air Inspect all parts for serviceability CAUTION BEFORE INSTALLING NEW SEALS AND RINGS CLEAN ALL SURFACES AND CAREFULLY REMOVE BURRS AND NICKS PARTS DISPLAYING EXCESSIVE WEAR OR DAMAGE SHOULD BE REPLACED 2 Stone out minor blemishes and polish with a fine crocus cloth 3 Clean with solvent and dry with compressed air any parts that have been stoned and polished 4 Inspect the barrel carefully for scoring ASSEMBLY NOTE Steps 1 2 3 and 4 are used only if the check valve has been removed 1 Check the inside of the port block for any sharp edges or burrs and remove as necessary with emery cloth 2 Install new O rings onto the check valve 3 Lubricate the check valve and O rings with clean hydraulic oil CAUTION DO NOT DAMAGE THE O RINGS DURING INSTALLATION OF THE CHECK VALVE IF THE CHECK VALVE TURNS FREELY THEN GETS HARD TO TURN THEN EASY TO TURN REMOVE THE CHECK VALVE AND CHECK THE O RINGS THEY HAVE PROBABLY BEEN DAMAGED BY A SHARP EDGE OF A PORT TM 10 3950 672 24 1 NOTE The holding valve should turn by hand until compression of the O rings begins 4 Carefully install the check valve into the port block until fully seated CAUTION WHEN INSTALLING NEW SEALS AND R
95. D with terminal washer 2 and terminal nut 1 refer to Figure 3 26 Detail A for terminal location Connect jumper wire from voltage regulator harness connector to rear housing terminal Stator AC with terminal washer 22 and terminal nut 21 refer to Figure 3 26 Detail A for terminal location Installation Position the alternator on the alternator support bracket 24 Figure 3 26 and install the pivot hex flange screw 23 Do not torque the capscrew at this time Install the alternator link capscrews 26 Torque the screws to 18 Ib ft 24 Nem Torque the pivot hex flange screw 23 to 32 Ib ft 44 N m Position the belt around the alternator pulley If necessary refer to TM 10 3950672 24 2 Maximum deflection should be 0 375 to 0 50 in 9 5 to 12 7 mm Gauge pressure should be 80 to 110 Ib ft 108 to 149 Nem If gauge reading is not acceptable replace automatic belt tensioner refer 2 Connect the electrical leads to the terminals as tagged during removal 3 85 BATTERY 3 85 1 3 85 2 Removal Lift the hinged deck cover Tag and disconnect wire lugs 4 15 and 16 Figure 3 31 from the negative terminal 1 Then tag and disconnect wire lugs 5 and 14 at positive terminal 3 Remove the bolt nut and lockwasher from the angle bracket holddown rod and remove the angle holddown bracket Remove the battery Installation Install the battery Install the angle holddown bracket and rod and
96. If you use new bolts ensure they are the correct length 0 875 inch 22 23 mm under head length Longer screws will not permit proper seal between the flange and housing 12 Clamp the housing in a vise gerotor end up Refer to step 1 of DISASSEMBLY or the correct clamping procedure CAUTION DO NOT STRETCH THE SEALS BEFORE INSTALLING THEM IN THE GROOVE NOTE To aid in the installation of the seals apply a light coating of clean petroleum jelly to the seal before installing 13 Pour approximately 35 cc of hydraulic oil in output shaft SPLINED DRIVE SEAL 2187 21 14 Install the 2 875 inch 7 3 cm diameter seal in the housing seal groove and install the wear plate on the housing TM 10 3950 672 24 1 GEROTOR STAR STAR POINT ALIGN WITH DOT ON DRIVE ORIVE TIMING DOT DRIVE ALIGN WITH SHAFT TIMING DOT PRIOR TO INSTALLING THE WEAR PLATE SHAFT TIMING DOT 2187 22 Motor Timing NOTE The timing marks are machined on the shaft and drive 15 Install the drive with the timing mark on the drive tooth aligned with the timing mark on the shaft Refer to the Motor Timing figure E 126 ORIVE SPACER low 8 GEROTOR 2187 23 16 Install the 2 875 inch 7 3 cm diameter seal in the gerotor seal groove 17 Carefully place the gerotor on the wear plate seal side toward the wear plate Install the gerotor with any tooth aligned with the timing mark on the drive 18
97. Improper boom alignment caused from side loading h Worn boom wear pads i Distorted boom section j Damaged telescope cylinder k Clogged broken or loose hydraulic lines or fittings Damaged control valve Low hydraulic oil level Damaged relief valve Air in cylinder Low engine rpm Lack of lubrication f Check valve malfunctioning g Improper boom alignment caused from side loading h Extremely tight boom nose sheaves i Distorted boom section j Worn boom wear pads k Bent cylinder rod Scored cylinder barrel m Damaged piston seals n Loose or damaged piston 3 156 TM10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION g Reduce and properly hoist load h Replace wear pads and prop erly lubricate i Replace distorted section j Repair or replace cylinder k Clean tighten or replace lines or fittings l Repair or replace control valve a Replenish hydraulic oil to proper level b Repair or replace relief valve c Bleed by lowering telescoping cylinders below horizontal and cy cle telescope cylinder d Increase engine rpm to recom mended setting e Properly lubricate all boom sec tions f Repair or replace check valve g Reduce and properly hoist load h Inspect and properly lubricate i Replace distorted section j Replace wear pads and properly lubricate k Replace cylinder rod and all cy linder seals Repa
98. Intermediate one way clutch damaged e Polished or glazed band or drum a Improper fluid level b Manual linkage misadjusted damaged Low main control pressure d Valve body bolts loose or too tight e Valve body dirty or sticking valves f Forward clutch piston ball check not seating or leaking g Forward clutch piston seals cut or worn h Low one way clutch planetary damaged 3 50 a Perform fluid level check b Check and adjust or service as required c Control pressure test a Perform fluid level check b Check and replace piston seal c Determine cause of condition Service as required a Adjust intermediate band b Perform control pressure test c Perform air pressure test of in termediate servo for leakage Ser vice as required d Replace e Service or replace as required a Perform fluid level check b Check and adjust or service as required c Control pressure test d Tighten bolts e Determine source of contami nation Service as required f Replace forward clutch cylin der Service transmission as re quired g Replace seals and service clutch as required h Determine cause of condition Service as required 9 Reverse shudder chatters slips 10 No drive slips or chatters in first gear in D All other gears normal 11 No drive slips or chatters in second gear 12 Starts up in 2nd or 3rd a Improper flu
99. LE 3 7 PLUG E a CREE TO E 7 Sen 17 88 R sToP ru TALL Bus 2 ay A T t E o Par Ogee 12 99 MARKER AREA DEF Sw 1 8 LT 2 e LI 076 4 AREA XF Sw 92 800M FLOOD LTS eh 73 Bo o Md 9 7 i CARRIER WITH CUMMINS ENGINE MESA SL i o olii esi 00 51 D sig Figure FO 1 Electrical Schematic Sheet 3 of 3 FP 5 FP 6 blank TM 10 3950 672 24 1 HOLDING VALVE TELESC RACINE HYO INC B O6 LIFT HOLDING VALVE BORE RACINE WYO INC TELESCOPE CYLINDER 6 5 DIA BORE roe a MOTOR ORAIN pr sl ma OLDING VALVE RACINE HYD INC 4 CHECK VALVE CARTRIDGE RACINE HYD DIV Ex Of YDRAULIC LOCKOUT ii SOLENOIO VALVE O R SELECTOR VALVE WATERMAN HYO To OIL COOLER TO Pump 2 SECTION 800M CROSS OVER RELIEF WITH SHUTTLE VALVE MANIFOLD MOUNTED TO SwING MOTOR HYDRAULICS HYDRAULIC LOCKOUT SOLENOIO VALVE lA M 4 Q R JACK CYLINDER WATERMAN HYO 3 00 BORE C ORBITROL X STEER VALVE V CHAR LYNN CO ITROL STEER VALVE CHAR LYNN CD BARNES C 194 CU IN STEER 3 0 DIA BORE SWITCH CLOSE amp 160 F AMONT LR PARKER MANI IN ___ 6 7 Do rows GEE gs o 6
100. LOCK ARE REPLACED AS AN ASSEMBLY LEGEND 1 Door Assembly 8 Nut 14 Nut 2 Bolt 9 Lockwasher 15 Lockwasher 3 Lockwasher 10 Screw 16 Bolt 4 Washer 11 Pin 17 Washer 5 Bushing 12 Washer 18 Strap 6 Extension 13 Handle 19 Rivet 7 Latch Figure 3 4 Door and Latch Assembly 3 10 TM10 3950 672 24 1 3 5 ACCELERATOR PEDAL ASSEMBLY 3 5 1 Removal a b Set outriggers refer to Operator s Manual TM 10 3950 672 10 From under the vehicle remove two nuts 1 Figure 3 5 two washers 2 U bolt 3 and cable mount 4 securing throttle cable to bracket 19 Remove spring clip 5 pin 6 and throttle cable from lever 23 Remove three bolts 7 three lockwashers 8 and pedal 9 with attached components from vehicle 3 5 2 Disassembly Remove spring clip 10 Figure 3 5 and pin 11 securing clevis 27 to lever 23 Remove two nuts 12 two washers 13 and U bolt 14 securing pedal 9 to bracket 15 Remove bracket 15 lever 23 and bracket 19 as an assembly Remove two nuts 16 two washers 17 two bolts 18 and bracket 19 from bracket 1 5 Remove circlip 20 two bearing liners 21 spring 22 and lever 23 from bracket 15 Remove spring clip 24 pin 25 and rod end bearing 26 with clevis 27 from pedal 9 NOTE Count and note number of turns when removing clevis 27 to aid in assembly Unscrew clevis 27 from rod end bearing 26
101. MPG grease around the inner diameter of the planet gear 49 Position one of the thrust washers 51 on a flat surface and place the planet gear 49 in position on top of it Install the needle bearings 50 in place using grease to hold them upright A socket just smaller than the diameter of the pin can be used to stabilize the rollers until they are all in place If assembling the primary carrier position the other thrust washer in place If assembling the secondary carrier install the second row of needle bearings before installing the thrust washer 3 Carefully install the planet gear 49 in the carrier and carefully install the pin 41 Ensure all the rollers are in position 4 Secure the pin 41 with the circlip 40 5 Repeat steps 2 3 and 4 for the other planet gears Hoist 1 Wipe the surface of the cable drum end clean Apply a light coat of Locquic Primer T to the area between the seal and drum end Allow 30 to 60 minutes to dry and apply Loctite 290 adhesive Install the seal 39 in the cable drum 2 2 3 Install the secondary carrier 12 into the drum 2 4 Clean the surface of the right hand drum end 3 Apply a thin even film of silicone adhesive sealant RTV silicone rubber to the surface and install the O ring 35 5 Wipe the surface of the cable drum 2 and right hand drum end 3 clean Apply a light coat of Locquic Primer T to the area between the seal and drum end Allow 30 to
102. O ring with clean hydraulic oil and install the CLEANING AND INSPECTION adjusting stem assembly into the valve body 1 Clean all parts in solvent and dry with air E 105 TM 10 3950 672 24 1 z amp e ri BPeesse 9 5 E amp oooooom suse Nas YS NEN Backup Ring Poppet O Ring O Ring O Ring o0 Body PS Holding Valve E 106 TM 10 3950 672 24 1 HOLDING VALVE DESCRIPTION The holding valve is ported to allow hydraulic flow in two directions To raise a load the oil must unseat the free flow poppet valve In this case oil pressure must overcome the main poppet spring To do this the oil flows through the oil ports of the pilot release poppet valve which applies pressure to the inside face of the free flow poppet When the main poppet unseats the oil flows past the main poppet seat to the component to be worked When a load is to be lowered as in retracting the boom better control is necessary because of the weight of the load For this reason a pilot pressure is used for positioning the main poppet valve which is being held against its seat by heavy springs The pilot pressure is sensed from the lowering side of the hydraulic circuit As the directional control valve is opened to the lower position pressure is applied to the pilot piston The pilot piston moves aga
103. Replace Repair Inspect Maint DDO Support D 5 Tools and Equipment Remarks Ref Code Code 10 11 15 16 24 21 23 24 20 TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 5 4 MAINTENANCE LEVEL Direct General Tools and Component i Support T Equipment Remarks Assembly Function F Ref Code Code Air Cleaner Air Cleaner Assembly Inspect Service Replace Repair Tanks Lines Fittings Headers Tank Fuel Assembly Inspect 0 5 24 12 16 Service Replace Lines Fittings Inspect Replace Fuel Filters Fuel Water Inspect 21 23 24 Separator Filter Service 20 Replace Engine Starting Aid Cold Start Assembly Inspect 21 23 24 Service Replace TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component i Support RUN BEEN Equipment Remarks Assembly Function ejoj F Ref Code Code Accelerator Throttle Choke Control Accelerator Control Inspect Replace Repair EXHAUST SYSTEM Muffler amp Pipes Inspect Replace COOLING SYSTEM Radiator Inspect 11 30 32 Test Service Replace Thermostat amp Housing Gasket Hoses amp Clamps Thermostat amp Housing Test Gasket Replace Hoses amp Clamps Inspect Replace TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART
104. Turn the gerotor to line up the holes for the capscrews be careful not to disengage the star from the drive 19 Install the drive spacer COUNTE RCLOCKWISE CLOCKWISE ROTATION 2187 24 20 With the orientation shown in the Motor Tim E 127 TM 10 3950 672 24 1 ing figure the output shaft will rotate as shown with the ports pressurized as shown CAPSCREW sinant 2187 25 21 Install the 2 875 inch 7 3 cm diameter seal the end cap then carefully place the end cap on the gerotor 2187 26 Torquing Sequence 22 Install the capscrews and sealwashers In the end cap Pretighten all screws 15 to 40 Ib 2 to 5 Nem Check to ensure the seals are seated properly in the grooves Tighten the capscrews to a final torque of 175 to 200 Ib in 20 to 23 Nem following the Torquing Sequence figure TM 10 3950 672 24 1 PLANETARY GEAR REDUCER DESCRIPTION The planetary gear reducer is bolted to the turntable frame weld The gear reducer pinion meshes with the turntable bearing to rotate the turntable The gear reducer has an integral brake mounted to it and the swing motor is mounted on the brake The crossover relief valve is mounted on the swing motor The swing motor drives the gear reducer through the brake assembly The gear reducer has a ratio of 27 98 1 MAINTENANCE DISASSEMBLY 1 Remove the drain plug and drain all oil from the gear reducer 2 Remove the capscrews and washers
105. Wrench HTW 4RCF 3 4 to 1 Multiplier 1 2 Input 3 4 Output TM750LW 4 1 1 8 Socket 3 4 Drive 6 636 5 6 x 1 1 8 12 Pt Box 3 4 Drive Step Wrench M 1081 1 6 10 Extension 3 4 Drive 6 110 7 13 Extension 3 4 Drive 6 113 8 Tool Box TB 11 9 1 1 8 x 5 8 Hex Nut Adapter Optional GROVE PART NO 9 999 100141 9 999 100159 9 999 100134 9 999 100142 9 999 100122 9 999 100138 9 999 100137 9 999 100146 9 999 100844 Special Turntable Bolt Torquing Tools Orders for special tools shall be referred to Grove Manufacturing Company Customer Services 1086 Wayne Ave Chambersburg Pa 17201 3 145 QUANTITY REQUIRED a N a TM 10 3950 672 24 1 FORWARD LOADING PLUG INNER RACE OUTER RACE Inner and Outer Race Bolt Pattern 3 146 REMOVAL Fully extend and set the outriggers Ensure the boom is in the travel position Elevate the boom slightly and shut down the engine 4 Remove the boom and lift cylinder following the procedures outlined in Section 8 BOOM 5 Tag and disconnect the battery cables from the battery 6 Remove the swivel following the procedure outlined in Section 9 SWIVELS 7 f necessary disconnect the electrical connectors from the terminal block 8 Remove the nuts spring washers and flatwashers securing the pinion guard and remove the guard Remove the slotted flat screws securing the pinion end cap and remove the end cap and pinion
106. allow fluid to flow into the jar until it is a solid stream free of air bubbles Close the bleeder valve NOTE Repeat steps 8 and 9 for the remaining wheel cylinders 10 Bleed the valve at each of the wheel cylinders 11 Remove the air supply from the bleeder tank 12 Close the bleeder tank valve and disconnect the hose from the bleeder adapter on the master cylinder 13 Remove the bleeder tank and hose 14 Remove the bleeder adapter from the master cylinder 15 Install and secure the master cylinder reservoir cover 16 Start the engine and pump the brake pedal several times until approximately full pedal is obtained 17 Release the brake pedal 18 Remove the master cylinder reservoir plugs and check the fluid level Add brake fluid as necessary 19 cover Install and secure the master cylinder reservoir Manually Bleeding the Brake System NOTE Before bleeding the brake system ensure the master cylinder is filled to the proper level Refer to Section 13 LUBRICATION for the proper brake fluid NOTE Always bleed the wheel units beginning with the wheel having the longest brake line 1 Connect the end of the bleeder hose to the bleed valve on the wheel cylinder Submerge the other end in a jar partially filled with clean brake fluid 2 Open the bleed valve on the wheel cylinder and allow fluid to flow into the jar while pumping the brake pedal until a solid stream free of air bubbles is acqu
107. an assembly from the crane 2 Block up the engine and attach an adequate lifting device to the transmission 3 Disconnect the neutral switch wire at the plug connector 4 f the transmission fluid has not yet been drained place the drain pan under the transmission fluid pan Starting at the rear of the pan and working toward the front loosen the attaching bolts and allow the fluid to drain Finally remove all of the pan attaching bolts except two at the front to allow the fluid to further drain With the fluid drained install two bolts on the rear side of the pan to temporarily hold it in place 5 Remove the converter drain plug access cover from the lower end of the converter housing 6 Remove the converter to flywheel attaching nuts Place a wrench on the crankshaft pulley attaching bolt to turn the converter to gain access to the nuts 7 With the wrench on the crankshaft pulley attaching bolt turn the converter to gain access to the converter drain plug Place a drain pan under the converter to catch the fluid and remove the plug After the fluid has been drained reinstall the plug 8 Disconnect the shift cable from the lever at the transmission 9 Disconnect transmission 10 Remove the vacuum hose from the vacuum diaphragm unit Remove the vacuum line from the retaining clip 11 Remove the remaining converter housing to engine attaching bolts 12 Move the transmission away from the engine the oil cooler line
108. and sun gear as an assembly into the transmission case 25 Install the intermediate band into the case around the reverse high clutch drum Install the struts and tighten the band adjusting screw sufficiently to retain the band 26 Install a selective thickness bronze thrust washer on the rear shoulder of the stator support and retain it with petroleum jelly If the end play was not within specification when checked prior to disassembly replace the washer with one of proper thickness Refer to the Selective Thrust Washer Thickness chart E 55 1 42 1 52 1 85 1 95 2 23 2 33 27 Using two 5 16 inch bolts three Inches long make two alignment studs Cut the heads from the bolts and grind a taper on the cut end Temporarily install the two studs opposite each other in the mounting holes of the case Slide a new gasket onto the studs Install the pump on the case ensuring no damage is done to the large seal on the outside diameter of the pump housing Remove the aligning studs Install six of the seven mounting bolts Torque the bolts 16 to 30 Ib ft 22 to 41 Nem 28 Clean all dirt from the band adjusting screw and remove and discard the locknut Adjust the intermediate band by Installing a new locknut and tightening the adjusting screw to 10 Ib ft 14 Nem Back off the adjusting screw exactly 1 1 2 turns Hold the adjusting screw from turning and torque the locknut 35 to 40 Ib ft 48 to 54 Nem After adjustment is made Inst
109. be automatically correct when drive side is correct As a rule coating about twelve teeth is sufficient for checking purposes CORRECT TOOTH CONTACT Gears Unloaded 1 With adjustments properly made pinion at correct depth and backlash set at 0 010 inch 0 254 mm the contacts shown above will be procured The area of contact favors the toe and is centered between the top and bottom of the tooth 2 The hand rolled pattern shown gears unloaded will result in a pattern centered in the length of the tooth when the gears are under load The loaded pattern will be almost full length and the top of the pattern will approach the top of the gear Gears Loaded 3 The pattern on the coast side of the teeth will appear the same width as the drive side shown However the overall length will be centered between the toe and heel of the gear tooth 4 Set a used hypoid gear to have the tooth contacts match the existing wear patterns Hand rolled patterns of used gears will be smaller in area and should be at the toe end of the wear patterns Incorrect Tooth Contact 0603 22 1 A high contact indicates the pinion is too far out Set the pinion to the correct depth by removing shims under the pinion cage Slight outward movement of hypoid gear may be necessary to maintain correct backlash x 2 A low contact indicates the pinion is too deep Set the pinion to the correct depth by adding shims under the pinion cage
110. cables g Grove recommends for cable extended booms that boom extension cables be replaced every seven 7 years TM 10 3950 672 24 1 3 65 BOOM NOSE SHEAVE ASSEMBLY 3 65 1 Removal a b C d Remove hook block and wind all wire rope onto hoist drum Remove two detent pins 1 Figure 3 17 and retainer 2 from boom nose Remove bolt 3 lockwasher 4 pin bolt 5 shaft 6 three bushings 7 9 and 10 and sheave 8 from boom nose Remove bolt 1 1 lockwasher 12 pin bolt 13 shaft 14 four bushings 15 16 19 and 20 and two sheaves 17 and 18 from boom nose 3 65 2 Installation Install two sheaves 17 and 18 Figure 3 17 in boom nose with four bushings 15 16 19 and 20 shaft 14 pin bolt 13 lockwasher 12 and bolt 11 Install sheave 8 in boom nose with three bushings 7 9 and 10 shaft 6 pin bolt 5 lockwasher 4 and bolt 3 Reeve wire rope through three sheaves 8 1 7 and 1 8 antitwo block weight and hook block Refer to Operator s Manual TM10 3950 672 10 for cable reeving Install retainer 2 on boom nose with two detent pins 1 3 168 LEGEND Detent Pin 8 Sheave Retainer 9 Bushing Bolt 10 Bushing Washer 11 Bolt Pin Bolt 12 Washer Shaft 13 Pin Bolt Bushing 14 Shaft Bushing Bushing Sheave Sheave Bushing Bushing Figure 3 17 Boom Nose Sheave Assembly 3 169 TM 10 3950 672 24 1 TM 10
111. check valve a cam ring assembly containing the rotor vanes vane springs and cam ring and the end cap assembly consisting of the end cap and needle bearing MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL INSTALLATION 1 Apply high strength thread locking 1 Tag and disconnect the hydraulic lines from the adhesive sealant and primer to the bolts Position the motor and hoist motor control valve Cap or plug all lines and openings 2 Remove the bolts and washers securing the motor to the end housing Remove the motor motor In place on the end housing and secure with the bolts and washers Torque the bolts to 68 Ib ft 92 N m 2 Connect the hydraulic lines to the motor and hoist motor control valve as tagged during removal 3 189 3 74 HOIST TO BOOM ALIGNMENT PROCEDURE 1 Lower the boom to the level position 2 Find a line on top of the hoist drum which is parallel to the drum axis as follows a Use Miracle Point Gauge and find a zero degree dial point next to each flange on top of the drum NOTE If this special equipment is not available sufficient accuracy in locating a centerline may be obtained by using a steel square against the machined inner surfaces of both flanges It is advisable to avoid using any cast surfaces in this procedure unless a check from both flanges indicates that the resultant line is straight TM 10 3950 672 24 1 b Draw a line between the hoist dru
112. compressor around the vanes and tighten the compressor gradually until the springs and vanes are in the position they will occupy while in the cam ring Place a backup plate slightly smaller than the outside diameter of the rotor in the ring compressor and push the rotor springs and vanes E 153 into the cam ring The backup plate will prevent the vanes from sliding end wise in the rotor slots and damaging the slots and springs WARNING ENSURE THE ROTOR AND VANE ASSEMBLY IS INSERTED FAR ENOUGH IN THE CAM RING TO PREVENT THE VANES FROM FLYING OUT OF POSITION WHEN THE RING COMPRESSOR IS REMOVED 18 Lubricate the running face of the port plate Thread two No 10 24 screws into the tapped holes on the side of the cam ring 7 that indicates the cam size Insert the dowel pin 5 in the cam ring 7 and position the complete assembly in the body over the other dowel pin 11 See the exploded drawing for the correct position 19 Press the needle bearing 4 into the end cap 2 The bearing should be flush with the counterbore approximately 1 32 deep from the wear face 20 Lubricate the rubber seal 3 and install around the diameter of the cap 2 21 Lubricate the pumping cartridge and running face of the end cap 2 Line up the dowel pin hole in the end cap 2 with the dowel pin 11 in the cam E 154 TM 10 3950 672 24 1 22 Install the cap 2 into the housing 24 and secure with the capscrews 1 Ib ft
113. connecting a pressure gauge 2500 psi 17 237 5 kPa 172 4 bar full scale recommended at the pump outlet port or at the IN port of the steering control valve With the engine running at a medium speed turn the steering wheel to one end of the travel and hold the cylinders at the travel limit briefly just long enough to read the pressure gauge Never hold the system at relief pressure for more than a few seconds at a time The pressure gauge should indicate 1500 psi 10 342 5 kPa 1 03 4 bar If not adjust the pressure relief valve to 1500 psi 10 342 5 kPa 103 4 bar TM 10 3950 672 24 1 3 33 POWER STEERING PUMP DESCRIPTION The power steering pump is mounted on and driven by 22 7 lpm and contains a relief valve with a relief the engine The pump is a gear type pump that supplies setting of 1500 psi 10 342 5 kPa 103 4 bar hydraulic oil from the hydraulic system reservoir to the steering system The pump has an output of 6 gom MAINTENANCE NOTE For more detailed information refer to Appendix E TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Noisy pump a Low oil supply a Fill reservoir b Oil too heavy b Change to proper viscosity c Airleak in inlet line Check plumbing d Partly blocked inlet line Check for foreign object and or clean lines 2 Foaming oil a Pump cavitation Refer to Symptom 1 b Water in the oil b Check reservoir 3 Pump or oil overheating a Oil supply too thin a Dra
114. cylinder shaft with the plate washers and bolts Torque the bolts to 75 Ib ft 102 N m 5 Connect the hydraulic lines to the lift cylinder as tagged during removal 6 Remove the lifting and supporting devices from the boom and lift cylinder Activate the hydraulic system and check the lift cylinder for proper operation and any leaks 3 63 HOOK BLOCK TM10 3950 672 24 1 Hook block for this crane is a 8 5 ton one sheave assembly weighing 152 Ib 68 9 kg The hook block uses a one piece pivot block and the hook is provided with a heavy duty safety latch A grease fitting is provided to ensure lubrication of all moving parts MAINTENANCE DISASSEMBLY 1 Remove the cotter pin slotted nut washer and bearing from the block weldment 2 Remove the hook from the block weldment 3 Remove the bolt washer and bushing from the rivet eye bolt in the sheave shaft 4 Remove the eye bolt sheave shaft bushings and sheave s assembly from the hook block weld INSPECTION 1 Examine all components for cracks and damage 2 Ensure the safety latch functions properly 3 Check for spreading of the hook ASSEMBLY 1 Install the sheave s assembly bushings and sheave shaft in the order and position removed 2 Install the rivet eye bolt through the sheave shaft Secure with the bushing washer and bolt Torque the bolt to 250 Ib ft 339 Nem 3 Grease the bearing and install the bearing into the block weldment
115. d Drain and flush cooling system a Drain and flush cooling system Check locate and repair Clean away obstruction Straighten blades or replace fan Check and repair or re time engine Check and correct e Check brakes and repair as re quired f Check and add oil as required SYMPTOM PROBABLE CAUSE 1 Engine overheating continued Engine overloaded Stiff rebuilt engine 2 Overcooling Damaged thermostat stuck open b Short runs and intermittent driving GENERAL The cooling system includes the radiator thermostat the fan and fan and water pump drive belts Radiator hoses are also included in this group Because the effects or damage that result from an improperly maintained cooling system usually occur gradually this system is often times neglected However the cooling system must be treated with the same attention to maintenance as is given such other systems as fuel air and brakes A review of the cooling system s function will show this more clearly In general the circulation of water through the cooling system relies entirely upon the water pump The water pump draws water from the radiator and forces it through the water jackets and cylinder head There it accumulates heat Then the water flows to the upper radiator tank and down through the radiator core being cooled by air from the fan This process of removing heat from water as it circulates holds the engine to i
116. does not run check for defective bearings brushes reduction gears armature and field windings Disassembly Remove nut Figure 3 47 yoke assembly lead wire 2 and washer 3 from magnetic switch assembly 26 Remove two bolts 4 two lockwashers 5 two washers 6 two packings 7 and yoke 12 from magnetic switch assembly 26 Discard lockwashers 5 and packings 7 Remove two screws 9 and yoke assembly end frame 10 Lift brush springs and remove brushes from brush holder 11 refer td Figure 3 48 Remove brush holder 11 Figure 3 47 from yoke 12 Remove armature 13 from magnetic switch assembly 26 Remove three screws 14 washers 15 and packings 16 from housing 17 Remove housing 17 from magnetic switch assembly 26 Remove and discard seal 18 Remove overrunning clutch 19 from magnetic switch assembly 26 Remove steel ball 20 from overrunning clutch 19 Remove starter pinion 21 retainer 22 and five rollers 23 from housing 17 Remove washer 224 and spring 25 from magnetic switch assembly 26 If necessary remove screw 27 and lockwasher 28 from magnetic switch assembly 26 3 248 3 99 4 a 50 10 3950 672 24 1 A SPRING B BRUSH Figure 3 48 Removing Brushes Inspect Measure and Repair Check armature commutator run out as follows 1 Place armature bearings on V blocks 2 Zero dial indicator on commutator 3 Rotate armature and
117. electricity and through wiring harnesses transmits the electricity to the superstructure components MAINTENANCE NOTE CAUTION Although the amount of slip rings ENSURE THE BRUSH AND ARM will vary disassembly and assembly ASSEMBLIES ARE PROPERLY procedures are the same TAGGED WITH THE CORRESPONDING CIRCUIT DISASSEMBLY NUMBERS NOTE NOTE Do not disconnect the collector core When removing the brush and arm wires at the top of the swivel assemblies it will help if they are assembly kept in order 1 Move the swivel to a clean work area and block it 7 Remove the brush and arm assemblies from moving Block against the center post 2 Perform Prior to Disassembly located in the CLEANING AND INSPECTION part of this Package 3 Tag and disconnect the knife disconnects on the brush and arm assemblies 4 Remove the nuts and washers on the brush holding studs 5 Remove the nylon outboard bearing 6 If there are any spacers on the brush holding studs located under the nylon outboard bearing remove and save them E 159 8 Loosen the setscrews securing the collector core to the mounting bracket and remove the collector core 9 Remove the nylon bearing from the mounting bracket 10 Perform After Disassembly located in the CLEANING AND INSPECTION part of this Package CLEANING AND INSPECTION Prior to Disassembly 1 Check all brushes for proper contact with the collector ring conductors Note any brush sets which
118. limited to the replacement of the defective components DISASSEMBLY 1 Remove the relief valve cartridges from the valve body 2 Remove and discard the O rings and backup rings from the relief valves 3 Remove the check valves from the valve body 4 Remove and discard the O rings from the check valves E 112 CLEANING AND INSPECTION 1 Clean all parts with solvent and dry with compressed air Check all parts for serviceability ASSEMBLY 1 Install new O rings onto the check valves 2 Install the check valves into the valve body 3 Install new O rings and backup rings onto the relief valve cartridges 4 Install the relief valve cartridges into the valve body TM 10 3950 672 24 1 CHECK VALVE RELIEF VALVE CARTRIDGE CHECK VALVE O RING RELIEF VALVE CARTRIOGE BACKUP RING BACKUP RING O RING E Crossover Relief Valve E 113 TM 10 3950 672 24 1 SOLENOID VALVE DESCRIPTION The two way solenoid valve is a normally closed valve in the valve This alignment of ports routes the with an electrical coil which when energized shifts the hydraulic flow in the desired direction cartridge in the valve body to align the ports MAINTENANCE NOTE ASSEMBLY Repair is limited to the replacement 1 Install new O rings onto the valve of the defective components 2 Install the cartridge solenoid valve s into the DISASSEMBLY valve body Torque the valve 450 to 500 Ib in 51 to
119. list TM 10 3950672 24P contains a listing of the repair parts for this equipment Section 2 Service Upon Receipt Subject Para SUMMARY tue WAPACKING NE Checking and Unpacking Deprocessing Unpacked Equipment Preliminary Servicing and Adjustment sss 2 3 SUMMARY The crane is shipped ready for operation and requires no maintenance or operator actions However it is recommended that a visual inspection of the hydraulic fuel air intake and coolant system lines be made to ensure that lines and fittings are not loose or damaged as a result of shipment 2 4 UNPACKING To unpack the crane remove the restraining strap securing the door Then remove the fire extinguisher and place it in the mounting bracket inside the cab 2 1 TM10 3950 672 24 1 2 5 CHECKING AND UNPACKING EQUIPMENT a Inspect the crane for damage If damaged report damage on DD Form 6 Packaging Improvement Report b Check the crane against the packing slip and ensure that shipment is complete Report any discrepancies on DA Form 738 700 c Check the crane for any unauthorized modifications 2 6 DEPROCESSING UNPACKED EQUIPMENT The crane should be clean and free of excess grease However if during inspection any excess grease or lubricant is found on the carrier frame or superstructure is should be cleane
120. manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
121. method used and amount of lubricant reaching the working parts of the rope PRECAUTIONS AND RECOMMENDATIONS DURING INSPECTION OR REPLACEMENT 1 Always lock out equipment power when removing or installing wire rope assemblies 3 165 TM 10 3950 672 24 1 2 Always use safety glasses for eye protection 3 Wear protective clothing gloves and safety shoes as appropriate 4 Use supports and clamps to prevent uncontrolled movement of wire rope parts and equipment 5 When replacing fixed length cable assemblies e g pendants having permanently attached end fittings use only pre assembled lengths of wire rope as supplied from Grove Product Support Do not build lengths from individual components 6 Replace an entire wire rope assembly Do not attempt to rework damaged wire rope or wire rope ends 7 Never electroplate wire rope assemblies 8 Do not weld any wire rope assembly or component unless welding is recommended by the wire rope manufacturer Welding spatter shall never be allowed to come in contact with the wire rope or wire rope ends In addition be sure that the wire rope is not an electrical path during other welding operations 9 Wire ropes are manufactured from special steels If heating a wire rope assembly is absolutely necessary for removal the entire wire rope assembly shall be discarded 10 On systems equipped with two or more wire rope assemblies operating as a matched set they shall be replaced as a
122. most important Brake lining badly worn requir ing shoe adjustment Faulty check valve 4 Spongy pedal REMOVAL 1 Disconnect the brake lines from the master cylinder Cap or plug all openings 2 Disconnect the brake linkage from the master cylinder 3 Remove the capscrews and washers securing the master cylinder to the mounting bracket and remove the master cylinder INSTALLATION Position the master cylinder to the mounting bracket and secure with the capscrews and washers 2 Connect the brake linkage to the master cylinder 3 Connect the brake lines to the master cylinder 4 If necessary bleed the brake system Refer to BLEEDING THE BRAKE SYSTEM in this section High pressure leaks 3 77 Adjust push rod to maintain a 0 0312 inch 0 792 mm maximum clearance to secondary piston con tact when pedal is fully retracted Refer to HYDRAULIC BRAKES in this section and adjust the shoes If fluid drains from the end of the cylinder when the end plug is removed the check valve is faulty and should be replaced Refer to for assembly procedures Check all fittings and joints for leakage while the system is under pressure If the cylinder end plug leaks remove the line connections and tighten by turning clockwise RELIEF VALVE ADJUSTMENT If Set Too High If the adjustment screw is set unnecessarily high the brake pedal will be very heavy during the first of the pedal stro
123. new gaskets and seals when assembling the transmission Tighten all bolts and screws to the recommended torque as outlined in the Torque Specifications chart Transmission Disassembly Mount the transmission 014 00106 or 1 Remove the converter holding fixture Rotunda model equivalent 2 If not already done remove the fluid pan attaching bolts Remove the pan and gasket E 45 TM 10 3950 672 24 1 3 If not already done remove the valve body attaching bolts Lift the valve body from the transmission case 4 Attach a dial indicator special tool 4201 C or equivalent to the front pump Center the output shaft using seal replacer tool T61L 7657 B or equivalent 5 Pry the gear train to the rear of the case and at the same time press the input shaft inward until it bottoms Set the dial indicator to read zero 6 Pry the gear train forward and note the amount of gear train end play on the dial indicator Record the end play to facilitate assembly of the transmission Remove the dial indicator from the pump and the tool from the output shaft 7 Remove the vacuum diaphragm valve rod and the throttle valve from the bore in the rear of the case Remove the input shaft out of the front pump 8 Remove the front pump attaching bolts Pry the gear train forward to remove the pump 9 Loosen the band adjustment screw and remove the two struts 10 Rotate the band 90 degrees counterclockwise to align the ends wi
124. of a corrugated container is frequently a very adequate assembly surface Assembly is generally easier and more satisfactory with clean dry parts After parts are rinsed clean in solvent they may be blown dry with an air hose or placed on clean paper towels to drain and dry TM 10 3950 672 24 1 Dust Ses Retaining Ring Seal Gland Bushing Seal 2 1 8 inch OD Quad Ring Seal Bearing Race Needle Thrust Bearing Bearing Race Housing Setscrew Seal 5 8 Inch OO Check Ball Seat Seat 7 16 inch OD Check Ball Check Gall Retainer Control Sleeve Centering Springs Centering Pin Control Spool Seal 3inch Spacer Plate 3 inch OD Drive Gerotor Specer s Seal 3 inch OO End Cap Capscrew Power Steering Control Valve Exploded View E 80 TM 10 3950 672 24 1 DISASSEMBLY Meter Gerotor End GEROTOR SPACER S 0868 3 5 Remove the meter Be careful not to drop the star 6 Remove the seal from the meter 7 Remove the drive spacer s 0868 1 1 Clamp the unit a vise meter end up Clamp lightly on the edges of the mounting area Use protective material on the vise jaws Do not overtighten the jaws e D 2 9 I SPACER PLATE aei 0868 4 CAPSCREW 8 Remove the drive Go END CAP 9 Remove the spacer plate s 0063 2 10 Remove the seal from the housing 2 Remove the 5 16 inch c
125. of the Brake Drum SM package CAUTION ASSEMBLY OF THE WHEEL ENDS DO NOT STRIKE WHEEL STUDS m one WITH A STEEL HAMMER OR TWIST Silicone RTV Gasket Application TO REMOVE THEM NOTE NOTE Where silicone RTV gasket material is used Dow Siliastic No RTV 732 Black and General Electric No RTV1473 Black meet the requirements However silicone RTV is also available in bulk under Rockwell part number 1199 Q 2981 in 10 oz tubes part number 1250 X 388 or in 3 oz tubes part number 1199 T3842 If a press is not available a brass hammer or a drift may be used to drive out the studs E 57 TM 10 3950 672 24 1 1 Axle Shaft to Hub Nut 2 Washer 3 Dowel 4 Stud 5 Drive Shaft 6 Gasket 7 Outer Wheel Bearing Lock Nut 8 Outer Wheel Bearing Lock Washer 9 Inner Wheel Bearing Adjusting Nut 10 Outer Wheel Bearing Cone 11 Outer Wheel Bearing Cup 12 Brake Drum 13 Wheel Bearing Hub 14 Hub Oil Slinger 15 Seal 16 Inner Bearing Cone 17 Inner Bearing Cup 18 Wheel Stud Wheel End Assembly Exploded View E 58 Removal of all gaskets including silicone RTV is accomplished by peeling or scraping the used gasket off the hub mating surface of the drive flange WARNING MINOR CONCENTRATIONS OF ACETIC ACID VAPOR MAY BE PRODUCED DURING APPLICATION ADEQUATE VENTILATION SHOULD BE PROVIDED WHEN SILICONE RTV IS APPLIED IN CONFINED AREAS WARNING EYE CONTACT WITH THESE SILICONE RTV MATERIALS MAY CAUSE I
126. off check fittings for h NOTE If resistance is encountered when lifting the cam ring assembly lightly tap the outside of the body while lifting the assembly This will help in removing the cam ring rotor vanes and springs as a unit 4 Check the needle bearing 4 in the end cap If it is worn or damaged remove it It must be replaced E 148 10 24 screws in the two tapped holes provided as puller holes in the cam ring 7 and remove the cam ring assembly 6 as a unit 7 8 9 and TM 10 3950 672 24 1 Capscrew 5 Vanes End Cap Cam Ring O Ring Snap Ring Bearing i Ring Pin Bearing Pin Shaft Plate Shaft Seal O Ring Felt Washer O Ring Body Vanes Belleville Washer Springs 1 2 3 4 5 6 7 8 9 10 11 Vane Motor Exploded View E 149 WARNING THE VANES ARE HELD AGAINST THE CAM RING BY TENSION FROM THE SPRINGS IN THE ROTOR IF THE ROTOR IS PULLED FROM THE CAM RING WITH NO PROTECTION TENSION FROM THE SPRINGS WILL THROW THE VANES OUT IN ALL DIRECTIONS THE FOLLOWING PROCEDURE MUST BE FOLLOWED WHEN DISASSEMBLING THE ROTOR AND VANES FROM THE CAM RING 7 Place the cam ring assembly on a clean flat surface Push the rotor and vanes from the cam ring far enough to secure a piston ring compressor over the vanes 8 and around the rotor 10 8 After the compressor is in place push the rotor and vanes the remainder of the way out of the cam ring 9 Releas
127. oil it may be detectable in pumps and motor operated components such as the swing mechanism and hoist s because it can cause these units to become noisy during operation Should noisy operation occur first check the level of the hydraulic reservoir and replenish as necessary Then inspect for leaks in the suction lines leading to the pumps Minute leaks may be difficult to locate Should you encounter a leak that is not readily detectable the following method may be used when checking for LINES AND LINE FUNCTIONS nen DIRECTION OF FLOW CYLINDER SINGLE ACTING CYLINDER DOUBLE ACTING DIFFERENTIAL NON DIFFERENTIAL VALVES ON OFF MANUAL SHUT OFF LINE TO RESERVOIR PRESSURE RELIEF ABOVE FLUID LEVEL BELOW FLUID LEVEL PRESSURE REDUCING LINE TO VENTED MANIFOLD FLOW CONTROL ADJUSTABLE ON ll PLUG OR PLUGGED FLOW CONTROL CONNECTION ADJUSTABLE TEMPERATURE AND PRESSURE RESTRICTION FIXED COMPENSATED TWO POSITION RESTRICTION VARIABLE TWO CONNECTION PUMPS SINGLE FIXED i DISPLACEMENT SINGLE VARIABLE OISPLACE MENT ACTUATORS MOTOR FIXED DISPLACEMENT REVERSIBLE TWO POSITION THREE CONNECTION TWO POSITION FOUR CONNECTION 59 THREE POSITION FOUR CONNECTION TWO POSITION IN TRANSITION MOTOR FIXED DISPLACEMENT HON REVERSIBLE MOTOR VARIABLE
128. or bands can be located by introducing air pressure into the various transmission case passages FORWARD CLUTCH Apply air pressure to the transmission case forward clutch passages A dull thud can be heard when the clutch piston is applied If no noise is heard place the finger tips on the input shell and again apply air pressure to the forward or front clutch passage Movement of the piston can be felt as the clutch is applied GOVERNOR Apply air pressure to the control pressure to governor passage and listen for a sharp clicking or whistling noise The noise indicates governor valve movement REVERSE HIGH CLUTCH Apply air pressure to the reverse high clutch A dull thud indicates that the reverse high or rear clutch piston has moved to the applied position If no noise is heard place the finger tips on the clutch drum and again apply air pressure to detect movement of the piston INTERMEDIATE SERVO Hold the air nozzle in the front servo apply tube or the intermediate servo apply passages Operation of the servo is indicated by a tightening of the front or intermediate band around the drum Continue to apply air pressure to the servo apply tube or passage and introduce air pressure into the front release tube or the intermediate servo release passage The front or intermediate servo should release the band against the apply pressure TM 10 3950 672 24 1 FONWARHU intct Rt vi nsa
129. out comvenren IN 044 IA 040 0 CONVERTER PRESS RELIEF 9 uu lex l O DRAIN BACK g ISTATOR m THROTTLE CONTROL supponti_eyme SCREEN n T 098 094 0 HOLE 90 L JJ ROO TRANSMISSION GEAR SELECTOR 3 46 LOW REVERSE CLUTCH Apply air pressure to the low reverse clutch apply passage A dull thud should be heard if the clutch is operating properly If the passages are clear remove the clutch assemblies and clean and inspect the malfunctioning clutch to locate the trouble Hydraulic Checks FLUID LEVEL CHECK Check the oil level in the transmission The fluid level indication on the dipstick will be different at operating temperature transmission hot and room temperature transmission cold The transmission should be checked at an operating temperature transmission hot of 150 degrees to 170 degrees F 66 degrees to 77 degrees C dipstick is hot to touch The dipstick reading at operating temperature should have the fluid level on the dipstick between ADD and DON T ADD marks and or between the arrows If the transmission is not at an operating temperature of 150 degrees to 170 degrees F 66 degrees to 77 degrees C and it becomes necessary to check the fluid level such as pre delivery the fluid may be checked at room temperature 70 degrees to 95 degrees F 21 degr
130. rN 55 E i 3 A be AL Li SIX A P Chassis Wiring Harness Sheet 1 of 2 3 237 TM 10 3950 672 24 1 5 rBS re A E oe m casas rP 10 T CL d E H on OLANDA Sulton CONTINUED BS i 2 BN FROM SHEET 1 r Staaten we AG eZ had Balto LT er ur i LY Chassis Wiring Harness Sheet 2 of 2 3 238 NX xX 3 lt fon 0 QOO v TM 10 3950 672 24 1 Tag and disconnect wires 372A 372B and 371 from gearshift switch Tag and disconnect wires 82 84 and 38D from left outrigger selector switch Tag and disconnect wires 81 83 38C and 38D from right outrigger selector switch Tag and disconnect wires 81 51AA and 51AB from right front outrigger solenoid Tag and disconnect wires 84 51 AC and 51AD from left rear outrigger solenoid Tag and disconnect wires 82 and 51 AD from left front outrigger solenoid Tag and disconnect wires 83 51AB and 51AC from right rear outrigger solenoid Tag and disconnect wires 7C 8D 7B and 8B from backup switch Tag and disconnect wire 25B from transmission oil temperature switch Tag and disconnect connector and wires 2C and 52C from neutral safety switch Tag and disconnect wires 1 0 and 51V from tachometer sender Tag and disconnect wires 4 and 1 69B from engine oil pressure sender
131. rapidly at acceleration and return immediately upon release of the accelerator If the vacuum reading does not change or changes slowly the transmission vacuum line is plugged restricted or connected to a reservoir supply Air Pressure Checks GENERAL A no drive condition can exist even with correct transmission fluid pressure because of inoperative clutches or bands On automatic transmissions an erratic shift can be caused by a stuck governor valve The inoperative units can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the malfunction 3 45 TM 10 3950 672 24 1 When the selector lever is at 2 second a no drive condition may be caused by an inoperative forward clutch A no drive condition at D drive may be caused by an inoperative forward clutch or one way clutch When there is no drive in 1 low the difficulty could be caused by improper functioning of the forward clutch or simultaneous malfunction of the low reverse band and the one way clutch Failure to drive in R reverse could be caused by a malfunction of the reverse high clutch or low reverse band or clutch To make air pressure checks loosen the oil pan bolts and lower one edge to drain the transmission fluid Remove the oil pan and the control valve body assembly The inoperative clutches or bands can be located by introducing air pressure into the various transmission case passages FORW
132. record run out Standard is 0 0008 in 0 02 mm with a limit of 0 00197 in 0 5 mm 4 If run out exceeds limit replace armature Using a micrometer measure OD of commutator If measurement is less than 1 38 in 35 mm replace armature Measure commutator segment mica depth as shown Figure 3 49 If depth is less than 0 0079 0 2 mm undercut the mica Check commutator surface for burn spots This usually indicates an open circuit Remove these spots using 400 abrasive paper Inspect bearings 30 and 31 Figure 3 47 for wear and damage If damaged or worn replace bearings using a press Check field windings of yoke 12 for wear or damage Check all connections for clean and tight solder joints Measure brush length If less than 0 51 in 13 mm replace brush holder and or yoke assembly Check brush springs for damage or corrosion If damaged or corroded replace brush holder Check that overrunning clutch rotates freely in direction of starter rotation and that it will be locked when trying to rotate in opposite direction 3 249 TM 10 3950 672 24 1 COMMUTATOR UNDERCUT Figure 3 49 Measuring Segment Mica Depth 3 99 5 Assembly o 2o If removed install screw 27 Figure 3 47 with lockwasher 28 Apply general purpose grease to retainer 22 rollers 23 overrunning clutch 19 steel ball 20 spring 25 and bearings 30 and 31 Install washer 24 and spring 25 in magnetic switc
133. rivets 19 and remove latch 7 from door assembly 1 Remove nut 14 lockwasher 15 bolt 16 washer 17 and strap 18 from door assembly 1 3 4 2 Installation a b C d e Install strap 18 Figure 3 4 on door assembly 1 with washer 17 bolt 16 lockwasher 15 and nut 14 Install latch 7 on door assembly 1 with four rivets 19 Install latch extension 6 and handle 13 on door assembly 1 with two washers 12 two pins 11 two screws 10 two lockwashers 9 and two nuts 8 Install latch extension 6 on latch 7 with bushing 5 four washers 4 lockwasher 3 and bolt 2 Set door assembly 1 onto cab hinges and close door assembly 3 4 3 Door Glass Replacement a b C WARNING Use care when removing cracked or broken glass Wear eye protection and gloves Follow silicone sealant manufacturer s instructions for applying sealant Pry locking strip open on molding around glass Remove glass and discard Remove and discard door glass molding TM10 3950 672 24 1 d Cut new door glass molding to window opening size e Install molding in window opening f Fit glass into channel of molding Work molding around glass until it is fully seated Seat locking strip onto molding to secure glass from outside of glass h Apply silicone sealant at joint where molding end meets Allow joint to dry and check for leaks NOTE DOOR LOCK 15 PART OF LATCH AND LATCH
134. seated in the tube FLUID CONDITION CHECK After making a normal fluid check according to the procedures under Fluid Checking Procedures check the condition of the transmission fluid as follows 1 Observe the color and odor of the fluid It should be dark reddish not brown or black A burnt odor can sometimes indicate that there is an overheating condition or clutch disc or band failure 2 Use an absorbent white facial tissue paper to wipe the dipstick Examine the stain for evidence of solids specks of any kind and for antifreeze signs gum or varnish on dipstick If specks are present in the oil or there is evidence of antifreeze the transmission oil pan must be removed for further inspection If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive solids in the oil pan the transmission must be disassembled and completely cleaned and repaired This includes cleaning the torque converter and transmission cooling system FLUID LEVEL HIGH BEFORE STARTING ENGINE NORMAL DURING NORMAL CHECK If the fluid level is high before starting the engine and normal during normal check check the following 1 Check for correct operation of the drainback valve in the stator support 2 Check the pump bushing 3 Repair or replace pump if required TRANSMISSION FLUID LEAKAGE CHECKS 1 Leakage at the oil pan gasket often can be stopped by tightening the attaching bolts to the proper
135. secure the rod to the angle with the bolt nut and lockwasher Connect all leads to the battery s terminals starting with the positive wire lugs 5 and 14 Figure 3 31 Close the deck cover 3 217 TM 10 3950 672 24 1 3 86 BATTERY CABLES 3 86 1 ACAUTION BATTERY CONNECTION PREVENT DAMAGE TO STARTING SYSTEM BY IDENTIFYING CABLES BEFORE DISCONNECTING Removal WARNING Always disconnect negative battery cable first to reduce chance of shorting and personal injury Disconnect negative battery cable clamp l Figure 3 3 from battery 2 Disconnect positive battery cable clamp 3 from battery 2 Disconnect negative battery cable 4 from crane chassis ground Remove negative battery cable from crane Remove nut 6 lockwasher 7 and positive battery cable 5 from starter Remove positive battery cable 5 from crane Remove nut 8 lockwasher 9 bolt 10 two wire lugs 15 and 16 and cable clamp 1 from negative battery cable 4 Remove nut 11 lockwasher 12 bolt 13 one wire lug 14 and cable clamp 3 from positive battery cable 5 3 218 TM 10 3950 672 24 1 3 86 2 Installation a Install cable clamp 3 Figure 3 31 and one wire lug 14 on positive battery cable 5 with bolt 13 lockwasher 12 and nut 11 b Install cable clamp 1 and two wire lugs 15 and 16 on negative battery cable 4 with bolt 10 lockwasher 9 and nut 8 c Posit
136. securing the relief valve to the motor and remove the relief valve NOTE The motor bolts were installed with thread sealant 3 Remove the socket head capscrews and lockwashers securing the motor to the brake housing and remove the motor 4 Remove the bolts 1 and washers 2 securing the brake housing 3 to the end cover 4 Remove the brake housing 3 and springs 16 5 Remove the piston 5 and cylinder head 6 6 Remove the O rings 7 and backup rings 8 from the head 6 and piston 5 7 Remove the brake discs 9 and stators 10 8 Remove the bolts 1 securing the end cover 4 to the internal gear 12 9 Remove the O ring 13 bearing 14 and bearing races 15 from the end cover 4 10 Press the primary sun gear 17 from the end cover 4 Remove the spacer 18 and oil seal 19 E 128 11 Remove the primary planetary assembly 20 and set aside for later disassembly 12 Remove the thrust races 21 and bearing 22 13 Remove the secondary sun gear 37 14 Remove the secondary planetary assembly 23 and set aside for later disassembly 15 Remove the O ring 24 from the internal gear 12 16 Bend down the tabs of the lockwasher 25 and remove the locknut 26 and lockwasher 25 17 Press the output shaft 27 from the hub 28 18 Remove the bearing 29 and oil seal 30 from the shaft 27 19 Remove the bearing 29 from the hub 20 Press the roll pi
137. serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system j Overhaul That maintenance effort service action necessary to restore an item to a completely serviceable operational condition as prescribed by maintenance standards i e DMWR in appropriate technical publications Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition k Rebuild Consists of those services actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with the original manufacturing standards Rebuild is the highest degree of material maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements hours miles etc considered in classifying Army equipment components B 3 EXPLANATION OF COLUMNS IN THE SECTION II 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 b Column 2 Component Assembly Column 2 contains the names of components assemblies subassemblies and modules for which maintenance is authorized c Column 3 Maintenance Function Column 3 lists the functions to be performed on the item listed in column TM
138. shaft 3 yoke Secure cross bearing 2 in drive line shaft 3 with snap ring 1 Remove tape securing exposed bearings Install drive line shaft 3 refer tq paragraph 3 22 2 NOTE Some shafts may have snap rings inside of yoke LEGEND 1 Snap Ring 2 Cross Bearing Assembly 3 Drive Line Shaft Figure 3 14 U Joint Bearing Assembly 3 72 3 29 HYDRAULIC BRAKES TM 10 3950 672 24 1 DESCRIPTION The brake is hydraulic actuated installed on the front wheels has a floating shoe design requires manual shoe clearance adjustments and is not power assisted The brake assembly consists of a backing plate two wheel cylinders two brake shoe assemblies two brake adjusters and return springs Actuation permits the shoes to center themselves in the drum with equal effectiveness in either direction MAINTENANCE NOTE For more detailed information refer to the applicable SM package NOTE All brake maintenance with the exception of replacement of the complete brake assembly can be performed without removing the brake assembly REMOVAL 1 Remove the wheels Refer to FRONT DRIVE AXLE in this section 2 Remove the wheel hub and drum assembly Refer to the axle SM package 3 Disconnect the brake lines from the brake assembly 4 Remove the brake assembly Refer to the axle SM package GENERAL schedule for the periodic adjustment cleaning inspection and lubrication of brake equipment
139. should be established by the operator on the basis of past experience and severity of operation Linings and drums are parts particularly subject to wear depreciation compensate for this wear brakes should be adjusted as frequently as required to maintain satisfactory operation and maximum safety Adjustments should provide uniform lining clearance correct travel of levers and proper equalization 3 73 Brakes should be cleaned inspected lubricated and adjusted each time the hubs are removed During a major overhaul the following parts should be carefully checked replaced with genuine replacement parts as required 1 Check the backing plate for distortion looseness and sheared rivets 2 Check the brake shoes for wear at the anchor pin holes 3 Shoe return springs should be replaced at the time of overhaul 4 Check the brake linings for grease saturation wear and loose rivets or bolts 5 Check the drums for cracks scoring or other damage INSTALLATION 1 Install the brake assembly Refer to the axle SM package 2 Connect the brake lines to the brake assembly 3 Install the wheel hub and drum assembly Refer to the axle SM package 4 Install the wheels Refer to FRONT DRIVE AXLE in this section 5 Adjust the brakes ADJUSTMENT in this section Refer to BRAKE SHOE 6 Bleed the brake system Refer to BLEEDING THE BRAKE SYSTEM in this section BLEEDING THE BRAKE SYSTEM The br
140. slip link on the fuel control lever and operate the crane to check for smooth up shifts in the transmission drive D mode If improper shifting is still apparent turn the slip link in or out on the threaded end of the modulator cable until smooth up shift occurs ENGINE FUEL CONTROL LEVER CLAMP POSITION BULKHEAD Wide Open Throttle Wide Open Throttle TM 10 3950 672 24 1 1 38 INCHES 35 0 mm ENGINE FUEL CONTAOL LEVER p um LINK SUPPORT BRACKET CLAMP WIDE OPEN THROTTLE Wide Open Throttle Modulator Control Lever in Idle 3 58 TM 10 3950 672 24 1 3 24 PARK BRAKE The park brake consists of a brake and shoe assembly bolted to the transmission The park brake is cable actuated and controlled from the cab The brake shoes are applied by pulling the cab mounted lever The lever pulls a cable attached to the brake cam The cam is rocked as the cable is pulled thus applying the brake shoes Refer to Figure 3 12 The intended usage is for holding the vehicle when standing in a parked condition The brake when applied holds the drive shaft from turning 3 24 1 Removal a Refer to DRIVE LINE in this section and remove the drive shaft b Disconnect the parking brake actuating lever from the linkage e Remove the transmission spline flange and drum d Remove the bolts holding the carrier plate to the transmission housing Slide the plate with the brake shoes and retaining springs off the transmi
141. spindle assemblies The cylinder provides the hydraulic power to turn the rear wheels when steering is required The spindle welds are attached to the frame by means of a pin arrangement The wheel hub contains the bearings seals washers and nuts necessary to mount and adjust the hub MAINTENANCE STEERING LINKAGE Removal 1 Fully lower and retract the boom 2 Chock the front and rear wheels 3 Using an adequate lifting device or the outriggers lift the frame until the wheels are at least two inches off the ground Install cribbing or blocking which is capable of handling the weight of the crane under the frame for support 4 Tag disconnect and cap the hydraulic lines to the steer cylinder 5 Remove the bolts locknuts and washers securing the rod eye assemblies of the steer cylinder to the spindle link plates 6 If necessary remove the capscrew flatwasher washer and locknut securing the link plates to the spindle assembly 7 Remove the bolts and washers securing the steer cylinder to the frame and remove the steer cylinder Installation 1 Install the steer cylinder to the frame and secure with the bolts and washers Torque the bolts to 75 Ib ft 102 Nem 3 67 2 If removed install the link plates to the spindle assembly and secure with the capscrew flatwasher washer and nut Torque the capscrew to 250 Ib ft 339 Nem NOTE If installing a new steer cylinder ensure the threads betwe
142. steering wheel TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Hard to steer left and right Hard to steer either left or right Steering is erratic left and right MAINTENANCE Hydraulic oil low Clogged or loose hydraulic lines or fittings Insufficient lubricant on steer cylinder Defective pressure relief valve Defective steering control valve Defective steering pump Clogged or loose hydraulic lines or fittings Insufficient lubricant on steer cylinder Defective steer cylinder Hydraulic oil low Clogged or loose hydraulic lines or fittings Defective pressure relief valve Defective steering control valve Defective steering pump 3 81 Refill hydraulic reservoir Clean or tighten lines or fit tings Lubricate steer cylinder Repair or replace valve Repair or replace valve Repair or replace pump Clean or tighten lines or fit tings Lubricate cylinder Repair or replace cylinder Refill hydraulic reservoir Clean or tighten lines or fit tings Repair or replace valve Repair or replace valve Repair or replace pump TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION Noisy steering pump caused by cavitation b Suction line plugged or too small Steering pump shaft seal leakage a Hydraulic oil low a Worn shaft seal NOTE Refill hydraulic reservoir Clean line and check for size
143. the circuit s directional control valves Refer HYDRAULIC PUMP in this section for Description and Maintenance of the hydraulic pump Refer to Section 9 SWIVELS for Description and Maintenance of the hydraulic swivel HYDRAULIC RESERVOIR AND FILTER The reservoir attached to the right side of the crane chassis has a total capacity of approximately 35 0 gallons 132 4 liters and a gauge level capacity of approximately 30 0 gallons 113 5 liters The all steel reservoir has an internally mounted full flow filter and integral baffles that help cool the oil and prevent oil foaming Oil flows through individual tubing from the back of the reservoir to the hydraulic pump The return flow is also to the back of the reservoir but on the opposite side of a baffle plate which acts to separate return and supply oil Two return lines are connected to the back of the reservoir One goes directly into the reservoir The other return line goes directly into the filter case inside the reservoir A sight gauge is located on the front of the reservoir to indicate oil level A breather used as a filter is located on the top of the reservoir to allow air to enter or exhaust from the reservoir It is most important that the breather be kept clean to prevent damage to the reservoir Change interval would be dependent upon environmental conditions Under severely dusty conditions the change interval should be once every 3 to 4 months moderate cond
144. the clamps Install the defroster hose to the heater Tighten clamp Install the heater hoses to the heater Secure the electrical leads to the motor as tagged during removal Check the heater for proper operation and ensure there are no leaks LEGEND 1 CLAMP 2 HOSE HEATER 3 HEATER 4 SCREW CAP 5 WASHER LOCK 6 CLAMP 7 HOSE DEFROSTER Heater Defroster Installation 3 15 TM 10 3950 672 24 1 Section 2 Engine Engine ccu seep eee eee 1 5 2 2 Mud rH Engine Oil Pressure Switch ccccccccceccssccssccsseccssccsseesseecseccssecsseccsescssecsaeecseccsseesseeeasesees IE I 3 20 2 InstallatiOlt eee ee uei ee Engine Oil Pressure Sender ccccccscccssccsscesseccssccsseesseccsescseeessescsacessecsaeecseceseesseeeaeessees IK PERMISIT 1 Removal 5i evi ceni eie re dle et PE e Ra d da VaL e a a a a a Le E E LL E a E Installation eee iei haee b eee Ee Engine Cool
145. the fuel quantity sender from the tank and install them in the new tank 3 13 2 Installation a b e d Position the tank on the mounting brackets and secure with the washers nuts and bolts Torque the bolts to 75 Ib ft 101 7 N m Connect the electrical lead to the fuel quantity sender unit Connect the line s to the tank Service the tank 3 14 FUEL FILTER Refer to TM 10 3950 672 24 2 Engine Manual Index under Fuel Filter Replacement 3 26 TM 10 3950 672 24 1 3 15 FUEL FILTER WATER SEPARATOR 3 15 1 Draining The sump of the fuel filter water separator should be drained daily 30 minutes after the engine is shut down to remove any water and sediment Adhere to the following procedure Remove the cap from the vent valve Open the petcock Press down the vent valve Drain until fuel appears Close the petcock Close the vent valve Replace the cap on the vent valve 3 15 2 Removal Clean all dirt from the filter especially the areas around the fuel line connections Tag disconnect and cap the fuel lines to the filter Remove the mounting nuts and washers Remove the filter oco oom 3 15 3 Installation Position the filter assembly on the mounting bracket Install the washers and nuts Connect the fuel lines as tagged prior to removal Bleed air from the fuel system Refer to TM 10 3950 672 24 2 Index under Bleeding the Fuel System 3 27 TM 10 3950 672 24 1
146. the hydraulic lines to the motor control valve Cap or plug all lines and openings 2 Remove the capscrews and lockwashers securing the valve to the hoist motor Remove the valve INSTALLATION 1 Install the valve on the hoist motor and secure with the capscrews and lockwashers 2 Connect the hydraulic lines to the motor control valve as tagged during removal 3 50 CROSSOVER RELIEF VALVE TM 10 3950 672 24 1 DESCRIPTION The crossover relief valve with shuttle valve is designed to protect the system from excessive pressure buildup and to maintain a given pressure in the system The crossover relief valve relieves surge pressure in the swing circuit that could occur if the motor is suddenly drilled and ported block with two relief valves and two check valves with orifice plugs installed in the block The relief valves relieve pressure from one line to the other and therefore there is no connection to the reservoir stopped It also provides for smoothly starting and stopping of the swing motor The valve consists of a MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL 1 Tag and disconnect the hydraulic lines to the valve Cap or plug all openings 2 Remove the capscrews and washers securing the valve Remove the valve 3 118 INSTALLATION 1 Install the valve and secure with the capscrews and washers 2 Connect the hydraulic lines to the valve as tagged during removal TM
147. the spring in the air restriction Indicator As the spring compresses it indicates the current level of air restriction FILTER ELEMENT REPLACEMENT CAUTION NEVER SERVICE THE AIR CLEANER WHILE THE ENGINE IS RUNNING 1 Loosen the hex head bolt on the clamp band and remove the clamp band and baffle 2 Remove the thumbscrew and washer then withdraw the element 3 Clean the element as outlined in ELEMENT CLEANING Replace the element after six cleanings or annually whichever comes first 4 Inspect all parts of the intake system and air cleaner 5 Install the cleaned or new element into the air cleaner body securing it with the washer and thumbscrew E 8 TM10 3950 672 24 1 6 Ensure the O ring around the air cleaner body is in place and not damaged 7 Install the baffle on the air cleaner body with the two arrows pointing up Secure with the clamp band and tighten the hex head bolt ELEMENT CLEANING Washing in a water detergent solution or blowing out with compressed air are two accepted methods for cleaning the element of the air cleaners If the elements contain substantial amounts of soot or oil fumes washing in water works better than compressed air If the contaminant is found to be mostly loose dust either method works equally well If cleaned with compressed air elements can be put back into service immediately however if cleaned by washing elements must be dried before returning them to serv
148. throttle to 2400 rpm 3 Position the LIFT control lever to LOWER and hold momentarily 3 110 TM 10 3950 672 24 1 4 f the pressure readings are not 100 psi 689 5 kPa 6 89 bar of 3000 psi 20 685 kPa 206 8 bar set the relief valve 5 After the required pressure setting has been obtained shut down the crane and remove the pressure gauge CIRCUIT RELIEF VALVE ADJUSTMENT Lift Retract NOTE Lift extend uses the valve bank main relief valve 1 Remove the pipe plug from the pressure test port and install the pressure gauge 2 Set the throttle to 1000 rpm 3 Move the BOOM control lever to DOWN and hold momentarily Note the maximum reading on the pressure gauge If the reading is 100 psi 689 5 kPa 6 89 bar of that listed in the CIRCUIT RELIEF SETTING table adjust the pressure setting as necessary 4 Shut down the engine Remove the pressure gauge and install the pipe plug Telescope Retract NOTE Telescope extend uses the valve bank main relief valve 1 Install the pressure gauge in the test port on the applicable control valve 2 Set the throttle to 1000 rpm 3 Move the TELESCOPE control lever to IN and hold momentarily Note the maximum reading on the pressure gauge If the reading is not 100 psi 689 5 kPa 6 89 bar of that listed in the CIRCUIT RELIEF SETTING table adjust the pressure setting as necessary 4 Shut down the engine Remove the pressure gauge and install the p
149. tight d Valve body dirty or sticking valves a Improper fluid level b Manual linkage misadjusted damaged c Low main control pressure Leakage Forward clutch stator support seal rings leaking 3 4 d Forward clutch assembly burnt Damaged leaking check ball in cylinder Leaking piston seal rings e Valve body bolts loose or too tight f Valve body dirty or sticking valves g Transmission filter plugged h Pump damaged or leaking E 33 Perform fluid level check Adjust idle Service as required Perform control pressure test Clean service or replace valve Perform fluid level check Adjust throttle valve linkage c Tighten bolts d Determine source of contami nation Service as required a Perform fluid level check b Check and adjust or service as required c Control pressure test note results d Perform air pressure test e Tighten bolts f Determine source of contami nation Service as required g Replace filter h Visually inspect pump gears Replace pump if necessary TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 5 No delayed reverse engage ment forward Ok 6 No delayed reverse engage ment and or no engine breaking In manual low 1 7 No engine braking in manual second gear 8 Forward engagement slips ishudders chatters a Improper fluid level b Manual linkage misadjusted damaged c Low
150. to Transmission Plug Case Throttle Pressure 5 16 Fitting Cooler Line Connector to Case Front and Rear Case Fitting 5 16 Tube Nut Cooler Line to Transmission Case Fitting End Plates to Body End Plates to Body Inner Downshift Lever Stop Reinforcement Plate to Body Screen and Lower to Upper Valve Body Shift Valve Plate to Upper Body Upper to Lower Body Reinforcing Right Side Plate to Lower Body Control Assembly to Case Governor Body to Collector Body Detent Spring to Case Rear Engine Support to Frame Neutral Switch to Case NAN ANN O1 C1 C1 C1 E 44 Extension Housing 1 Remove the extension housing attaching bolts Slide the extension housing off the output shaft Remove the gasket Governor 1 Remove the four governor body to oil collector attaching bolts 2 Remove the governor from the collector body flange TRANSMISSION DISASSEMBLY AND ASSEMBLY SUBASSEMBLIES General Before removing any of the subassemblies thoroughly clean the outside of the transmission to prevent dirt from entering the mechanical parts Handle all transmission parts carefully to avoid nicking or burring the bearing or mating surfaces Lubricate all internal parts of the transmission with clean automatic transmission fluid before assembly Do not use any other lubricants except on gaskets and thrust washers These may be coated with petroleum jelly to facilitate assembly Always use
151. to perform electrical maintenance on live or hot circuits remove all rings watches and other jewelry before performing maintenance as serious burns may result from accidental grounding or shorting circuits WARNING Ensure the battery is disconnected before performing any maintenance on an electrical circuit which is not fused Multimeter resistance and continuity checks should be made with either the wire or component to be checked out of the circuit or the battery cables disconnected from the negative post CAUTION Never replace original wiring with wiring of a smaller diameter 3 83 3 Troubleshooting Most troubles associates with the electrical system can be traced to the electrical swivel Troubles common to the swivel are ce Doo o g Improper mounting Foreign material between the brushes and slip rings Incorrect wiring from the swivel to the components Incorrect wire size Worn brushes Improper spring tension on the brush assembly Loose setscrews on the collector ring assembly To isolate electrical troubles a multimeter should be used The multimeter when used properly can provide readings necessary for service personnel to determine the following a b Opens in the electrical system Resistance in the electrical system The following is a list of tools necessary for connector maintenance 3 210 TM 10 3950 672 24 1 Extraction Amp FOR BLACK CIRCUIT CONNECTORS AMP 14 gauge wire P N
152. torque The flange must be held with a suitable tool or fixture to tighten the nut 11 Recheck the pinion bearing preload torque If the rotating torque is not within 5 to 25 Ib in 1 to 3 Nem for new bearings or 5 to 15 Ib in 1 to 2 Nem for reused bearings repeat the foregoing procedure 12 Hold the flange and remove the pinion shaft nut and flange 13 Lubricate the pinion shaft oil seal and cover the outer edge of the seal body with a non hardening sealing compound Press the seal against the cover shoulder with a seal driver 14 Install a new gasket and the bearing cover 15 Press the flange against the forward gearing and install the washer and the pinion shaft nut CAUTION DO NOT BACK OFF TO ALIGN COTTER KEY HOLES E 67 TM 10 3950 672 24 1 16 Tighten to the correct torque If a drilled or castellated fastener is employed install a cotter key Refer to Torque Values in this Sub Section Installation of the Pinion and Cage Assembly 1 Install the correct shim pack Locate thin shims on both sides for maximum sealing ability 2 Position the pinion and cage assembly over the studs and tap it into position with a soft mallet 3 Install the lockwashers and the stud nuts or capscrews Tighten to the correct torque Assembly of the Differential Gear Assembly and Ring NOTE Refer to NoSPIN DIFFERENTIAL in this Section for assembly of the NoSPIN differential Proper service replacement of
153. transmission Overfill can cause the fluid to foam and spill out through the transmission vent with resultant transmission malfunction Underfill can result in transmission loss of engagement or slipping This condition is most evident in cold weather or when the crane is parked or being driven on a hill 6 Install the dipstick making sure it is fully seated in the tube FLUID CONDITION CHECK After making a normal fluid check according to the procedures under Fluid Checking Procedures check the condition of the transmission fluid as follows 1 Observe the color and odor of the fluid It should be dark reddish not brown or black A burnt odor can sometimes indicate that there is an overheating condition or clutch disc or band failure 2 Use an absorbent white facial tissue paper to wipe the dipstick Examine the stain for evidence of solids specks of any kind and for antifreeze signs gum or varnish on dipstick If specks are present in the oil or there is evidence of antifreeze the transmission oil pan must be removed for further inspection If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive solids in the oil pan the transmission must be disassembled and completely cleaned and repaired This includes cleaning the torque converter and transmission cooling system FLUID LEVEL HIGH BEFORE STARTING ENGINE NORMAL DURING NORMAL CHECK If the fluid level is high before sta
154. under proper conditions But when the rope is put into service the initial lubrication may be less than needed for the full useful life of the rope Because of this possibility periodic applications of a suitable rope lubricant are necessary The following are important characteristics of a good wire rope lubricant 1 It should be tree from acids and alkalis 2 It should have sufficient adhesive strength to remain on the ropes 3 It should be of a viscosity capable of penetrating the interstices between wires and strands 4 t should not be soluble in the medium surrounding it under the actual operating conditions i e water 5 It should have a high film strength 6 It should resist oxidation Before applying lubrication accumulations of dirt or other abrasive material should be removed from the rope Cleaning can be accomplished by using a stiff wire brush and solvent compressed air or live steam Immediately after the wire rope is cleaned it should be lubricated techniques may be used these include bath dripping pouring swabbing painting or pressure spray methods Whenever possible the lubricant should be applied at the top of a bend in the rope because at that point the strands are spread by bending and are more easily penetrated There should be no load on the rope while it is being lubricated lt should be noted the service life of wire rope will be directly proportional to the effectiveness of the
155. valve body and install the retaining pin in the body Disassembly of the Intermediate Servo 1 If not previously removed apply air pressure to the port in the servo cover to remove the piston and rod If the piston or piston sealing lips are damaged replace the complete piston and rod assembly 2 Remove the seal and gasket from the cover Assembly of the Intermediate Servo 1 Dip the new seals in transmission fluid Install a new seal and gasket on the cover 2 Dip the piston in transmission fluid and install it in the cover Disassembly of the Governor 1 If not previously removed remove the governor body attaching bolt and remove the governor 2 Remove the snap ring that secures the governor oil collector body on the output shaft and slide it off the front of the shaft 3 Remove the seal rings from the oil collector body Assembly of the Governor 1 Carefully install new seal collector body 2 Working from the front end of the output shaft slide the governor oil collector body into place on the shaft and secure with the snap ring Ensure the snap ring is seated in the groove 3 Install the governor assembly on the oil collector body and secure with the attaching screws Torque the screws 90 to 120 Ib in 10 to 14 Nem rings on the oil Disassembly of the Downshift and Manual Linkage 1 Remove the nut and lockwasher that secures the outer downshift lever to the transmission and remove the lever
156. with PMCS table Check boom nose sheaves guides hoist drum rollers and other wire rope contact surfaces for sharp edges or other conditions that could damage wire rope m Inspect the hook block for nicks gouges cracks and other damage Replace hook that is cracked spread or twisted Be sure safety latch operates and is aligned n Inspect air restriction indicator Check air intake tubing for damage and loose clamps Inspect muffler and exhaust tubing for corrosion damage and loose clamps p Check charge indicator on fire extinguisher for green indication q Check and service the fluid level in the windshield washer fluid bottle Section 3 Organizational Preventive Maintenance Checks and Services Subject Para Page General FR eve ed be EE E T ER Organizational Preventive Maintenance Checks and Services Leakage Definitions for Organizational Organizational Preventive Maintenance Checks and Services Chart 2 6 2 7 2 8 GENERAL To make sure that your vehicle is ready for operation at all times inspect it systematically so you can discover defects and have them corrected before they result in serious damage or failure The charts on the next few pages contain your organizational PMCS The item numbers indicate the sequence of minimum inspection requirements lf you re operating the vehicle and not
157. 0 For parts heavily coated with oil decrease torques 10 0637 Drive Unit Torque Values E 78 TM 10 3950 672 24 1 FRONT STEERING CONTROL VALVE DESCRIPTION The steering control valve is located under the dash and is actuated by a conventional steering column and wheel providing precise full hydraulic steering This is accomplished by a metering system within the valve that is directly connected to the steering column and wheel THEORY OF OPERATION Turning the steering wheel to the left or right causes a spool enclosed in a precision sleeve to rotate As the spool is rotated a set of lateral springs tend to move the sleeve in the same direction Due to the springs there is a time lag between the movement of the spool and sleeve During this time lag hydraulic oil from the IN port of the valve is permitted to flow to the gerotor set which meters hydraulic oil to the steering cylinders through the appropriate L or R port of the valve When the sleeve rotates to the same position as the spool the metered flow of hydraulic oil stops and oil flows from the IN port to the OUT port and back to the return manifold It is the action between the spool and sleeve that permits incremental steering left or right If hydraulic oil flow to the IN port is lost due to failure of the engine torque converter or steering pump front wheel steering can still be accomplished with the steer control valve When pressure is lost a po
158. 0 Install rear access cover refer td paragraph 3 80 3 39 TM 10 3950 672 24 1 3 231 ENGINE COOLING FAN 3 21 1 Removal o Disconnect negative battery cable and two electrical leads from battery Remove fan guard refer 10 paragraph 3 20 1 step Remove four bolts 2 Figure 3 11 four washers 3 securing engine cooling fan 1 and spacer 4 to water pump CAUTION Fan blades are plastic and can crack in cold weather if mishandled Handle with care d Remove engine cooling fan 1 and spacer 4 leaving pulley 5 and drive belt in place 3 21 2 Installation CAUTION Ensure the word FRONT on the fan hub faces the radiator Position engine cooling fan 1 Figure 3 11 and spacer 4 on fan pulley 5 Align mounting holes in engine cooling fan spacer and fan pulley to water pump holes Apply loctite to threads of four bolts 2 Install four bolts 2 and four washers 3 Torque bolts to 18 Ib ft 24 N m Install fan guard refer to paragraph 3 20 2 step Connect negative battery cable and two electrical leads to battery 3 40 TM 10 3950 672 24 1 LEGEND Engine Cooling Fan Bolt Washer Spacer Fan Pulley ROM Figure 3 11 Engine Cooling Fan 3 41 TM 10 3950 672 24 1 Section 3 Drive Train Subject Para Page 8 22 Removal 0
159. 014 00028 or equivalent Under no circumstances should an attempt be made to clean converters by hand agitation with solvent ASSEMBLY PROCEDURES Selective Parts 1 Certain parts are provided graduated thicknesses to provide correct clutch clearances Because the initial selection has already been made for the particular transmission it should not be necessary to re select components if components affecting the original selection are not replaced NOTE To maintain relationship of involved components it may be desirable to identify the related parts during disassembly E 43 TM 10 3950 672 24 1 2 If any parts require replacement the correct clutch clearances will be given in the affected assembly procedure Torque Specifications Toque specifications for various items are provided in chart form These same torque values are included In the assembly procedures TRANSMISSION DISASSEMBLY COMPONENT REMOVAL MAJOR Control Valve Body 1 If not already done remove the transmission pan attaching bolts and remove the pan and gasket Remove and discard the nylon shipping plug from the pan This plug is used to retain transmission fluid within the transmission during shipment and should be discarded when the oil pan is removed 2 Remove the valve body attaching bolts and remove the valve body from the case Intermediate Servo 1 Remove the bolts that attach the servo to the transmission case 2 Re
160. 1 00 066 s tres sire sse rer see res sete serere 3 22 1 5 E PER EET TRETEN 3 22 2 Lubrication 3 22 3 C 6 Automatic Transmission 2 2 0020 000 10 60 3 23 Description Troubleshooting Removal Installation Transmission Shift Modulator Adjustment Park Brake aententia t dre ve ree eene ae eee ee Due ov oe i o eos Removal ere euet eet ett Te Ee Ee e aerem A A MMC Mx iocum E hei Transmission Shifting Lever PAC US TIMMS E 3 22 DRIVE LINE 3 22 1 Removal a Scribe an alignment mark across the flanges of the drive shaft b Support the shaft so it does not fall when disconnected c Remove the capscrews washers nuts bolts and clamp drive securing the shaft to the transmission and the capscrew nut washer and clamp securing the shaft to the axle differential d Remove the drive shaft 3 22 2 Installation a Position the drive shaft aligning the alignment marks made during removal b Grind a flat on the washers to allow clearance for bend radius on the clamp and clamp drive and to provide proper torque of the capscrews and bolt Secure the shaft to the axle differential or with the clamp capscrews nuts and washers Torque the nuts 27 to 29 Ib ft 36 6 to 39
161. 1 7 Long Term Storage Engine 5 341 Low Oil Pressure 0 441 11 etre nnne 5 121 Low Power 0 5 23 Low Pressure Fuel Line 5 87 Lube Oil Loss 5 37 Lube Oil Pump 5 133 EU ies Cc 5 369 Lubricating for the Power 5 117 Lubricating Oil Pressure Low 0 44 0000 0 111 0 5 34 Lubricating Oil Pressure Too High 5 36 Lubricating Oil 5 117 Lubricating System 7 5 117 Lubricating System Replacement 5 128 Lucas DPA Back Leakage Valve and Sealing Washer
162. 10 3950 672 24 1 from cup 7 to flow directly into the reservoir Cup 8 flares due to the pressure drop across it and the cylinder displacement to the brake line is made up only of the displacement of cup 8 Line pressure is developed in relation to the diameter of cup 8 input force and the pedal ratio used Sp E Sly 77 4 1 E Ss all NS Brakes Fully Applied E 93 TROUBLESHOOTING MAINTENANCE TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 1 Slow pedal return sticking piston 2 Brake drag or pressure build up 3 Pedalloss pedal too low be fore braking action starts Fluid return ports of the relief valve may have become plugged through entrance of foreign matter b Runout O D and I D of low pressure pistons a No push rod end clearance b Incorrect fluid or oil in the fluid causing cups to swell and stick a Too much clearance between push rod and piston pedal loss at the start of the stroke means loss at the end of the stroke where it is most important b Faulty check valve c Relief valve setting too low d Relief valve setting too low E 94 a Remove relief valve and wash in alcohol Clean the return ports by hand using a 0 0625 inch 1 58 mm drill b Replace defective component a Adjust the push rod to maintain a 0 0312 inch 0 792 mm maxi mum clearance to the secondary piston contact when p
163. 10 3950 672 24 1 B 3 EXPLANATION OF COLUMNS IN THE MAC SECTION II Continued 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 C Operator Crew Unit Level Maintenance O Organizational Unit Level Maintenance F Direct Support H General Support D Depot e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets not individual tools and special tools TMDE and support equip
164. 112 Cup Plug Replacement MM 5 257 Cup Plugs Replacement Coolant System 5 65 Cup Plugs Replacement Lubricating System 00010110 5 141 Cylinder Block Assembly RM 5 288 Cylinder Block Cleaning RM 5 281 Cylinder Block Disassembly 2022 en eee eee eee 5 279 Cylinder Block Inspection MM 5 287 Cylinder Block Operation and Description of 5 167 Cylinder Block Specifications 2 2 2 eee ee nnn nnns sse 5 188 Cylinder Block Storing nn 5 293 Index 3 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page C continued Cylinder Block Troubleshooting ts haath 5 180 Gyli der Bore Specifications 5 189 Cylinder Bores De Glaze In Chassis Overhaul 5 223 Cylinder Head and Gasket Installation In Chassis 5 242 Cylinder Head and Valve Train Operation and Description 5 162 Cylinder Head Assembly 5 255 Cylinder Head Clean and gt 5 247 Cylinder Head Deck Flatness Specifications 5 359 Gylinder Head B
165. 12 Rotate the gears to distribute the oil 13 Position the thrust plate 18 on top of the gears in the center section with the bronze face toward the gears The open side should be toward the inlet 14 Install the O ring 11 into its back cover face groove Oil the O ring the cover face and the bearings Install the back cover so the scribe marks are in line with the marks on the center section and front cover 15 Install the housing retaining screws and tighten alternately to 190 to 210 Ibin 122 to 24 Nem 16 Add a generous amount of clean hydraulic oil into both ports to ensure the pump is adequately lubricated Rotate the drive shaft to distribute the oil and check for freedom of shaft rotation The shaft should be free to rotate with the help of a short wrench 100 Ib in 11 Nem maximum TM 10 3950 672 24 1 BRAKE MASTER CYLINDER DESCRIPTION The brake master cylinder is located under the deck to the front of the cab The master cylinder which has its own oil reservoir is actuated directly by linkage to the brake pedal The master cylinder incorporates two integrally designed pistons the large piston for large volume and the small piston for high pressure Transfer from low pressure large piston to high pressure small piston is accomplished by means of a metered pressure relief valve The low pressure bore has a diameter of 1 75 inch 4 4 cm and the high pressure bore has a diameter of 1 inch 2 5 cm T
166. 18 Ib ft 24 N m AXLE DIFFERENTIAL Check for cracks or leaks TM10 3950 672 24 1 2 11 ORGANIZATIONALPREVENTIVE MAINTENANCE CHECKS AND SERVICES CHART continued MONTHLY S SEMI ANNUALLY BIANNUALLY 200 Hours 1000 Hours Q QUARTERLY A ANNUALLY W WEEKLY H HOURS 500 Hours 50 Hours ITEM TO BE INSPECTED ITEM PROCEDURE CHECK REPAIR FILL ADJUST NO PERFORM ALL OPERATOR PMCS FIRST FRONT amp REAR AXLE PLANETARY HUB Check for proper working order STEERING LINKAGE Check for excessive wear ENGINE COOLANT SYSTEM Clean and flush coolant system 2 9 2 10 blank TM10 3950 672 24 1 CHAPTER 3 MAINTENANCE E 5 Subject Section e Mmmm DCSE p 4 Axles Brak6S sscscsssesssesssesessccccccccccaccccccdsccccccdaccccccdcccccccdccccccddccccccddeccececcecceceecececeees Steering Hey iida Swing SYSTEMI BOOM SWIVGIS esu d eeee exa eeen Led end La d ea ded d Frame and Outriggers Electrical System Subject CEIPICCI Is a REMOVAL
167. 2 Thermostat 0 000 risa nnns nnn nnns 5 56 Timing Advance Assembly Injection 9 5 274 Timing Pin Assembly or Gasket 1 000 5 209 Timing Pin Installation 2 5 211 Tools Required to Repair the B Series 0 5 348 Torque Specification ARR 5 364 Torgu Value Charts EOM D 1 Torquing Turntable 0002 ere aaa eee 3 143 Transmission Assembly x 54 Transmission Assembly nnns 43 Transmission Automatic C 6 Description Replacement and 3 44 Transmission Cleaning and E 41 Transmission Description REM E 20 Transmission Disassembly and Assembly Subassemblies E 45 Transmission Disassembly Major Component 20 24 4 E 43 Transmission General Overhaul Information nnne nnn nnne nisse nnn nnns E 40 LUD RM E 56 Transmission Maintenance sssssssssssssssssseeeeennnn nenne nenne
168. 2 0 ct 5 ng o ring Head Spacer Rod Barrel 0 Wiper Ring Head Plate Rod Seal Buffer Seal Wear Ring Backup Ring 14 Steer Cylinder 3 129 CAUTION BEFORE INSTALLING NEW SEALS AND RINGS CLEAN ALL SURFACES AND CAREFULLY REMOVE BURRS AND NICKS PARTS DISPLAYING EXCESSIVE WEAR OR DAMAGE SHOULD BE REPLACED 2 Stone out minor blemishes and polish with a fine crocus cloth 3 Clean with solvent and dry with compressed air any parts that have been stoned and polished 4 Inspect the barrel carefully for scoring ASSEMBLY NOTE Coat all seals and rings with clean hydraulic oil CAUTION AVOID STRETCHING THE SEALS AND RINGS ENSURE THE SEALS AND RINGS ARE INSTALLED IN THE PROPER ORDER 1 Install the wiper ring in each head plate 2 Install the O ring and backup ring onto the outside of the heads NOTE Ensure the rod seal is installed in the sequence as noted during disassembly 3 Install the rod seal buffer seal assembly and wear ring into the inside of the heads 3 130 TM 10 3950 672 24 1 4 Install the crown seal and wear rings onto the outside of the piston 5 Lubricate the rod with clean hydraulic oil 6 Install the heads and spacers onto the rod Remove the cover from the cylinder barrel 7 Install the piston onto the rod CAUTION AVOID SCRATCHING OR DAMAGING THE GROOVED GLAND SURFACES OR THE RINGS AND SEALS CAUTION EXERCISE EXTREME CARE WHEN HANDLING
169. 246 Starting Motor 5 155 Starting Motor Test ing p 3 243 Starting Motor Troubleshooting eee eee 5 147 Steer Cylinder Description and 3 89 Steer Cylinder Description Replacement and 3 128 Steer HUM P ASSOM DIY oret t E 90 Steer PUM Ps DESCH Pll eL E 88 Steer Pump Bisassermibly ziis 89 Steer Pump Generalnem eR Poe ee ree E A ee ee eee E 90 Steer UMP wetness 90 Steer T 88 Steer Pump aaa aa aaa anakaa Teana eee E 88 Steering Control Valve Description and 3 85 Steering System Description and Repair 2 00 1 3 81 Steering System 3 80 Supply Pressure and Return eee 3 101 Surging Engine Speed Change
170. 3 15 as applicable from fitting 2 c Remove fitting 2 from component 3 37 2 Installation WARNING Never use standard plumbing fittings for the hydraulic system Always use high pressure hydraulic fittings Standard fittings could fail resulting in severe personal injury a Install fitting 2 in component b Install hose or line 1 as applicable on fitting 2 WARNING Hydraulic fluid under pressure can penetrate skin or damage eyes Fluid leaks under pressure may not be visible Use a piece of cardboard or wood to find leaks but do not use bare hand Wear safety goggles for protection If fluid enters skin or eye get immediate medical attention c Start up hydraulic system and check for leaks LEGEND 1 Hose Line E qi as 2 Fitting 55 Figure 3 15 Hydraulic Hoses Lines and Fittings Typical 3 97 TM 10 3950 672 24 1 3 38 HYDRAULIC TANK 3 38 1 Removal a Disconnect negative battery cable and two electrical leads from negative battery post b Remove drain plug 2 Figure 3 16 from hydraulic tank 1 and drain hydraulic oil into suitable container tank capacity 35 gal Dispose of oil according to local regulations c Remove two bolts 3 and two lockwashers 4 securing hydraulic line 5 to return filter assembly 19 d Remove two locknuts 6 two washers 7 and two bolts 8 securing bottom of hydraulic tank to crane frame e Tag and disconnect two electrical leads from temperature switch 26
171. 3 31 WHEELS AND TIRES TM 10 3950 672 24 1 DESCRIPTION The tires are size 10 00 x 1 5H 16 PR The tires and rims are available from different manufacturers CAUTION DO NOT MIX TIRES AND RIMS OF DIFFERENT MANUFACUTRERS Each wheel assembly tire weighs approximately 114 pounds 51 7 kg and is mounted on the hub with 6 3 4 16 UNF bolts NOTE The tire diameters widths and weights may vary slightly depending on the tire manufacturer Off highway tires are designed to operate with a certain sidewall deflection or bulge Correct air pressure ensures prior deflection which in turn ensures proper traction flotation support of load and prevents excessive flexing of the tire Over inflation increases rim stresses which results in lowered rim life Refer to and adhere to the inflation pressures on the Tire Inflation decal on the crane MAINTENANCE WARNING DO NOT ATTEMPT TO DEMOUNT OR MOUNT TIRES WITHOUT PROPER TRAINING THE HIGH PRESSURES INVOLVED CAN CAUSE TIRE AND RIM PARTS AND TOOLS TO FLY WITH EXPLOSIVE FORCE IF PROPER PROCEDURES ARE NOT USED CAUSING SEVERE INJURY OR DEATH TO PERSONNEL AND DAMAGE TO THE CRANE AND SURROUNDING AREA MOUNTING WHEEL ASSEMBUES NOTE Do not lubricate the wheel studs or lug nuts 1 Position the wheel assembly on the mounting studs Install the lug nuts and washer and tighten them 3 79 until they are just snug rotating the wheel so the nut being t
172. 3 Nem Secure the shaft to the transmission with the clamp drive capscrew washers nuts and bolts 3 42 TM 10 3950 672 24 1 3 22 3 Lubrication The universal joints should be lubricated with EP MPG refer to Operator s Manual 10 3950 672 10 The interval between lubrications is generally satisfactory for normal service When subjected to extremely severe conditions more frequent lubrication may be required Lubrication must be done with a low pressure adapter only High pressure will rupture the cork seals 3 43 3 23 C 6 AUTOMATIC TRANSMISSION TM 10 3950 672 24 1 DESCRIPTION GEAR RATIOS The transmission is a three speed automatic capable of providing automatic upshifts and downshifts through the three forward gear ratios The stall ratio is 1 89 1 Low 1st Gear ratios are as follows Int 2nd Direct 3rd Reverse MAINTENANCE NOTE For more detailed information refer to Appendix E TROUBLESHOOTING 3 44 ENGINE IDLE SPEED CHECK Before removal or operation of the transmission Check the engine idle speed If the idle speed is too perform a visual inspection Visually inspect all lines plugs and tube connections at the transmission for oil leakage To make a thorough test of the transmission ensure the engine is properly tuned and the oil level in the transmission is correct During troubleshooting the engine and transmission must be regarded as a single package If inspection does not reveal t
173. 35 ounce 1 decagram 10 grams 35 ounce 1 hectogram 10 decagrams 3 52 ounces 1 kilogram 10 hectograms 2 2 pounds 1 quintal 100 kilograms 220 46 pounds 1 metric ton 10 quintals 1 1 short tons To change inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound feet pound inches To centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons Newton meters Newton meters Fahrenheit temperature The Metric System and Equivalents Approximate Conversion Factors Liquid Measure 1 centiliter 10 milliters 34 fl ounce 1 deciliter 10 centiliters 3 38 fl ounces 1 liter 10 deciliters 33 81 fl ounces 1 dekaliter 10 liters 2 64 gallons 1 hectoliter 10 dekaliters 26 42 gallons 1 kiloliter 10 hectoliters 264 18 gallons Square Measure 1 sq centimeter 100 sq millimeters 155 sq inch 1 sq decimeter 100 sq centimeters 15 5 sq inches 1 sq meter centare 100 sq decimeters 10 76 sq feet 1 sq dekameter are 100 sq meters 1 076 4 sq feet 1 sq hectometer hectare 100 sq dekameters 2 47 acres 1 sq kilometer 100 sq hectometers 386 sq mile Cubic M
174. 3950 672 24 1 3 66 ANTITWO BLOCK SYSTEM SWITCH 3 66 1 Removal Disconnect negative battery cable and two electrical leads from negative battery post Unscrew link 1 Figure 3 18 and disconnect weight assembly 2 and link 1 from antitwo block switch 3 Disconnect cable connector 4 from junction box 5 Remove two screws 6 two lockwashers 7 and antitwo block switch 3 from boom nose 3 66 2 Installation Install antitwo block switch 3 Figure 3 1 8 boom nose with two lockwashers 7 and two screws 6 Connect cable connector 4 to junction box 5 Connect negative battery cable and two electrical leads to negative battery post Start crane and position hook block to a minimum dimension of 4 ft 10 in from bottom of boom nose Shut down crane Lay weight assembly 2 on hook block and attach weight assembly 2 chain to antitwo block switch 3 cable with link 1 so that no slack exists in chain 3 170 TM 10 3950 672 24 1 LEGEND 1 Link 2 Weight Assembly 3 Antitwo Block Switch 4 Cable Connector 5 Junction Box 6 Screw 7 Lockwasher Figure 3 18 Antitwo Block System Switch 3 171 TM 10 3950 672 24 1 3 67 ANTITWO BLOCK SYSTEM CABLE REEL 3 67 1 Removal a Disconnect negative battery cable and two electrical leads from negative battery post b Disconnect cable connector 1 Figure 3 19 from junction box 2 NOTE Count and record number of
175. 5 kPa 34 4 bar THEORY OF OPERATION The hydraulic swivel allows oil to flow from the control valve to various crane functions on the superstructure All oil is routed into the spool portions of the swivel where through a series of internally drilled passages oil is transferred to a channel on the spool exterior This channel corresponds with a mating port on the barrel of the swivel Each channel is separated by a series of teflon and O ring seals that prevent transfer of oil between the channels MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL 1 Ensure the boom is over the front 2 Extend the outriggers and set them just enough to make contact with the ground Do not lift the crane on the outriggers 3 Elevate the boom enough from horizontal to install blocking between the boom base and the lift cylinder Shut down the engine 4 Remove the electrical swivel Refer to ELECTRICAL SWIVEL Removal in this Section 5 Remove the capscrews and lockwashers securing the swivel mounting plate to the carrier bearing plate 6 Lift the swivel up enough to tag and disconnect the hydraulic lines from the spool of the swivel Cap or plug all openings 7 Tag and disconnect the hydraulic lines from the barrel of the swivel Cap or plug all openings 8 Using a suitable lifting device insert two eyebolts on the swivel top plate and lift straight up on the swivel 3 178 9 Remove the swivel from t
176. 68 Nem while rotating the hub in both directions to seat the bearings 2 Back off the adjusting nut 1 16 to 1 4 turn 3 Torque the jam nut to 250 Ib ft 339 Nem 4 The end play must be within the limits of 0 001 to 0 010 inch 0 025 to 0 254 mm loose DISASSEMBLY OF THE DRIVE UNIT Removal of the Drive Unit from the Housing 1 Remove the plug from the bottom of the axle housing and drain the lubricant 2 Disconnect the propeller shaft E 60 TM 10 3950 672 24 1 NOTE Step 3 is for axles with a two gear gear box only 3 Remove the gearbox Refer to Two Gear Gearbox in the Service Manual WARNING DO NOT HIT THE CIRCULAR DRIVING LUGS ON THE SHAFT HEAD AS THIS MAY CAUSE THE LUGS TO SHATTER OR SPLINTER DO NOT USE CHISELS OR WEDGES TO LOOSEN THE SHAFT OR DOWELS AS THIS WILL DAMAGE THE HUB SHAFT AND OIL SEAL NOTE To loosen the dowels hold a 1 5 inch 3 81 cm diameter brass drift against the center of the axle shaft head inside the circular driving lugs Strike the drift a sharp blow with a 5 to 6 pound 2 3 to 2 8 kg hammer or sledge 1 5 inch 3 81 cm diameter brass hammer is an excellent and safe drift 4 Remove the axle shaft stud nuts lockwashers and tapered dowels 5 Remove the axle shaft from the drive unit and housing 6 Remove the carrier to housing stud nuts and lockwashers Loosen the two top nuts but leave them on the studs to prevent the carrier from falling 7 Break the
177. 7 mm increments as needed to correct the rough lowering condition Install the spring and end cap Too many shims may create loss of or poor control If this happens remove shims until control is obtained 3 Hoist has loss of or poor control when lowering a load Remove the cap and spring and remove the shim s in the valve Install an amount of shims smaller in thickness than the original shim s to correct the problem Install the spring and cap 4 Hoist brake is chattering during the lowering of a load Remove the cap and spring and add the needed thickness of shims in 0 005 inch 0 0127 mm increments to correct the chattering condition Install the cap and spring FOR SHIMMING REMOVE CAP AND SPRING 4 Z gt lOOOOO Cd ADD OR REMOVE SHIMS HERE 1994 2 Hoist Motor Control Valve Adjustment 3 185 3 72 CABLE FOLLOWER TM 10 3950 672 24 1 DESCRIPTION The cable follower is installed on the rear side of the hoist It applies a downward spring pressure against the cable onto the hoist drum The pressure ensures the cable will be uniformly wound onto the hoist drum and also prevents cable jumping under abnormal line conditions MAINTENANCE REMOVAL 1 Loosen the adjusting nuts and remove the extension springs 2 Remove the bolts washers and nuts securing the lever welds to the side plate weld 3 Remove the capscrews securing one of the side plates ensuring the roller assembly is n
178. 95 to 108 Torque the capscrews 70 to 80 TM 10 3950 672 24 1 HYDRAULIC SWIVEL DESCRIPTION The hydraulic swivel is used to provide hydraulic oil located at the centerline of rotation of the from the carrier to the superstructure or from the superstructure The hydraulic swivel consists of a case superstructure to the carrier The hydraulic swivel is a spool a mounting plate and seals THEORY OF OPERATION All oil is routed into the spool portion of the swivel by a series of teflon and O ring seals that prevents where through a series of internally drilled passages oil transfer of oil and pressure Return oil flow from the is transferred to a circumferential channel on the spool crane functions is accomplished In the same manner exterior This channel corresponds with a mating port through another set of ports on the barrel of the swivel Each channel is separated MAINTENANCE DISASSEMBLY NOTE dust free area and block the spool to prevent movement There are two major differences in during disassembly hydraulic swivels they may vary in the amount of ports and the method CAUTION in which the spool is retained in the WHEN REMOVING THE SEALS AND case The spool may be held within RINGS AVOID SCRATCHING THE the case by either a snap ring or by GROOVED AND GLAND SURFACES capscrews with retaining clips 4 Remove the seals and rings from the spool NOTE NOTE Aligning the discarded seals and rings in the order of Any maintenance r
179. APOR MAY BE PRODUCED DURING APPLICATION ADEQUATE VENTILATION SHOULD BE PROVIDED WHEN SILICONE RTV IS APPLIED IN CONFINED AREAS WARNING 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 Application of silicone RTV gasket material is as follows 1 Remove dirt grease or moisture from the surface of the carrier and housing 2 Dry the surface 3 Apply a thin bead maximum 0 125 inch 3 175 mm diameter completely around one mating surface and all fastener holes to ensure complete sealing and prevent leakage 4 Assemble the components immediately to permit silicone RTV gasket material to spread evenly Assembly of the Pinion and Cage Assembly 1 If new cups are to be installed press firmly against the pinion bearing cage shoulders 2 Lubricate the bearings and cups with light machine oil E 65 TM 10 3950 672 24 1 3 Press the rear thrust and radial bearing firmly against the pinion shoulders with a suitable sleeve that will bear only on the bearing inner race 4 Install the radial bearing lock ring and squeeze the ring into the pinion shaft groove with pliers 5 Insert the pinion and bearing assembly in the pinion cage and position the spacer or spacer combination over the pinion shaft 6 Press the front bearing firmly against the spacer 7 Rotate the cage several revol
180. ARD CLUTCH Apply air pressure to the transmission case forward clutch passages A dull thud can be heard when the clutch piston is applied If no noise is heard place the finger tips on the input shell and again apply air pressure to the forward or front clutch passage Movement of the piston can be felt as the clutch is applied GOVERNOR Apply air pressure to the control pressure to governor passage and listen for a sharp clicking or whistling noise The noise indicates governor valve movement REVERSE HIGH CLUTCH Apply air pressure to the reverse high clutch A dull thud indicates that the reverse high or rear clutch piston has moved to the applied position If no noise is heard place the finger tips on the clutch drum and again apply air pressure to detect movement of the piston INTERMEDIATE SERVO Hold the air nozzle in the front servo apply tube or the intermediate servo apply passages Operation of the servo is indicated by a tightening of the front or intermediate band around the drum Continue to apply air pressure to the servo apply tube or passage and introduce air pressure into the front release tube or the intermediate servo release passage The front or intermediate servo should release the band against the apply pressure TM 10 3950 672 24 1 CLUTCH t vo 2 t INE PRESS COASTING REGULATOR INTERMEDIATE SERVO CAPACITY MODULATOR BACK CHECK VALVE STATOR SUPPORT OOLEAR REAR LUBE
181. ASS Seepage of fluid as indicated by wetness or discoloration not great enough to form drops CLASS 11 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 1 or Il Of course consideration must be given to the fluid capacity in the item system being checked inspected When operating with Class or Il leaks continue to check fluid levels as required on your PMCS Class leaks should be reported to your supervisor 2 6 TM10 3950 672 24 1 2 11 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES CHART M MONTHLY S SEMI ANNUALLY BIANNUALLY 200 Hours 1000 Hours Q QUARTERLY A ANNUALLY W WEEKLY H HOURS 500 Hours 50 Hours ITEM TO BE INSPECTED PROCEDURE CHECK REPAIR FILL ADJUST PERFORM ALL OPERATOR PMCS FIRST AXLE DIFFERENTIAL Check for proper level TRANSMISSION Change oil filters TRANSMISSION MOUNTING BOLTS Check torque lb ft N m Trans to Engine 50 65 Ib ft 60 88 Nem Rear Engine Support to Trans 60 80 Ib ft 81 108 Nem TURNTABLE BOLTS CAUTION Turntable bearing bolts cannot be retorqued more than one time Stretching takes place each time they are torqued If torque is lost replace bolts Check torque lb ft N m
182. Always follow the directions on the Loctite container as not all Loctite types are suitable for all applications Various types of Loctite are specified throughout the Service Manual The following types of Loctite brand adhesives are available from the Parts Department of Grove Manufacturing Company Loctite Number Grove Part Number 277 9999100806 242 9999100805 592 9999100804 FASTENERS AND TORQUE VALVES NOTE Refer to for Torque Value tables Use bolts of the correct length A bolt which is too long may bottom before the head is tight against the part it is to hold If a bolt is too short there may not be enough threads engaged to hold the part securely Threads can be damaged Inspect them and replace fasteners as necessary Torque values should correspond to the type bolts studs and nuts being used The torque tables are provided by Grove Manufacturing Company for reference when performing maintenance Use of proper torque values is extremely important Improper torquing can seriously affect performance and reliability Identification of fastener grade is always necessary When marked as a high strength bolt grade 3 5 etc the mechanic must be aware that he is working with a highly stressed component and the fastener should be torqued accordingly NOTE Some special applications require variation from standard torque values Reference should always be made to component overhaul procedures for recommen
183. BLY NOTE Any maintenance involving disassembly of the hoist should include replacement of all gaskets and O rings Brake Assembly T Disconnect the hydraulic lines to the brake housing 6 cap or plug all lines and openings 2 Remove the capscrews 29 and washers 30 securing the brake assembly to the brake end housing Remove the brake assembly 3 Remove the springs 21 from the piston 7 4 Using a suitable puller remove the piston and clutch assembly 5 Remove the stators 9 discs 10 and spacer 20 6 Remove the snap ring 19 from the shaft 13 7 Using a soft faced hammer remove the piston 7 from the clutch assembly 8 E 137 TM 10 3950 672 24 1 8 Tap the shaft 13 spacer 20 and bearings 1 7 from the clutch 8 9 Remove the O rings 22 and 23 from the piston 7 Hydraulic Motor 1 Tag and disconnect the hydraulic lines from the motor 1 5 and the hoist motor control valve 1 6 Cap or plug all lines and openings 2 Remove the bolts and washers securing the motor to the motor end cover 4 Remove the motor For maintenance of the vane type motor refer to the applicable SM package 1 2 3 4 5 6 7 8 9 Housing Cable Drum R H Drum End Motor End Housing Brake End Housing Brake Housing Piston Clutch Assembly Stator Friction Disc Primary Carrier Assy Second Carrier Assy Main Shaft Input Shaft Motor Brake Co
184. CASE ASSEMBLY PLUG RETAINER SHAFT VENT SHAFT INPUT SEAL SMALL BOLT PUMP ASSEMBLY BUSHING STATOR BOLT SEAL PISTON OUTER SEAL PISTON INNER DRUM BRAKE ANCHOR BAND STRUT GASKET SEAL INTERMEDIATE SEAL LARGE E 29 1 0 3950 672 24 1 WASHER 114 WASHER 119 WASHER 057 WASHER 078 WASHER 094 RING RETAINING RING RETAINING RING RETAINING RING RETAINING RING RETAINING WASHER PLATE PRESSURE PLATE CLUTCH EXTERNAL PLATE CLUTCH INTERNAL RING RETAINING RETAINER SPRING PISTON SEAL CYLINDER ASSEMBLY DISC SPRING SEAL PISTON OUTER SEAL RING RETAINING PISTON PLATE PRESSURE SPRING PRESSURE PLATE CLUTCH INTERNAL PLATE PRESSURE RING RETAINING RING RETAINING WASHER HUB THRUST RING RETAINING HUB OUTPUT SHAFT GEAR RING OUTPUT RING RETAINING WASHER PLANET CARRIER GEAR RING RETAINING RING RETAINING WASHER SHELL INPUT GEAR RACE BEARING REAR BEARING SUN GEAR RACE BEARING FRONT PLANET GEAR FORWARD GEAR RING FORWARD HUB FORWARD CLUTCH WASHER FORWARD CLUTCH CLUTCH REVERSE RING RETAINING CLUTCH OVERRUNNING RING RETAINING PLATE CLUTCH EXTERNAL PLATE CLUTCH INTERNAL SPRING CLUTCH SEAL PISTON OUTER SEAL PISTON INNER RACE OVERRUNNING CLUTCH RETAINER SPRING PISTON ASSEMBLY BOLT GEAR ASSEMBLY WASHER OUTPUT SHAFT BOLT TAG COVER SEAL GASKET PISTON SPRING SCREW NUT AND WASHER LEVER SHA
185. CUIT REUEF SETTING table adjust the pressure setting as necessary 5 f the valve cannot be adjusted to within the 100 psi 689 5 kPa 6 89 bar tolerance shut down the crane and replace the relief valve 6 After the required pressure setting has been obtained shut down the engine Connect the swing brake release line to the swing brake remove the pressure gauge and install the pipe plug NOTE Release the control lever after taking each reading and while making adjustments When the proper pressure setting has been attained tighten the adjustment screw locknut and recheck the pressure It is possible that the setting may change while tightening the locknut NOTE An accurate 0 to 6000 psi 0 to 34 475 kPa 344 75 bar pressure gauge should be used when adjusting relief valves Pressure test ports are located on the hydraulic test panel These test ports are connected to the inlet line of each valve bank PREPARATION 1 Start and warm up the engine until the hydraulic oil temperature reaches a minimum of 70 degrees F 21 1 degrees C WARNING DO NOT ATTEMPT TO LOOSEN THE FITTINGS IN PRESSURIZED LINES OR WHILE THE HYDRAULIC PUMP IS IN OPERATION 2 Shut down the engine MAIN RELIEF VALVE ADJUSTMENT WARNING NEVER USE STANDARD PLUMBING FITTINGS FOR THE HYDRAULIC SYSTEM ALWAYS USE HIGH PRESSURE HYDRAULIC FITTINGS 1 Plumb the pressure gauge into the pressure test port on the control valve bank 2 Set the
186. Check For Filter Restriction As a dry cleaner element becomes loaded with dust the vacuum on the engine side of the air cleaner at the air cleaner outlet increases The vacuum is generally measured as restriction in inches of water The engine manufacturer places a recommended limit on the amount of restriction the engine will withstand without loss of performance before the air filter element is cleaned or replaced For the Cummins diesel engine the maximum allowable air restriction is 20 inches 50 8 cm of water maximum with a dirty air filter at maximum governed speed Mechanical gauges warning devices indicators and water manometers can be used to determine when the air intake restriction reaches the maximum recommended limit The AP308T features an air restriction indicator mounted in the air intake piping just after the air cleaner assembly The indicator consists of a spring in a clear tube with graduated scale lines scribed on the outside of the tube to indicate vacuum pressure A red line on the graduated scale indicates when the air filter should be cleaned or replaced With a new air filter installed the engine draws air through the filter virtually unrestricted As dirt and other foreign matter become trapped by the air filter vacuum pressure in the air intake piping gradually increases as the engine pulls air through the restricted filter The gradual increase in vacuum pressure results in a gradual compression of
187. Discard the O rings CAUTION 2 Remove the screws securing the end caps Remove USE CARE WHEN HANDLING THE the end caps and centering springs VALVE HOUSING AVOID DAMAGING THE FACES OR O RING GROOVES 3 Remove the holding check valve from the housing Discard the O ring E 116 TM 10 3950 672 24 1 Acorn Nut Jam Nut Screw Relief Valve w Cap O Ring Follower Spring Poppet Slipper Seal Backup Ring Seal Backup Ring Relief Barrel Backup Ring Seal Screw End Cap Retaining Plate Collar SO gg pP OM Spring Collar Collar Stop Spacer Spring Retainer Spool Seal Check Plug Holding Check O Ring Check Spring Poppet Housing Spool Spool Pin Connecting Plate Cotter Pin Bracket Plug 3 BANK ASSEMBLY Directional Control valve E 117 4 Remove the plugs from the unused ports ASSEMBLY CAUTION INSTALL NEW O RINGS AND SEALS ON OR IN ALL COMPONENT PARTS COAT O RINGS AND SEALS WITH CLEAN HYDRAULIC FLUID PRIOR TO ASSEMBLY E 118 TM 10 3950 672 24 1 1 Remove any burrs from the face of the housing and ensure all mating surfaces are clean 2 Install the plugs in the unused ports 3 Install a new O ring and the holding check valve into the valve housing 4 Install the centering springs and end caps and secure with the screws 5 Install new O rings and the relief valve into the valve body Install the relief cap and nuts TM 10 3950 672 24 1 SWING MOTOR DESCRIPTION
188. ERS AT OPPOSITE OPENINGS REAR HOUSING STATOR Figure 3 27 Stator and Rear Housing Separation 3 214 TM 10 3950 672 24 1 3 84 4 Testing a Set multimeter for ohms and check brush assembly refer 19 Figure 3 28 for continuity between mount A and brush B and terminal C and brush D Check for open circuits between mount A and terminal C mount A and brush D terminal C and brush B and brush B and brush D refer to Figure 3 28 Replace brush assembly if indications are other than stated Figure 3 28 Testing Brush Assembly b Set multimeter for ohms and check stator for open circuits between point D lamination and each terminal A B and C refer to Figure 3 29 If continuity is noted between lamination and any terminal stator is defective and must be replaced c Set multimeter for ohms and check stator windings for continuity between terminals A B A C and B C refer to Figure 3 29 If open replace stator d Set multimeter for ohms and check resistance of rotor assembly for 3 0 to 3 6 ohms between slip rings as shown on Figure 3 30 Also check that open circuits are indicated between pole fingers and each slip ring Replace entire rotor assembly if indications are other than stated Figure 3 29 Testing Stator Windings 3 215 TM 10 3950 672 24 1 POLE FINGERS REAR BEARING BEARING AREA SHAFT TEST CURRENT THREADS DRAW OR RESISTANCE BETWEEN RINGS Figure 3 30 Testing Rotor 3 84 5 Ass
189. FT PARKING PAWL PAWL PARKING SPRING PARKING PAWL SCREW BRACKET SEAL OIL LEVER SEAL CONTROL LEVER E 30 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 TM 10 3950 672 24 1 SWITCH NEUTRAL REVERSE SCREW WASHER LOCK NUT LEVER ASSEMBLY DOWN SPRING PLATE ASSEMBLY SHAFT PARKING PLATE PLUG PARKING PLATE SCREW LEVER ASSEMBLY LEVER ROD ASSEMBLY PARKING LEVER DOWNSHIFT NUT PLATE SHIFT VALVE BOLT PLATE THROTTLE RETAINER VALVE MANUAL PLATE PLATE TUBE PLATE CONTROL UNIT ASSY BODY VALVE GASKET GASKET FILTERING DISK FLUID TUBE BOLT LOW REVERSE CLUTCH Apply air pressure to the low reverse clutch apply passage A dull thud should be heard if the clutch is operating properly If the passages are clear remove the clutch assemblies and clean and inspect the malfunctioning clutch to locate the trouble Hydraulic Checks FLUID LEVEL CHECK Check the oil level in the transmission The fluid level indication on the dipstick will be different at operating temperature transmission hot and room temperature transmission cold The transmission should be checked at an operating temperature transmission hot of 150 degrees to 170 degrees F 66 degrees to 77 degrees C dipstick is hot to touch The dipstick reading at operating temperature should have
190. Failure to comply could result in scalding or serious burns 3 11 1 Testing d Open engine access door With an assistant in cab observing engine coolant temperature gauge disconnect electrical lead from sender and ground lead If engine coolant temperature gauge does not move sender is OK If gauge peaks to the right replace sender Close and secure engine access door 3 11 2 Removal Doc og m Disconnect negative battery cable and two electrical leads from battery Open engine access door Drain engine coolant to a level below coolant temperature sender 4 Figure 3 6 Tag and disconnect electrical lead to coolant temperature sender 4 Remove coolant temperature sender 4 from engine 3 11 3 Installation ococmp Install coolant temperature sender 4 Figure 3 6 in engine Connect electrical lead to coolant temperature sender 4 and remove tag Service engine coolant system Close and secure engine access door Connect negative battery cable and two electrical leads to battery 3 24 TM 10 3950 672 24 1 3 12 FUEL SYSTEM 3 12 1 Description The fuel system consists of the fuel tank filters and or strainer fuel pump and the fuel injectors a Fuel Tank The fuel tank is located on the right side of the crane The tank has a total capacity of approximately 35 gal 132 4 L and a gauge level of 30 gal 113 5 L The tank is equipped with a lock type filler cap and a fuel quantity sender unit which prov
191. Firmly hand tighten the setscrew This should jam the chamfered end of the adaptor valve 14 into the chamfered seat between the no 4drill and Q drill in the port plate 12 to create a metal to metal seal 12 Lubricate the seals 15 and 16 Install seal 15 in the bottom of the bore of the housing 24 and seal 16 around the small diameter of the port plate 12 13 Position the housing 24 centerline vertical and the large bore up and install the belleville washer 25 in the bottom of the housing bore The outside diameter of the belleville washer should contact the housing 24 and should also be centered inside seal 15 Refer to Location of Belleville Washer illustration BELLEVILLE WASHER HOUSING PORT PLATE TM 10 3950 672 24 1 SHAFT C L Location of Belleville Washer 14 Install the port plate 12 into the housing 24 until it bottoms on the belleville washer 25 15 Line up the dowell pin hole with the threaded hole for the end cap at the lower right corner of the housing 24 Install the dowel pin 11 in the dowel pin hole in the port plate 12 16 Place the cam ring 7 rotor 10 vanes 8 and vane springs 9 on a clean flat surface Arrange the vanes side by side with the three spring holes up Insert the vane springs in the vanes Install the vanes with the springs in slots in the rotor CAUTION ENSURE THE SPRINGS ARE STARTED IN THE HOLES IN EACH ROTOR SLOT 17 Place a ring
192. For this reason the best possible lubricants should be used The grease recommendations are based on commercial products that have given satisfactory results in normal operation However there are many proprietary grease products on the market which will perform satisfactorily and may be preferable because of supply problems common usage for other truck components etc Where such products are recommended by reputable grease suppliers for the specific lubrication of Rockwell components Rockwell has no objections provided that these substitute products are equal to or better than the Rockwell recommendations in lubrication properties water resistance corrosion protection high and low temperature characteristics oxidation stability shear stability etc It is advisable to consider the reputation of the refiner or vendor when selecting a lubricant He is responsible for the quality and correct application of his product A high quality lubricant incorrectly applied may greatly reduce the maximum service built into our product Past experience has proven that a large portion of service problems can be traced to an improper lubricant application The purpose in compiling these specifications is to provide a guide to aid in the selection of a lubricant which will render the most satisfactory service New and Reconditioned Axle Service All new axles should be checked for correct oil level before being placed into service E 75
193. G THE CAP LOOSEN IT SLOWLY AND THEN PAUSE A MOMENT THIS WILL AVOID POSSIBLE BURNING BY HOT WATER OR STEAM CONTINUE TO TURN THE CAP TO THE LEFT UNTIL IT CAN BE REMOVED 4 Tubes Because these are very small they can be come easily clogged or partially so by rust and scale The general condition of the cooling system and operating temperature are indications as to whether or no1 tubes are clean Another good test is to feel the core for cold spots 5 Fins These thin metal sheets dissipate heat picked up by the tubes They should be kept free of bugs leaves straw etc so as to allow the free passage of air Bent fins should be straightened Engine Water Jacket The water jacket permits coolant to be circulated around the cylinder walls combustion chamber and valve assemblies Some of these coolant passages are small and can easily become clogged if the cooling system does not receive the proper maintenance 1 Core Plugs These are sometimes mistakenly called freeze plugs They do not provide protection against freezing expansion but are only present because of engine block casting methods Remove and replace core plugs that show signs of leaking or rusting through Use an installation tool for core plug replacement 2 Drain Plugs The water jacket of each engine has one or more drain plugs These should receive seasonal care and kept free of rust and scale 3 Gaskets Gaskets must be in good condition to prevent b
194. G THE SPOOL IS REQUIRED DO NOT FORCE THE SPOOL INTO THE BARREL Insert the spool into the berrrel Secure the spool to the barrel with the capscrews and retaining clips or the snap ring TEST NOTE For individual port test pressures refer to the HYDRAULIC SWIVEL in the Service Manual E 158 TM 10 3950 672 24 1 NOTE Use only 10W hydraulic oil during pressure testing 1 Install a pressure gauge into a port on the swivel case 2 Install a pressure line in the corresponding port in the swivel spool 3 Allow the ports on each side of the port to be tested to vent in order to detect leakage 4 Pressurize the port to be tested while rotating either the spool or case 360 degrees 5 If leakage is detected disassemble the swivel and determine the cause 6 Pressure check each port individually until all ports have been tested TM 10 3950 672 24 1 ELECTRIC SWIVEL DESCRIPTION The electrical swivel consists of brushes collector rings and a cover assembly It is mounted on top of the air hydraulic swivel The electrical swivel is used to conduct power between the carrier and the superstructure THEORY OF OPERATION The electrical swivel is located on top of the air transmission swivel and transfers electricity between the carrier and superstructure Wiring harnesses transmit the electricity from the carrier components to the collector ring assembly on the swivel The brush assembly then picks up the
195. GER SELECTOR valve is located in the cab to the left of the seat It is an eight position hydraulic NOTE valve that directs the flow of hydraulic oil from the For a more detailed DESCRIPTION and outrigger directional control valve to the appropriate MAINTENANCE of the outrigger outrigger s selector valve refer to VALVES in Section 6 HYDRAULIC SYSTEM 3 197 DARON Cotter Pin Slotted Nut Washer Pintle Hook Assy Cotter Pin Slotted Nut LEGEND 7 Bolt 8 Hook Jaw 9 Hook Body 10 Cotter Pin 11 Rivet 12 Chain Figure 3 21 Pintle Hook Assembly 3 198 TM 10 3950 672 24 1 TM 10 3950 672 24 1 3 78 PINTLE HOOK 3 78 1 3 78 2 oaoo p 3 78 3 Removal Remove radiator refer 10 paragraph 3 20 1 Remove cotter 1 Figure 3 21 slotted nut 2 washer 3 and pintle hook assembly 4 from crane frame Repair Remove cotter pin 5 Figure 3 21 slotted nut 6 bolt 7 and hook jaw 8 from hook body 9 Remove cotter pin 10 rivet 11 and chain 12 from hook body 9 Inspect parts for damage and replace as necessary Install chain 12 on hook body 9 with rivet 11 and insert cotter pin 10 in chain Apply anti seize compound to threads of bolt 7 and install hook jaw 8 on hook body 9 with bolt 7 slotted nut 6 Tighten slotted nut 6 and back off nut until hook jaw 8 will pivot and hole in shaft of bolt 7 aligns with slots in nut 2 Secure slotted nut
196. HAPTER 1 INTRODUCTION Subject Section Page General Information 1 1 General Maintenance 2 2 2 0000 00 0000 1 3 2 Maintenance Forms Records and Reports of Maintenance and Unsatisfactory Equipment Reporting of Item and Packaging Discrepancies Transportation Discrepancy Report Destruction of Army Materiel to Prevent Enemy Use Administrative Storage Reporting Equipment Improvement Recommendations EIRs 1 1 mj 1 1 J 1 1 SCOPE This manual gives procedures for maintenance of the 10K Warehouse Crane M469 The manual contains maintenance procedures to be performed by organizational direct support and general support level personnel 1 2 MAINTENANCE FORMS RECORDS AND REPORTS a Reports of Maintenance and Unsatisfactory Equipment Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738 750 as contained in Maintenance Management Update b Reporting of Item and Packaging Discrepancies Fill out and forward SF 364 Report of Discrepancy ROD as prescribed in AR 735 11 2 DLAR 4140 55 SECNAVINST4355 18 AFR 400 54 MCO 4430 3J c T
197. HOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component i Support RUN BEEN Equipment Remarks Assembly Function ejoj F Ref Code Hydraulic Swivel Inspect 0 5 Replace Repair Test Electrical Swivel Inspect Replace Repair B 21 Tool or Test Equipment Ref Code Section Ill TOOL AND TEST EQUIPMENT REQUIREMENTS Maintenance Level FOR CRANE WAREHOUSE M469 Nomenclature Analyzer Set Engine STE ICE Lubrication Service Unit Trailer Mtd Shop Equipment Battery Servicing Shelter Mtd Shop Equipment Contact Maintenance Truck Mtd C4940 95 CL B05 Shop Equip Electrical Rep Semitrailer Mtd C4940 95 CL B05 Shop Equip Gen Purpose Rep Semitrailer Mtd C4940 95 CL B02 Shop Equipment Organizational Repair Light Truck Mtd C4940 95 CL B03 Shop Equipment Machine Shop FM Heavy Less Power Shop Equipment Machine Shop FM Heavy Suppl No 1 Shop Equipment Machine Shop FM Basic Shop Equipment Welding Field Maintenance B 22 National NATO Stock Number 4910 00 124 25 4930 00 017 9167 4940 00 209 6234 4930 00 294 9518 4940 01 150 3113 4930 01 006 3229 4940 01 028 2672 3470 00 754 0738 3470 00 754 0739 3470 00 754 0708 4940 00 37 7268 TM10 3950 672 24 1 Tool Number 2389409 901765 1 5 4940 95 CL A58 SECM 1975 13221E9020 SEORLT S 12 050 118 C3470 95 CLA15 5 3470 95 16 5 3470 95 02 5 3470 95
198. INGS AVOID STRETCHING THE SEALS OR SCRATCHING THE GROOVED AND GLAND SURFACES NOTE Lubricate new seals and rings with clean hydraulic oil 5 Install the O ring and backup ring onto the outside of the head NOTE Ensure the rod seal is installed in the sequence as noted during disassembly 6 Install wiper ring rod seal buffer seal assembly and wear ring into the inside of the head 7 Lubricate the rod with clean hydraulic oil 8 Install the head onto the rod Remove the cover from the cylinder barrel 9 Install the seal assembly onto the outside of the piston CAUTION AVOID SCRATCHING OR DAMAGING THE GROOVED GLAND SURFACES OR THE RINGS AND SEALS CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD DAMAGE TO THE ROD SURFACE MAY CAUSE UNNECESSARY MAINTENANCE AND EXPENSE TM 10 3950 672 24 1 10 Lubricate the piston and head with clean hydraulic oil and install the rod assembly into the barrel with a twisting motion 11 Apply Locquic Primer T to the threads of the setscrew Allow to dry and apply Loctite 271 adhesive sealant to the threads of the setscrew Install the setscrew into the barrel securing it to the head WARNING DO NOT USE AIR PRESSURE TO CYCLE OR PRESSURIZE THE CYLINDER 12 Pressurize and cycle the cylinder Check for proper operation and any leakage 3 134 Swing System Description Theory of Operation Troubleshooting Swing Motor Description
199. If removed install two new shock mounts 42 on radiator mounting studs Then place radiator 12 with shroud 29 in engine compartment lining up mounting holes in vehicle frame with studs on bottom of radiator If removed secure two straps 40 to studs on vehicle frame with two nuts 29 and two lockwashers 28 Install two nuts 25 and two washers 26 to secure bottom of radiator to vehicle frame Remove caps and connect two transmission oil cooler lines at fittings 24 3 38 TM 10 3950 672 24 1 Install fan guard 16 as follows 1 Install supports 17 and 18 on fan guard 16 with eight screws 22 eight washers 23 and 21 eight lockwashers 20 and eight nuts 19 2 Install fan guard 16 on radiator with ten screws 13 ten lockwashers 14 and ten washers 15 Connect radiator hoses 10 and 11 and secure with hose clamps 8 and 9 Install coolant recovery bottle 6 and secure with circle clamp 7 Install recovery bottle cap with hoses 4 and 5 attached then connect hose 4 to radiator neck and tighten clamp 3 Fill radiator with previously drained coolant Connect negative battery cable and two electrical leads to negative battery post Start engine and inspect radiator hoses and transmission oil cooler lines for leaks Check transmission fluid level Shutdown engine and tighten clamps fittings as needed Service transmission and coolant system if required refer to Operator s Manual TM 10 3950 672 1
200. Inspection Replacement Injection 5 268 Vibration Damper Cleaning and 5 303 Vibration Damper Specifications 0c ci tne eee 5 356 W X 2 Water Coolant Pump Troubleshooting 5 54 Water Cooling System Antifreeze 18 Water Cooling System 2 00 100 15 Water Cooling System Component 16 Water Cooling System Coolant E 18 Water Cooling System Coolant 18 Water Gooling System Description 12 Water Cooling System Description and 3 35 Water Cooling System 2 1 0 14 Water Cooling System 12 Water Cooling System Pressure Flushing 4 E 16 Water Cooling System Rust Prevention 0 0 0 0 cece eee ee eee eee eee eee E 15 Index 15 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page W X Y Z continued Water Cooling System Seasona
201. Install new O rings onto the holding valve 3 Lubricate the holding valve and O rings with clean hydraulic oil CAUTION DO NOT DAMAGE THE O RINGS DURING INSTALLATION OF THE HOLDING VALVE IF THE HOLDING VALVE TURNS FREELY THEN GETS HARD TO TURN THEN EASY TO TURN REMOVE THE HOLDING VALVE AND CHECK THE O RINGS THEY HAVE PROBABLY BEEN DAMAGED BY A SHARP EDGE OF A PORT NOTE The holding valve should turn by hand until compression of the O rings begins 4 Carefully install the holding valve into the port block until fully seated 3 113 3 46 PILOT OPERATED CHECK VALVE DESCRIPTION The pilot operated check valve is located in the outrigger stabilizer port block The check valve TM 10 3950 672 24 1 NOTE For more detailed information refer provides two functions the first function is a holding to Appendix E valve the second function provides a thermal relief of the stabilizer THEORY OF OPERATION Pressure is applied through port A of the valve The pressure lifts the poppet off its seats and fluid flows through port C to the component The return flow from the component is held in check by the check valve until sufficient pressure builds against the base of the piston to cause the stem to unseat the check valve When the check valve is unseated oil flows through port C and through port B in the poppet Fluid then flows around the check valve seat and out the piston stem hole to port A If the piston is
202. J FRONT DRIVE AXLE and adjust the wheel bearings d Refer td Appendix EJ FRONT DRIVE AXLE and adjust the anchor settings a Replace drums lathe turning the drums will not correct drum stretching TM 10 3950 672 24 1 ROCKWELL FSH HYDRAULIC BRAKES DESCRIPTION The brake is a floating shoe hydraulic actuated brake consisting of a backing plate assembly wheel cylinder Actuation permits the shoes to center themselves in the drum with equal effectiveness in either direction assembly two brake shoe assemblies two brake adjustment bolts and shoe hold down spring assemblies MAINTENANCE DISASSEMBLY 1 Refer Chapter 3 Section 4 FRONT DRIVE AXLE and remove the wheels CAUTION DO NOT APPLY MORE THAN 20 LB FT 27 Nem TORQUE TO THE HEADS OF THE ADJUSTMENT BOLTS DO NOT USE A POWER WRENCH ON THE ADJUSTMENT BOLTS 2 Remove the brake drums If necessary manually retract the brake shoes by rotating the adjustment bolts so that the brake drums will clear the linings To retract each brake shoe rotate the adjustment bolt heads 1 8 turn 3 Release and remove the shoe return spring 4 Push down on the shoe retainers so that the retainer nails can be reached with pliers Hold the retainers so that they do not twist while rotating the nails 1 4 turn Remove the retainers springs and retainer nails 5 Remove the brake shoes 6 If complete disassembly is necessary disconnect the hydraulic line
203. LT M WITH Sw 1 8 o Bru TS m ALARM 5 CIRC F 5 9 WITH Sw 7 i 1 i WIPER WASHER gt WINDSHIELD e M WASHER WINDSHIELD e UN E HEATER FAN i WIPER irs HTR FAN 14 SLIP RINGS 4 4 i 1 pose OL 1 roy 1 10010698 nin tatu tadou lai naaa aaa ee ee Kl 7 7 o fi B6 s Figure FO 1 Electrical Schematic Sheet 1 of 3 FP 1 FP 2 blank TM 10 3950 672 24 1 STANDARD WIRING OPTIONAL WIRING EXISTING WIRING FURNISHED WIRING BUT NOT USED CONNECTED WIRES NON CONNECTED WIRES FUSIBLE LINK WIRE TO BOOM PLUG PULL SLIP RING ON SWIVEL 60 FLOOD LTS 9 9 0 4 fou 9 4 TM 10 3950 672 24 1 HEATER HEATER Sw 169 136 lt 102 80 CAB CIRC FAN WITH Sw IF 10 CAB FAN jHTR SPOT LT FU3 STOP TURN LTS r PARK BRAKE SW 32 52 101 rr 25 18 as I COLD START n BOOM LTS Sw C Bo du vee 169 4 it 40 H 1t KIJ j Era B 36 9 Bux m 33 69 Ru 1 16 BRN q 17 ORG 13723 4 7 111213 145 41 RED 5 14 9 GRN 15 YEL
204. MBLIES ARE INSTALLED IN THE PROPER ORDER CAUTION ENSURE THAT ANY BRUSH AND ARM ASSEMBLIES THAT HAVE BEEN REPLACED ARE OF THE PROPER ELECTRICAL CAPACITY NOTE When installing the brush and arm assemblies do not unhook the springs Use your fingers to spread the brush arms while sliding the brush and arm assemblies onto the holding studs 3 Install the brush and arm assemblies 4 Install any spacers that were taken off 5 Install the nylon outboard bearing and the nuts and washers 6 Connect the knife disconnects on the brush and arm assemblies Slide the plastic sleeves over the knife disconnects TM 10 3950 672 24 1 Collector Ring Harness Mounting Bracket Brush and Arm Assembly Brush Holder Stud Nylon Outboard Bearing Brass Studs Crimp Connectors Nylon Ring Brass Ring Collector Core Brush Spring Knife Disconnect Plastic Sleeve Setscrew Nylon Bearing Not Visible Center Post 1 2 3 4 5 6 d 8 E 161 TM 10 3950 672 24 1 CAB HEATER DEFROSTER HOT WATER DESCRIPTION The heater system consists of a heater core heater assembly prevents personnel from accidentally coming hoses a fan and an electric motor The heater box in contact with the fan or heater core THEORY OF OPERATION Hot water is carried by the heater hoses from the engine is vented through the box assembly for either heat or to the heater core A fan is used to circulate the heated defrost The vent is contro
205. N The cooling system consists of the radiator engine cooling circuit and the connecting hoses Its capacity varies according to the engine being used temperature is controlled by a 180 degree F 82 degrees C thermostat located between the top of the engine and the top of the radiator The radiator in addition to cooling the engine also contains a cooler which cools the automatic transmission oil At all times the coolant should be properly inhibited against corrosion If antifreeze is used follow the antifreeze manufacturers requirements for proper protection in regards to cooling system capacity and only ethylene gylcol base permanent antifreeze should be used MAINTENANCE NOTE For more detailed information refer to Appendix E 3 35 TM 10 3950 672 24 1 3 20 RADIATOR 3 20 1 Removal a Disconnect negative battery cable and two electrical leads from negative battery post b Remove rear access cover refer paragraph 3 80 WARNING Allow engine and radiator to cool down before opening cap Open radiator cap slowly to allow pressure to escape Failure to comply could result in scalding or serious burns c Remove radiator 1 Figure 3 1D and open radiator drain valve 2 Drain coolant 24 5 quart capacity into clean adequate container d Remove recovery bottle 6 cap with two hoses 4 and 5 attached and set aside Then loosen hose clamp 3 at radiator neck and disconnect hose 4 e Loosen
206. ND NAVIGATIONAL INSTRUMENTS Anti Two Block Inspect 5 12 13 Warning System Replace 24 TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component i Support RUN BEEN Equipment Remarks Assembly Function iC oO F Ref Code Code CRANES SHOVELS AND EARTH MOVING EQUIPMENT AND COMPONENTS Crane Attachments Boom Assembly Inspect Service Replace Repair Sheave Assembly Inspect Boom Nose Service Replace Repair Cable Wire Rope Inspect Service Replace Hook Block Inspect Service Replace Repair TM10 3950 672 24 1 Section MAINTENANCE ALLOCATION CHART Continued Component Assembly Hoists Hoist Assembly Hydraulic Motor Hoist Cable Follower Turntable Swing Bearing Planetary Gear Reducer Swing Motor FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Maint Support Support Depot Equipment Remarks Function H DY Ref Code Code Inspect 2 4 5 10 Service 12 13 15 Replace 22 24 Repair Inspect Replace Repair 3 Inspect 0 Replace Repair i 24 12 13 Replace 15 Test Inspect Replace Repair Test Inspect i Replace Repair Test 20 TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WARE
207. NOTE Count and note number of turns when removing bolt 29 to aid in assembly Loosen nut 28 and remove bolt 29 from base of pedal 9 Remove bellows 30 from base of pedal 9 3 11 TM10 3950 672 24 1 3 5 3 Assembly a Install bellows 30 Figure 3 5 on base of pedal 9 b Screw bolt 29 with nut 28 into base of pedal 9 the same number of turns noted during disassembly Tighten nut 28 c Screw clevis 27 into rod end bearing 26 the same number of turns noted during disassembly d Install rod end bearing 26 with clevis 27 on pedal 8 with pin 25 and spring clip 24 e Install two bearing liners 21 spring 22 and lever 23 on bracket 15 Secure lever 23 with circlip 20 f Install bracket 19 on bracket 15 with two bolts 18 two washers 17 and two nuts 16 g Position bracket 15 lever 23 and bracket 19 as an assembly under pedal 9 and attach clevis 27 to lever 23 with pin 11 and spring clip 10 h Secure bracket 15 to pedal 9 with U bolt 14 two washers 13 and two nuts 12 3 5 4 Installation a Install pedal 9 Figure 3 5 with attached components on cab floor with three bolts 7 and three lockwashers 8 b Attach throttle cable to lever 23 with pin 6 and spring clip 5 c Secure throttle cable to bracket 19 with cable mount 4 U bolt 3 two washers 2 and two nuts 1 NOTE Ensure there is no slack in throttle cable between lev
208. NTRODUCTION 1 1 General Information General 2 1 3 2 CRANE MAINTENANCE INSTRUCTIONS 2 1 Repair Parts Special Tool TMDE and Support Equipment Service 2 1 Section 3 Organizational Preventive Maintenance 2 3 Checks and Services Approved for public release Distribution is unlimited CHAPTER 3 e Section 4 ection ection ection O ection 1 ection 1 ection 12 APPENDIX F NDEX THE 0 50 v lu lv d 10 v mj jm im jm im zi 12 12 iz gt ee 4 lt lt NEGIS m jo gt 10 3950 672 24 1 TABLE OF CONTENTS Continued MAINTENANCE rre re erts 3 1 Gab BITS Brakes HR Steering SVSIelm Hydraulic Swing System BOOM MA Swivels SRM RM Frame and Outriggers Electrical REFERENCES MAINTENANCE ALLOCATION CHART
209. OLING SYSTEM DESCRIPTION The cooling system consists of the radiator engine cooling circuit and the connecting hoses Its capacity varies according to the engine being used temperature is controlled by a 180 degree F 82 degrees C thermostat located between the top of the engine and the top of the radiator The radiator in addition to cooling the engine also contains a cooler which cools the automatic transmission oil At all times the coolant should be properly inhibited against corrosion f antifreeze is used follow the antifreeze manufacturers requirements for proper protection in regards to cooling system capacity and only ethylene glycol base permanent antifreeze should be used Engines equipped with cooling system filters should not use antifreeze with antileak additives because the additives will clog the filter MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Engine overheating Coolant Loss a Leaks at any of the following gas kets hose connections water pump ra diator heater core plugs drain cock or a Chock locate and repair leaks Replace hoses clamps and other parts as required plugs cracked head or block Internal leakage is Indicated by the presence of coolant in the engine crankcase or oil in the radiator Check for cracked cylinder head or block or a blown head gasket Boiling a Radiator or other parts of cooling Drain and flush cooling system
210. OR SETTING DOWN THE CYLINDER ROD DAMAGE TO THE ROD SURFACE MAY CAUSE UNNECESSARY MAINTENANCE AND EXPENSE 8 Remove the caps or plugs from the rod ends Lubricate the piston and heads with clean hydraulic oil and install the rod assembly into the barrel with a slight twisting motion 9 Install the head plates on each end of the cylinder and secure with the bolts torque the bolts to 75 lb ft 101 Nem WARNING DO NOT USE AIR PRESSURE TO CYCLE PRESSURIZE THE CYLINDER 10 Pressurize and cycle the cylinder Check for proper operation and any leakage 3 55 STABILIZER OUTRIGGER CYLINDER TM 10 3950 672 24 1 DESCRIPTION The four stabilizer cylinders have 3 inch 7 6 cm diameter bores and are the double acting type The barrel end of the cylinders are attached to the frame and the rod end of the cylinders are attached to the outrigger beam The retracted length of the cylinder from the center of the barrel to the center of the rod attach point is 40 19 inches 102 0 cm and the extended length of the cylinder is 69 19 inches 175 7 cm A port block is welded to the cylinder barrel and a pilot operated check valve is threaded into the port block O rings are used within the cylinder to prevent internal and external damage A wiper ring is mounted in the cylinder head to wipe the rod as it is retracted into the barrel MAINTENANCE DISASSEMBLY NOTE Any maintenance requiring disassembly of the cylinder should i
211. Outer race 370 Ib ft 502 Nem Inner race 370 Ib ft 502 N m ENGINE MOUNTING BOLTS Check torque lb ft N m 75 lb ft 102 Nem ENGINE RPM Governed RPM 2400 WHEEL LUGS Check torque lb ft N m 300 Ib ft 407 Nem MUFFLER CONNECTIONS Check for cracks or leaks BOOM ALIGNMENT Check for proper adjustment TM10 3950 672 24 1 2 11 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES CHART continued M MONTHLY S SEMI ANNUALLY BI ANNUALLY 200 Hours 1000 Hours Q QUARTERLY A ANNUALLY W WEEKLY H HOURS 500 Hours 50 Hours ITEM TO BE INSPECTED ITEM PROCEDURE CHECK REPAIR FILL ADJUST NO PERFORM ALL OPERATOR PMCS FIRST HOIST MOUNTING BOLTS Check torque lb ft N m 370 Ib ft 502 N m GEARBOX MOUNTING BOLTS Planetary Gear Reducer Check torque lb ft N m 99 Ib ft 134 Nem AXLE MOUNTING BOLTS Check torque lb ft N m Front Drive Axle 250 Ib ft 339 Nem DIFFERENTIAL BREATHERS Clean or replace FUEL TANK FILLER SCREEN Clean and check for broken screen WIRING HARNESS Check connectors and wiring for proper insulation SWING GEARBOX CASE Planetary Gear Reducer Check for cracks or leaks TRANSMISSION CASE Check for cracks or leaks BOOM WEAR PADS Notify Direct Support Maintenance to check boom wear pads for excessive wear Clean or replace as necessary ENGINE INTAKE MANIFOLD Check for cracks or leaks Check torque lb ft N m
212. PHABETICAL INDEX Subject Page G continued Gear Housing and Timing Pin Assembly 5 304 Gear Housing 5 304 Gear Housing or Gasket 9 9 9 5 210 Gear Train eene 35 sane nisse nnns 5 186 General Information 1 1 General Maintenance UU Ue aUe turus d 1 4 General Safety Instructions b e e ee reu 4 4 Generic Symbols 3 a RU ERE ou 4 1 Grove Model HO 12 Hoist 141 Grove Model 12 Hoist Cleaning and E 141 Grove Model HO 1 2 Hoist Enna E 132 Grove Model HO 12 Hoist Disassembly E 137 Grove Model 1 2 Hoist E 133 Grove Model HO 12 Hoist Theory of 220 E 132 Grove Model 1 2 Hoist nennen nennen E 133 H High Oil Pressure 5 121 High Pressure Fuel Lines Troubleshooting 2 2
213. R LEFT To operate two outriggers at one time position the selector valve lever to either FRONT RIGHT LEFT or REAR MAINTENANCE NOTE For more detailed information refer to Appendix REMOVAL 1 Remove the hoses and fittings from the selector valve Cap or plug all openings 2 Remove the eleven bolts and washers securing the selector valve to the mounting bracket INSTALLATION 1 Position the outrigger selector valve on the mounting bracket and secure with the eleven bolts and washers 2 Connect the hoses and fittings to the selector valve as tagged prior to removal 3 115 FUNCTIONAL CHECK 1 Activate the hydraulic system 2 Using the outrigger control lever and outrigger selector extend and retract the outriggers 3 Observe the outrigger for adequate speed of extension and retraction and smooth operation 4 Check the hydraulic connections for evidence of leakage TM 10 3950 672 24 1 3 48 SOLENOID VALVE DESCRIPTION Three two way solenoid valves are used in the hydraulic the cartridge in the valve body to align the ports in the override installation and are installed between the frame valve This alignment of ports routes the hydraulic flow rails under the cab floor The valve is a normally closed in the desired direction valve with an electrical coil which when energized shifts MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL INSTALLATION 1 Remove the bolt
214. REHOUSE M469 4 MAINTENANCE LEVEL Direct General Support RES EUN Function ejoj F Inspect Test Service Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace 0 1 0 5 1 5 16 0 0 5 10 0 TM10 3950 672 24 1 5 Tools and Equipment Remarks Ref Code Code 1 2 6 12 18 14 16 18 19 20 22 24 37 38 39 40 Section Il Component Assembly Flywheel Assembly Flywheel Flywheel Housing Pistons Connect Rods Pistons Connect Rods Valves Camshaft amp Timing System Rocker Arm Assembly Valves Camshaft TM10 3950 672 24 1 MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Support RUN BEEN Equipment Remarks Function ejoj F Ref Code Code Inspect 10 11 15 Replace 16 24 Repair Inspect Replace Inspect 9 9 12 Replace Repair Inspect Replace Inspect 0 8 9 12 22 Adjust 1 5 24 Replace Inspect Replace Repair TM10 3950 672 24 1 Section MAINTENANCE ALLOCATION CHART Continued Component Assembly Engine Lubricate System Oil Cooler Oil Pan Oil Pump FUEL SYSTEM Fuel Injector Fuel Pumps Fuel Injection Lift Pump Replace FOR CRANE WAREHOUSE M469 4 MAINTENANCE LEVEL Function Inspect Replace Inspect Replace Inspect Replace Test Replace Inspect
215. RES 2 SPACERS 24 Install the drive spacer s when used in the meter 25 Install the 3 inch diameter seal in the end cap 26 Install the end cap on the gerotor and align the holes 0668 26 27 Install seven dry capscrews in the end cap Pretighten the screws to 150 Ib in torque the screws to 275 in sequence shown in the figure 17 Nem then 31 Nem in the TM 10 3950 672 24 1 STEER PUMP DESCRIPTION The power steering pump is a gear type pump relief valve and a flow control valve The pump is spline Mounted in the end cover of the pump are a pressure driven MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Noisy pump Low oil supply Fill reservoir Oil too heavy Change to proper viscosity Air leak in inlet line Check plumbing Partly blocked inlet line d Check for foreign object and or clean lines 2 Foaming oil Pump cavitation a Refer to Symptom 1 Water in the oil b Check reservoir 3 Pump or oil overheating Oil supply too thin a Drain and fill with proper vis cosity oil Oil supply contaminated b Drain clean filter and fill with clean oil Pump cavitating c Refer to Symptom 1 d Pump drive shaft excessively d Check alignment misaligned with pump driven shaft e Pump drive shaft axially loaded e Check for clearance at ends of by driving shaft shafts for shaft misalignment or worn driving splines f System relief valve bypassing f C
216. RIODIC Maintaining proper torque values for bolts is extremely INSPECTION SHOULD BE important for structural strength performance and ACCOMPLISHED EVERY 500 HOURS reliability of the crane Variations in torque can cause THEREAFTER ENSURING THE distortion binding or complete separation of the BOLTS ARE PROPERLY TORQUED superstructure from the carrier KNOW YOUR TORQUE WRENCH Flexible beam type CAUTION wrenches even though they might have a preset feature must be pulled at right angles and the force REPEATED RETORQUING MAY must be applied at the center of the handle Force CAUSE BOLTS TO STRETCH IF value readings must be made while the tool is in motion BOLTS KEEP WORKING LOOSE Rigid handle type with torque limiting devices that can THEY MUST BE REPLACED WITH be preset to required values eliminate dial readings and NEW BOLTS AND NUTS OF THE provide more reliable less variable readings PROPER GRADE AND SIZE 3 143 NOTE If multipliers and or special tools are used to reach hard to get at areas ensure torque readings are accurate Torque wrenches are precision instruments and must be handled with care To ensure accuracy calibrations must be made on a scheduled basis Whenever there is a possibility that a torque wrench may have been overstressed or damaged it should immediately be removed from service until recalibrated When using a torque wrench any erratic or jerking motion can result in the application of exce
217. ROT SEARING SNAPRING DRIVE PINION BEARING SPACER BEARING CUP THRUST BLOCK ADJUSTING SCREW THRUST BLOCK ADJUSTING SCREW JAM NUT Drive Unit Exploded View E 62 TM 10 3950 672 24 1 CASE HALF DAFF BEARING ADJUSTING NUT LOCK DIFF SIDE GEAR LOCKWRE DIFF SIDE GEAR THRUST WASHER PINION THRUST WASHER TM 10 3950 672 24 1 1 If the original identification marks are not clear Removal of the Pinion and Cage Assembly mark the differential case halves with a punch or chisel for correct alignment on assembly 2 Remove the lockwire if used and capscrews and separate the case halves 3 Remove the spider spider pinions side gears and thrust washers 4 If the gear is to be replaced for any reason remove the rivets and separate the gear from the case RIGHT WRONG 1 Hold the flange or yoke with a suitable tool and remove the pinion shaft nut and washer CAUTION DRIVING THE FLANGE OFF WILL CAUSE EXCESSIVE RUNOUT CAUTION DO NOT CHISEL OUT THE RIVETS a Carefully center punch the rivets in the center of the head b Use a drill 0 03125 inch 0 79375 mm smaller than the body of the rivet to drill through the head from the gear side c Press out the rivets 5 If it is necessary to replace the differential bearings remove them with a suitable puller E 63 2 Remove the flange or yoke with a suitable puller 3 Remove stud nuts Capscrews the pinion cage or
218. RRITATION IF EYE CONTACT TAKES PLACE FLUSH THE EYES WITH WATER FOR 15 MINUTES AND HAVE THE EYES EXAMINED BY A DOCTOR Application of silicone RTV gasket material is as follows 1 Remove dirt grease or moisture from the hub mating surface of the drive shaft 2 Dry the surface 3 Apply a thin bead maximum 0 125 inch 3 175 mm diameter completely around one mating surface to ensure complete sealing and prevent leakage 4 Assemble the components immediately to permit silicone RTV gasket material to spread evenly Installation of the Oil Slinger and Brake 1 Install the brake assembly to the backing plate and secure with the bolts lockwashers and nuts 2 Install the oil slinger on the hub Assembly of the Bearing Cups and Seal to the Hub 1 If the wheel bearings were removed from the hub install the inner and outer bearing cups into the hub using a press and suitable sleeve E 59 TM 10 3950 672 24 1 CAUTION DO NOT USE EXCESSIVE PRESSURE TO INSTALL THE SEAL OR TAP THE SEAL AFTER IT HAS BUTTOMED AS IT WILLCRUSHTHE SEAL RETAINER AND CAUSE SEAL DAMAGE 2 Place the inner bearing cone into position inside the hub against its cup and install a new hub oil seal Tap the seal into position until it bottoms in the bore Installation of the Brake Drum 1 Place the hub in a press with the inner end pointing upward CAUTION DO NOT STRIKE THE STUDS WITHA STEEL HAMMER NOTE Before pressing the wheel s
219. Removal Installation Test Planetary Gear Reducer Description Removal Installation Test Swing Bearing Description General Torquing Turntable Bolts Removal Inspection Installation Testing Section 7 Swing System 3 135 Para 3 56 3 57 3 58 3 59 TM 10 3950 672 24 1 3 141 e A 3 143 3 56 SWING SYSTEM TM 10 3950 672 24 1 DESCRIPTION The superstructure swing system provides 360 degrees continuous rotation Swinging in either direction is controlled by the swing control lever in the cab The swing circuit consists of the directional control valve drive motor gear reducer with integral brake and a crossover relief valve containing a shuttle valve relief valves and check valves A multi disc type brake is an integral part of the gear reducer and is mounted between the motor and the gear reducer The crossover relief valve is mounted to the swing motor THEORY OF OPERATION The system is supplied by the 22 0 83 2 Ipm pump The oil flows to the swing directional control valve bank A 3000 psi 20 685 kPa 206 8 bar main relief valve is located in the valve bank When the directional control lever is pushed forward RIGHT the flow is directed through the crossover relief valve set at 1780 psi 12 273 1 kPa 122 7 bar to the swing motor causing the gear reducer to rotate the superstructure to the right Pulling the directional control lever back LEFT causes the gear
220. Remove the seal from the housing 4 0 50 INCH 12 7 MM 2187 5 0 50 INCH 12 7 MM 2187 6 11 Reposition the motor in the vise clamping across the ports as shown above not on the housing Excessive clamping pressure on the housing causes distortion E 121 TM 10 3950 672 24 1 12 Remove the 4 capscrews from the mounting flange These motors are assembled using Loctite on the screws to hold them in place The screws will require approximately 300 to 400 Ib in 34 to 45 Nom of torque to break loose and approximately 100 Ib In 11 Nem torque to remove after they are broken loose Do not use an impact wrench on screws held with Loctite this may result In rounded heads or broken sockets f It requires more than 400 Ib In 45 Nem to remove the capscrews proceed to step 13 otherwise proceed to step 14 EN No 2187 7 SMALL PROPANE TORCH 2 b MOUNTING FLANGE 9 2197 8 ou CAPSCREW CAUTION BE CAR EFUL NOTTO OVERHEAT AND DAMAGE THE MOTOR 13 Use a small flame propane torch to heat a small area of the housing where the screw enters see the figure above Apply torque to the capscrew with a socket wrench gradually as heat is applied for 8 to 10 seconds As soon as the screw breaks loose remove the heat from the housing and continue turning the screw until it is completely removed 14 Remove the motor from the vise and place it on clean flat surface Carefully remove the flange f
221. Repair Org Suppl No 1 Tool Kit General Mechanic Auto Tool Kit Body and Fender Repair Tool Kit Metal Workers Tool Kit Hyd Repair Army Aircraft Tool Kit Machinist Post Camp Station Tool Kit General Mechanic Equip Maintenance and Repair Welding Shop Trailer Mtd Oxy Acet Elec Arc Tool Kit Rigging Wire Rope Tool Kit Welders B 24 4910 00 754 0650 4910 00 754 0653 5180 00 177 7033 5180 00 357 7731 5180 00 754 0643 5180 00 323 4891 5280 00 511 1950 5180 00 699 5273 3431 01 090 1231 5180 00 596 1513 5180 00 754 0661 5 4910 95 CL A72 5 4910 95 CL A73 SC5180 90 CL N26 SC5180 90 CL N62 SC5180 90 CL N34 SC5180 99 CL A03 SC5280 95 CL A02 SC5180 90 CL N05 11022000 SC5180 90 CL N17 5 5180 90 CL N39 TM10 3950 672 24 1 Section TOOL AND TEST EQUIPMENT REQUIREMENTS Continued FOR CRANE WAREHOUSE M469 Tool or Test Equipment Maintenance National NATO Tool Ref Code Level Nomenclature Stock Number Number Torch Arc Weld 3431 00 165 4112 MIL W80105 Gas Shield 400 AMP Welding Machine 3431 00 620 5999 425ACDCG Arc Transformer 300 AMP AC DC Welding Set Arc 3431 00 731 4163 EDTS004 61 Inert Gas Shield Water Cool General Purpose Aluminum SC3431 95 CL A02 Shop Equipment 4940 00 209 6239 5 4940 95 Canvas and Glass CL A63 Shop Shelter Mtd Liner Puller 5120 01 143 2032 3376015 Liner Driver ST 1229 Intake Valv
222. Replace Repair REAR AXLE Rear Axle Assembly Service 2 4 6 12 Replace 13 17 24 Repair Steering Mechanism Steering Cylinder amp Inspect 4 6 10 Linkage Service 21 23 24 Replace Repair BRAKES Service Brakes Brakeshoes and Inspect Related Parts Adjust Replace TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 5 4 MAINTENANCE LEVEL Direct General Tools and Component Maint Support Support Depot Equipment Remarks Assembly Function H DY Ref Code Code Hydraulic Brake System Master Cylinder Service Inspect Replace Adjust WHEELS amp TRACKS Tires Inspect 21 23 24 Service Replace STEERING Steering Control Valve Replace 2 12 13 Assembly with Inspect 22 23 24 Steering Wheel Repair Hoses Lines amp Inspect 2 15 24 Fittings Replace 27 Hydraulic Pump Inspect 0 2 15 24 Steering Replace 27 Repair TM 10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component Maint Support Support Depot Equipment Remarks Assembly Function pc oO F H DY Ref Code Code FRAME TOWING ATTACHMENTS amp DRAWBARS Pintle Hook Service Replace Repair Landing Gear Leveling Jack Outrigger Assembly Inspect 21 23 24 Replace Oylinder Stabilizer I
223. Replace shaft seal If replacing the shaft seal does not stop leakage the pump should be disassembled and checked for the following b Broken diaphragm seal or back up gasket c Bearing out of position Functional Check A normal periodic functional check of the entire power steering system will generally be adequate to ensure satisfactory service 1 Check all fittings for leakage An accumulation of moist black dirt is a good indication of leakage 2 With the engine running at idle and at full throttle and with the machine standing still and moving turn the steering wheel through the full range of travel Note any speed irregularities and sticky sensation This may indicate dirt in the fluid If the steering wheel continues to rotate when started and released a condition known as Motoring exists This may also indicate dirty fluid in the system 3 Ensure the system has adequate power If there 3 82 Replace seal or gasket Replace bearing is an indication of hard steering this can be caused by either a reduced oil flow to the control valve or a reduced system relief pressure Adequate oil flow under all conditions can best be checked by timing the full travel of the cylinder with the steered axle unloaded and loaded If there is a great difference at low engine speed and slight difference at high engine speeds this may indicate a defective pump drive Adequate oil pressure can only be determined by
224. Replacement RRRRRRRRRRRRRRRRRRRRMMEEMMMMM 5 59 Fasteners and Torque 1 7 Fatigue of Welded 2 022 11100 eee eae eee 1 7 Flywheel Housing and Flywheel Operation and Description of 5 164 Flywheel Housing and Flywheel 5 180 Flywheel Housing 5 306 Flywheel Housing 5 305 Flywheel Ring Gear and Rear Seal 9 5 215 Frame and Outriggers 3 192 Front Access Cover 3 201 Front Access Cover cette i ne 3 201 Front Crankshaft Seal Operation and Description nnn nennen nnns 5 163 Front Drive Axle Assembly of the Drive E 64 Front Drive Axle Cleaning 3 65 Front Drive Axle Cleaning Inspection and E 73 Front Drive Axle Description RRRRREEMMMMMM E 57 Front Drive Axle Di
225. SE 5 Motor fails to start turning 6 Shaft play 7 Excessive noise DISASSEMBLY Insufficient torque Excessive motor leakage c Worn port plates d Worn rotating group e Defective O ring on OD of front port plate Insufficient pump delivery Motor too small Worn bearings Hammering coupling on shaft a Worn or damaged internal parts b Air in system 5 Remove the dowel pin 5 from the cam ring assembly 6 Drain all fluid from the motor and thoroughly clean all exterior surfaces Prepare a clean lint free surface on 6 Thread two No which to lay the internal parts of the motor 1 Secure the motor in a vise or other suitable 10 holding fixture with the shaft 21 extended down 2 Remove the screws 1 and remove the end cap 2 from the body 3 2 Remove the rubber seal ring 3 from the end cap TM 10 3950 672 24 1 SOLUTION a Increase relief valve pressure setting b Check flow from motor outlet if excessive check shuttle valve in front port plate Pressure not load ing plate causing plate to move away from cam ring Replace Replace Replace O ring if damaged Pump worn Use larger size cam ring Replace Coupling bore should be slip fit on shaft a Disassemble to remove rotor vane cam ring assembly Inspect for exessive wear Check condition of faces of port plate and end cap Rework lap or replace if scuffed b Bleed air
226. SEMBLY LEFT SIDE 3 82 1 Removal a Remove locknut 1 Figure 3 25 screw 2 cushion washer 3 nut 4 lockwasher 5 washer 6 screw 7 locking plate 8 star washer 9 and mirror assembly 10 from bracket 11 b Loosen jam nut 12 and screw 13 and remove bracket 11 from socket in crane frame 3 82 2 Installation a Install bracket 11 Figure 3 25 in socket in crane frame and tighten screw 13 and jam nut 12 b Install mirror assembly 10 on bracket 11 with locking plate 8 star washer 9 screw 7 washer 6 lockwasher 5 nut 4 cushion washer 3 screw 2 and locknut 1 3 207 TM 10 3950 672 24 1 Section 12 Electrical System Subject Para Page Electrical System nnne te nennt tnnt tenen B 83 DSS CHAT 5 3 209 General Maintenance roubleshooting PCIE SERRE Remova sni 3 84 1 3 212 eR Inspection sorore nns Men MUNI INIM ME TESNO E Assembly ne ie HERE PEE Ee 6 IristallaliOn 7 3 85 Pinoy eka eee ate Installation
227. SME B30 5 federal regulations and Grove The inspection interval shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by experience on the particular installation or similar installations severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock loads Periodic Inspections need not be at equal calendar intervals and should be performed at shorter time intervals as the wire rope approaches the end of its useful life A periodic inspection shall be performed at least once a year The following provides inspection and maintenance procedures for wire ropes used on Grove products e g wire rope used as load lines hoisting cables boom extension and retraction cables pendant cables tow winch cables and hook block tie down cables ENVIRONMENTAL CONDITIONS The life expectancy of wire rope may vary due to the degree of environmental hostility and other conditions to which these mechanical devices subjected Variation in temperature continuous excessive moisture levels exposure to corrosive chemicals or vapors or subjecting the wire rope to abrasive material may shorten normal wire rope life Frequent periodic inspections and maintenance of your wire rope is TM 10 3950 672 24 1 recommended for preventing premature wear and to insure long term satisfactory performance DYNAMIC SHOCK LOADS Subjecting wire rope
228. Slight inward movement of the hypoid gear may be necessary to maintain correct backlash E 72 TM 10 3950 672 24 1 New Gear Set CAUTION IF THE PINION OR DRIVE GEAR REQUIRE REPLACEMENT BOTH MUST BE REPLACED IN MATCHED SETS Before installing a new pinion and gear set check and compare the Matching number of both the pinion and drive gear they must be the same An example of this number would be M29 or any combination of a letter and number marked on the nose of the pinion and on the front face of the drive gears Installation of the Thrust Screw 1 Remove the carrier from the stand and position it with the backface of the hypoid gear upward 2 Remove the thrust screw and the locknut 3 Install the thrust screw and the locknut and tighten the thrust screw firmly against the backface of the hypoid gear 4 To secure the correct adjustment of 0 010 to 0 020 inch 0 254 to 0 508 mm clearance loosen the adjusting screw or thrust screw 1 4 turn and lock it securely with the nut 5 Recheck to ensure the minimum clearance of 0 010 inch 0 254 mm during full rotation of the bevel gear Assembly of the Drive Unit 1 Remove any accumulation of dirt grit or gum from the housing bowl and sleeves Clean the housing thoroughly with solvent and blow it dry with compressed air 2 Inspect the housing for cracks loose studs nicks and burrs at machined surfaces Remove nicks and burrs with stone or file Make al
229. Snap lens 2 on light assembly 1 and connect electrical connector to crane electrical harness Connect negative battery cable and two electrical leads to battery LEGEND Light Assembly Lens Nut Lockwasher 2 Screw Bulb Figure 3 32 Clearance Light 3 225 RON 7 6 LEGEND Bolt Cylindrical nut Handle Screw Shaft and Light Assy 6 Screw 7 Retaining Ring 8 Retainer 9 Sealed Beam Figure 3 33 Spotlight 3 226 TM 10 3950 672 24 1 TM 10 3950 672 24 1 3 91 SPOTLIGHT 3 91 1 oaoop 3 91 2 0 Removal Disconnect negative leads from negative battery post Disconnect spotlight assembly electrical connector from crane electrical harness Remove bolt 1 Figure 3 33 and cylindrical nut 2 and separate handle 3 from shaft and light assembly 5 Remove two screws 4 and pull shaft and light assembly 5 from cab frame Remove screw 5 retaining ring 6 four retainers clips 8 two electrical leads and sealed beam 7 from shaft and light assembly Remove four retainers 8 and separate retaining ring 7 and sealed beam 9 Installation Install sealed beam 9 Figure 3 33 in retaining ring 7 and secure with four retainers 8 Position sealed beam 9 with retaining ring 7 to shaft and light assembly 5 connect two electrical leads and secure assembly with screw 6 Push shaft and light assembly 5 through cab frame and secure w
230. TED THE SYNTHETIC LUBRICANT Synthetic lubricants may be used in drive axles provided they meet all of the requirements of Rockwell Standard specifications 0 76 0 76 A 0 76 B 0 76 C 0 76 D 0 76 F or 0 76 J Preparation for Storage In the event the carrier is a spare and may not be immediately installed all gears and bearings should be thoroughly oiled and the carrier placed in a dust proof container Specifications of Recommended Lubricants Oil and Grease DRIVE UNITS The design of hypoid gear teeth which mesh with a sliding action enables them to withstand higher unit pressures Therefore the lubricant should have extreme pressure properties Only lubricants with the S A E designation API GL 5 meet these requirements are recommended for hypoid gears LUBRICANT Standard 0 76 0 76 A or 0 76 B Refer to OIL VISCOSITIES Optional 0 76 C 0 76 D 0 76 F or 0 76 J Refer to OIL VISCOSITIES CHANGE INTERVAL Check every 1000 miles 1600 km Drain and refill to the top of the filler neck or the bottom of the tapped hole every 25 000 to 30 000 miles 40 000 to 48 000 km when yearly mileage is in excess of 60 000 miles 96 000 km If yearly mileage is less than 60 000 96 000 km change twice a year spring and fall E 77 TM 10 3950 672 24 1 WHEEL BEARINGS LUBRICANT Oil filled hubs standard 0 76 C or 0 76 D optional 0 76 F or 0 76 J JT b wn 4 aoi CHANGE INTERVAL Ch
231. TENANCE GENERAL Relief valves are checked and adjusted by causing a given circuit to reach its prescribed pressure limit stall At this point the relief valve opens returning oil to the reservoir Hydraulic motor circuits may be stalled by preventing rotation of the motor shaft prior to actuating the control valve Cylinder circuits may be stalled by extending or retracting a cylinder to its limit of travel By placing a pressure gauge in the proper line or port a pressure reading will indicate the point at which the relief valve opens The needle on the meter face will climb until it reaches the relief valve setting At that point the needle will stop climbing and fluctuate indicating the relief valve is open and returning oil to the reservoir Correct relief valve adjustment is mandatory if any hydraulic circuit is to function properly Settings must be within tolerances Therefore adjustment should be performed only by qualified technicians using the correct equipment after the need for adjustment has been established Each valve bank has one main relief valve limiting maximum operating pressure of the component s in that circuit In addition circuit relief valves further limit operating pressures as required by circuit design The following test and Tables list Main and Circuit Relief Valve Settings If the pressure setting of any relief valve is not 100 psi 4689 5 kPa 6 8 bar of that listed in the tables adjustment
232. TION Mark the universal so it can be assembled as taken apart otherwise severe drive line vibration may occur h Remove the capscrews washers nuts bolts and clamp drive securing the shaft to the transmission and the capscrew nut washer and clamp securing the shaft to the axle differential Remove the drive shaft Refer td paragraph 3 22 i Tag and disconnect radiator hoses heater hoses lines and tubing from the engine transmission and all other components Remove the radiator and oil cooler Refer 222 j Tag and disconnect all electrical leads from the engine and engine components k Tag and disconnect the lines from the hydraulic pump and cap or plug all openings Remove the pump refer paragraph 3 41 3 17 S TM 10 3950 672 24 1 If necessary remove the steering pump refer td paragraph 3 33 Disconnect the throttle cable from the throttle linkage Disconnect any transmission shifting linkage from the transmission refer tol paragraph 3 23 Attach an adequate lifting device to the engine and transmission assembly and take up any slack With the lifting device supporting the weight of the engine remove the bolts nuts and washers securing the engine to the mounting bracket Remove the bolts nuts and washers securing the transmission to the frame Using the lifting device lift the engine from the crane If a new engine is to be installed remove all components fittings etc f
233. TM 10 3950 672 24 1 TECHNICAL MANUAL Unit Direct Support and General Support Maintenance Manual for WAREHOUSE CRANE 10 000 LB CAPACITY M469 WHEELED DIESEL POWERED NSN 3950 01 412 5345 Grove Model AP 308T Approved for public release Distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY JUNE 1997 TM10 3950 672 24 1 SAFETY SUMMARY WARNING Cleaning with compressed air can create airborne particles that may enter the eyes or penetrate the skin Pressure shall not exceed 30 psig Wear goggles Do not direct compressed air against the skin WARNING Remove all jewelry such as rings dog tags bracelets etc If jewelry contacts battery terminal a direct short may result in instant heating tools damage to equipment and injury or DEATH to personnel WARNING Extreme care should be taken when removing radiator filler cap if temperature gage reads above 180 F 82 C Contact by steam or hot coolant may result in injury or DEATH to personnel 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 WARNING Exhaust components can be hot causing burns to exposed skin Allow exhaust components to cool before proceeding WARNING Corrosion inhibitors contain alkali Do not get in eyes wear goggles safety glasses when using Avoid contact with skin In case of contact wash area with soap and water If eyes are
234. TM 10 3950 672 24 1 With new axles the original drive axle lubricant should be drained at 1000 miles 1600 km but no later than 300 miles 4800 km Drain the lubricant initially used in the assembly while the assembly is still warm Axles should not be flushed with any solvent such as kerosene For reconditioned axles follow the same procedures as above after overhaul Fill the axle housings to the bottom of the level hole in the carrier or housing with specified lubricant with the vehicle on level ground Magnetic Drain Plugs Any drive axle while it is working generates wear particles at a fairly steady rate These wear particles are very fine but hard If these hard wear particles are allowed to circulate in the lubricant the anti friction bearings will wear at a faster rate than they would if the hard wear particles were removed as they are generated Magnetic drain plugs perform the vital function of trapping these small metallic particles that circulate in the lubricant through the gears and bearings causing rapid wear and premature failure The magnet must be strong enough to firmly hold the particles under service conditions Plugs with elements having a minimum pickup capacity of 2 pounds 0 907 kg of low carbon steel in plate or bar forms are recommended Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Change plugs before this occurs It may be necessary t
235. This permits the barrel portion 3 176 of the swivel to rotate around the stationary spool as the superstructure rotates The electrical swivel center or collector ring assembly is secured by setscrews to a center post which is bolted to the spool of the hydraulic swivel This allows the collector ring assembly to remain stationary with the carrier The outer portion or brush assembly is spring mounted on two pins which are located on a mounting plate attached to the swivel barrel This allows the brush assemblies to rotate with the superstructure The springs on the mounting plate pins allow the swivel to float and not bind when the superstructure rotates TM 10 3950 672 24 1 Turntable Capscrew Cover Washer Capscrew Bearing Plate Nut Washer Seal Mounting Plate 1 2 3 4 5 6 7 8 9 Hydraulic and Electrical Swivel Installation 3 177 3 69 6 PORT HYDRAULIC SWIVEL TM 10 3950 672 24 1 The function of each port is described below Test Pressure 3000 PSI 20685 kPa 206 8 bar 3000 PSI 20685 kPa 206 8 bar 3000 PSI 20685 kPa 206 8 bar 3000 PSI 20685 kPa 206 8 bar 3000 PSI 20685 kPa 206 8 bar 3000 PSI 20685 kPa 206 8 bar DESCRIPTION Each of the ports on the spool and barrel of the swivel is stamped with the port number Port Number Function 1 Lift Down 2 Lift Up 3 Hoist Down 4 Hoist Up 5 Telescope Extend 6 Telescope Retract Hoist Motor Weep Line 500 PSI 3447
236. YLINDER PISTON FACE Poor cylinder action can be caused by a Corrosion or deposits in the cylinder bore b Swollen cups caused by contaminated or wrong type of brake fluid c Cups wedged into excessive clearance between the piston and the cylinder bore d Wrong type of pistons for push rods or brake shoe ends Light corrosion or rough areas can be removed with crocus cloth or a cylinder hone Use brake fluid as a lubricant when cleaning the cylinder If the bore cannot be easily cleaned the cylinder must be replaced E 99 TM 10 3950 672 24 1 NOTE The wheel cylinder is a consumable part No seal kit or other repair parts are available ASSEMBLY NOTE Do not permit grease to come in contact with the brake drum or linings Grease on the linings can cause poor brake performance Contaminated linings must be replaced 1 Before assembly apply a thin layer of brake lubricant NLGI Grade No 2 Rockwell specification 0 616 to the following parts a The push rod ends of the shoes and cylinder b Surfaces of the adjusting cams and the matching surfaces of the brake shoes C Surfaces of the shoe support pads on the backing plate assembly and the ends of the shoe webs that slide against the anchor bracket 2 Install the wheel cylinder to the backing plate Tighten the wheel cylinder attaching screw and capscrew 25 to 35 Ib ft 34 to 48 N m 3 Connect the hydraulic line 4 Install the brake
237. a complete crane ensure the crane is blocked securely and the weight is supported by blocks rather than by lifting equipment When using hoisting equipment follow the hoist manufacturers recommendations and use lifting devices that will allow you to achieve the proper balance of the assemblies being lifted and to ensure safe handling Unless otherwise specified all removals requiring hoisting equipment should be accomplished using an adjustable lifting attachment All supporting members chains and cables should be parallel to each other and as near perpendicular as possible to the top of the object being lifted CAUTION THE CAPACITY OF AN EYEBOLT DIMINISHES AS THE ANGLE BETWEEN THE SUPPORTING MEMBERS AND THE OBJECT BECOMES LESS THAN 90 DEGREES EYEBOLTS AND BRACKETS SHOULD NEVER BE BENT AND SHOULD ONLY HAVE STRESS IN TENSION Some removals require the use of lifting fixtures to obtain proper balance The weights of some components are given in their respective sections of the manual If a part resists removal check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering DISASSEMBLY AND ASSEMBLY When assembling or disassembling a component or system complete each step in turn Do not partially assemble one part and start assembling some other part Make all adjustments as recommended Always check the job after it is completed to see that nothing has been overlooked Recheck th
238. able as Char Lynn Part No 600057 Position three pairs of centering springs two sets of three each on the bench so the extended edge is down and the arched center section is together this position enter one end of the entire spring set into the spring installation tool 8 Compress the extended end of the centering spring set and push it into the spool sleeve assembly withdrawing the installation tool at the same time 9 Center the spring set in the parts so they push down evenly and are flush with the upper surface of the spool and sleeve PIN 09 10 Install the pin through the spool and the sleeve assembly until the pin becomes flush at both sides of the sleeve 0868 16 11 Position the spool and sleeve assembly so the splined end of the spool enters the fourteen hole end of the housing first CAUTION BE EXTREMELY CAREFUL THAT THE PARTS DO NOT TILT OUT OF POSITION WHILE ENTERING PUSH THE PARTS GENTLY INTO PLACE WITH A SLIGHT ROTATING ACTION KEEP THE PIN NEARLY HORIZONTAL BRING THE SPOOL ASSEMBLY ENTIRELY WITHIN THE HOUSING BORE UNTILTHE PARTS ARE FLUSH ATTHE METER END OR FOURTEEN HOLE END OF THE HOUSING DO NOT PULL THE SPOOL ASSEMBLY BEYOND THIS POINT TO PREVENT THE CROSS PIN FROM DROPPING INTO THE DISCHARGE GROOVE OF THE HOUSING WITH THE SPOOL ASSEM BLY THIS FLUSH POSITION CHECK FOR FREE ROTATION WITHIN THE HOUSING BY TURNING WITH LIGHT FINGERTIP FORCE AT THE SPLINED END 12 Pl
239. ace Torquing in this subsection NOTE If a new bearing is being installed a new pinion gear must also be used 5 Install the gearbox pinion aligning the high point maximum eccentricity on the turntable bearing Using a 0 005 inch 0 127 mm thick shim check the backlash see figure If the pinion must be moved to achieve 3 148 TM 10 3950 672 24 1 service Services proper backlash contact representative or Grove Chambersburg Pennsylvania your local Customer ECCENTRICITY TOOTH Backlash Adjusting Shim 6 Install the swivel following the procedure outlined in Section 9 SWIVELS 7 f disconnected connect the electrical connectors to the terminal block 8 Install the pinion and cap and secure with the slotted flat screws Install the pinion cover and secure with the nuts spring washers and flatwashers 9 Install the boom and lift cylinders following the procedures outlined in Section 8 BOOM 10 Connect battery cables to the battery TESTING Activate the crane and check for proper function NOTE If the superstructure does not turn freely after bearing and pinion replacement contact your local service representative or Grove Customer Services Chambersburg Pennsylvania Section 8 Boom BOOI inizio L DISASSOMDIY pienien aa ARE A eee htcc nje d Functional CHECK Alignment and Inspection
240. ace the housing on a clean cloth and install the 2 1 8 inch diameter seal in the housing E 85 TM 10 3950 672 24 1 NEEDLE THRUST BEARING BEARING RACE 2 0868 17 13 Install the two bearing races and the needle thrust bearing as shown in the figure 14 Install the 1 1 4 inch diameter dust seal in the seal gland bushing The flat or smooth side of the dust seal must face down towards the bushing 15 Install the dry quad ring seal in the seal gland bushing Smooth the seal in place with a finger Do not use any seal that falls freely into the pocket of the bushing RETAINING RING SEAL GLAND BUSHING WITH SEALS 16 Install the seal gland bushing over the spool end with a twisting motion Tap the bushing in place with a rubber hammer flush against the bearing race Ensure the bushing is DUST SEAL SCREWDRIVER RETAINING RING L M 7 SEAL GLAND BUSHING 0868 19 17 Install the retaining ring in the housing After installing the ring tap on the ring end or pry with a screwdriver around the entire circumference of the ring to properly seat the ring in the groove _ 0868 20 18 Clamp the housing in the vise Clamp lightly on the edges of the mounting area Do not over tighten the jaws NOTE Check to ensure the spool and sleeve are flush or Slightly below the fourteen hole surface of the housing Clean the upper surface of the housing by wiping with the p
241. ain all hydraulic oil from the cylinder 2 Remove the four bolts from the head retaining plate on the rod end of the cylinder WARNING DO NOT USE AIR PRESSURE TO REMOVE THE CYLINDER ROD ASSEMBLY USE ONLY A SOURCE OF CONTROLLED HYDRAULIC OIL PRESSURE IF THE ROD ASSEMBLY IS HARD TO MOVE CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD 3 Withdraw the cylinder rod assembly from the barrel and move it to a clean work area TM 10 3950 672 24 1 centerline of the port block is 263 75 in 669 9 cm Foreign matter is prevented from entering the cylinder by a wiper seal during rod retraction The cylinder rod is secured to the boom base and the cylinder barrel is attached to the fly section NOTE It is advisable to cover the cylinder barrel opening to prevent contamination 4 Secure the cylinder rod to prevent it from moving Remove the setscrew from the piston and rod 5 Unscrew the piston from the rod 6 Remove the spacer and head from the rod 7 Remove the head retaining plate from the rod CAUTION WHEN REMOVING SEALS AND RINGS AVOID SCRATCHING GROOVED AND GLAND SURFACES NOTE Aligning discarded seals and rings in the order of disassembly will facilitate installation of new items 8 Remove the seal assemblies from the outside of the piston and the O ring and backup rings from the inside of the piston 0mm Barrel Piston Socket Setscrew Seal Assembl
242. ake system should be bled whenever air becomes entrapped within the brake system usually characterized by a spongy feeling during brake pedal application whenever any brake system line has been opened or whenever any brake component has been replaced Pressure Bleeding the Brake System NOTE Before bleeding the brake system ensure the master cylinder is filled to the proper level Refer to Section 13 LUBRICATION for the proper brake fluid 1 Fill the master cylinder reservoir with brake fluid 2 Install the bleeding adapter on the master cylinder 3 Fill the bleed tank at least one half full with brake fluid CAUTION DO NOT LIFT MOVE OR SHAKE THE BLEED TANK AFTER THE AIR PRESSURE IS APPLIED THIS MAY CAUSE ANY SEDIMENT IN THE TANK TO GO INTO SUSPENSION IN THE BRAKE FLUID 4 Position the tank so it will not have to be moved again until the bleeding is finished 3 74 TM 10 3950 672 24 1 5 Connect a 35 psi 241 kPa 2 41 bar air source to the bleeder tank 6 Open the bleeder tank valve and bleed all air out of the hose to be connected to the master cylinder adapter 7 Connect the bleeder hose to the master cylinder adapter NOTE Always bleed the wheel units beginning with the wheel having the longest brake line 8 Connect one end of a bleeder hose to the bleeder valve on the wheel cylinder Submerge the other end in a glass jar partially filled with clean brake fluid 9 Open the bleeder valve and
243. al a Remove bolt 6 Figure 3 1 securing seat belt buckle 4 to seat back b Remove bolt 6 securing seat belt and retainer 5 to seat back 3 1 4 Seat Belt Installation a Secure seat belt and retainer 5 Figure 3 1 to seat back with bolt 6 b Secure seat belt buckle 4 to seat back with bolt 6 3 2 TM10 3950 672 24 1 Lo LEGEND Release Handle Seat Assembly Rail Seat Belt Buckle Seat Belt and Retainer Bolt Figure 3 1 Seat Assembly 3 3 TM10 3950 672 24 1 3 2 CAB FAN ASSEMBLY 3 2 1 Removal a Disconnect negative battery cable and two electrical leads from battery b Disconnect fan assembly 3 Figure 3 2 electrical connector from cab electrical harness c Remove three mounting screws 1 three lockwashers 2 and fan assembly 3 from dash panel 3 2 2 Installation NOTE Ensure fan control knob 4 Figure 3 2 faces rearward a Install fan assembly 3 on dash panel with three mounting screws 1 and three lockwashers 2 b Connect fan assembly 3 electrical connector to crane electrical harness c Connect negative battery cable and two electrical leads to battery 3 4 LEGEND 1 Screw 4 Knob TM10 3950 672 24 1 3 3 WINDSHIELD WIPER AND WASHER ASSEMBLY 3 3 1 Removal a Disconnect negative battery cable and two electrical leads from battery Pry wiper arm 1 Figure 3 3 with wiper blade 2 from shaft of wiper mo
244. al and gear assembly is mounted on the pinion teeth to carry the radial load tapered roller bearings MAINTENANCE DISASSEMBLY OF THE WHEEL ENDS 1 Remove the wheel studs from the brake drum and hub by placing the hub and drum assembly in a Removal of the Wheel Hub and Drum Assembly press Position the open end of the drum downward and press out the studs 1 Remove the axle shaft to hub nuts washers dowels and studs Remove the axle drive shaft and Disassembly of the Bearing Cups and Seal from the drive shaft gasket hub 2 Remove the outer wheel bearing lock nut and 1 If the seal is still seated in the hub remove it by washer and inner wheel bearing adjusting nut from the using a long screwdriver or other pointed tool to pry spindle loose Discard the seal 3 Pull the hub and drum straight off the spindle 2 Remove the inner and outer bearing cups from being careful that the outer bearing cone does not drop the hub using a press and sleeve or a suitable puller off the spindle Removal of the Oil Slinger and Brake NOTE The inner and outer bearing cups will 1 Remove the oil slinger from the hub remain seated inside the hub cavity If the inner bearing cone slides off 2 Remove the bolts lockwashers and nuts and the spindle the hub oil seal will remove the brake from the backing plate Remove the remain inside the hub brake assembly to a clean work area If maintenance is required on the brake assembly refer to the BRAKES Removal
245. all the input shaft with the long splined end installed into the forward clutch assembly 29 Install tool 4201 C dial indicator or equivalent at the seventh pump mounting bolt and check the transmission end play following steps 2 3 and 4 of Disassembly End play should be 0 008 to 0 044 inch 0 203 to 1 117 mm If end play is not within specification install a selective thrust washer Refer to the Selective Thrust Washer Thickness chart Remove the dial indicator 30 Install the seventh pump mounting bolt Torque the bolt 16 to 30 Ib ft 22 to 41 Nem 31 Install the main control valve body on the case ensuring the selector and downshift levers engage the valves properly and secure with the attaching bolts Torque the bolts 95 to 125 Ib In 11 to 14 Nem 32 Install the primary throttle valve rod and the vacuum diaphragm in the case Torque the diaphragm attaching bolt 12 to 16 Ib ft 16 to 22 Nem 33 Clean the transmission pan and gasket surfaces thoroughly Install a new pan gasket and the pan Secure the pan to the transmission case with the attaching bolts Torque the bolts 8 to 12 Ib ft 11 to 16 Nem 34 Install the converter assembly Installation of the Governor 1 Install the governor to the oil collector flange and secure with the attaching bolts Torque the bolts 90 to 120 Ib In 10 to 14 Nem Installation of the Extension Housing NOTE Perform steps 1 and 2 if not done during Transmission Ass
246. alm of the clean hand Clean each of the flat surfaces of the meter section parts in a similar way when ready for assembly Do not use cloth or paper to clean the surfaces E 86 TM 10 3950 672 24 1 0868 21 19 Install the 3 inch diameter seal in the housing 20 Install the spacer plate Align the bolt holes in the spacer plate with the tapped holes in the housing PORT FACE PIN PARALLEL PIN WITH POAT FACE 21 Rotate the spool and sleeve assembly until the pin is parallel with the port face Install the drive and ensure the drive is engaged with the pin To ensure proper alignment mark the drive as shown in the figure ref 8 Note the relationship between the slotted end of the drive to the splined end of the drive when marking METER GEROTOR SEAL 0868 22 22 Install 3 inch diameter seal in the gerotor METER GEROTOR STAR VALLEY A DRIVE MARKED D 4 PORT FACE f 0868 24 23 With the seal side of the meter toward the spacer plate align the star valleys ref A on the drive ref B Note the parallel relationship of reference lines A B C and D Align the bolt holes without disengaging the meter from the drive E 87 TM 10 3950 672 24 1 CAPSCREW END CAP SEAL DRIVE SPACER S 580 Disp cu firer Length 45 px 62 30 and X392 e 139 2387712 11 9 CU IN REV DISPLACEMENT 72356 2613 UNIT REQUI
247. ant Temperature Switch eee ee th Dev d Removal isis secre eere kd a Ve aD red a e T 3 22 installation x ree reete Oe UR Engine Coolant Temperature Sender Ecc p Removal i Cea EL EE aD red a 3 24 Installation FUMED SS cci Me EI Description Tank cha eve Te d uaa vL Va ee wa eet lu v ve aad Removal Installation FUL sl Fuel Filter Water Separator Mihi Be Cold Start Assembly cive 3 28 Installation ler rt S Air Intake and Exhaust System 2 40 422 1 Description mii xS inesse eec ri ves ve veu vuv M filerand Exhaust Pipes Pr E eR 3 18 FREIMOVAL IrniStallatiOni Water Cooling System Description Maintenance Installation E E 3 38 Engine Cooling EET Removal
248. apscrews 3 Remove the end cap 4 Remove the seal from the end cap E 81 Control End 11 Remove the housing from the vise Place the housing on a clean soft cloth to protect the surface finish Use a thin bladed screwdriver to pry the retaining ring from the housing SEAL GLAND BUSHING 0868 6 12 Rotate the spool and sleeve until the pin is horizontal Push the spool and sleeve assembly forward with the thumbs just far enough to free the seal gland bushing from the housing Remove the bushing QUAD RING SEAL SEAL GLAND BUSHING OUST SEAL 0868 7 13 Remove the quad ring seal from the seal gland bushing E 82 TM 10 3950 672 24 1 14 Use a thin bladed screwdriver to pry the dust seal from the seal gland bushing Do not damage the bushing BEARING RACE NEEDLE THRUST 7 BEARING RACE 15 Remove the two bearing races and the needle thrust bearing from the spool and sleeve assembly PIN 16 Remove the spool and sleeve assembly from the fourteen hole end of the housing CAUTION DO NOT BIND THE SPOOL AND SLEEVE IN THE HOUSING ROTATE THE SPOOL AND SLEEVE ASSEMBLY SLOWLY WHEN REMOVING IT FROM THE HOUSING 17 Push the centering pin from the spool and sleeve assembly 18 Push the spool partially from the control end of the sleeve then carefully remove the six centering springs from the spool by hand 19 Push the spool back through and out of the sleeve R
249. aring adjusting nut on the side opposite the gear only sufficient to notice end play on the indicator 2 Tighten the same adjusting nut only enough to obtain 0 000 end play 3 Check the gear for runout If runout exceeds 0 008 inch 0 203 mm remove the differential and check for cause 4 Tighten the adjusting nuts one notch each from 0 000 end play to preload the differential bearings Checking Hypoid Gear Backlash It the driver gear is not going to be replaced we suggest the established backlash recorded before disassembly be used For new gears the new backlash should be initially set at 0 010 inch 0 254 mm Adjust backlash by moving the gear only This is done by backing off one adjusting ring and advancing the opposite ring the same amount After satisfactory contacts have been established the backlash can be altered within the limits of 0 005 to 0 015 inch 0 127 to 0 381 mm to obtain a better contact position Check Tooth Contact 1 Apply oiled red lead lightly to the hypoid gear teeth When the pinion is rotated the red lead is squeezed away by the contact of the teeth leaving bare areas the exact size shape and location of the contacts E 71 TM 10 3950 672 24 1 2 Sharper impressions may be obtained by applying a small amount of resistance to the gear with a flat steel bar and using a wrench to rotate the pinion When making adjustments check the drive side of the gear teeth Coast side should
250. artificial respiration if necessary and SEEK MEDICAL ATTENTION IMMEDIATELY 6 Be aware that nuclear biological chemical NBC protection will not protect you for carbon monoxide poisoning SAFT 2 TM10 3950 672 24 1 SAFETY SUMMARY Continued WARNING Ensure hydraulic system is shut down and pressure is relieved A high pressure oil stream can pierce body and cause severe personal injury WARNING Never use standard plumbing fittings for the hydraulic system Always use high pressure hydraulic fittings Standard fittings could fail resulting in severe personal injury WARNING Hydraulic fluid under pressure can penetrate skin or damage eyes Fluid leaks under pressure may not be visible Use a piece of cardboard or wood to find leaks but do not use bare hand Wear safety goggles for protection If fluid enters skin or eye get immediate medical attention WARNING When removing boom lift cylinder ensure cylinder is properly supported before disconnecting it from the boom WARNING When removing the boom assembly ensure blocking and lifting devices are capable of supporting the boom assembly WARNING When removing the outrigger beam 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 could result in death or injury to personnel WARNING Do not be misled by the term low voltage Voltages as low as 50 volts may cause death For artif
251. arts If it is necessary to make gaskets select material of the proper type and thickness Be sure to cut holes in the right places Blank gaskets can cause serious damage When removed always install new cylinder head and manifold gaskets using recommended gasket compound on head gaskets to allow uniform sealing BATTERIES Clean batteries by scrubbing them with a solution of baking soda and water Rinse with clear water After cleaning dry thoroughly and coat terminals and connections with an anticorrosion compound or grease If the machine is to be stored or not used for an extended period of time the batteries should be removed Store the batteries in a warm dry place preferably on wooden shelves Never store on concrete A small charge should be introduced periodically to keep the specific gravity rating at recommended level TM10 3950 672 24 1 HYDRAULIC SYSTEMS WARNING EXERCISE EXTREME CARE AROUND PRESSURIZED HYDRAULIC SYSTEMS DO NOT WORK ON A HYDRAULIC SYSTEM WHILE IT IS IN OPERATION OR UNTIL ALL PRESSURE IS RELEASED Cleanliness Contaminants in a hydraulic system affect operation and will result in serious damage to the system components Dirty hydraulic systems are a major cause of component failures Keep the System Clean When removing components of a hydraulic system cover all openings on both the component and the crane If evidence of foreign particles is found in the hydraulic system flush th
252. atdecds REMOVAL Clea NNO InstallatiOn 2 on SE d eI rni NETT RACIO 13 27 Description Steering Linkage Hub and Spindle Assembly Hub Brake and Spindle Assembly U Joint Bearing 3 28 3 28 1 Installation 2 3 28 2 Hydraulic 3 29 Description Removal General Installation Bleeding the Brake System Brake Shoe Adjustment Brake Master 3 30 3 76 Description Troubleshooting Removal Installation Relief Valve Adjustment Wheels and Tires 2 3 31 3 79 Description Mounting Wheel Assemblies 3 26 FRONT DRIVE AXLE The front drive axle is a single reduction solid mounted axle with floating axle shafts and a high traction differential and is manufactured by Rockwell NOTE For more detailed information refer to Appendix E NOTE The axle does not have to be removed from the crane to disassemble and perform maintenance on the drive unit 3 64 TM 10 3950 672 24 1 3 26 1 Removal CAUTION Use care in handling the U joint cross bearing assembly When removed from the yoke the inside needle bearings tend to fall out if any bearing caps slide off R
253. ating condition i e to clean decontaminate to preserve to drain to paint or to replenish fuel lubricants chemical or gases B 1 TM10 3950 672 24 1 B 2 MAINTENANCE FUNCTIONS Continued 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 f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision measurement Consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared 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
254. b ft 16 to 22 Nem 4 If there is an indication of scraping the trailing edges of the stator blades may be interfering with the 3 Install two new seal rings on the stator support leading edges of the impeller blades and the converter Ensure the ends of the rings are engaged to lock them in place 4 Install a new square seal on the outside diameter of the pump housing 5 Install the selective thrust washer Front Pump Support Thrust Washer Selection chart to ensure the thickness of the washer is correct NOTE Before installing the pump on the converter perform the Stator to Impeller Interference Check the Stator to Turbine Interference Check the Converter End Play Check and the One Way Clutch Check 6 Install the pump on the converter ensuring the drive gear engages the converter hub Rotate the pump to ensure the gears rotate freely E 50 should be replaced Stator to Turbine Interference Check 1 Install the converter on the bench front side down Refer to the 2 Install the front pump assembly to engage the mating splines of the stator support and stator and pump drive gear lugs 3 Install the input shaft engaging the splines with the turbine hub 4 Hold the pump stationary and attempt to rotate the turbine with the input shaft The turbine should rotate freely in both directions without any signs of interference or scraping noise 5 If interference exists the stator front thrust washer may b
255. bent sticking or leaking Poor engine performance Valve body bolts loose or too tight Valve body dirty sticking valves Governor valve stuck Output shaft collector body seal rings damaged 3 54 TM 10 3950 672 24 1 SOLUTION Perform fluid level check Adjust linkage Service as re quired Control pressure test Note re Suits Tighten bolts Determine source of contami nation then service as required Check engine tune up Check engine vacuum lines Service as necessary Check vacc uum diaphragm unit Service as necessary Perform vacuum supply and diaphragm tests Air pressure test the interme diate servo apply and release the high clutch piston check ball Ser vice as required Tighten bolts Check diaphragm and rod Replace as necessary Tighten bolts Determine source of contami nation Service as required Check diaphragm and rod Re place as necessary Check engine tune up Tighten bolts Line pressure test note re suits Determine source of contam ination Service as required Perform governor test Service as required Service as required TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 22 Shifts 1 3 in D 23 Engine over speeds on 2 3 shift 24 No forced downshifts 25 Crane will not start Intermediate band out of adjust ment Damaged intermediate servo and or internal leaks
256. between the washer and jam nut 5 Install the washer pin and jam nut onto the end of the spindle Torque the jam nut to 250 Ib ft 339 Nem End play must be within 0 001 to 0 010 inches 0 025 to 0 254 mm 6 Install the cover on the hub and secure with the bolts and washers Installation 1 Using an adequate lifting device position the hub and spindle assembly to the frame 2 Install the bronze bushing and pin weld 3 Secure the pin weld to the hub and spindle assembly with the bolts and washers Torque the bolts to 75 Ib ft 102 Nem 4 Install the tire and wheel assembly on the hub and secure with the nuts Torque the nuts to 300 Ib ft 407 N m 5 Remove the cribbing and blocking and lower the wheels to the ground HUB BRAKE AND SPINDLE ASSEMBLY Removal 1 Fully lower and retract the boom 2 Chock the front wheels 3 Loosen the wheel lug nuts one quarter turn while the wheels are still on the ground 4 Using an adequate lifting device or the outriggers lift the frame until the wheels are at least two inches off the ground Install cribbing or blocking which is capable of handling the weight of the crane under the frame for support NOTE The tire and wheel assembly weighs approximately 114 pounds 51 7 kg 5 Remove the wheel lug nuts and remove the tire and wheel assembly 6 Support the hub and spindle assembly with a suitable lifting device 3 70 TM 10 3950 672 24 1 7 R
257. bly into the crane 13 Ensure the drain pan is securely attached and fill the transmission to the correct level with the specified fluid TRANSMISSION SHIFT MODULATOR ADJUSTMENT PROCEDURE CAUTION THE MODULATOR UNIT IS FACTORY ADJUSTED AND DISASSEMBLY OF THE MODULATOR LID SHOULD NOT BE REQUIRED DISASSEMBLY COULD RESULT IN UNEQUAL TORQUING OF SCREWS CAUSING GASKET LEAKAGE AND OR LOSS OF INTERNAL PARTS NOTE The modulator is designed with positive stop at both ends of its 1 50 inch 3 81 mm travel The cable slip link must allow the lever to return to idle regardless of cable position 1 5 INCHES 38 1 mm WIDE OPEN THROTTLE Ht e 7 13 INCHES 181 1 mm TM 10 3950 672 24 1 1 Position the fuel control lever to wide open throttle Pull the threaded cable rod end until resistance is felt against its internal stop Adjust the cable slip link to provide free pin to pin condition for full lever Refer to figure titled Wide Open Throttle 2 Inspect linkage for ease of movement and return to idle position 3 If preliminary adjustment performed in step 1 fails to provide smooth up shifts at full throttle perform the following adjustment procedure With engine fuel control lever at wide open throttle and the modulator contro cable threaded rod end in idle retracted position set the slip link to 1 38 inches 35 0 mm Refer to figure titled Wide Open Throttle Modulator Control Lever In Idle Install the
258. bracket Remove screw 4 disconnect two electrical leads 8 and 9 and remove sealed beam 6 with retaining ring 5 from boom light assembly 1 Remove retainer 7 and separate retaining ring 5 from sealed beam 6 Installation NOTE Align tabs on retaining ring 5 Figure 3 36 with boss on sealed beam 6 Install retaining ring 5 on sealed beam 6 and secure with retainer 7 Position sealed beam 6 with retaining ring 5 to boom light assembly 1 connect two electrical leads 8 and 9 and secure with screw 4 Install boom light assembly 1 on mounting bracket position harness ground wire 11 on mounting stud and secure assembly with lockwasher 3 and nut 2 Connect boom light assembly 1 electrical connector 10 to crane electrical harness receptacle 12 Connect negative leads to battery negative post 3 231 ROM TM 10 3950 672 24 1 LEGEND Light Assy 6 Screw Nut 7 Star Washer Lockwasher 8 Sealed Beam Washer 9 Retaining Ring Bolt 10 Retainer Figure 3 37 Headlight Back up Light 3 232 TM 10 3950 672 24 1 3 95 HEADLIGHT BACK UP LIGHT 3 95 1 3 95 2 Removal Disconnect negative battery cable and two electrical leads from battery Disconnect light assembly Figure 3 37 electrical connector from crane electrical harness Remove four nuts 2 four lockwashers 3 four washers 4 four bolts 5 and light assembly 1 from crane frame Remove screw
259. c Replace relief valve d Bleed cylinder rods e Replace pivot shaft SYMPTOM PROBABLE CAUSE 2 Boom lowers erratically 3 Boom raise slowly 4 Boom lowers slowly a Low hydraulic oil b Low engine rpm c Circuit and or relief valve in operative d Air in hydraulic cylinders e Control valve linkage out of ad justment f Damaged hydraulic pump sec tion a Low hydraulic oil level Low engine rpm Damaged relief valve Extremely cold hydraulic oil e Improper hose or fitings in stalled f Control valve linkage out of ad justment g Operating two functions within the same control valve bank assem bly h Restriction in return hose i Cylinder piston seals leaking j Scored cylinder barrels k Worn hydraulic pump section a Low hydraulic oil level b Low engine rpm 3 159 TM 10 3950 672 24 1 SOLUTION a Replenish hydraulic oil to pro per oil level b Increase engine rpm to recom mended level c Repair or replace relief valve d Bleed air from cylinders e Adjust linkage to obtain full spool travel f Repair or replace pump section a Replenish hydraulic oil to pro per level b Increase and maintain engine rpm c Repair or replace relief valve d Operate unit to bring oil to op erating temperature e Replace hose or fittings Refer to Parts Manual f Adjust linkage to obtain full spool travel g Feather
260. carrier loose from the housing with a rawhide mallet 8 To remove the carrier from the housing place a roller jack under the carrier Remove the top nuts and lockwashers and work the carrier free A small pinch bar may be used to straighten the carrier in the housing bore However the end must be rounded to prevent indenting the carrier flange 9 Place the carrier in a suitable holding fixture Removal of the Differential Case and Gear Assembly NOTE If the initial inspection indicates the drive gear is not going to be replaced the established backlash should be measured and noted for reference and used at assembly 1 Loosen the jam nut and back off the thrust block adjusting screw 2 Center punch one differential carrier leg and bearing cap to identify in assembly 3 Cut the lockwire if used and remove the leg capscrews and cotter key 4 Remove the bearing adjusting ring and the carrier cap 5 Repeat Steps 3 and 4 for removal of the carrier cap on the opposite side E 61 TM 10 3950 672 24 1 6 Lift out the differential and gear assembly Disassembly of the Differential Case and Gear Assembly NOTE Refer to NoSPIN DIFFERENTIAL in this Section for disassembly of the NoSPIN differential 0603 3 DRIVE PINION FLANGE AND SUNGER ASSEMBLY COTTER KEY PINION CAGE COVER ORIVE PINION NUT DRIVE PINION DRIVE PRION OUTER BEARING PILOT BEARING DRIVE PINION OUTER PILOT BEARING WASHER P
261. cassacaeeassecaesacaes E 18 all SRM TIAMSMISSION PRENNE Description 0 2 ce 100 nn nn eee E 20 Maintenance RRR Troubleshooting RR General Overhaul Cleaning and 00 eee errr nins Assembly Procedures Transmission Disassembly Major Component Transmission Disassembly and Assembly Subassemblies Transmission Assembly Lubrication Front Drive E 57 Description 0 eee eee E 57 Maintenance ccccccssssssscsscssessessesscsscsscsscsssssssesssssssssssasssssassssssssasssssassassassassasssssassassassassassassussassassussasasasaseatees E 57 Disassembly of the Wheel tenet E 57 Assembly of the Wheel Ends 57 TM10 3950 672 24 1 TABLE OF CONTENTS continued Subject Page Front Drive Axle continued Disassembly of the Driv SIT REN ES Assembly of the Drive Unit 2 2 et x ur
262. causes for stiff spool movement or jammed spool action are system overheating excessive pressure contaminated or deteriorated oil or warped mountings When scorched or deteriorated oil or contamination is the cause flushing the system and replenishing with clean oil may solve the problem If the spool bores are badly scored or galled the valve must be removed for servicing Warping occurs when mounting plates are not level or they become distorted from machine damage As mentioned previously the valve can be shimmed level Also check the valve for rust Rust or dirt collecting on the linkages can prevent free movement of the spool and keep it from the true center position Excessive system pressure can create both internal and external leaks in valves that are otherwise sound Therefore it is extremely important that relief valves be adjusted only by qualified personnel using the proper equipment TM 10 3950 672 24 1 3 37 HYDRAULIC HOSES LINES AND FITTINGS TYPICAL 3 37 1 Removal WARNING Fluid leaks under pressure may not be visible A high pressure oil stream can pierce body and cause severe personal injury Always wear safety goggles to protect eyes and heavy gloves to protect hands Prior to servicing any component reduce hydraulic pressure in system to zero and then disconnect power source a Relieve hydraulic pressure by moving control levers through full range with engine shut down b Remove hose or line 1 Figure
263. check for bent condition Intermediate Servo 1 Inspect the servo bore for cracks and the servo piston for damage and the piston bore and the servo piston stem for scores Check fluid passages for obstructions Replace damaged seals 2 Check the servo spring and servo band sirut s for distortion 3 Inspect the cover seal and gasket cover sealing surface for damage Extension Housing 1 Inspect the housing for cracks Inspect the gasket surface for burrs or warpage 2 Inspect the bushing for scores or wear Replace if required 3 Inspect the rear seal for hardness cracks or wear If the seal shows wear or deterioration replace the seal 4 Inspect the seal counterbore and remove all burrs and scores with crocus cloth Governor 1 Inspect the governor valves and bores for scores Minor scores may be removed from the valves with crocus cloth Replace the governor if the valves or body is deeply scored 2 Check for free movement of the valves in the bores The valves should slide freely of their own weight in the bores when dry Inspect fluid passages in the valve body and counterweight for obstructions All fluid passages must be clean 3 Inspect the mating surfaces of the governor body and governor distributor for burrs and distortion Mating surfaces must be smooth and flat Front Pump 1 Inspect the mating surfaces of the pump body and case for burrs 2 Inspect the drive and driven gear bearing su
264. circle clamp 7 and remove coolant recovery bottle 6 f Remove two hose clamps 8 and 9 securing radiator hoses 10 and 11 to radiator 12 Figure 1 Then disconnect both radiator hoses g Remove fan guard 16 as follows 1 Remove ten screws 13 ten lockwashers 14 ten washers 15 and fan guard 16 with supports 17 and 18 2 Remove eight nuts 19 eight lockwashers 20 eight washers 21 eight screws 22 and eight washers 23 Separate fan guard 16 and supports 17 and 18 h Disconnect two transmission oil cooler lines at bottom of radiator at fittings 24 Plug both transmission cooler lines i Remove two nuts 25 and two flatwashers 26 securing bottom of radiator 12 to vehicle WARNING The radiator assembly weighs 72 lbs To prevent personal injury use a suitable lifting device to remove radiator assembly NOTE Radiator and lower shroud 29 are hoisted out of vehicle as a unit 3 36 Radiator Cap Drain Valve Hose Clamp Hose Hose Recovery Bottle Circle Clamp Hose Clamp Hose Clamp 10 Hose 11 Hose 12 Radiator Screw Lockwasher Washer Fan Guard Support RH Support LH Nut Lockwasher Washer Screw Washer Fitting Nut Lockwasher Nut Lockwasher Lower Shroud Screw Lockwasher Screw Lockwasher Upper Shroud Figure 3 10 Radiator and Fan Guard TM 10 3950 672 24 1 Baffle Elbow
265. clutch plate serrations for scores or burrs Minor scores or burrs may be removed with crocus cloth Replace the clutch cylinder if it is badly scored or damaged 2 Check the fluid passage in the clutch cylinder for obstructions Clean out all fluid passages Inspect the clutch piston for scores and replace if necessary Inspect the piston check ball for freedom of movement and proper seating 3 Check the clutch release spring for distortion and cracks Replace the spring if distorted or cracked 4 Inspect the composition clutch plates steel clutch plates and clutch pressure plate for worn or scored bearing surfaces Replace all parts that are deeply scored 5 Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear 6 Check the splines on the stator support for wear Inspect the bushing in the stator support for scores Check the input shaft for damaged or worn splines Replace the shaft if the splines are excessively worn Direct Clutch Piston Inspect the piston check ball for freedom of movement Improper seating of check ball will cause leakage Leakage can be detected by turning the piston upside down flat side of piston facing you allowing the check ball to seat in the piston Pour a small quantity of solvent over the check ball If solvent drips past the check ball replace the piston Low Reverse Clutch 1 Inspect the clutch cylinder piston born and clutch plate serrations for scores or b
266. components Install any clamps that were removed ss Connect negative battery cable 150 and wires 70 and 51J to negative battery post 3 242 TM 10 3950 672 24 1 3 99 STARTER 3 99 1 Test Testing Starter Motor Installed a Make sure battery is fully charged and that all battery and starter cables are serviceable and properly installed b Connect a multimeter as shown Figure 3 40 Momentarily connect a jumper as shown ir Figure 3 40 Multimeter should indicate battery voltage and starter should crank engine If multimeter does not read battery voltage the starter relay is defective If multimeter indicates battery voltage but starter does not operate starter is defective IGNITION SWITCH 18 GA JUMPER Figure 3 40 Starter Relay Test Circuit 3 243 TM 10 3950 672 24 1 Testing Starter Components a Using a growler tester place armature on it and hold a hack saw blade against armature core while slowly rotating armature A short circuited armature causes blade to vibrate and be attracted to core An armature which is short circuited must be replaced b Set multimeter for ohms and touch one probe to a commutator segment and other probe to armature core refer to Figure 3 41 There should be no continuity If there is continuity armature is grounded Replace armature if grounded Figure 3 41 Testing for Grounded Windings Set multimeter for ohms and touch probes to two segments refer tg Figure 3 42 T
267. 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 138 F 38 to 59 C 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 gloves etc a Keep it clean dirt grease oil and debris only get in the way and may cover up a serious problem Clean as your 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 b 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 TM10 3950 672 24 1 c Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to intermediate direct support d 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 e Hoses and fluid lines Look for wear damage and leaks Make sure clamp
268. controls to obtain de sired speed of both functions h Replace return hose i Replace all cylinder seals j Hone or replace barrel k Repair or replace pump sec tion a Replenish hydraulic oil to pro per level b Increase rpm to recommended level TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 4 Boom lowers slowly continued 5 Boom will not raise per level 6 Boom will not lower c Damaged relief valve d Operating two functions within the same control valve bank assem bly e Extremely cold hydraulic oil f Improper hose or fittings in stalled g Control valve linkage out of adjustment h Restriction in return hose i Cylinder piston seals worn j Scored cylinder barrels k Worn hydraulic pump section Piston rod broken loose from piston a Low hydraulic oil b Main relief valve or circuit relief valve damaged c Excessive load d Improperly adjusted control valve linkage e Worn or damaged hydraulic pump section Broken pump shaft Broken pump drive coupling Broken control valve spool Low hydraulic oil Main relief valve or circuit relief valve damaged 3 160 c Repair or replace relief valve d Feather controls to obtain de sired speed of both functions e Operate unit to bring oil to op erating temperature f Replace hose or fittings Refer to Parts Manual g Adjust linkage to obtain full spool travel
269. cquic Primer T to the threads of the setscrew Allow to dry and apply Loctite 271 adhesive sealant to the threads of the setscrew Install the setscrew and secure the piston on the rod CAUTION AVOID SCRATCHING OR DAMAGING THE GROOVE AND GLAND SURFACES OR THE RINGS AND SEALS 3 127 TM 10 3950 672 24 1 CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD DAMAGE TO THE ROD SURFACE MAY CAUSE UNNECESSARY MAINTENANCE AND EXPENSE 14 Lubricate the piston and head with clean hydraulic oil and install the rod assembly into the barrel with a twisting motion 15 Bolt the head retaining plate to the cylinder barrel Torque to 250 Ib ft 339 Nem WARNING DO NOT USE AIR PRESSURE TO CYCLE PRESSURIZE THE CYLINDER 16 Pressurize and cycle the cylinder Check for proper operation and any leakage 3 54 STEER CYLINDER TM 10 3950 672 24 1 DESCRIPTION The steer cylinder has a 3 inch 7 62 cm diameter bore and is the double acting type The cylinder is mounted on the rear axle O rings are used within the cylinder to prevent internal and external leakage A wiper ring is mounted on each end of the cylinder barrel to wipe dirt from the rod as it is retracted MAINTENANCE DISASSEMBLY NOTE Any maintenance requiring disassembly of the cylinder should include replacement of all cylinder seals 1 Drain all hydraulic oil from the cylinder 2 Remove the bolts from the head plates
270. cut the hand SAFT 5 SAFT 6 blank TM 10 3950 672 24 1 Technical Manual HEADQUARTERS DEPARTMENT OF THE ARMY No 10 3950 672 24 1 Washington DC 15 June 1997 Unit Direct Support Maintenance Manual for WAREHOUSE CRANE 10 000 LB CAPACITY M469 WHEELED DIESEL POWERED NSN 3950 01 412 5345 Grove Model AP 308T REPORTING OF ERRORS You can improve this manual If you find any mistakes or if you know of a way to improve the procedures please let us know Mail your letter DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual direct to Commander US Army Tank automotive and Armaments Command ATTN AMSTA IM OPIT Warren MI 48397 5000 A reply will be furnished to you You may also provide DA Form 2028 2 information to TACOM via datafax or e mail TACOM s datafax number for AMSTA IM OPIT is 810 574 6323 and e mail address is tacom tech pubs cc tacom army mil This manual is an authentication of the manufacturer s commercial literature and does not conform with the format and content specified in AR 25 30 Military Publications This technical manual does however contain valuable information that is essential to the operation and maintenance of the equipment TABLE OF CONTENTS VOLUME 1 Page SAFETY SUMMARY SAFT 1 HOW TO USE THIS ii WARRANTY 1 2 0 000 0 100 nnne enne CHAPTER 1 I
271. d cover 4 over the primary sun gear 17 with a slight rotating motion Do not damage the oil seal 19 on the splines of the sun gear 23 Apply thread sealant to the bolts 11 and install the bolts 11 securing the end cover 4 to the Internal gear 12 Torque the bolts to 35 Ib ft 48 24 Install the brake discs 9 and the stators 10 another brake disc 9 and then a thin stator 10 25 Install the O rings 7 and backup rings 8 on both the inside and outside of the cylinder head 6 with the o rings 8 up as the head would be installed in the brake housing 3 26 Install the O ring 7 and backup ring 8 into the piston 5 so the O ring 7 faces the O ring 7 in the head 6 27 Install the springs 16 into the piston and install the head 6 and piston 5 into the brake housing 3 E 131 TM 10 3950 672 24 1 28 Remove dirt grease or moisture from the end cover surface Dry the surface or allow to dry naturally Apply never seez compound and RTV silicon to the surface of the end cover 29 Install the brake housing assembly 3 with the brake release port lined up with the alignment hole used earlier 30 Apply thread sealant to the bolt 1 threads and Install the bolts 1 and washers 2 securing the brake housing 3 to the end cover 4 Torque the bolts to 35 Ib ft 48 Nem 31 Install the motor to the brake housing Apply thread sealant to the socket head capscrews Install the
272. d immediately 2 7 PRELIMINARY SERVICING AND ADJUSTMENT The crane is shipped completely serviced except for diesel fuel A complete walk around visual inspection of the crane should always precede operation Special attention should be given to structural damage loose equipment leaks or other conditions that could be affect safe operation The following checklist should be considered the minimum requirement for such a visual inspection NOTE See Section 3 PMCS for checking and servicing procedures a Fuel system Ensure fuel tank is full and cap is on tight Open valve on fuel water separator 1 4 turn and drain water from bowl Do not tighten plastic valve b Check engine oil and service as required Do not overfill c Check and service engine coolant at overflow bottle Do not overfill d Ensure battery cables are tight and not corroded e Check all signal and running lights for proper operation Replace burned out bulbs as needed Ensure backup alarm and horn operate f Check foot brake pedal and parking brake lever for proper operation g Check fan belt for damage and for proper tension h Check and service transmission oil level i Ensure all daily lubrication has been performed j Check and service hydraulic tank Check hydraulic filter indicator 2 2 TM10 3950 672 24 1 k Check tires four places for severe cuts and for correct inflation Check lug nuts for proper torque Inspect wire rope in accordance
273. d nuts NOTE Ensure the fuses are of the proper amperage before placing in the fuse blocks b If removed install the fuses in the fuse blocks c lf removed install the terminal blocks and secure with the screws lockwashers and nuts d Install the panel to the cab wall and secure with the nuts and lockwashers e Connect the leads to the terminal blocks as tagged during removal f Connect the leads to the fuse blocks as tagged during removal g Connect negative leads to battery negative post FUSE DATA Fuse No Amps Circuits FU1 6 Left Headlights Work Lights FU2 6 Right Headlights Work Lights FUS 10 Stop Lights Turnsignals Taillights FUA 4 Gauge Lights FU5 4 Boom Floor Lights FU6 10 Horn Backup Lights FU7 10 Dome Light Gauge Lights A2B Engine Distress FUB 10 A2B FU9 15 Oil Fan Gearshift FU10 15 Cab Fan Heater Fan Spotlight FU11 10 Windshield Wiper 3 220 TM 10 3950 672 24 1 E 1 i e apak m E S Fo C 3 EE Fuse and Relay Panel Sheet 1 of 2 3 221 TM 10 3950 672 24 1 3 88 INSTRUMENTS 3 88 1 Removal a Disconnect negative leads from negative battery post b Remove the nuts washers and screws securing the cover to the front of the console Remove the cover and disconnect the worklight connector and lay the cover aside c Remove the hardware securing the gauge to the instrument panel then remove the gauge d Tag and disconnect the electrical leads
274. d tailpipe 11 on exhaust tube 12 Adjust position of both exhaust tube 12 and tailpipe 11 Then tighten both pipe clamps 9 and 10 Slide pipe clamp 3 over muffler 16 inlet and position two pipe clamps 1 and 2 on tube 4 Install elbow 5 in muffler inlet Then install tube 4 in elbow 5 Do not tighten three pipe clamps 1 2 and 3 at this time 3 32 ROM 8 Ru 7 f 2 oe si 0 it H 10 3950 672 24 1 EXHAUST MANIFOLO Pipe Clamp Pipe Clamp Pipe Clamp Tube Elbow 6 T 8 9 Flange Bolt Lockwasher Pipe Clamp 10 Pipe Clamp LEGEND 11 Tailpipe 12 Exhaust Tube 13 Muffler Clamp 14 Bolt 15 Nut Figure 3 9 Muffler and Exhaust Pipes 3 33 Muffler Muffler Bracket Nut Lockwasher TM 10 3950 672 24 1 Remove cover over exhaust manifold opening and connect flange 6 and tube 4 Secure flange 6 to exhaust manifold with four bolts 7 and four lockwashers 8 Reposition tube 4 and elbow 5 as required Then tighten three pipe clamps 1 2 and 3 WARNING Exhaust components can be hot causing burns to exposed skin Start diesel engine and check exhaust system for leaks Shut down diesel engine If necessary allow exhaust system components to cool and tighten pipe clamps to stop leaks Stow rear outriggers refer to Operator s Manual TM 10 3950 672 10 3 34 3 19 WATER COOLING SYSTEM TM 10 3950 672 24 1 DESCRIPTIO
275. dations Special attention should be given to the existence of lubricant plating or other factors that might require variation from standard torque values When maximum recommended torque values have been exceeded the fastener should be replaced When referring to the applicable torque charts use values as close as possible to the torque values shown to allow for wrench calibration tolerance An erratic or jerking motion of the wrench can easily result in excessive torque ALWAYS use a slow wrench movement and STOP when the predetermined value has been reached Torque wrenches are precision instruments and are to be handled with care to ensure calibrated accuracy Calibration checks should be made on a scheduled basis Whenever the wrench might be either overstressed or damaged it should immediately be removed from service until recalibrated TM10 3950 672 24 1 KNOW YOUR TORQUE WRENCH Flexible beam type wrenches even though they might have a preset feature must be pulled at right angles and the force must be applied at the exact center of the handle Force value readings must be made while the tool is in motion Rigid handle type torque wrenches are available with torque limiting devices that can be preset to required values and which eliminate dial readings NOTE To convert pounds feet of torque to Newton meters Nem multiply quantity by 1 356 NOTE To convert pounds inch of torque to Newton meters multipl
276. des of the gears 5 Gears and shafts are available only as assemblies One gear assembly may be replaced separately if the other is in good condition E 90 TM 10 3950 672 24 1 Front Cover and Back Cover Assemblies 1 If any bearing bore diameter exceeds 0 7518 inches 19 096 mm the cover should be discarded The bearings are not supplied separately 2 Replace the shaft seal 1 only if it shows excessive wear or cracking 3 Check all internal threads for damage 4 The bearings must be below the cover faces and show no signs of contact with the snap rings on the gear shafts 5 f the bearings are scored rough or show signs of heat discoloration the cover assembles should be re placed Center Section 1 Inspect the wall of the gear bore diameters for excessive wear or score marks The center section gear bores will show signs of wear on the inlet side of the pump A wear ridge will develop at the end of the gear bore where the thrust plate is located This wear ridge should not exceed 0 03125 inch 0 79375 mm 2 Lightly lap the faces to remove any nicks or burrs Do not break the inside edges GENERAL The following parts should be replaced at every major overhaul wear plate 10 thrust plate 18 fiber heat shield 9 paper gasket 8 V seal 6 and O rings 11 The shaft seal 1 should be replaced only when necessary ASSEMBLY 1 All parts must be thoroughly cleaned prior to assembly by
277. ding Valves Telescope Pilot Operated Check Valve Outrigger Selector Valve Hydraulic Lockout Solenoid Valves Boom Lift Hoist Hoist Motor Control Valve Crossover Relief Valve assembly Thermal Relief Valve VALVE USAGE TABLE Circuit Used In Physical Location Swing Under the front console Telescope Under the front console Under the front console Outrigger Boom Lift Port block of each cylinder Outrigger Outrigger Telescope the cab floor HO 12 Hoist Swing Lift 3 106 Under the front console Under the front console In the battery box Port block of each cylinder Port block of each cylinder In the cab Between the frame rails under On the hoist motor On the swing drive In Line TM 10 3950 672 24 1 LIFT CYLINDER HOLDING VALVE HOIST MOTOR CONTROL VALVE TELESCOPE CYLINDER HOLDING VALVE EEE M IE PILOT OPERATED CHECK VALVE PILOT OPERATED CHECK VALVE d EE JL OUTRIGGER SELECTOR VALVE HYDRAULIC LOCKOUT SOLENOID VALVES DOUBLE SELECTOR VALVE CROSSOVER RELIEF VALVE DIRECTIONAL CONTROL VALVES Valve Locations 3 107 3 43 RELIEF VALVES TM 10 3950 672 24 1 DESCRIPTION Relief valves are used to protect a component a circuit or a system from overpressurization Most of the relief valves are located in the directional control valves but some are located in the line between components e g double crossover relief valve while others are part of a component MAIN
278. dipping in solvent and brushing to remove all traces of contamination The pump should be assembled in a dirt free area 2 Install the shaft seal 1 if it was removed in the front cover with the spring loaded lip facing inward Force the seal into place using a flat steel rod slightly smaller in diameter than the OD of the seal This will permit the tool to enter the seal recess and bottom the rotary seal on the stop The front cover 5 must be backed up on a smooth clean surface to prevent damaging its face NOTE The load to force the seal into place should be applied exactly in line with the housing seal bore to prevent bending the steel seal retainer and or scoring the seal housing bore 3 Install the V seal 6 the gasket 8 and heat shield 9 into the front cover cavity as follows Ensure the small vent hole through the parts is in line and positioned next to the scribe mark on the island This position locates the vent holes on the outlet side of the pump 4 Face the lips on the U seal toward the cavity and insert it into the groove with the aid of a dull tool to prevent damage to the rubber surface A small screwdriver can be used 5 Firmly press the gasket toward the bottom of the cavity with the thumbs to ensure all of its perimeters are completely within the groove to avoid interference with subsequent assembly 6 Firmly press the heat shield toward the bottom of the cavity with the thumbs to pro
279. djustment band d Vacuum diaphragm bent stick ing or leaking e Valve body bolts loose or too tight f Valve body dirty sticking valves g Intermediate clutch band and or servo assembly burnt E 36 a Perform fluid level check b Check and adjust or service as required c Perform governor test Service d Control pressure test Service e Tighten bolts f Determine source of contami nation Service as required g Check vacuum lines to dia phragm unit Service as necessary Perform vacuum supply and dia hragm tests a Control pressure test Note re b Tighten bolts c Determine source of contami nation Service as required d Perform governor test Repair a Perform fluid level check b Check and adjust or service as required c Perform governor test Service as required Adjust intermediate d Check diaphragm unit Service as necessary e Tighten bolts f Determine source of contami nation Service as required g Perform air pressure test TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 16 Rough harsh delayed 1 2 upshift 17 Mushy early soft slipping 1 2 upshift a Improper fluid level b Poor engine performance c Intermediate band out of adjust ment d Main control pressure too high results e Governor valve sticking as required f Engine vacuum leak g Valve body bolts loose or too tight h Valve body dirty sticking va
280. dle for at least two hours or as specified by the cleaning compound manufacturer with the coolant temperature at 180 F 82 C Do not drive the crane and If necessary add water to the overflow bottle to maintain the cleaning solution at the HOT level Stop the diesel engine as needed if the cleaning solution begins to boil 6 Stop the diesel engine and observe the coolant temperature gauge When there is no change in the temperature gauge reading indicating the coolant temperature has dropped slowly remove the radiator cap and open the radiator drain cock and drain the cleaning compound into a suitable container Then open the engine block drain cock and drain the engine block into a suitable container Close both drain cocks 7 f the radiator core clogging is relieved but not fully corrected after allowing the engine to cool pressure flush the cooling system and repeat the cleaning operation 8 If pressure flushing the system does not correct coolant system problems then the radiator must be replaced PRESSURE FLUSHING 1 Disconnect the upper radiator hose which connects the radiator core to the engine water outlet and remove the thermostat from the engine water outlet 2 Clamp a convenient length of hose to the radiator core outlet opening and attach another suitable length of hose to the radiator inlet opening to carry away the flushing stream 3 Connect the flushing gun to compressed air and water pressure a
281. e The converter one way clutch should lockup and hold a 10 Ib ft 14 N m force The converter one way clutch should rotate freely in a clockwise direction Try the clutch for lockup and hold in at least five different locations around the converter mm 0 533 Max E 51 New or Rebuilt Converter Used Converter inch mm 0 040 Max 1 01 Max 4 If the clutch fails to lock up and hold at 10 pounds foot 1 38 kgm torque replace the converter unit Disassembly of the Reverse High Clutch T Separate the drive train Remove the pressure plate snap ring 2 Remove the pressure plate and the drive and driven internal and external spline clutch plates 3 Install the clutch spring compressor tool T65L77515 A or equivalent on the reverse high clutch drum Ensure the legs clear the snap ring enough to remove it Remove both snap rings and remove the tool 4 Remove the spring retainer and the piston return springs 5 Apply air pressure to the piston apply hole in the clutch hub using air nozzle tool 7000 DE or equivalent and remove the piston 6 Remove the piston outer seal from the piston and the inner seal from the clutch drum 7 Remove the front and rear bushings from the clutch drum If they are worn or damaged To remove the front bushing use a cape chisel and cut along the bushing seam until the chisel breaks through the bushing wall Pry the loose ends of the bushing up with an awl and remove the bushin
282. e Seat 337796 Extractor Exhaust Valve Seat ST 1276 1 Extractor B 25 Reference Code Section IV REMARKS No heating welding cutting or drilling unless authorized by the manufacturer Reference TC9 510 Metal body repair and related operations B 26 TM10 3950 672 24 1 TM10 3950 672 24 1 APPENDIX C EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST Section INTRODUCTION C 1 SCOPE This appendix lists the expendable supplies and materials you will need to operate and maintain the Crane Warehouse M469 These items are authorized to you by CTA 50 970 Expendable Items except Medical Class V Repair Parts and Heraldic Items C 2 FORMS a Column 1 Item Number This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the material e g use cleaning compound item tape E b Column 2 Level This column identifies the lowest level of maintenance that requires the listed item One of the following codes appears in column 2 C Operator Crew Unit O Organizational Unit c Column 3 National Stock Number This is the national stock number assigned to the item Use it to request or requisition the item d Column 4 Description Indicates Federal item name and if required a description to identify the item The last line for each item indicates the Contractor and Government Entity CAGE code in parentheses followed by the part number e Column
283. e age of the equipment the severity of the application and the experience of the operators and maintenance personnel The following are known high stress areas applicable to Grove machines and a visual inspection of these areas should be made part of an owner s planned preventive maintenance program a Power Telescope Boom wear pad retaining structures hydraulic cylinder attaching points boom pivot shaft retaining structures b Outrigger pads beams boxes and attachment structures c Main frames generally in the area of doubler plates and crossmembers at the junction of front and rear frame members on truck cranes d Turntable bearing connection where bearing is welded to the crane superstructure or chassis e Counterweight support structures f Chassis axle and structures suspension mounting g Hydraulic cylinder end connections The above is provided only as a guide and your inspection plan should not be limited to the areas listed A thorough visual inspection of all weldments is good practice Anyone requiring more detailed inspection instructions and or repair procedures may request same by contacting Grove Manufacturing Company Customer Services Department P O Box 695 1086 Wayne Avenue Chambersburg Pennsylvania 17201 TM10 3950 672 24 1 LOCTITE WARNING LOCTITE TYPE ADHESIVES CONTAIN CHEMICALS THAT MAY BE HARMFUL IF MISUSED READ AND FOLLOWTHE INSTRUCTIONS ON THE CONTAINER
284. e baffle system provided NOTE On cranes with booms that can not be lowered to below horizontal the outriggers may be used to raise the machine in order to lower the boom nose below horizontal CAUTION LOCATE THE CRANE ON A FIRM SUPPORTING SURFACE AND POSITION THE BOOM IN THE MOST STABLE POSITION WHEN EXTENDING THE BOOM AT LOW ANGLES On cranes with boom telescope cylinders attached so the rod ram moves while the cylinder barrel remains stationary cycling may not remove the air Lowering the boom to below horizontal and fully telescoping the boom in and out several times should remove entrapped air from the cylinders However if the air is not readily removed lower the boom to below horizontal extend the telescope cylinder as far as practicable and allow the boom to remain in this position overnight This should allow entrapped air to find its way to the holding valve where telescoping the boom IN the next morning should force the air back to the reservoir While allowing the boom to remain in an extended and lowered position overnight is helpful in removing 3 95 TM 10 3950 672 24 1 entrapped air from the hydraulic cylinder ensure the boom is first telescoped IN not OUT in the morning Telescoping OUT may cause air to be forced back into a cylinder WARNING EXTREME CARE MUST BE USED WHEN REMOVING ANY PLUGS OR RESTRICTIONS FROM A HYDRAULIC SYSTEM SUSPECTED TO HAVE ENTRAPPED AIR THAT MAY BE PRESSURIZED
285. e blocking or cribbing WARNING ENSURE THE LIFTING SUPPORTING DEVICE IS CAPABLE OF SUPPORTING THE LIFT CYLINDER 4 Attach an adequate lifting supporting device to the lift cylinder 3 161 c Adjust linkage to obtain full spool travel d Repair or replace pump sec tion e Replace pump shaft and seals f Replace drive coupling g Replace control valve 5 Remove the nuts washers bolts and plates securing the lift cylinder shaft 6 Block the cylinder in place and pry out the pivot shaft 7 Retract the cylinder rod 8 Tag and disconnect the hydraulic hoses from the lift cylinder Cap or plug all openings 9 Remove the bolts washers and plates securing the boom pivot shaft to the turntable 10 Take up any slack in the lifting device Tap out the boom pivot shaft and remove the lift cylinder DISASSEMBLY AND ASSEMBLY Disassembly and assembly procedures of the lift cylinder holding valve and control valve are provided in Section 6 under CYLINDERS and VALVES respectively INSTALLATION 1 Attach an adequate lifting device to the lift cylinder and lower the cylinder into place on the turntable 2 Install the boom pivot shaft and secure with the plates washer and bolts Torque the bolts to 75 Ib ft 102 N m 3 Align the lift cylinder rod end with the attach point on the boom Install the lift cylinder shaft through the cylinder and boom attach points Shut down the engine 4 Secure the lift
286. e inside of the converter housing only near the outside diameter of the housing 2 Fluid leakage by the outside diameter of the seal and front pump body will follow the same path which the leaks by the front pump seal follow 3 Fluid that leaks by a front pump to case bolt will be deposited on the inside of the converter housing only Fluid will not be deposited on the back of the converter 4 Leakage by the front pump to case gasket may cause fluid to be deposited inside the converter housing or it may seep down between the front of the case and converter housing 5 Fluid leakage from the converter drain plugs will appear at the outside diameter of the converter Perform fluid level check Service or adjust linkage Perform fluid condition check Perform control pressure test plication or low main control pressure TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 2 Rough initial engagement in either forward or reverse 3 Harsh engagements warm engine 4 No delayed forward engage ment reverse OK a Improper fluid level b High engine idle c Looseness in the driveshaft U joints or engine mounts d Improper clutch or band appli cation or oil control pressure e Sticking or dirty valve boy body a Improper fluid level b Throttle valve linkage misad justed long disconnected stick ing damaged return spring discon nected c Valve body bolts loose or too
287. e system Disassemble and assemble hydraulic components on a clean surface Clean all metal parts in a nonflammable cleaning fluid Then lubricate all components to aid in assembly Sealing Elements Inspect all sealing elements 0 ring gaskets etc when disassembling and assembling the hydraulic system components Installation of new elements is always recommended Hydraulic Lines When installing metal tubes tighten all bolts finger tight Then in order tighten the bolts at the rigid end the adjustable end and the mounting brackets After tubes are mounted install the hoses Connect both ends of the hose with all bolts finger tight Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting Tighten bolts in both couplings Due to manufacturing methods there is a natural curvature to a hydraulic hose The hose should be installed so any bend is with this curvature FATIGUE OF WELDED STRUCTURES Experience has shown that highly stressed welded structures when repeatedly subjected to varying stresses caused by twisting shock bending and intentional and or unintentional overloads often become subject to weld cracking which may be attributed to fatigue of the welded joint This condition is not uncommon in construction equipment Equipment should be periodically inspected for evidence of weld fatigue The frequency of these inspections should be commensurate with th
288. e the boom clear of the crane and lower it to ground level for service 3 60 2 Installation WARNING Ensure blocking and lifting devices are capable of supporting the boom assembly Attach the boom lifting device to provide equal weight distribution Suspend the boom over the crane Lower the boom into position and align the boom pivot shaft mounting holes for installation of the pivot shaft Lubricate and install the boom pivot shaft Shim as necessary and secure it with the washers bolts and retainer plates Torque the capscrews to 75 lb ft 102 Nem CAUTION Extend the cylinder rod ends only enough to align them with the holes in the lift cylinder attach fitting CAUTION Before installing the lift cylinder rod end pivot shaft ensure the lift cylinder rod ends are aligned with the lift cylinder attach fitting e TELG Lubricate and install the rod end pivot shaft Install the plates washers nuts and bolts securing the rod end pivot shaft to the lift cylinder attach fittings Torque the bolts to 75 Ib ft 102 Nem Connect the hydraulic lines to the telescope cylinder as tagged prior to removal Connect the electrical wires to the boom as tagged prior to removal Remove the lifting device from the boom Activate the hydraulic system and raise the boom slightly to remove the boom and lift cylinder support blocking Check for proper operation of the boom 3 151 TM 10 3950 672 24 1 3 60 3 Disasse
289. e the tension on the compressor and remove the vanes 8 and vane springs 9 from the rotor 10 10 Remove the dowel pin 11 from the port plate assembly 1 2 11 Thread two No 10 24 screws into the puller holes in the port plate assembly 12 and remove it from the body 24 12 Remove the setscrews 13 in the side Remove the adapter valve 14 and balls 26 from the drilled passage The drilled holes in the port plate must be clean and free from burrs 13 Remove the rubber seals 15 and 16 and the belleville washer 25 14 Remove the snap ring 17 from the housing 24 15 Press on the external end of the shaft 21 and remove the shaft and bearing assembly 18 from the housing E 150 TM 10 3950 672 24 1 16 Examine the bearing 20 for wear before removing it from the shaft Apply a little pressure to the outer race and rotate the bearing to check the steel balls and race for wear or cracks Check for looseness Remove the bearing from the shaft if a replacement is needed Inspect the outside diameter of the shaft at the point of contact with the bearing and also the sealing surface area for the shaft seal CAUTION THE TWO SNAP RINGS 19 MUST BE REMOVED BY PASSING OVER THE INTERNAL END OF THE SHAFT AND NOT THE SHAFT SEAL SURFACE DAMAGED SEAL SURFACE WILL CAUSE THE SEAL TO LEAK BEARING SURFACE SEAL SURFACE SNAP RING GROOVE FOR RING 19 Motor Shaft 17 Remove one of the snap rings
290. e various adjustments by operating the machine before returning it to the job PRESSING PARTS When pressing one part into another use an antiseize compound or a molybdenum disulfide base compound to lubricate the mating surfaces Assemble tapered parts dry Before assembling parts with tapered splines be sure the splines are clean dry and free from burrs Position the parts together by hand to mesh the splines before applying pressure Parts which are fitted together with tapered splines are always very tight If they are not tight inspect the tapered splines and discard the part if the splines are worn LOCKS Lockwashers flat metal locks or cotter pins are used to lock nuts and bolts Flat metal locks must be installed properly to be effective Bend one end of the lock around the edge of the part Bend the other end against one flat surface of the nut or bolt head Always use new locking devices on components which have moving parts When installing lockwashers on housings made of aluminum use a flat washer between the lockwasher and the housing WIRES AND CABLES Batteries should always be disconnected prior to working on the electrical system When removing or disconnecting a group of wires or cables tag each one to ensure proper identification during assembly TM10 3950 672 24 1 SHIMS When shims are removed tie them together and identify them as to location Keep shims clean and flat until they a
291. e worn allowing the stator to hit the turbine If this condition exists the converter should be replaced TM 10 3950 672 24 1 TORQUE CONVERTER END PLAY Converter End Pla Transmission Model Inch C6 0 021 Max Converter End Play Check 1 Install the end play checking tool T80L 7902 A or equivalent into the converter pump drive hub until it bottoms 2 Expand the sleeve in the turbine spline by tightening the threaded inner post until the tool is securely locked into the spline 3 Attach a dial indicator tool 4201 C or equivalent to the tool Position the indicator button on the converter pump drive hub and set the dial face at zero 4 Lift the tool upward as far as it will go and note the indicator reading The indicator reading is the total end play which the turbine and stator share Replace the converter unit if the total end play exceeds the limits 5 Loosen the threaded inner post to free the tool and then remove the tool from the converter Converter One Way Clutch Check 1 Insert the one way clutch holding tool T77L7902 A or equivalent in one of the grooves in the stator thrust washer 2 Insert the one way clutch torquing tool T77L7902 D or equivalent In the converter pump drive hub so as to engage the one way clutch inner race 3 Attach a torque wrench to the one way clutch torquing tool With the one way clutch holding tool held stationary turn the torque wrench counterclockwis
292. easure 1 cu centimeter 1000 cu millimeters 06 cu inch 1 cu decimeter 1000 cu centimeters 61 02 cu inches 1 cu meter 1000 cu decimeters 35 31 cu feet Multiply by To change To 2 540 ounce inches Newton meters 305 centimeters inches 914 meters feet 1 609 meters yards 6 451 kilometers miles 093 square centimeters square inches 836 square meters square feet 2 590 square meters square yards 405 square kilometers square miles 028 square hectometers acres 765 cubic meters cubic feet 29 573 cubic meters cubic yards 473 milliliters fluid ounces 946 liters pints 3 785 liters quarts 28 349 liters gallons 454 grams ounces 907 kilograms pounds 1 356 metric tons short tons 11296 Temperature Exact 5 9 after Celsius C subtracting 32 temperature Multiply by 007062 394 3 280 1 094 621 155 10 764 1 196 386 2 471 35 315 1 308 034 2 113 1 057 264 035 2 205 1 102 PIN 075558 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free
293. eat NOTE For more detailed information refer to Appendix E WARNING Before performing maintenance or inspection disconnect battery negative leads from battery negative post 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 3 6 3 Removal a Disconnect battery at negative battery post Tag and disconnect the electrical leads to the motor NOTE A suitable container should be used to catch draining coolant b Ensure heater control knob is off Then disconnect the heater hoses from the heater by loosening the hose clamps c Capor plug all openings d Loosen clamp and disconnect the defroster hose from the heater e Mark control cable to aid in installation Remove the clamps securing the control cable to the heater assembly and disconnect the cable from the heater f Remove the three capscrews and lockwashers securing the heater to the cab Remove the heater from the crane 3 14 TM 10 3950 672 24 1 3 6 4 Inspection Inspect the fan for any damage Inspect the heater core for any signs of leakage or other damage Inspect the heater hoses for frays soft spots wear or any other damage Repair or replace any damaged component as necessary 3 6 5 Installation moaonop Install the heater under the seat and secure with the three capscrews and lockwashers Install the control cable to the heater with
294. eck around the chamfered area of the shaft for burrs nicks or sharp edges that can damage the seals when assembling the flange Nicks or burrs may be removed with a hard smooth stone such as an Arkansas stone Do not try to file or grind this part 4 Wash the housing with non petroleum base solvent to remove oil grease and debris Petroleum base solvents may leave residue detrimental to the successful use of Loctite Pay particular attention to the four tapped holes on the flange end NOTE Fully cured Loctite resists most solvents oils gasoline kerosene and is not effected by cleaning operations 5 Blow dry the motor with compressed air Clean and dry the tapped holes NOTE It is not necessary to remove the cured Loctite that is securely bonded in the tapped holes however any loose particles of cured Loctite should be removed 6 Wire brush the screw threads to remove any cured Loctite and other debris Discard any screws that have damaged threads or a corroded damaged or rounded head 7 Wash the screws with non petroleum base solvent Blow dry with compressed air E 123 TM 10 3950 672 24 1 ASSEMBLY NOTE Use all new seals when assembling the motor Lubricate the seals with petroleum jelly before assembly Do not stretch the seals before installing 2187 14 1 If the plug and seal were removed lubricate the seal and install it on the plug Push the plug into the housing so the plug and ho
295. eck every 1000 miles 1609 km and change whenever the seals are replaced or when the brakes are relined or at least once a year Lubricant Capacities Lubricant capacities are given as a guide only All measurements are taken still filled with the pinion shaft on the horizontal centerline to the bottom of the tapped level hole Refer to Section 18 LUBRICATION for the capacity The lubricant capacities of two similar axles in the same series may vary considerably due to design changes and the vehicle manufacturer s installation The actual service capacity may be accurately determined by carefully measuring the amount of specified lubricant necessary to fill the assembly to the correct level and measuring the lubricant again as it is drained from the unit The vehicles should be on a level surface when this inspection is made TM 10 3950 672 24 1 PINION SHAFT INPUT NUTS Fastener Size Torque Lbs Ft Kem OIL FILLER PLUG Thread into carrier 7 8 inch 20 200 275 27 7 380 housing to allow one thread standout ADJUSTING RING LOCK TO DIFF inch 20 300 400 415 55 3 BEARING CAP CAPSCREWS 1 4 inch 20 700 900 968 1244 1 4 inch 18 700 900 96 8 124 4 Fastener Size Torque Lbs Ft Kem Fastener Size Torque Lbs Ft Kem 1 2 inch 12 8001100 110 8 152 1 Capscrews Using Lockwire 1 2 inch 18 800 1100 110 6 152 1 3 4 inch 14 35 4 8 5 16 inch 18 15 20 2 128 3 4 inch 12 900 1200 196 8 165 9 Capscrewt Not Using L
296. ectrical connector from crane electrical harness Remove three nuts 2 three lockwashers 3 three washers 4 three bolts 5 and light assembly 1 from crane frame Remove retaining ring 6 lens 7 gasket 8 and bulb 9 from light assembly 1 Installation Install bulb 9 Figure 3 35 gasket 8 lens 7 and retaining ring 6 in light assembly 1 Install light assembly 1 in crane frame with three bolts 5 three washers 4 three lockwashers 3 and three nuts 2 Connect light assembly 1 electrical connector to crane electrical harness Connect negative battery cable and two electrical leads to battery 57 L 8 9 LEGEND 1 Light Assy 6 Retaining Ring 2 Nut 7 Lens 3 Lockwasher 8 Gasket 4 Washer 9 Bulb 5 Bolt Figure 3 35 Turn Signal Light 3 229 5 LEGEND Boom Light Assy 8 Ground Lead Nut 9 Power Lead Lockwasher 10 Power Connector Screw 11 Harness Ground Wire Retaining Ring 12 Harness Receptacle Sealed Beam Retainer Figure 3 36 Boom Light 3 230 TM 10 3950 672 24 1 12 TM 10 3950 672 24 1 3 94 BOOM LIGHT 3 94 1 3 94 2 Removal Disconnect negative leads from negative battery post Disconnect boom light assembly 1 Figure 3 36 electrical connector 10 from crane electrical harness receptacle 12 Remove nut 2 lockwasher 3 harness ground wire 11 and boom light assembly 1 from mounting
297. ed primary drive assem d Repair or replace primary drive bly assembly e Motor control valve out of e Refer to Adjustment of the adjustment Motor Control Valve in this Section and adjust the valve 3 Slow operation down Lowengine rpm a Increase speed Damaged circuit relief valve b Refer to Chapter 3 Section 6 VALVES HYDRAULIC SYSTEM Damaged hydraulic pump c Install flow meter in exhaust line of the pump Under moderate load TSEC om et output Refer to Section 6 HYDRAULIC PUMPS HYDRAULIC SYSTEM Damaged pumps normally build heat By hand carefully check the temperature of the pump in relation to the other hydraulic pump 4 Slow operation up Lowengine rpm a Increase engine rpm to recom mended setting Damaged main relief valve b Refdr to Chapter 3 Section 6 HYDRAULIC SYSTEM c Install flow meter in exhaust line Damaged hydraulic pump of the pump Under moderate load check for proper output Refer to Section 6 HYDRAULIC PUMPS HYDRAULIC SYSTEM Damaged pumps normally build heat By hand carefully check the temperature of the pump in relation to the other hydraulic pump E 134 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 4 Slow operation up continued 5 Erratic operation up lb Damaged motor 5000 psi 0 to 34 475 kPa 344 8 bar in the inlet and exhaust line of he motor Hoist upwards in low speed Observe meter readings If he motor has excessiv
298. ed vega RARE ML DM 3 99 5 3 83 ELECTRICAL SYSTEM 3 83 1 Description The electrical system is 12 volt operation with 12 volt starting and consists of an alternator and one lead acid battery The system is the single wire ground return type utilizing the machine s structure as ground Electrical power is transferred to and from the carrier and superstructure through the electrical swivel The Swivel has ten slip rings For more detailed information on the electrical Swivel refer to Section 9 SWIVELS The fuse and relay panel is located on the cab wall under the front console Electrical schematics and wiring diagrams are located in Appendix F The 65 ampere alternator is mounted on the engine and is belt driven When the engine is running the alternator supplies the crane electrical leads and the voltage to recharge the batteries and maintain them at a full state of charge The 12 volt battery is located in a box to the right front of the cab under the deck cover The battery is the maintenance free type and is completely sealed except for a small vent hole in the side of the battery The vent hole allows what small amount of gasses that are produced in the battery to escape 3 83 2 General Maintenance Electrical system maintenance includes replacement of damaged components Standard wiring practices should be observed when replacement is necessary 3 209 TM 10 3950 672 24 1 WARNING If it should become necessary
299. edal is fully retracted b Disassemble cylinder and re build replacing all gaskets a Adjust push rod to maintain a 0 0312 inch 0 792 mm maximum clearance to secondary piston con tact when pedal is fully retracted b If fluid drains from the end of the cylinder when the end plug is removed the check valve is faulty and the cylinder should be replaced c Refer 19 Appendix E Relief Valve Adjustment and adjust the relief valve d Refer Appendix E Relief Valve Adjustment and adjust the TROUBLESHOOTING TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 4 Spongy pedal Air trapped in system b High pressure leaks c Loose wheel bearings NOTE If wheel bearings are loose the relief valve will release the low pressure piston with its large vo lume displacement capacity be fore the wheel cylinders have centralized the drums When this occurs the high pressure piston falls short of the volume dis placement capacity required d Incorrect anchor adjustment If this condition exists the relief valve will release and cause the same results as loose wheel bear ings e Worn cracked brake drums E 95 a Refer to HYDRAULIC BRAKES in Section 3 and bleed the brake system b Check all fittings and joints for leakage while the system is under pressure If the cylinder end plug leaks remove the line connections and tighten by turning clockwise c Refer to Appendix E
300. ees to 35 degrees C giving the dipstick a cool feeling The dipstick reading at room temperature should have the fluid level on the dipstick between the middle and top holes FLUID CHECKING PROCEDURE Check the transmission fluid using procedure the following 1 With the transmission in Park engine at curb idle rpm foot brakes applied and crane on level surface move the transmission selector lever through each range Allow time in each range to engage the transmission return to Park and apply parking brake fully Do not turn off the engine during the fluid level check 2 Clean all dirt from the transmission fluid dipstick cap before removing the dipstick from the filler tube 3 47 TM 10 3950 672 24 1 3 Pull the dipstick out of the tube wipe it clean and push all the way back into the tube Be sure it is fully seated 4 Pull the dipstick out of the tube again and check the fluid level 5 For correct fluid level reading on the dip stick follow the appropriate instructions stated previously for transmission hot and transmission cold check Do not overfill the transmission Overfill can cause the fluid to foam and spill out through the transmission vent with resultant transmission malfunction Underfill can result in transmission loss of engagement or slipping This condition is most evident in cold weather or when the crane is parked or being driven on a hill 6 Install the dipstick making sure it is fully
301. efer to U Joint Bearing Assembly in this Section a Loosen the wheel lug nuts one quarter turn while the wheels are still on the ground b Using the outriggers lift the frame until the wheels are at least two inches off the ground Install cribbing or blocking which is capable of handling the weight of the crane under the crane for support CAUTION Mark the universal so it can be assembled as taken apart otherwise severe drive line vibration may occur C Scribe a timing mark across the mating flanges of the drive shaft yoke to front axle and on the drive shaft U joint to ensure original reassembly position d If installed remove the nuts washers capscrews and clamps securing the drive shaft to the axle differential or gearbox and disconnect the drive shaft e Tag disconnect and cap the hydraulic brake line at each wheel NOTE The tire and wheel assembly weighs approximately 114 Ibs 51 7 kg depending on tire size f Remove the wheel lug nuts and slide the tire and wheel assembly from both sides of the axle NOTE The axle weighs approximately 526 Ibs 238 5 kg If the two gear gearbox is installed the axle weighs approximately 609 25 Ibs 276 3 kg g Position jacks which are capable of handling the weight of the axle under the axle for support 3 26 2 Cleaning Completely assembled axles may be steam cleaned on the outside only to facilitate initial removal and disassembly providing all openings are closed Breather
302. egards to flow from the pump in order to provide sufficient flow to the valves located last in the bank The closed spool directional control valve functions basically the same way as the open spool directional control valve in that the through passage of the valve must be blocked off by the valves spool to divert flow to the dead end parallel passage With flow diverted to the parallel passage pressure then must unseat the load check valve to allow the flow to reach the open work port The load check valve is provided to prevent back sliding of components which support heavy loads as is evidenced by the circuits this valve is used in Return flow from the component is through the return work port to the reservoir return passage MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL 1 Gain access to the control valves by removing the capscrews nuts washers and clamps securing the console assembly to the frame Lift the console assembly off the control valves 2 Tag and disconnect the hydraulic lines from the valve bank Cap and plug all openings 3 Tag and disconnect any electrical leads from the valve bank 4 Remove the cotter pins and clevis pins attaching the control levers to the valve s Replace the hardware in the linkage to prevent loss 3 111 5 Remove the capscrews and washers securing the valve bank to the mounting plate and remove the valve bank INSTALLATION 1 Position
303. ely and the clutch is not defective test starter under no load conditions CAUTION Do not conduct the no load test unless the armature turns freely d Connect a 12 VDC source A to starter battery terminal B and starter frame C Use heavy duty cables refer to Figure 3 46 A 12 VOLT BATTERY B BATTERY TERMINAL C STARTER FRAME D REMOTE START SWITCH STARTING RELAY SWITCH TERMINAL Figure 3 46 Starter Bench Test Setup 3 246 10 3950 672 24 1 Nut Lead Wire Washer Bolt Lockwasher Washer Packing Rubber Cover 9 Screw End Frame Brush Holder Yoke Armature Screw Washer Packing 17 Housing 18 Seal 19 Clutch 20 Ball 21 Pinion 22 Retainer 23 Roller 24 Washer Figure 3 47 Starter Assembly 3 247 Spring Mag Switch Screw Lockwasher Boot Bearing Bearing 3 99 3 10 3950 672 24 1 Connect remote start switch 0 between switch terminal and battery terminal When switch is activated starter should engage and run If magnetic switch plunger only chatters hold in winding is open circuited If nothing happens either the pull in winding is open circuited or mechanical parts are sticking To check for sticking remove magnetic switch end cover and push plunger by hand NOTE The magnetic switch cannot be repaired If plunger engages properly but starter
304. ely more or less pressure than normal it is damaged repair or replace dam aged motor 6 Erratic operation down 7 Sticking spool in the control valve d Damaged O rings in brake piston e Warped brake piston f Motor control valve out of adjustment Low engine rpm Install pressure gauge 0 to Air in brake release line Low engine rpm Damaged circuit relief valve Motor control valve out of adjustment a Excessively high oil tempera ture b Dirt in oil c Valve warped from mounting d Excessively high pressure In valve Relief valves not working properly e Handle or linkage binding E 135 d Install a pressure gauge 0 to 5000 psi 0 to 34 475 kPa 344 8 bar in the pipe plug hole in the line going into the center of the brake housing The inability to build or hold pressure at 500 psi 3447 5 kPa 34 48 bar in this line indi cates defective O rings replace if damaged e Replace piston f Refer to Adjustment of the Motor Control Valve in this Section and adjust the valve a Increase speed a Bleed pilot pressure line going into brake housing b Increase speed c Refer to Chapter Section 6 VALVES io a 8 2 5 5 Refer to Adjustment of the Hoist Motor Control Valve a Eliminate any restriction in pipe line or filtering system b Change oil and flush system c Loosen valve and check d Check pressure at inlet and at working ports
305. embly 1 Clean the mounting surface on the transmission case and extension housing Install a new gasket on the transmission case 2 Hold the extension housing in place and secure with the attaching bolts Torque the bolts 25 to 35 Ib ft 34 to 48 Nem Installation of the Extension Housing Bushing and Rear Seal 1 Install a new bushing using bushing replacer tool T77L 7697 C or equivalent 2 Before installing the seal inspect the counterbore of the housing for burrs Remove any burrs with crocus cloth Install the seal into the housing with seal replacer tool T61L 7657 B or equivalent The seal should be firmly seated in the bore Coat the inside diameter of the end of the seal with Multi Purpose Long Life Lubricant Installation of the Intermediate Servo NOTE Perform steps 1 through 6 if not done during Transmission Assembly E 56 TM 10 3950 672 24 1 1 Dip the new seal in transmission fluid 2 Install a new seal on the cover 3 Coat a new gasket with petroleum jelly and install on the servo cover 4 Dip the piston transmission fluid and install it in the cover 5 Install the servo spring on the piston rod 6 Install the servo piston and cover in the case and secure the cover to the case with the attaching bolts taking care to back off the band adjusting screw as the cover bolts are tightened Torque the bolts 14 to 20 Ib ft 19 to 27 Nem Installation of the Control Valve Body NOTE Perf
306. embly a Using press install front bearing 16 Figure 3 26 in front housing 15 Install front bearing retainer 13 c Using arbor press press front housing 15 over rotor assembly 12 until inner bearing race contacts shoulder on shaft d Position pulley spacer 16 fan 17 and pulley 20 on rotor assembly 12 shaft e Install lockwasher 19 and nut 18 on rotor assembly 12 shaft Place rotor assembly in soft jawed vise and torque nut 40 to 50 Ib ft 54 to 68 N m f Position stator 10 in front housing 15 with stator leads at top and notches in lamination aligned with bolt holes g lf damaged replace retainer 9 in rear housing 8 h Position rear housing 8 over slip rings of rotor assembly 12 with front and rear housing bolt holes aligned and stator leads extending through openings at top of rear housing 8 i Install four screws 7 Torque screws to 50 to 60 Ib ft 67 to 81 Nom j If necessary remove four screws 7 and rotate rear housing 8 and stator 10 to align housings as match marked on disassembly Reinstall screws and torque screws to 50 to 60 Ib ft 5 65 to 6 78 Nom k Install brush assembly 6 in rear housing 8 with two screws 5 3 216 3 84 6 oc e TM 10 3950 672 24 1 Connect voltage regulator 4 electrical connector to brush assembly 6 and install voltage regulator 4 on rear housing 8 with two screws 3 Connect voltage regulator lead to terminal
307. emove the bolts washers and pin weld securing the hub brake and spindle assembly to the frame 8 Remove the pin weld and bronze bushing from the hub and spindle assembly 9 Remove the hub brake and spindle assembly from the frame Disassembly Remove the bolts and washers securing the cover to the hub Remove the cover CAUTION ENSURE THE ROLLER BEARINGS AND OTHER COMPONENTS ARE KEPT FREE OF DIRT 2 Remove the washer pin and nuts from the end of the spindle 3 Support the spindle and pull the hub and drum straight off the spindle being careful that the outer bearing cone does not drop off the spindle NOTE The inner and outer bearing cups will remain seated inside the hub cavity If the inner bearing cone slides off the spindle the hub oil seal will remain inside the hub NOTE It is not necessary to remove the bearing if inspection reveals no damage 4 If necessary remove the bearings from the hub using a press and sleeve or a suitable puller 5 Using a long screwdriver or other pointed tool pry the seal loose and discard NOTE For removal of the brake drum and brake assembly refer to the Front Axle in Assembly NOTE For installation of the brake assembly and brake drum refer to the Front Axle In 1 Install the seal in the hub 2 If removed clean repack and install the bearings 3 Install the hub and drum onto the spindle 4 Install the adjusting nut on the spi
308. en the jam nut and rod eye assembly are free of dirt and oil and apply Locquic Primer T to the threads Allow to dry and apply Loctite 242 adhesive sealant or equivalent to the threads before tightening the jam nut The rod eye assemblies must be adjusted equally on both sides of the cylinder 3 Install the rod eye assemblies of the steer cylinder to the spindle link plates and secure with the capscrews locknuts and washers Torque the capscrews to 583 Ib ft 790 N m 4 Connect the hydraulic lines to the steer cylinder as tagged during removal HUB AND SPINDLE ASSEMBLY Removal 1 Fully lower and retract the boom 2 Chock the front wheels TM 10 3950 672 24 1 Rear Axle Assembly 3 68 TM 10 3950 672 24 1 1 Brake 11 Roller Bearing Cone 21 Flatwasher 2 Seal 12 Spindle Weld 22 Washer 3 Washer 13 Capscrew 23 Locknut 4 Pin 14 Lockwasher 24 Grease Fitting 5 Nut 15 Locknut 25 Bolt 6 Cover 16 Washer 26 Washer 7 Capscrew 17 Rod Eye Assembly 27 Pin Weldment 8 Lockwasher 18 Capscrew 28 Jam Nut 9 Roller Bearing Cone 19 Capscrew 29 Steer Cylinder 10 Hub and Drum Assy 20 Link Plate 30 Frame Weldment Legend for Rear Axle Assembly 3 Loosen the wheel lug nuts one quarter turn while 2 Remove the washer pin and nuts from the end the wheels are still on the ground of the spindle 4 Using an adequate lifting device or the 3 Support the spindle and pull the hub from the ou
309. ensure that the motor is installed in the same manner 1 Clean the port area around the motor Tag and disconnect the hydraulic lines from the motor assembly Cap or plug all openings 2 Remove the capscrews and washers securing the cross over relief valve to the motor and remove the relief valve CAUTION Pull straight up on the motor assembly to avoid damaging the splined shaft 3 Remove the capscrews and washers securing the motor to the gear reducer and lift the swing motor free INSTALLATION CAUTION Use care when engaging the swing motor drive gear do not force the shaft to engage 3 141 NOTE Apply Never Seez compound to splines and pilot areas prior to assembly 1 Apply RTV silicone to the surface of the brake Position the swing motor on the brake engaging the shaft with the brake input shaft 2 Install the cross over relief valve to the motor and secure with the capscrews and washers 3 Apply thread sealant to the capscrews Install the capscrews and secure the motor to the brake housing Torque the capscrews to 109 Ib ft 148 Nom 4 After motor has been installed remove four of the 3 8 inch bolts from the motor end of the brake assembly Clamp the stops firmly against the motor flanges and torque the bolts to 35 Ib ft 47 Nom 5 Connect the hydraulic lines to the swing motor as tagged during removal TEST 1 Test the swing of the superstructure direction Stop and start swing several times
310. eplace valve body a Service or adjust linkage b Service Internal kickdown link age c Perform control pressure test d Perform governor test Service or replace governor clean screen e Clean service or replace valve body a Adjust neutral start switch b Adjust linkage c Replace neutral switch TM 10 3950 672 24 1 GENERAL OVERHAUL INFORMATION lowing special tools and equipment will be beneficial in Special Tools and Equipment servicing the transmission and are available from Ford Motor Company Dearborn Michigan In addition to common tools ordinarily used the fol SPECIAL SERVICE TOOLS Number Description T50T 100 A Impact Slide Hammer T59L 100 B Impact Slide Hammer T58L 101 A Puller Attachment T57L 500 B Bench Mounted Holding Fixture Tool 1175 AC Seal Remover Tool 4201 C Dial Indicator with Bracketry Tool 7000 DD Rubber Tip for Air Nozzle Tool 7000 DE Air Nozzle Assembly T66L 7003 CZ Front Pump Bushing Replacer T67P 7341 A Shift Linkage Insulator Tool T84P 7341 A Shift Linkage Grommet Remover T84P 7341 B Shift Linkage Grommet Remover T61L 7657 B Extension Housing Seal Replacer T77L 7697 C Extension Housing Bushing Replacer T77L 7697 D Extension Housing Bushing Remover T76L 7902 C Converter Clutch Torquing Tool T80L 7902 A End Play Checking Tool T77L 7902 A Converter Clutch Holding Tool T73P 77060 A Output Shaft Retainer Pliers Tool 77288 Shift Lever Seal Replacer T71P 77370 A Band Adjus
311. equence of each seal making up the rod seal and its location on the rod to ensure proper assembly 8 Remove the O ring and backup ring from the outside of the head and the wear ring buffer seal assembly rod seal and wiper ring from the inside of the head 9 If necessary remove the holding valve from the port block 10 If necessary remove the grease fittings 1 2 3 4 5 6 7 8 Cylinder Barrel 9 Socket Setscrew 10 Seal Assembly Piston Backup Ring O Ring Rod Head TM 10 3950 672 24 1 Wear Ring O Ring Backup Ring Buffer Seal Assembly Rod Seal 14 Wiper Ring A Grease Fitting Socket Setscrew Lift Cylinder 3 121 CLEANING AND INSPECTION 1 Clean all parts with solvent and dry with compressed air Inspect all parts for serviceability CAUTION BEFORE INSTALLING NEW SEALS AND RINGS CLEAN ALL SURFACES AND CAREFULLY REMOVE BURRS AND NICKS PARTS DISPLAYING EXCESSIVE WEAR OR DAMAGE SHOULD BE REPLACED 2 Stone out minor blemishes and polish with a fine crocus cloth 3 Clean with solvent and dry with compressed air any parts that have been stoned and polished 4 Inspect the barrel carefully for scoring ASSEMBLY 1 If removed install the grease fittings NOTE Steps 1 2 3 and 4 are used only if the holding valve has been removed 2 Check the inside of the port block for any sharp edges or burrs and remove as necessary with emery cloth 3 Ins
312. equiring disassembly will assist with installation of new seals and disassembly of the hydraulic swivel nngs should include replacement of all seals and rings CLEANING AND INSPECTION dg Clean the spool and barrel with a suitable solvent 1 Remove the capscrews and retaining clips or the IFR and dry with compressed air snap ring that secures the spool in the swivel case 2 Check the spool and the inside of the barrel for scratches grooves scoring etc If any grooves have developed with a depth exceeding 0 005 inch 0 1270 NOTE mm the unit should be replaced 2 Withdraw the spool from the barrel During routine maintenance it is not necessary to remove the mounting plate Use the mounting plate for PSSEMBLY blocking 1 Lubricate the spool seals and rings with hydraulic 3 Plate the spool on a clean work surface in 155 TM 10 3950 672 24 1 SET SCREW are O RING SEAL SEAL O RING BARREL PORT BARREL SNAP RING uu Typical Hydraulic Swivel with Snap Ring Exploded View 3404 E 156 TM 10 3950 672 24 1 WES Rl Typical Hydraulic Swivel with Capscrews and Retaining clips Exploded View E 157 CAUTION WHEN INSTALLING NEW SEALS AND RINGS AVOID STRETCHING THE SEALS OR SCRATCHING THE GROOVED OR GLAND SURFACES Install new seals and rings on the spool using a walking method CAUTION PROPER ALIGNMENT WHEN INSERTIN
313. er 23 and bracket 19 If necessary loosen nuts 1 and reposition throttle cable to take up slack d Stow outriggers refer to Operator s Manual TM10 3950 672 10 3 12 o dog TM 10 3950 672 24 1 Nut Washer U bolt Cable Mount Spring Clip Pin Bolt Lockwasher 9 Pedal Spring Clip Pin Nut Washer U bolt Bracket Nut Figure 3 5 Accelerator Pedal Assembly LEGEND Washer Bolt Bracket Circlip Bearing Liner Spring Lever 3 13 Spring Clip Pin Rod End Bearing Clevis Nut Bolt Bellows TM 10 3950 672 24 1 3 6 CAB HEATER DEFROSTER ASSEMBLY 3 6 1 Description The cab heater defroster is a hot water type with a variable speed fan It is mounted under the operator s seat The heater system consists of a heater core heater hoses a fan and an electric motor The heater box assembly prevents personnel from accidentally coming in contact with the fan or heater core 3 6 2 Theory of Operation Hot water is carried by the heater hoses from the crane s engine to the heater core A fan is used to circulate the heated air around the heater core out into the cab The speed of the fan is controlled by a rotary switch located on the left side of the cab beside the seat The air flow is vented through the box assembly for either heat or defrost The vent is controlled by the push pull knob located on the left side of the cab beside the s
314. er Some engines may have a push button valve on the rear of the water pump housing that must be closed pushed in when changing the water filter TM 10 3950 672 24 1 lt snl 138 280 me PE 196 340 eS an DR 8 COOLANT FR amp EZING amp BOILING TEMPERATURES vs ANTI FREEZE CONCENTRATION FREEZING POINTS BOILING POINTS L Neco l PT TINE TTL PTT LIN TTY eo Reet ake 10 20 30 40 90 70 90 100 ANT EREEZE CONCENTRATION SBY VOLUME 0253 Anti Freeze Concentration Chart E 19 TM 10 3950 672 24 1 TRANSMISSION DESCRIPTION The transmission is a three speed automatic GEAR RATIOS transmission manufactured by Ford Motor Company The transmission is capable of providing automatic up LOW 1st 2 46 1 shifts and downshifts through the three forward gear INT 2nd 1 46 1 ratios The stall ratio is 1 89 1 Gear ratios are as DIRECT 3rd 1 00 1 follows REVERSE 2 175 1 MAINTENANCE TROUBLESHOOTING Before removal or operation of the transmission perform a visual inspection Visually inspect all lines plugs and tube connections at the transmission for oil leakage To make a thorough test of the transmission ensure the engine is properly tuned and the oil level in the transmission is correct During troubleshooting the engine and transmission must be regarded as a single package If inspecti
315. essesseeen nnne 3 44 3 111 Description Removal Installation Functional Check Holding Valves 5 3 45 3 113 Description Removal Installation Pilot Operated Check 3 46 3 114 Description Theory of Operation Removal Installation 3 90 TM 10 3950 672 24 1 Para Page Outrigger Selector Valve 2 2 2 20202000200002 0010 000000000000 11 Description Removal Installation Functional Check Solenoid 3 48 Description Removal Installation Hoist Motor Control n enn nnn nnn nnn nnn nnn nnns nnns 3 49 Description Removal Installation Grossover Relief Valve ceca 3 50 Description Removal Installation GAY ale TD 3 51 General Maintenance Nue lg 3 52 Description Disassembly Cleaning and Inspection Assembly Telescope Cylinder teet te ote te d oet e eed eat 3 53 Disassembly Cleaning and Inspection Assembly Description Disassembly Cleaning and Inspection Assembly Stabilizer Outrigger Cylinder 9796 3 55 Description Disassembly Cleaning and Inspection Assembly 3 ep p M p p m A o D p eo 4 3 91 3 36 HYDRAULIC SYSTEM TM 10 3950 672 24 1 DESCRIPTION This Section describes the supply
316. f valve notworking working ports properly f Handle or linkage binding f Free linkage g Return spring damaged or broken h Spring or valve cap binding 9 Replace faulty parts h Loosen cap and retighten TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 2 Leaking seals a Paint or dirt on or under seal a Remove and clean as neces sary b Excessive back pressure b Open or enlarge line to reser voir c Scored spool c Replace valve d Cut or scored seal d Replace faulty parts 3 Unable to move spool in or a Dirtin valve a Clean and flush out valve as out sembly b Spool cap full of oil b Replace seals c Bind in linkage c Free linkage 4 Poor hydraulic system per a Damaged pump a Repair or replace pump formance or failure b Dirt in relief valve b Disassemble and clean relief valve c Relief valve damaged c Replace relief valve d Worn cylinder s or motor s d Repair or replace damaged components e Load too heavy e Reduce load Refer to load chart for rated capacities f Internal valve crack f Replace valve g Spool not at full stroke g Check movement and linkage h Oil low in reservoir h Add oil Fill to FULL mark on sight gauge i System filter clogged i Clean or replace filter element j Line restricted j Check lines Clean or repair as necessary DISASSEMBLY 1 Remove the nuts and relief cap and remove the relief valve from the valve bank
317. for specifications on making these special tools 3 Saturate the felt wiper 23 in oil and remove all excess oil Position the housing 24 on a clean flat surface with the center line vertical and the large bore up Install the felt wiper 23 into the bore in the housing 24 4 Position the shaft seal 22 on the shaft seal driver special tool with the open face of the seal against the driver 5 Apply lubricating fluid to the OD of the seal and install the seal in the 1 1 2 inch bore of the housing 24 E 152 TM 10 3950 672 24 1 NOTE Ensure no sealing compounds get on the seal element or the shaft Keep all foreign matter from the sealing lips of the seal to prevent cuts and abrasions 6 Position the thimble special tool over the coupling end of the shaft assembly 18 and press the assembly into the housing 24 7 Press on the outer race of the bearing until the bearing is seated against the bottom of the bearing bore Remove the thimble from the shaft 8 Install the snap ring 17 in the housing 24 Ensure the snap ring is fully seated in the groove NOTE Inspect the check valve drilling in the port plate to ensure all the passages are clean 9 Position the port plate 12 so the check valve drilling is vertical Install one 0 187 diameter ball 26 10 Install the adaptor valve 14 with the chamfered end first 11 Install the setscrew 13 until it bottoms against the adaptor valve 14
318. freeze should be used An inhibitor is included in this type of antifreeze and no additional inhibitors are required on initial fill if a minimum antifreeze concentration of 30 percent by volume is used Solutions of less than 30 percent concentration do provide sufficient corrosion protection Concentration over 67 percent adversely affect freeze protection and heat transfer rates E 18 TM 10 3950 672 24 1 Inhibitor depletion will occur in ethylene glycol base antifreeze through normal service The inhibitors should be replenished at approximately 500 hour intervals with a non chromate inhibitor Commercially available inhibitors may be used to re inhibit antifreeze solutions COOLANT RECOMMENDATIONS 1 Always use a proper inhibited coolant 2 f freeze protection is required always use ethylene glycol antifreeze 3 Re inhibit antifreeze with a non chromate inhibitor 4 Always follow the manufacturer s recommendations on inhibitor usage and handling 5 Do not use soluble oil 6 Chromate inhibitors should NEVER be used with permanent antifreeze 7 Sealer type antifreeze should NOT be used 8 Maintain the prescribed inhibitor strength COOLANT FILTER The Cummins engines have a coolant filter of the canister or spin on type that requires periodic servicing It is suggested that this be done when the coolant is changed Close the shut off valves in the inlet and drain lines before disassembling the filt
319. g To remove the rear bushing use tool T69L 7D044 A or equivalent and press the bushing from the drum Assembly of the Reverse High Clutch 1 If the clutch drum bushings were removed Install the drum in a press and press new bushings into the drum with bushing tool T69L 7DO44 A or equivalent TM 10 3950 672 24 1 TRANSMISSION CLUTCH PLATE USAGE Transmission Clearance Model Steel Friction Inch Forward Clutch PGD PJD High Clutch PGD PJD Reverse Clutch PJD PGD 2 Dip the new seals in transmission fluid and install one on the drum and one on the piston 3 Install the piston in the clutch drum 4 Install the piston return springs in the piston sockets Install the spring retainer on the springs NOTE Before releasing the pressure on the clutch spring compressor tool ensure the snap ring is positioned inside of the four snap ring guides on the spring retainer 5 Install the clutch spring compressor tool T65L7751 5 A or equivalent and compress the springs Ensure the spring retainer is centered while compressing the springs Install the snap ring 6 Refer to the Transmission Clutch Plate Usage chart for the number of plates to be used Dip the clutch plates in clean transmission fluid Install the clutch plates alternately starting with a steel drive internal plate If using new clutch plates soak the plates in automatic transmission fluid for 15 minutes before they are assembled 4 1 4 3 3 52 5
320. g and Wheel Cylinder Maintenance 9 Hoist Motor Control Valve Grove 1 5B Hoist een Maintenance DiSASSEMDIY AEE Cleaning and Inspection ccccccccsccsccsecsecsecsecsecsecsecsesaessessessessessessessesaessesaesaesaesaesaesassassaesaesaesascaeaeeasaseaeaeeass E195 MM E 102 Pilot Operated Check Valve E 103 103 Maintenance 103 BIETET wo M EROR MME E 103 TM10 3950 672 24 1 TABLE OF CONTENTS continued Subject Page Pilot Operated Check Valve Continued Cleaning and 22 PASSO DIY Holding BIE ein oio EDEN Ae ery LA LIE I LL LE tL LM LL IVAN ANG Se crea eee ees eae EMEN DiSASSEMDIY AEE Cleaning Inspection ARN ee er Description ieee einen eee 107 Maintenance
321. g from the bore of the control column 6 Remove the control shaft and bearing assembly from the column If the control shaft and bearing assembly is hard to remove tap lightly with a plastic or rubber hammer on the splined end of the control shaft until the shaft breaks loose from the column Bearing Ass y Retaining Ring Shaft Sa Control Shaft 0868 29 NOTE The retaining ring fit is very tight Be careful not to distort it when removing it from the shaft NOTE Remove the retaining ring only if it is necessary to remove the bearing assembly from the shaft 7 If removing the bearing assembly from the shaft remove the retaining ring from the shaft using a thin bladed screwdriver 8 If necessary remove the bearing assembly from the threaded end of the shaft INSTALLATION Integral Column Bearing Race Needie Thrust Bearing Bearing Race Bearing Locator Bearing Locator Bearing Race Needle Thrust Bearing i Bearing Race 1 Install the bearing locator over the two bearing races and the needle thrust bearing Using a soft plastic or rubber hammer lightly tap the bearing locator in the housing 3 87 TM 10 3950 672 24 1 Cap Screw Control Column Quad Ring Seal Seal 0868 31 2 Install the quad ring seal dry Lubricate the 1 15 1 6 inch diameter seal and install the seal in the column 3 Install the column on the housing 4 Align the bo
322. g of the mounting lugs might be necessary 3 191 Section 11 Frame and Outriggers Subject Theory of Operation 3 75 2 Removal NRI MR ETT Tite LF BRUN ERN EPOD 3 75 5 Outrigger Stabilizer Cylinder nnns Description Removal Installation Functional Check Outrigger Selector Valve 3 77 3 197 Description PING HOOK NE REMOVAL RR MR C E PE 3 78 2 3 199 Front Access Covers REMOVAL cuum 3 79 2 Rear Access EEEE EEEE Ena 3 80 3 80 1 Mirror Assembly Right Side SE EC 13 81 1 13 81 2 Mirror Assembly Left Side c c ccccccscsesesssssssssesssssssscsesesesesesseecscasesssevesscscseneneneees cuu 2 2 2 2 3 82 2 3 75 OUTRIGGERS 3 75 1 Description The outriggers are the oblique telescoping type and consist of a removable outrigger beam and a cylinder assembly The outriggers are controlled by a toggle swi
323. h assembly 26 Install five rollers 23 retainer 22 and starter pinion 21 in housing 17 Place steel ball 20 in overrunning clutch 19 and install both in housing 17 Position assembled housing 17 with new seal 18 on magnetic switch assembly 26 and secure with three screws 14 washers 15 and new packings 16 Torque screws 5 1 to 8 7 ft Ibs 6 9 to 11 8 Nom Install armature 1 3 in magnetic switch assembly 26 Position brush holder 11 to yoke 1 2 Lift springs and install brushes refer to Ensure negative brushes connected to brush holder are installed in negative holes not insulated and positive brushes connected to yoke are installed in positive holes separated from plate with insulator Ensure positive brush leads are not grounded Position yoke assembly end frame 10 Figure 3 47 on yoke 12 engaging tab on end frame with lead wire grommet Secure with two screws 9 Torque screws 1 95 to 3 40 ft Ibs 2 6 to 4 6 Nem Position yoke 12 on magnetic switch assembly 26 engaging tab on yoke assembly with notch in magnetic switch assembly Secure with two bolts 4 two new lockwashers 5 two washers 6 and two new preformed packings 7 Torque bolts 5 1 to 8 7 ft Ibs 6 9 to 11 8 Nem Connect yoke assembly lead wire 2 to terminal on magnetic switch assembly 26 with washer 3 and nut 1 Torque nut 18 1 to 26 ft Ibs 24 5 to 35 3 Nem Ensure rubber cover 8 for lead wire is installed sec
324. he stroke of the cylinder is 1 50 inches 3 8 cm THEORY OF OPERATION BRAKES COMPLETELY RELEASED With the brakes completely released fluid is at reservoir pressure Relief valve 1 is closed and reservoir ports 2 and 5 are open allowing fluid to pass freely Initial brake pedal movement carries the low pressure piston 4 forward closing reservoir ports 2 and Relief Valve Reservoir Port Cup Piston Reservoir Port By pass Port B 27 S y m UU gt gt SUX NTIS E b Oylinder displacement to the brake line is made up of the displacement of cup 7 in the low pressure chamber and cup 3 in the high pressure chamber Fluid displaced by cup 7 travels through by pass port 6 over cup 3 and into the brake lines Relief valve 1 remains closed during this portion of the cylinder cycle Ue 22 62445 m 20222446 WWE FT 2 et TL 2 Brakes Completely Released BRAKES FULLY APPLIED Displacement continues until the braking surfaces are in contact and a line pressure buildup occurs When the line pressure reaches the pre determined pressure setting of the relief valve factory set the relief valve opens allowing further displacement Retief Valve Reservoir Port Return Spring Piston Reservoir Port By pess Port Cup Cup ON AARUN SG DA J Sie ZA N En RN MUM S S 4 LL 22 20 222823 x 777 TM
325. he cause of the trouble and the crane is operational further troubleshooting is necessary Do not remove the transmission from the crane until the mechanical hydraulic and air pressure tests are performed and the causes of trouble are checked against the troubleshooting chart Mechanical Checks LINKAGE CHECK 1 A check should be made to ensure the linkage is free and returns to idle when released 2 Ensure the D detent in the transmission corresponds exactly with the stop in the console Leakage at the manual valve can cause delay in engagements and or slipping while operating if the linkage is not correctly adjusted 3 44 low the engine will run roughly An idle speed that is too high will cause the crane to creep have harsh transmission engagements and harsh closed throttle downshift CONTROL PRESSURE TEST There are two methods of performing the control pressure test One is to perform the test using the engine vacuum The second method is to use a hand operated vacuum pump 1 To perform the control pressure test using the engine vacuum perform the following a Attach a tachometer to the engine and a vacuum gauge to the transmission vacuum line at the manifold vacuum port CAUTION PRESSURE GAUGES AFFECT THE SHIFT QUALITY OF THE TRANSMISSION CARE SHOULD BE TAKEN NOT TO ACCELERATE OR DECELERATE RAPIDLY POSSIBLE TRANSMISSION FAILURE COULD RESULT b Firmly apply the parking brake and start the engine
326. he clutch piston 2 Using the lip seal protector tool T77L 77548 A or equivalent install the clutch piston and lip seal 3 Install the installation tool into the forward clutch cylinder so that the bore of the tool is aligned with the piston bore in the cylinder Press the piston into the cylinder until it bottoms in the bore Remove the installation tool NOTE Position the disc spring the cylinder with the dished face downward 4 Ensure the steel pressure ring is in the groove on the piston Install the spring so that the pressure ring and spring are in contact Secure the disc with the retaining snap ring 5 Install the forward pressure plate with the flat side up and the beveled side down Dip the clutch plates in clean transmission fluid Install the wave plate a steel plate and a composition driven plate Install the remaining plates in the previous sequence Refer to the Transmission Clutch Plate Usage chart for the number of plates required The last plate installed will be the rear pressure plate Install the snap ring and ensure it seats fully in the groove 6 With a feeler gauge check the clearance between the snap ring and the pressure plate while exerting downward pressure on the plate The clearance should be 0 021 to 0 046 inches 0 533 1 168 mm If the clearance is not within specifications refer to the Clutch Plate Selective Snap Rings chart for the correct size snap ring Install the correct size sna
327. he crane and move it to a clean work area INSTALLATION 1 Install the eyebolts to be used for lifting the swivel 2 Carefully position the swivel into place on the crane 3 Before lowering the swivel completely into the carrier bearing plate connect the hydraulic lines to the spool of the swivel as tagged during removal 4 Connect the hydraulic lines to the barrel as tagged during removal TM 10 3950 672 24 1 5 Secure the swivel mounting plate to the carrier bearing plate with the capscrews and lockwasher Torque the capscrews to 31 Ib ft 42 N m 6 Unhook the lifting device from the eyebolts and remove the eyebolts and lifting device 7 Install the electrical swivel Refer to ELECTRICAL SWIVEL Installation in this Section 8 Remove the blocking material from the lift cylinder 9 Activate all systems cycle all functions and observe for proper operation and any leakage 3 179 3 70 ELECTRICAL SWIVEL TM 10 3950 672 24 1 DESCRIPTION The swivel consists of ten sets of brushes and collector rings and a cover Each brush set incorporates two brushes leads and clips which are attached to a brush holder assembly The collector ring leads are formed into one harness routed downward through the center of the hydraulic swivel The swivel cover is secured with capscrews and washers that attach it to the mounting plate of the electric swivel The mounting plate is attached to the barrel of the hydraulic swive
328. he free flow check valve is provided for venting the oil flows past the main poppet seat to the component to pressure side of the pilot piston be worked A vent is provided for venting the area between the pilot When a load is to be lowered as in retracting the boom piston O rings should weepage occur A second vent is better control is necessary because of the weight of the provided at the adjustment end of the pilot release load For this reason a pilot pressure is used for poppet valve should weepage occur past the O ring seal positioning the main poppet valve which is being held into the spring area against its seat by heavy springs The pilot pressure is sensed from the lowering side of the MAINTENANCE DISASSEMBLY ASSEMBLY NOTE NOTE Do not remove the allen head plug on the top end of the It is recommended that all O rings holding valve and backup rings be replaced at 292 assembly with new parts 1 Remove the adjusting stem assembly from the valve by turning the nut counterclockwise 1 Install all O rings and backup rings onto the valve and lubricate with clean hydraulic oil prior to assembly 2 Remove the stem spring and spool from the valve 2 Install the plug in the base of the valve 3 Remove the plug from the base of the valve 3 Install the spool spring and stem into the valve body 4 Remove all O rings and backup rings from the valve assembly 4 Install the O ring onto the adjusting stem assembly Coat the
329. heck relief valve setting Refer to Solution 4c 4 Low flow a Pump cavitating a Refer to Symptom 1 b Foaming oil b Refer to Symptom 2 E 88 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 4 Low flow Relief valve leaks or set too low c Check relief valve for foreign continued particles Speed too low d Increase engine speed Oil too hot e Check temperature Refer to Symptom 3 Solution a through e 5 Failure to build pressure Defective relief valve a Check and reset or replace Low oil supply b Fill reservoir DISASSEMBLY 1 Clean the unit thoroughly with solvent kerosene or other non corrosive cleaning fluid which will not affect rubber components 2 Scribe a line across the three sections of the pump to act as a guide in assembly 3 Remove the six hex screws 3 and two capscrews 2 4 Remove the front cover 5 by lightly tapping the flange with a soft metal hammer 5 The center section 12 will remain attached to either the front cover 5 or back cover 17 Place the drive gear 13 into the unseparated section and while holding the center section 12 tap lightly to separate Be careful to avoid cocking on the dowel pins 7 6 Remove the wear plate 10 and thrust plate 18 Sheft Ses Capecrew Hex Screws Weshers Front Cover V Seal Dowel Pins Gasket Hest Shieid Weer Plate O Rings Center Section Drive Gear Assy Driven Geer Assy
330. here should be continuity at any point If there is no continuity winding is open circuited Replace armature if open circuited Figure 3 42 Checking for Open Circuit Windings 3 244 TM 10 3950 672 24 1 d Set multimeter for ohms and touch one probe to positive brush holder plate and other probe to the holder plate refer to Figure 3 43 There should be no continuity If there is continuity replace brush holder Figure 3 43 Checking Brush Holder e Using a multimeter touch one probe to field winding end of brush and other probe to bare surface of yoke body refer to Figure 3 44 There should be no continuity If there is continuity field windings are grounded Replace yoke assembly Figure 3 44 Checking Field Coils f Using a multimeter touch one probe to lead wire and other probe to brush refer to Figure 3 45 There should be continuity If there is no continuity field windings are open circuited Replace yoke assembly Figure 3 45 Checking for Open Field Coil 3 245 TM 10 3950 672 24 1 3 99 2 Bench Test NOTE Refer to TM 10 3950 672 24 2 Electrical Section for starter removal and installation data a Turn overrunning clutch 19 Figure 3 47 clockwise by hand Pinion 19 should turn freely b Turn overrunning clutch counterclockwise A definite resistance should be felt If a definite resistance is not felt clutch assembly is defective disassemble the starter clutch c If armature turns fre
331. hers 4 three lockwashers 3 and three nuts 2 Connect two electrical connectors for light assembly 1 to crane electrical harness Connect negative leads to battery negative post LEGEND 1 Light Assy 6 Retaining Ring 2 Nut 7 Lens 3 Lockwasher 8 Gasket 4 Washer 9 Bulb 5 Bolt Figure 3 38 Tail Brake and Turn Signal Light 3 234 TM 10 3950 672 24 1 3 97 BACK UP ALARM 3 97 1 Removal a Disconnect negative battery cable and two electrical leads from battery Tag and disconnect two electrical leads from back up alarm 11 Figure 3 39 c Remove two nuts 2 two lockwashers 3 two washers 4 and back up alarm 1 from crane frame 3 97 2 Installation a Install back up alarm 1 Figure 3 39 on crane frame with two washers 4 two lockwashers 3 and two nuts 2 Connect two electrical leads to back up alarm 1 and remove tags c Connect negative battery cable and two electrical leads to battery RIGHT REAR FRAME LEGEND 1 Alarm 2 Nut 3 Lockwasher 4 Washer Figure 3 39 Back up Alarm 3 235 TM 10 3950 672 24 1 3 98 CHASSIS WIRING HARNESS 3 98 1 Removal oD o s 3 NOTE To aid removal refer to electrical schematic in Appendix F Disconnect negative battery cable 150 and wires 70 and 51 J from negative battery post Tag and disconnect wire 13A from right headlight Tag and disconnect wire 13B from right front side marker light
332. ice NOTE Some elements are partially covered by a plastic sleeve with fins The covered portion can be cleaned with water or air without removing the sleeve Use a stiff fiber not wire brush to remove oil and grease deposits from the sleeve and fins Never remove the sleeve and fins from the element Cleaning With Compressed Air 0262 1 CAUTION PRESSURE ATTHE AIR NOZZLE MUST NOT EXCEED 100 PSI 689 KPA 6 89 BAR 1 Direct a jet of clean dry air from the inside of the filter element perpendicular to the pleats 2 Move the air jet up and down along the pleats slowly rotating the element until no more dust is being removed Do not rupture the element with the nozzle or the air jet Cleaning With Water 1 The elements can be cleaned by washing with water and a good non sudsing detergent Direct a jet of clean dry air from the inside of the filter element E 9 TM 10 3950 672 24 1 When the loose dust and soot have been removed the element is ready to be washed CAUTION NEVER USE GASOLINE OR SOLVENTS CLEAN THE ELEMENTS 2 Dissolve the detergent in a small amount of cool water 3 Add warm water approximately 100 degrees F 38 degrees C to get the proper proportions of detergent and water about one cup of detergent to five gallons of water 4 Soak the element in the solution for at least 15 minutes 0282 2 5 Agitate the element for about two minutes to loosen the dirt
333. ice a year to ensure against a buildup of rust and scale NOTE Remove the radiator cap when draining the system to ensure proper draining E 15 TM 10 3950 672 24 1 CLEANING WARNING THE COOLING SYSTEM IS PRESSURIZED PERSONNEL INJURY FROM SCALDING MAY RESULT WHEN REMOVING THE RADIATOR CAP AFTER THE COOLANT HAS REACHED OPERATING TEMPERATURE ALLOW THE ENGINE TO COOL BEFORE BEGINNING THE CLEANING OPERATION 1 Turn on coolant flow to the heater to allow complete circulation during the draining cleaning and flushing operation 2 Slowly open radiator cap to allow any pressure in the system to escape Then open the radiator drain cock and drain the engine coolant into a suitable container Open the drain cock on the engine block and drain the coolant from the engine Close both drain cocks 3 Following the cleaning compound manufacturer s instructions pour cleaning compound into radiator Then fill coolant system with clean fresh water Install the radiator cap 4 Place a clean suitable drain pan under the radiator to catch any overflow from the overflow bottle Do not allow cleaning solution to spill onto painted surfaces of the vehicle 5 Start the diesel engine and allow the engine coolant temperature to reach its operating temperature of 1800 F 82 C or above If necessary cover the radiator to achieve the necessary operating temperature but do not allow the coolant to boil over Allow the engine to i
334. ice something wrong which could damage the equipment if your continue operation stop operation immediately Record all deficiencies and shortcomings along with eh corrective action taken on a DA Form 2404 The Number column is the source for the numbers used on the TM Number column on DA Form 2404 2 9 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES The item numbers of the table indicated the sequence of the PMCS Perform at the intervals shown below a Do your Q PREVENTIVE MAINTENANCE quarterly every three months b Do your S PREVENTIVE MAINTENANCE semi annually every six months c Do your A PREVENTIVE MAINTENANCE annually once every year 2 3 TM10 3950 672 24 1 d Do your B PREVENTIVE MAINTENANCE bi annually once every two years e Do your H PREVENTIVE MAINTENANCE at the hour interval listed f Do your M PREVENTIVE MAINTENANCE monthly once a month If something doesn t work troubleshoot it according to the instructions in this manual Always do your preventive maintenance in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If anything looks wrong and you can t fix it write it down on your DA Form 2404 If you find something seriously wrong report it to direct support as soon as possible WARNING Dry cleaning solvent PD 680 is toxic and flammable Wear protective goggles and gloves and use only in a well ventilated area Avoid
335. icial respiration refer to FM 21 11 SAFT 3 TM10 3950 672 24 1 SAFETY SUMMARY Continued WARNING Ensure the battery is disconnected before performing any maintenance on an electrical circuit which is not fused WARNING Lead acid battery gases can explode Do not smoke have open flames or make sparks around the battery If a battery is gassing it can explode and cause injury to personnel Always wear safety goggles and acid proof gloves when handling the battery Avoid contact with the electrolyte If spills occur take immediate action to stop the burning effects Wash skin with cold running water Flush eyes with cold water for at least fifteen minutes If taken internally drink large amounts of water or milk followed with milk of magnesia beaten egg or vegetable oil In each case SEEK IMMEDIATE MEDICAL HELP If electrolyte is spilled on clothing wash at once with cold water and neutralize with baking soda or household ammonia solution WARNING Always disconnect negative battery cable first to reduce chance of shorting and personal injury Such disconnections prevent electrical shock to personnel or equipment WARNING Always connect positive battery cable first to reduce chance of shorting and personal injury WARNING Always use the same fastener part number or equivalent when replacing fasteners Do not risk using a fastener of lesser quality and do not mix metric and inch customary fasteners Mismatched or inco
336. id level b Low main control pressure in reverse Low reverse servo leaking d Low planetary one way clutch damaged e Reverse clutch drum bushing damaged f Reverse clutch stator support seal ring grooves worn or damaged g Reverse clutch piston seals cut or worn h Looseness in the driveshaft U joints or engine mounts a Damaged or worn planetary one way clutch a Intermediate band out of ad justment b Improper band or clutch appli cation or control pressure c Damaged or worn intermediate servo piston seals and or internal leaks d Dirty or sticking valve body body e Polished glazed intermediate band or drum a Improper band and or clutch application or oil pressure control system b Damaged or worn governor Sticking governor c Valve body loose d Dirty or sticking valve body e Cross leaks between valve body and case mating surface 3 51 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION a Perform fluid level check b Control pressure test c Air pressure test visually in spect seal rings and piston bore d Determine cause of condition Service as required e Determine cause of condition Service as required f Determine cause of condition Service as required g Determine cause of condition Service as required h Service as required a Service or replace one way clutch Adjust intermediate band Perform contro
337. ides a signal to a quantity indicator on the instrument panel in the cab b Fuel Pump The diesel engine has a positive displacement gear type metering fuel pump driven by an engine power take off through a coupling to one of the accessories The pump supplies fuel at low pressure to the injectors where the high pressure necessary for atomization of the fuel is created The fuel is finely atomized as it is injected into the cylinder and ignited by the heat of the compression it is metered also before injection to meet the load requirements imposed upon the engine Surplus fuel returning from the injectors is bypassed back to the fuel tank or to the inlet side of the pump The continuous flow of fuel through the injectors helps to cool the injectors and to bypass air from the system C Fuel Filter The gasoline engine uses a replaceable cartridge type filter in the fuel system to remove impurities from the fuel The filter is installed between the pump and the transfer pump outlet 3 25 TM 10 3950 672 24 1 3 13 FUEL TANK 3 13 1 Removal ao Position a suitable container under the fuel tank and drain all fuel from the tank Tag and disconnect the fuel line s from the tank Disconnect the electrical lead from the fuel quantity sender unit Support the weight of the tank and remove the bolts nuts and washers securing the tank to the mounting brackets Remove the tank If a new tank is to be installed remove the fittings and
338. ightened is in the top position 2 Ensure the wheel assembly is positioned properly on the hub 3 Torque the lug nuts to 300 Ib ft 407 Nem in the sequence shown in the Lug Nut Torquing Sequence figure 2 ALL WHEELS WITH 6 OR MORE POSITIONS 4637 2 Lug Nut Tightening Sequence ERE ELM Description Troubleshooting Functional Check Power Steering PUMP tenet Description Troubleshooting n AStA A O REESE Steering Control Valve nnns nnns nnns Description Theory of Operation Removal Installation Steer Cylinder 1 Description Removal Installation Section 5 Steering System 3 80 TM 10 3950 672 24 1 E ov TM 10 3950 672 24 1 3 32 STEERING SYSTEM DESCRIPTION The steering system consists of a power steering pump a steering control valve and a steer cylinder The steering pump is driven by the engine and supplies hydraulic oil from the reservoir to the steering control is turned the steering control valve will route the hydraulic flow t the applicable end of the steer cylinder The rod of the steer cylinder will act against the applicable spindle to move the rear wheels in the desired direction valve Depending upon the direction the
339. ilt or shift Leave the lifting device attached NOTE If the same bearing is to be used again mark the position of the bearing on the carrier so it can be installed in the exact position it was before removal 13 Remove the bolts and washers attaching the turntable bearing to the carrier NOTE Depending upon the manufacturer the bearing weighs between 134 and 139 pounds 60 7 and 63 0 kg Ensure the bearing lifting device is capable of supporting the weight 14 Using the lifting device remove the turntable bearing from the carrier INSPECTION Check the bearing teeth for chipping or cracking If any evidence of these is found replace the bearing Ensure the bolt holes are free of dirt oil or foreign material INSTALLATION CAUTION ANYTIME A GRADE 8 TURNTABLE BOLT HAS BEEN REMOVED IT MUST BE REPLACED WITH A NEW GRADE 8 BOLT NOTE Installation is in the travel position 1 Using an appropriate lifting device set the turntable bearing in position on the carrier If the same bearing is being used position it as marked prior to removal 2 Install new bolts nuts and washers securing the bearing to the carrier Refer to Inner Race Torquing in this subsection NOTE Installation is in the travel position 3 Using an appropriate lifting device align the superstructure over the bearing on the carrier Lower the superstructure into position on the bearing 4 Install the bolts and washers Refer to Outer R
340. in and fill with proper vis cosity oil b Oil supply contaminated b Drain clean filter and fill with clean oil c Pump cavitating Refer to Symptom 1 d System relief valve bypassing Check relief valve setting Re fer to Solution 4c 4 Low flow a Pump cavitating a Refer to Symptom 1 b Foaming oil b Refer to Symptom 2 3 83 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 4 Low flow Relief valve leaks or set too Check relief valve for foreign low particles Speed too low Increase engine speed Oil too hot Check temperature Refer to Symptom 3 Solutions a through d 5 Failure to build pressure Defective relief valve Check and reset or replace 3 33 1 3 33 2 3 33 3 Low oil supply Fill reservoir Removal a Tag and disconnect the hydraulic lines at the power steering pump Cap the lines and openings b Remove the bolts and washers securing the pump to the engine Remove the pump Installation a Install the pump and secure with the bolts and washers Torque the bolts to 165 Ib ft 224 Nem b Connect the hydraulic lines as tagged during removal Test After the pump has been installed run it for two to three minutes before pressurizing ensuring the gears are constantly running in oil Apply pressure gradually for an additional five minutes and monitor the pressure with a pressure gauge installed in a plugged outlet line Ensure a sufficient quantit
341. ing a Insufficient hydraulic volume b Damaged relief valve c Damaged swing motor a Control valve spool sticking or valve otherwise damaged a Improper port connections a Air in system b Motor binding 3 140 a Level crane using outriggers b Repair or replace relief valve c Adjust valve Refer to VALVES in Section 6 d Replace hose or fitting e Torque turntable bearing a Check delivery of hydraulic pump Ensure sufficient fluid is available to pump Check pump drive speed Adjust repair or replace valve Repair or replace motor Repair or replace valve Reverse port connections a Refer to Section 6 HYDRAU LICS for removal of air from the System b Repair or replace motor 3 57 SWING MOTOR TM 10 3950 672 24 1 Description The swing motor is mounted on the brake housing and drives the gear reducer through the brake assembly The swing motor is a hydraulic characteristics It has only three moving parts the commutator valve the drive and the gerotor star The motor has two ports for connection to the hydraulic gerotor type with low speed and high torque system MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL NOTE Indents in the swing motor housing are for clearance and for accessibility to the turntable bolts with the swing motor installed Before removing the swing motor note the orientation of the housing indents and
342. inst the pilot release poppet until it unseats the pilot release poppet valve which port oil to the return side of the directional control valve The free flow check valve is provided for venting the pressure side of the pilot piston A vent is provided for venting the area between the pilot piston O rings should weepage occur A second vent is provided at the adjustment end of the pilot release poppet valve should weepage occur past the O ring seal into the spring area MAINTENANCE DISASSEMBLY NOTE Do not remove the adjustment stem or locknut during disassembly 1 Remove the adjustment end of the valve by turning the large nut counterclockwise Do not remove the adjusting stem 2 Remove the O ring from the nut 3 Remove the valve spring and seats 4 Remove the inner sleeve from the valve 5 Remove the plug from the inner sleeve Remove the spring and ball 6 Remove the O rings and backup rings from the valve E 107 ASSEMBLY NOTE It is recommended that all O rings and backup rings be replaced with new parts at assembly 1 Install all backup rings and O rings onto the valve 2 Install the ball and spring into the sleeve and secure with the plug 3 Coat the sleeve with clean hydraulic oil and install the sleeve into the valve 4 Install the valve seats and spring into the valve body 5 Install the O ring onto the adjustment end nut and install the adjusting stem into the valve
343. ion E 162 Cab Heater Defroster Hot Water Disassembly nnna E 162 Cab Heater Defroster Hot Water Inspection nnne nennen nns E 162 Cab Heater Defroster Hot Water Maintenance E 162 Cab Heater Defroster Hot Water Theory of Operation E 162 Cable Follower Description Replacement and Repair nennen nnne 3 186 Camshaft and Gear Inspection eee ei nn eerie 5 297 Camshaft and Tappet Replacement Procedures 5 199 Camshaft Bushing Installation 2 000 eee eee nsns 5 291 ttm 5 297 Camshaft Expansion Plug Installation 5 290 Camshaft Gear Replacement 4 2224 0000 0 eee 5 302 Camishalt Specifications lec E 5 186 Camshaft Tappets and Push Rods Operation and Description 5 163 Capscrew Markings and Torque Values 5 364 Index 2 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page C continued Chassis Wiring 3 240 Chassis Wiring Harness Removals 2
344. ion RR E 107 Holding Valve E 105 Holding Valve 107 Holding Valve ET Te ze o RM E 107 Holding Valve 105 Holding Valves Description and 10200000 3 113 Hook Block Description Replacement and 3 162 Hub Brake and Spindle 3 67 Hydraulic Brakes Cleaning and 1 1 E 96 Hydraulic Brakes 96 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page H continued Hydraulic Brakes Description and Replacement sss 3 73 Hydraulic Brakes 5 96 Hydraulic Brakes 9 96 Hydraulic Brakes Wheel Cylinder 98 Hydraulic Filter nnne nnn nnns nsns 3 104 Hydraulic Hoses Lines and Fittings 3 97 Hydraulic Hoses Lines and Fittings 3 97 Hydraulic Oil Draining and Flushing
345. ion positive battery cable 5 in crane and connect to starter with lockwasher 7 and nut 6 d Position negative battery cable in crane and connect to crane chassis ground WARNING Always connect positive battery cable first to reduce chance of shorting and personal injury e Clean positive battery post and connect positive battery cable clamp 3 at battery 2 f Clean negative battery post and connect negative battery cable clamp 1 at battery 2 1 J e 5 eA 4 STARTER 2 P qg V MN CRANE CHASSIS GROUND LEGEND 1 Neg Cable Clamp 9 Lockwasher 2 Battery 10 Bolt 3 Pos Cable Clamp 11 Nut 4 Neg Battery Cable 12 Lockwasher 5 Pos Battery Cable 13 Bolt 6 Nut 14 Wire Lug Alternator Terminal 7 Lockwasher 15 Wire Lug Oil Cooler Lockout Solenoids 8 Nut 16 Wire Lug Turnsignal Flasher Panel Gauges Figure 3 31 Battery Cables 3 219 TM 10 3950 672 24 1 3 87 FUSE AND RELAY PANEL 3 87 1 Removal oaoop Disconnect negative leads from negative battery post Tag and disconnect all leads to both fuse blocks Tag and disconnect all leads to the terminal blocks Remove the nuts and lockwashers securing the panel to the cab wall and remove the panel If necessary remove the screws lockwashers and nuts securing the terminal blocks and fuse blocks 3 87 2 Installation a If removed install the two fuse blocks and secure with the screws lockwashers an
346. ipe plug 3 44 DIRECTIONAL CONTROL VALVE TM 10 3950 672 24 1 DESCRIPTION The directional control valves are four way three position valves with either an open or closed spool Whether a valve has an open or closed spool is determined by whether with the spool in the neutral position the work ports are open to the reservoir return passage If the work ports are open to the reservoir return passage the valve is classified as an open spool type if they are not the valve is a closed spool type Refer to the Valve Usage Table for circuit applicability by valve type Additionally the valve spool is spring loaded to the neutral position The open spool directional control valve is constructed with a through passage to allow flow to pass to the next valve s in the bank and on to the reservoir when the valve spool is in the neutral position By positioning the valve spool to a work position the through passage is blocked and flow is diverted to the dead end parallel passage This causes flow to be directed to the component s open supply work port Return flow is routed from the return work port to the reservoir return passage by the opposite end of the valve spool This flow pattern is applicable in either direction the valve may be positioned If it is necessary to open more than one directional control valve in the same valve bank it may be required to partially close or feather the valves that are located in the bank first in r
347. ir or replace cylinder barrel m Replace all cylinder seals n Replace all seals and retorque or replace piston TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 3 extend Telescope cylinder will not Low hydraulic oil level Relief valve malfunctioning Excessive load Clogged hose and fittings Broken valve linkage Broken valve spool Damaged piston seals Damaged piston i Bent boom section Replenish oil to proper level Repair or replace relief valve Reduce load Replace hose or fittings Refer to manufacturer s specifications Repair or replace linkage Replace valve Replace all cylinder seals h Replace piston and all cylinder seals i Replace damaged boom sec tion j Broken hydraulic pump cou j Replace broken hydraulic pump pling coupling k Worn or damaged hydraulic k Repair or replace pump sec pump section tion 4 retract Telescope cylinder will not Low hydraulic oil level Relief valve damaged Excessive load Inoperative check valve Clogged hose and fittings Broken valve linkage Broken valve spool Broken piston a Replenish oil to proper level b Repair or replace relief valve c Reduce load Refer to load chart d Replace check valve e Replace hose or fittings Refer to manufacturer s specifications f Replace or repair linkage g Replace valve section h Replace piston and all cylinde
348. ired Depress the brake pedal and close the bleeder valve then release the brake pedal 3 Repeat steps 1 and 2 for the remaining wheel cylinders 4 Remove the master cylinder reservoir plugs and check the fluid level Add brake fluid as required 3 75 TM 10 3950 672 24 1 BRAKE SHOE ADJUSTMENT 1 Two eccentric cams ride against the inside surface of each brake shoe The cams can be adjusted by adjusting the bolts on the back of the backing plate with a 15 16 inch open end wrench 2 Upon assembly first actuate the brake to center the shoes in the drum TO EXPAND TO EXPAND SHOE Brake Shoe Adjustment 3 Adjust the liners out until a slight drag can be felt while the drum is in rotation then back off the adjusting bolt until the drum can rotate freely Subsequent adjustments to compensate for lining wear may be made by moving the shoe in or out by turning the eccentric cam in the desired direction 3 30 BRAKE MASTER CYLINDER TM 10 3950 672 24 1 DESCRIPTION The brake master cylinder is located under the deck to the front of the cab The master cylinder which has its own oil reservoir is actuated directly by linkage to the brake pedal The master cylinder incorporates two integrally designed pistons the large piston for large volume and the small piston for high pressure Transfer from low pressure large piston to high pressure small piston is accomplished by means of a metered pressure relief valve
349. is always the number one consideration when working around machines Safety is a matter of thoroughly understanding the job to be done and the application of good common sense It is not just matter of do s and don ts Stay clear of all moving parts CLEANLINESS An important item in preserving the long life of the machine is keeping dirt out of working parts Enclosed compartments seals and filters have been provided to keep the supply of air fuel and lubricants clean It is important that these enclosures be maintained Whenever hydraulic fuel lubricating oil lines or air lines are disconnected clean the adjacent area as well as the point of disconnect As soon as the disconnection is made cap plug or tape each line or opening to prevent entry of foreign material The same recommendations for cleaning and covering apply when access covers or inspection plates are removed Clean and inspect all parts Be sure all passages and holes are open Cover all parts to keep them clean Be sure parts are clean when they are installed Leave new parts in their containers until ready for assembly Clean the rust preventive compound from all machined surfaces of new parts before installing them REMOVAL AND INSTALLATION When performing maintenance do not attempt to manually lift heavy parts when hoisting equipment should be used Never locate or leave heavy parts in an unstable position When raising a portion of a crane or
350. is necessary CAUTION DO NOT OVERTIGHTEN THE SCREW OR LOCKNUT CAUTION DO NOT HOLD THE RELIEF VALVE OPEN FOR MORE THAN ONE MINUTE AT A TIME NOTE To adjust a relief valve turn the adjustment screw in to increase or out to decrease until the proper setting is reached MAIN RELIEF SETTINGS Valve Bank Setting psi kPa bar Two Section 2500 17 237 172 3 Three 3000 20 685 206 8 CIRCUIT RELIEF SETTINGS Valve Bank Circuit Relief psi kPa bar Main Relief psi kPa bar ek n a a 3000 20 685 206 8 Lift dOWD itte ae 350 2413 24 eet 3000 20 685 206 8 Telescope 2 Section Boom Retract 1000 6 895 68 9 tis 2500 17 237 172 3 SWING usu e tut 17804 12 273 122 7 3 3 A thi ad ed 3000 20 685 206 8 AA N AN br 3000 20 685 206 8 Swing 1 Install the pressure gauge in the test port on the control valve 2 Set the throttle to 1000 rpm 3 Disconnect the hydraulic line to the swing brake release port and cap the line Plug the open port on the brake 4 Swing first one direction then the other holding momentarily in each position Note the maximum 3 109 TM 10 3950 672 24 1 pressure reading at each position If the readings are not 100 psi 689 5 kPa 6 89 bar of that listed in the CIR
351. is prevented from entering the cylinder by a wiper seal O rings are used within the cylinders to prevent internal and external damage MAINTENANCE DISASSEMBLY NOTE Any maintenance requiring disassembly of the cylinders should include replacement of all seals and rings 1 Drain all hydraulic oil from the cylinder 2 Remove the socket setscrew from the barrel on the rod end of the cylinder WARNING DO NOT USE AIR PRESSURE TO REMOVE THE CYLINDER ROD ASSEMBLY USE ONLY A SOURCE OF CONTROLLED HYDRAULIC OIL PRESSURE IF THE ROD ASSEMBLY IS HARD TO MOVE CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD DAMAGE TO THE ROD SURFACE MAY CAUSE UNNECESSARY MAINTENANCE AND EXPENSE 3 Withdraw the cylinder rod assembly from the barrel and move it to a clean work area NOTE It is advisable to cover the cylinder barrel opening to avoid contamination 3 120 4 Secure the cylinder rod to prevent it from moving Remove the setscrew from the piston and rod 5 Unscrew the piston from the rod 6 Remove the head from the rod CAUTION WHEN REMOVING THE SEALS AND RINGS AVOID SCRATCHING THE GROOVED AND GLAND SURFACES NOTE Aligning discarded seals and rings in the order of disassembly will facilitate installation of new seals and rings 7 Remove the seal assemblies from the outside of the piston and the backup rings and O ring from the inside of the piston NOTE Note the s
352. isassembly neret ede dide deed nie deat ra tias 5 246 Cylinder Head Removal In Chassis Overhaul 5 220 Cylinder Head Valve Inspection Specifications 5 358 Cylinders General Maintenance 2 3 119 D Damage from Non Filtered Air 0 5 112 em MELLE 5 2 Dataplate Nameplate Fuel Pump 5 3 Definition OF EIER 4 2 Delivery Valves Back Leakage Valves on Lucas CAV Pumps Troubleshooting 222 5 76 Deprocessing Unpacked Equipment 0 100 00 e eene e eee nnn nnn n nnnnet 2 2 Destruction of Army Materiel to Prevent Enemy Use 0 1 00 1 1 Diagnosing Air System Malfunctions 5 111 Diagnosing Base Engine Component 5 169 Diagnosing Electrical Malfunctions 5 147 Diagnosing Lubricating System Malfunctions ssesssssssssssssssssseeesee eene n nennt 5 121 Dipstick T be Replac ment th Pare puoi t tabe pate Eten 5 292 Directional Control Valve Assembl
353. isting of the port plate with a built in balanced motor that converts hydraulic oil flow into check valve a cam ring assembly containing the rotor rotary mechanical motion The motor consists of four vanes vane springs and cam ring and the end cap basic subassemblies a body or housing and shaft with a assembly consisting of the end cap and needle bearing permanently lubricated bearing a front port THEORY OF OPERATION During operation hydraulic oil flows through either one pressure applied against the vanes forces the rotor to of the two ports in the end cap and is directed to both turn and at the same time rotates the motor shaft As sides of the cam ring assembly through the cast ports in the rotor turns the oil moves to the discharge ports in the end cap and port plate assembly The the port plate and end cap MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 External leakage a Seal failure a Replace seal b Defective casting b Replace casting 2 Leakage at fittings Cracked casting Replace Defective threads Replace Damaged O ring Replace Burr Stone or file flat 3 Loss in speed under load Lowinlet pressure a Check pressure Excessive back pressure at out b Check pressure Check the line let for restrictions c Scored port plate or end cap c Relap flat to clean up d High oil temperature d Use heavier oil adjust relief valve setting E 147 SYMPTOM PROBABLE CAU
354. ith a high quality extreme pressure grease 1 Install the bearings 34 into the inside of all three primary planet assembly gears 33 2 Install two of the gears 33 with bearings 34 into the primary planet assembly 20 with the planet shafts 32 When pressing in the planet shafts 32 ensure the roll pin 31 hole is aligned with the hole in the primary planet assembly 20 housing 3 Secure the two planet shafts 32 into position with the roll pins 31 4 Install the spacer 36 into the splined end of the primary planet assembly 20 and under the two previously installed gears 33 5 Install the other gear 33 with bearing 34 into the primary planet assembly 20 with the planet shaft 32 When pressing in the planet shaft 32 ensure the roll pin 31 hole is aligned with the hole in the primary planet assembly 20 housing 6 Repeat steps 1 through 5 for the secondary planetary assembly 23 7 Press the upper bearing 29 onto the output shaft 27 and press the output shaft into the hub 28 CAUTION USE EXTREME CARE WHEN INSTALLING THE OIL SEAL 30 INTO THE HUB 28 ENSURE IT IS FLUSH WITH THE HUB 28 AND NOT DAMAGED ON THE OUTPUT SHAFT 27 SPLINES E 130 TM 10 3950 672 24 1 8 Install the oil seal 30 into the hub 28 ensuring that it is flush with the hub 28 and not damaged on the splines of the output shaft 9 Turn the assembly over with the output shaft 27 down 10 Insta
355. ith the bolts and washers 2 Connect the hydraulic hoses to the control valve as tagged during removal 3 Prior to securing the cover to the front of the crane cab start the engine and check for proper operation and any leaks 4 Connect any wiring disconnected during removal Install and secure the cover to the front of the cab 3 35 STEER CYLINDER TM 10 3950 672 24 1 DESCRIPTION A single 3 inch 7 62 cm hydraulic steer cylinder is installed on the rear axle The cylinder is attached by a rod end assembly to link plates that are attached to the spindle assemblies Depending on the direction the steering wheel is turned hydraulic oil from either the R port or L port of the steering control valve is directed to the appropriate side of the steer cylinder Flow to the cylinder causes the cylinder to extend or retract thus turning the wheels MAINTENANCE NOTE INSTALLATION Refer to CYLINDERS in Section 6 for 1 Position the steer cylinder to the frame Disassembly and Assembly secure with the bolts and washers Torque the bolts procedures to 75 Ib ft 102 Nem REMOVAL 2 Align the rod end assemblies to the spindle link plates ensuring the rod end is equally adjusted on both 1 Tag and disconnect the hydraulic hoses from sides of the cylinder rod Install the bolts locknuts the steer cylinder ports Cap or plug all openings 2 Remove the bolts locknuts and washers secur ing the rod end assembly on both side
356. ith two screws 4 Install handle 3 on shaft and light assembly 5 with bolt 1 and cylindrical nut 2 Connect spotlight assembly electrical connector to crane electrical harness Connect negative leads to battery negative post 3 227 TM 10 3950 672 24 1 3 92 DOME LIGHT 3 92 1 3 92 2 The dome light switch which is integral to the base 1 Figure 3 34 is not replaceable If damaged replace the entire dome light assembly Removal Disconnect negative battery cable and two electrical leads from battery Disconnect electrical connector from crane electrical harness Remove three screws 2 Figure 3 34 lens 3 and bulb 4 from dome light base 1 Remove three nuts 5 three lockwashers 6 three screws 7 and dome light base 1 from cab frame Installation Install dome light base 1 Figure 3 34 cab frame with three screws 7 three lockwashers 6 and three nuts 5 Install bulb 4 and lens 3 in dome light base 1 with three screws 2 Connect electrical connector to crane electrical harness Connect negative battery cable and two electrical leads to battery LEGEND Light Assy Screw Lens Bulb Nut Lockwasher 3 Screw Figure 3 34 Dome Light 3 228 TM 10 3950 672 24 1 3 93 TURN SIGNAL LIGHT FRONT 3 93 1 Removal Disconnect negative battery cable and two electrical leads from battery Disconnect light assembly 1 el
357. ition change interval should be 6 to 8 months and mild condition interval should be once yearly A large round access cover on the top center of the reservoir provides access for cleaning 3 101 This opening may also be used to fill the reservoir after it has been completely drained The oil filter is located in the reservoir The filter housing contains a replaceable 3 micron filter element An indicator on the filter tells what condition the filter is in i e dirty or clean whether the filter is functioning or by passing or if an element was not installed The filter bypass valve is either positively closed when normal filtration is in progress or is positively open when the filter has reached its bypass setting OIL COOLER The air cooled hydraulic oil cooler is mounted to the front of the crane under a bolt on cover The oil cooler consists of a fan an electric motor and a temperature switch The fan draws cool air through the cooling fins on the cooler The oil cooler cools the oil utilized in the swing and telescope circuits Return oil flows from the oil cooler directly to the return filter in the reservoir A temperature switch installed in the back of the reservoir controls the operation of the fan motor When the temperature switch senses a temperature of 160 degrees F 71 degrees C the motor is energized and continues running until the oil temperature is reduced to 148 degrees F 65 degrees C PUMP DISTRIBUTION
358. ka and a part of the continental United States during the winter Optional viscosity lubricants should be used whenever vehicles are parked at outside temperatures lower than the minimum given for the Standard lubricant The proper viscosity of oil for the specific component shall be selected from the table of ambient temperatures Where more than one lubricant can be selected from this table the high viscosity oil should be used However experience has shown that the use of an S A E 140 viscosity grade lubricant Rockwell specifications 0 76 0 76 A and 0 76 B will result in longer gear life Unusual temperature or operating conditions may require other more specific lubricant recommendations Rockwell will review these circumstances upon request and make optional gear oil or grease recommendations It is essential that all details of vehicle operation loads area temperatures etc are clearly and completely stated when applying to Rockwell Engineering department for an optional lubricant recommendation Multigrade and synthetic lubricants may be used provided the complete specifications including viscosity stability in service of each viscosity grade listed are met CAUTION THE SYNTHETIC LUBRICANT MUST COMPATIBLE WITH THE STANDARD COMMERCIAL SEALS USED IN THE AXLE PINION AND WHEEL END OTHERWISE SPECIAL SEALS MUST BE INSTALLED FURTHER THE SEALS USED MUST PASS ROCKWELL SPECIFICATION 4 11 WHEN TES
359. ke and then a very noticeable pop will be felt with a resulting pedal drive To correct this condition perform the following steps 1 Remove the filler plug to gain access to the adjustment screw in the top of the relief valve assembly 2 Using a screw driver release the adjustment by turning counter clockwise on full turn at a time After each adjustment try the brake pedal for proper feel Depress the brake pedal both rapidly and slowly No pedal travel should be lost If adjustment by release of the relief valve adjustment screw will not correct pedal action remove the entire relief valve assembly Disassemble the relief valve and wash all parts in alcohol to eliminate piston sticking within the body of the valve If the corrections above do not correct pedal action the relief valve may be mechanically defective If so replace with a new valve If Set Too Low If the setting of the relief valve is too low loss of pedal low pedal or inconsistent pedal action may occur This is caused by the relief valve releasing the low pressure 3 78 TM 10 3950 672 24 1 piston before full shoe extension has been attained To correct this condition perform the following steps 1 Remove the filler plug to gain access to the adjustment screw in the top of the relief valve assembly 2 Using a screw driver turn the relief valve adjusting screw clockwise Continue to adjust in this direction until pedal travel becomes constant
360. king heat spotting scoring pitting and distortion Replace damaged brake drums 7 Inspect the wheel cylinders for leaks and smooth action Refer to WHEEL CYLINDER MAINTENANCE WHEEL CYLINDER MAINTENANCE When the brake shoes are replaced or a cylinder is leaking check to see if the wheel cylinders need overhauling or replacing There are two types of wheel cylinder failures leaks and poor cylinder action CAUTION LEAKS WHICH COAT THE OUTSIDE OF THE BOOT AND CYLINDER WITH FLUID CAUSE A DECREASE FLUID LEVEL IN THE RESERVOIR OR DAMPEN AND STAIN THE BRAKE LININGS ARE DANGEROUS THESE LEAKS CAN CAUSE THE BRAKES TO GRAB OR FAIL AND MUST BE IMMEDIATELY CORRECTED CONTAMINATED LININGS MUST BE REPLACED Cylinder leaks can be caused by a Wrong type of brake fluid causing the seals to leak CAUTION ENSURE THE CORRECT BRAKE FLUID AND SEALS ARE USED THE USE OF THE WRONG BRAKE FLUID CAN DAMAGE THE CUP SEALS OF THE WHEEL CYLINDER DIFFERENT TYPES OF BRAKE FLUID MUST NOT BE MIXED REFER TO THE OPERATORS MANUAL TM 10 3950 672 10 FOR CORRECT LUBRICATION b Corrosion or damage on the surface of the cylinder bore Worn or oversize cylinder bore d Damaged seal cups To find leaks that are not immediately visible pull back the cylinder boot A small amount of fluid on the inside of the boot is normal Unless other conditions causing poor brake performance are known the wheel cylinder must be checked C
361. l MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL 1 Perform steps 1 through 3 of HYDRAULIC SWIVEL Removal in this section 2 Remove the bolts lockwashers and nuts securing the swivel cover Remove the cover NOTE On swivels equipped with crimp type connectors on the collector core wires do not disconnect the collector core wires at the top of the swivel assembly 3 Tag and disconnect the wires on the top of the Swivel collector 4 Secure the wires in the center harness and if the hydraulic swivel is to be removed route the harness down through the center of the hydraulic swivel 5 Loosen the setscrews securing the electrical Swivel collector to the center post Remove the swivel 6 If necessary remove the springs from the mounting plates INSTALLATION 1 If removed route the collector ring harness through the center of the hydraulic swivel 2 f removed install the springs onto the mounting posts 3 Guide the collector ring assembly over the center post and onto the two springs and pins on the mounting plate 4 Exert a downward pressure on the collector core and brush assembly Compress the springs to a height of 1 625 inches 4 1 cm Secure the collector and brush assembly to the center post by tightening the setscrews in the collector core 5 Connect the wires on the top of the swivel collector Ensure the numbers on the collector ring harness wires match the nu
362. l Feste cnet att HERE URBIUM E 158 Hydraulic Swivel Theory of E 155 Hydraulic System 77738 3 92 Hydraulic System Maintenance 2 000 Aaa aaas 3 92 Hydraulic Systems General Maintenance of 1 6 Hydraulic Tank Inst llatiQniz uoti oor REEF EERRRRR a a aa a A 3 98 NIMES LL ILS MILD E LL 3 98 l J K OE OA ESSICRO Z Qr NEM 5 219 Injection Pump Fuel Shut Off Valve Description Operation 5 145 Injection Pump nnns seis 5 110 Injection Pump Repairs Lucas CAV 5 264 Injection Pump Service 0 77777 5 264 Injection Pump Supply Line 5 93 Injection Pump Timing 5 77 Injection Pump Troubleshooting 0000 5 72 Injector Replacement RR 5 95 Injectors Troubleshooting eee essere 5 80 Instruments Main Control Panel Func
363. l Care seen rennen E 15 Water Cooling System Test 17 Water Cooling System Troubleshooting 12 Water Pump 5 61 Wheels and Tires 3 79 Windshield Wiper Washer Installation 3 6 Windshield Wiper and Washer 3 6 Wire Rope Inspectlon a eU UU e UU tu US etu eU uU 3 165 Wire Rope E bricatlon aee ee s 3 164 Wire Rope Replacement RR 3 167 Wires and Gables General Mairtenance of teo i E Te 1 5 Index 16 6 on ALTERNA TOR DISCHARGING ALTERNATOR 715 NEUTRAL T4 fa Ye SAFETY Tiig i Sw I STAT B 1 RELAY D No te 28 COLO START Sw 198 R A m VACUUM SAFETY SW e IGNITION Sw 35 TACH al 975 DIESEL ENG IGN STR SOL 07 LEGEND d EE SD IS xm y E M NOE Lo 0 PARK o BRAKE CE RELAY i LI VL TER Q Q 0 1 9 DOE LT a WITH Sw I t PANEL lt K LT WITH Sw 1 69 TEMP SW t 52 OPT ud i A 02 o SPOT
364. l and clean hydraulic oil 3 Cycle the crane through all functions several times then return the crane to its stowed position and turn the front and rear wheels to the extreme left Shut down the engine 4 Remove the reservoir drain plug and drain the reservoir Clean and install the drain plug and fill the reservoir with clean oil CAUTION OIL SUPPLY LINES MUST BE CONNECTED TO THE CYLINDERS WHEN FLUSHING THE SYSTEM NOTE Draining the various components will be facilitated by connecting a drain line in place of the disconnect return line 5 Disconnect the return line from the lift cylinder and raise the boom to maximum elevation 6 Connect the cylinder return line and lower the boom to its stowed position Replenish the reservoir oil level as required CAUTION WHEN DRAINING THE STABILIZER CYLINDERS ALWAYS OPERATE EITHER BOTH FRONT OR BOTH REAR CYLINDERS TOGETHER TO PREVENT TWISTING THE CRANE 7 Disconnect the return lines from a pair of outrigger stabilizer cylinders and activate the cylinders to their maximum down position 8 Connect the return lines and raise the stabilizer cylinders to the stowed position Replenish the oil level as necessary 9 Repeat steps 7 and 8 for the remaining two outrigger stabilizer cylinders 10 Disconnect the return line from the telescope cylinder and fully extend the boom 11 Connect the return line and retract the boom Replenish the reservoir oil level as nece
365. l necessary repairs or parts replacement before installing the drive unit in the housing 3 Apply silicone RTV gasket material to the drive unit or the housing in accordance with the procedure under Silicone RTV Gasket Application CAUTION DRIVING THE CARRIER INTO THE HOUSING WITH A STEEL HAMMER WILL DAMAGE THE CARRIER FLANGE 4 Roll the carrier into position on a roller jack Start the carrier into the housing with four flatwashers and nuts equally spaced and tighten alternately to draw the carrier squarely into the axle housing 5 Remove the nuts and flatwashers and install the lockwashers and stud nuts or capscrews Tighten to the correct torque Refer to Torque Values in this package 6 Install the axle shafts in the housing 7 Install the tapered dowels the lockwashers and the stud nuts Tighten the nuts 60 to 75 pounds foot 8 2 to 10 3 kgm NOTE Step 8 is for axles with a two gear gearbox only 8 Install the gearbox Refer to Two Gear Gearbox in the Service Manual 9 Connect the propeller shaft 10 the check hole REPAIR Fill the axle housing until the oil starts to run out CLEANING INSPECTION AND Cleaning Parts having ground and polished surfaces such as gears shafts and bearings should be cleaned in a suitable solvent such as kerosene or diesel fuel oil CAUTION AVOID THE USE OF GASOLINE DO NOT CLEAN THESE PARTS IN A HOT SOLUTION TANK OR WITH WATER AND ALKALINE SOLUTIONS SUCH
366. l pressure test Perform air pressure test Clean service or replace valve Replace or service as required Perform control pressure test b Perform governor check Re place or service governor clean Screen c Tighten valve d Clean service or replace valve body e Service or replace valve body and or case as required TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 13 All upshifts harsh delayed or no upshifts 14 Mushy early all upshifts 15 No 1 2 upshift a Improper fluid level b Manual linkage misadjusted or damaged c Governor sticking as required d Main control pressure too high e Valve body bolts loose or too tight f Valve body dirty or sticking valves g Vacuum leak to diaphragm unit a Low main control pressure pile up upshifts b Valve body bolts loose or too tight c Valve body valve or throttle control valve sticking d Governor valve sticking a Improper fluid level b Manual linkage misadjusted damaged c Governor valve sticking Inter mediate band out of adjustment band d Vacuum diaphragm bent stick ing or leaking e Valve body bolts loose or too tight f Valve body dirty sticking valves g Intermediate clutch band and or servo assembly burnt 3 52 a Perform fluid level check b Check and adjust or service as required c Perform governor test Service d Control pressure tes
367. lar Location for proper location Install the washers 47 flatwashers 46 and screws 45 and secure the collars and deflector Torque the screws 12 to 14 Ib ft 16 to 19 Nem TM 10 3950 672 24 1 Brake Assembly 1 Install the shaft 13 into the clutch 8 with the two bolt holes in the clutch up 2 Install the bearing 17 and spacer 18 on the shaft 13 3 Install the O rings 22 and 23 on the piston 7 5 Install the clutch assembly 8 into the brake housing 6 6 Install the snap ring 19 onto the shaft 4 Install the spacer 20 into the brake housing 6 I 145 TM 10 3950 672 24 1 7 Install a brake stator 9 followed by a brake disc 10 alternating until all discs and stators are installed NOTE The 0 030 diameter vent hole in the piston should be located toward the 10 Position the brake assembly in place on the brake top of the brake housing end housing cover 5 Secure with the capscrews 29 and lockwashers 30 Torque the bolts to 31 Ib ft 42 8 Install the piston 7 into the brake housing 6 Nem Hydraulic Motor 1 Position the motor in place on the motor end housing cover 4 Secure with the washers and bolts Torque the capscrews to 75 Ib ft 101 Nem 9 Install the springs 21 into the piston 7 E 146 TM 10 3950 672 24 1 VANE TYPE MOTOR DESCRIPTION The vane type motor is a fixed displacement rotary plate assembly cons
368. leads to negative battery post 3 28 TM 10 3950 672 24 1 LEGEND 1 Clamp 6 Elbow 2 Cylinder 7 Nut 3 Valve 8 Lockwasher 4 Tubing 9 Washer 5 Atomizer Figure 3 7 Cold Start Assembly 3 29 TM 10 3950 672 24 1 3 17 AIR INTAKE AND EXHAUST SYSTEM 3 17 1 Description The engine air intake system consists of an air cleaner and associated piping for channeling the air from the atmosphere to the engine intake manifold The intake pipe also provides the necessary connections for starting aid to be injected into the air intake for quick start and a restriction indicator to indicate a dirty air cleaner see Figure 3 8 The air cleaner is the dry type with a replaceable element It is located on the deck behind the cab The optional cold weather starting system consists of an atomizer valve assembly and starting aid bottle customer supplies The quick start system is normally used during cold weather operations to facilitate engine starting To operate the system starter switch must be in the start position before the control is depressed Depressing the control actuates the valve assembly passing starting aid from the bottle through the atomizer into the air intake manifold where it mixes with the intake air to facilitate engine combustion 3 17 2 Maintenance NOTE For more detailed information refer to Appendix 3 30 TM 10 3950 672 24 1 AIR CLEANER AIR RESTRICTION INDICATOR Figure 3 8 Exhaust and
369. leads to the engine and engine components as tagged during removal Install the radiator and oil cooler and connect the heater hoses lines and tubing as tagged during removal Grind a flat on the washers to allow clearance for bend radius on the clamp and clamp drive and to provide proper torque of the capscrews and bolt Secure the shaft to the axle differential with the clamp capscrews nuts and washers Torque the nuts 27 to 29 Ib ft 36 6 to 39 3 Nem Secure the shaft to the transmission with the clamp drive capscrew washers nuts and bolts Service the transmission engine lubrication system and engine cooling system Connect the muffler exhaust piping and air filter tubing to the engine refer to paragraphs 3 17 3 18 Bleed air from the fuel system Refer to TM 10 3950 672 24 2 Engine Manual Index under Bleeding the Fuel System Start the engine Check all hoses and fittings for leaks Shut down the engine and check all fluid levels 3 19 3 8 3 8 1 3 8 2 3 8 3 TM 10 3950 672 24 1 ENGINE OIL PRESSURE SWITCH NOTE This switch closes when oil pressure is below 5 psi illuminating the low oil pressure high engine temperature indicator Testing a Using multimeter check continuity across switch connectors b If continuity is not indicated replace switch Removal a Disconnect negative battery cable and two electrical leads from battery b Tag and disconnect two electrical connectors for engine oil press
370. leaned and heated 3 Parts must be dried immediately after they are cleaned with clean paper or rags or compressed air NOTE Wheel cylinders and cup seals must only be lubricated with the fluid used in the brake system Cylinder boots must be kept dry 4 To prevent corrosion and rust on cleaned parts apply axle lubricant to the cleaned and dried metal parts that are not damaged and are to be immediately assembled If parts are to be stored apply a special material that prevents rust and corrosion to all surfaces Also put a cover over the parts of a special paper or other material that prevents corrosion and rust Inspection It is important that all parts be carefully inspected before assembly Check all parts for wear or damage and repair or replace them as required Replacement of these parts now can prevent failure of the assembly later 1 Check all castings and backing plates for cracks loose rivets and correct alignment Replace all damaged parts 2 Check all adjusting bolts guide pins and pawl pins for corrosion and wear Replace or repair damaged parts 3 Check brake shoes for rust expanded rivet holes broken welds and correct alignment Replace damaged shoes 4 Check anchors anchor pins and shoe bushings for wear or damage Replace as necessary 5 Replace all shoe return springs at time of brake overhaul E 98 TM 10 3950 672 24 1 6 Check the brake drums for cracks severe heat chec
371. ling to the hoist 3 Tag and disconnect the hydraulic supply lines to the hoist cap or plug all lines and openings 4 Remove the capscrews nuts washers and plates securing the hoist and remove the hoist from the back of the turntable HOIST INSTALLATION AND ALIGNMENT 1 Ensure the hoist mount is clean and free from debris and the hoist has not been damaged during handling 2 With the hoist supported in a suitable lifting sling position the hoist on the mount 3 Check the hoist to boom alignment according to the HOIST TO BOOM ALIGNMENT procedure in this section 4 Place a level between the boom pivot shaft bushings 3 183 5 Place a level across the top of the hoist drum and determine if the hoist is sitting in the same plane in relation to the level positioned between the boom pivot shaft bushings 6 Install the plates washers nuts and capscrews and secure the hoist Torque the capscrews to 370 Ib ft 501 Nem 7 Connect the hydraulic lines and hoses as tagged prior to removal 8 Remove the lifting sling from the hoist 9 Install the cable follower Refer to CABLE FOLLOWER INSTALLATION in this section 10 Service the hoist Refer to SERVICING in this section 11 Install the cable following procedures outlined under INSTALLING CABLE ON THE HOIST in the Operator s Manual TM 10 3950 672 10 TM 10 3950 672 24 1 FUNCTIONAL CHECK 1 Attach a test weight to the hook and raise and lower the load se
372. ll the lockwasher 25 with the tabs up 11 Install the locknut 26 with the bevel side down Tighten the nut until the output shaft 27 turns with the locknut 26 Continue to tighten until the next tab on the lockwasher 25 lines up Bend the tabs until the locknut 26 is secure 12 Install the secondary planetary assembly 23 with the splined side down and engaged with the output shaft 27 13 Install the secondary sun gear 37 14 Install the thicker bearing race 21 then the bearing 22 then the thinner bearing race 21 15 Install the O ring 24 onto the internal gear 1 2 and install the internal gear 12 onto the hub 28 16 Install the spacer 18 onto the primary planetary assembly 20 17 Install two thin bearing races 15 and the bearing 14 onto the primary planet assembly 20 18 Temporarily install the end cover 4 onto the internal gear 12 and check for a small amount of clearance between the end cover 4 and the primary planetary assembly 20 19 Remove the end cover 4 and spacer 18 20 Install the oil seal 19 into the end cover 4 and the O ring 13 onto the internal gear 12 21 Lubricate the primary sun gear 17 shaft with grease and install the shaft Install the spacer 18 over the shaft and onto the primary planetary assembly 20 CAUTION DO NOT DAMAGE THE OIL SEAL WHEN INSTALLING THE END COVER 4 ONTO THE INTERNAL GEAR 22 Carefully install the en
373. lled by the push pull knob air around the heater core out into the cab The air flow MAINTENANCE DISASSEMBLY 3 Inspect the heater hoses for frays soft spots wear or any other damage 1 Remove the four screws securing the motor to the heater box Remove the motor 4 Repair or replace any damaged component as necessary 2 Remove the setscrew securing the fan to the motor shaft Remove the fan ASSEMBLY 3 Remove the chrome strip from the clips on the 1 Install the heater core into the box assembly front upper cover 2 Install the front upper cover to the heater box with 4 Remove the front lower cover the two screws 5 Remove the two screws securing the front upper 3 Install the front lower cover to the heater box cover to the heater box and remove the cover 4 Install the chrome strip to the clips on the front 6 Slide the heater core from the box assembly upper cover INSPECTION 5 Install the fan to the motor shaft using the setscrew to secure it 1 Inspect the fan for any damage 6 Install the motor to the heater box with the four 2 Inspect the heater core for any signs of leakage or Screws other damage E 162 TM 10 3950 672 24 1 HEATER CORE UPPER COVER SETSCREW STRIP MOUNTING SCREW HEAT DEFROST CONTROL LEVER ELECTRICAL LEADS Cab Heater Defroster E 163 E 164blank TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page A Accelerator PedalvAssembly 2
374. lt holes and install the four capscrews dry Using a criss cross pattern torque the capscrews to 200 Ib 23 Nem Bearing Ass y Retaining Ring Shaft Control Red Seal Shaft 0868 32 5 Press the bearing assembly on the control shaft with the seal red side of the bearing assembly facing toward the threaded end of the shaft Ensure the bearing assembly seats against the shoulder of the shafts 6 Install the retaining ring on the control shaft Ensure the ring seats properly in the ring slot above the bearing assembly C gt Retaining Ring Bore Control Shaft and Bearing Assembly Apply clean grease to splines and spring hole in face of shaft 3 88 TM 10 3950 672 24 1 7 Apply clean grease to the splines and spring hole located in the face of the control shaft Install the spring in the hole The grease should hold the spring in place until the control shaft is installed in the column 8 Insert the splined end of the control shaft in the column first and install the control shaft and bearing assembly in the column Turn the shaft to engage it with the spool Push the bearing assembly in far enough to allow for installation of the retaining ring in the bore of the column 9 Install the retaining ring in the bore of the column Ensure that the retaining ring is fully seated in the ring groove Control Valve 1 Position the control valve to the steering column and secure w
375. lve 2 Install O ring 16 onto the bottom plug Install the plug into the valve 3 Install the poppet 12 ball 5 spring end 9 and springs 6 and 10 into the top of the valve 4 Install the O ring 7 and plug 8 into the body 1 5 Install the O ring 11 onto the body 1 6 Install the O rings 2 and 4 and backup rings 13 and 15 onto the body 1 Oo PON Body O Ring Spring O Ring Ball Spring O Ring Plug Spring End Spring O Ring Poppet Backup Ring Piston Backup Ring O Ring Pilot Operated Check Valve E 104 17 18 19 20 21 22 23 25 TM 10 3950 672 24 1 O Ring Orifice Piston Stem Port A Port B Port C Seal Ring Retaining Ring 1143 TM 10 3950 672 24 1 HOLDING VALVE DESCRIPTION hydraulic circuit As the directional control valve is The holding valve is ported to allow hydraulic flow in two opened to the lower position pressure is applied to the directions To raise a load the oil must unseat the free pilot piston The pilot piston moves against the pilot flow poppet valve In this case oil pressure must release poppet until it unseats the pilot release poppet overcome the main poppet spring To do this the oil valve which port oil to the return side of the directional flows through the oil ports of the pilot release poppet control valve valve which applies pressure to the inside face of the free flow poppet When the main poppet unseats the T
376. lve body on a clean surface with the passage side facing up Install the converter relief valve spring in its bore Coat the converter pressure relief valve with petroleum jelly and place it on top of the spring Install the 2 3 shift valve check ball in its cavity Install the throttle pressure relief valve spring in its bore Coat the throttle pressure relief valve check ball with petroleum jelly and place it on top of the spring 3 If previously removed install the separator screen in the separator plate ensuring that the screen tabs are flush with the separator plate surface Carefully position the separator plate and new gasket on the lower valve body Install the two hold down plates on the separator plate and install the attaching screws finger tight 4 Install the lower body and plate assembly on the upper valve body and install the attaching screws finger tight 5 Install the oil screen screws loosely without the screen to properly align the upper and lower valve bodies gasket and separator plate 6 Torque the two bolts that are covered by the screen 40 to 55 Ib in 5 to 6 Nem 7 Remove the oil screen attaching screws and install the gasket and oil screen in position on the lower valve body install the screen attaching screws 8 Torque all the valve body and screen attaching screws 40 to 55 Ib in 5 to 6 Nem E 47 TM 10 3950 672 24 1 9 Install the cutback control valve and the line pressure coasting regulato
377. lves a Improper fluid level b Incorrect engine performance quired c Intermediate band out of adjust ment d Low main control pressure e Valve body bolts loose or too tight f Valve body dirty sticking valves 0 Governor valve sticking as required h Damaged intermediate servo or band i Polished glazed band or drum E 37 a Perform fluid level check b Tune engine c Adjust intermediate band d Control pressure test Note e Perform governor test Service f Check engine vacuum lines Service as necessary Check vac uum diaphragm unit Service as necessary Perform vacuum supply and diaphragm tests g Tighten bolts h Determine source of contami nation Service as required a Perform fluid level check b Tune adjust engine idle as re c Adjust intermediate band d Control pressure test Note re sults e Tighten bolts f Determine source of contami nation Service as required g Perform governor test Service h Perform air pressure test Ser vice as required i Service or replace as required 19 Harsh delayed 2 3 upshift 20 Soft early mushy 2 3 up igh a Low fluid level b Throttle valve linkage misad justed long sticking or damaged c Low main control pressure to direct clutch d Valve body bolts loose or too tight e Valve body dirty sticking valves a Incorrect engine performance b Engine vacuum leak c Damaged or
378. ly 3 from shaft 4 Pull rod assembly 3 forward toward front of vehicle through detents until movement stops Then move rod assembly 3 rearward one detent reverse position Move shift lever 5 rearward until shaft 4 contacts stop bolt 8 Loosen jam nut 6 and turn yoke 7 until holes in yoke 7 align with holes in shaft 4 Attach yoke 7 to shaft 4 with clevis pin 2 secure with hitch pin 1 and tighten jam nut 6 against yoke 7 Stow outriggers refer to Operator s Manual TM10 3950 672 10 3 62 TM 10 3950 672 24 1 2 poe a wok Wes Teo 7 ab I Yorn Y PA 4 078 a Pd u yr Id e 7 7 4 LI n In e 7 L 2 p 4 4 4 4 Wy 2 47 MS Os Nes 0 a 4 A x A h X S bus E CLAN T d p gt Ls 7 k 7 as Ma ioi a 7 Ww l 5 N 2 AE y v t Q x i l 7 7 AN 2 Ne 1 7 y 4 7 M NU d 4 477 y v 7 4 7 A 7 e v lt ioe LEGEND ea 0 20 2 gt 0 lO OK oo Eg gt 8988 Figure 3 13 Transmission Shifting Lever Assembly 3 63 TM 10 3950 672 24 1 Section 4 Axles and Brakes Subject Para Front Driv G AXIG cise 2eccctccticadestiancdeattaateee s talaaahidarshancdtuatavcatastducntatdaantaateuectiatia
379. m f the vacuum reading is OK rapidly accelerate the engine momentarily The vacuum reading must drop rapidly at acceleration and return immediately upon release of the accelerator If the vacuum reading does not change or changes slowly the transmission vacuum line is plugged restricted or connected to a reservoir supply Air Pressure Checks GENERAL A no drive condition can exist even with correct transmission fluid pressure because of inoperative clutches or bands On automatic transmissions an erratic shift can be caused by a stuck governor valve The inoperative units can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the malfunction When the selector lever is at 2 second a no drive condition may be caused by an inoperative forward clutch A no drive condition at D drive may be caused by an inoperative forward clutch or one way clutch E 21 TM 10 3950 672 24 1 When there is no drive in 1 low the difficulty could be caused by improper functioning of the forward clutch or simultaneous malfunction of the low reverse band and the one way clutch Failure to drive in R reverse could be caused by a malfunction of the reverse high clutch or low reverse band or clutch To make air pressure checks loosen the oil pan bolts and lower one edge to drain the transmission fluid Remove the oil pan and the control valve body assembly The inoperative clutches
380. m flanges passing through both points as located above and determine the midpoint 3 Find the midpoint of the lines drawn across the top of the base boom section perpendicular to its length at both ends of the boom section Figure points A and B 4 Check as follows to see if the hoist is aligned perpendicularly to the boom a String a chalk line from point A outer boom centerline across the base section centerline and the hoist drum midpoint b Pull the line taut aligning it directly over the top of point B c With a protractor measure the angle between the chalk line and the cross line drawn on the hoist If the measurement of the angle exceeds 90 degrees 1 2 degree realignment will be necessary BOOM CENTERLINE LOCATING CENTERLINE WITH SQUARE POINT A TAUT CHALK BOOM CENTERLINE POINT B PROTRACTOR Hoist to Boom Alignment 3 190 CAUTION DO NOT ALTER HOLES OR STOP BLOCKS ON THE CRANE MOUNTING PLATE AS VERY SMALL ADJUSTMENTS RESULT IN LARGE ANGULAR CHANGES EXTREME CARE SHOULD BE TAKEN TO AVOID OVERCORRECTION TM 10 3950 672 24 1 5 If realignment is necessary remove the hoist mounting bolts and shift the hoist as necessary to achieve the minimum angular tolerance Trial and error location may be necessary for proper line up of the bolt holes and stop blocks If all bolts cannot be inserted or the stop blocks interfere with line up a slight elongation of the hoist bolt holes and or shimmin
381. m off with a lint free cloth New clutch plates or bands should be soaked in transmission fluid specified for that transmission type for fifteen minutes before being assembled Do not reuse the control valve body to filter gasket or try to clean in solvent Replace the valve body to filter gasket upon assembly of the transmission Control Valve Body 1 Clean all parts thoroughly in clean solvent and blow dry with moisture free compressed air If the valve body to screen gasket is removed the gasket should not be cleaned in a degreaser solvent or any type of detergent solution To clean the gasket wipe it off with a lint free cloth 2 Inspect all valve and plug bores for scores Check all fluid passages for obstructions Inspect the check valve for free movement Inspect all mating surfaces for burrs or scores Use crocus cloth to polish valves and plugs Avoid rounding the sharp edges of the valves and plugs with the cloth 3 Inspect all springs for distortion Check all valves and plugs for free movement in their respective bores Valves and plugs when dry must fall from their own weight in their respective bores E 41 TM 10 3950 672 24 1 4 Inspect the separator plate screen for obstructions The screen must be clean and free of foreign material If contaminated remove it from the separator plate clean in a suitable solvent and thoroughly blow clean with compressed air 5 Roll the manual valve on a flat surface to
382. main control pressure In reverse Reverse clutch stator sup port seal rings leaking 1 2 a Improper fluid level b Low reverse servo piston seal leaking c Planetary low one way clutch damaged a Intermediate band out of ad justment b Improper band or clutch appli cation or oil pressure control System c Intermediate servo leaking d Intermediate one way clutch damaged e Polished or glazed band or drum a Improper fluid level b Manual linkage misadjusted damaged c Low main control pressure d Valve body bolts loose or too tight e Valve body dirty or sticking valves f Forward clutch piston ball check not seating or leaking g Forward clutch piston seals cut or worn h Low one way clutch planetary damaged E 34 a Perform fluid level check b Check and adjust or service 5s required c Control pressure res a Perform fluid level check b Check and replace piston seal c Determine cause of condition Service as required a Adjust Intermediate band b Perform control pressure es c Perform air pressure test of In termediate servo for leakage Ser vice as required d Replace e Service or replace as required a Perform fluid level check b Check and adjust or service as required c Control pressure test d Tighten bolts e Determine source of contami nation Service as required f Replace forward clutch cvlin der Service transmission a
383. mbers on the collector ring wires 6 Install the swivel cover and seal Secure with the capscrews lockwashers and nuts 7 Remove the blocking material from the lift cylinder 8 Activate all systems cycle all functions and observe for proper operation and any leakage 3 180 PREVENTIVE MAINTENANCE It is recommended that a normal inspection of the electrical swivel collector ring and brush assembly be established An example of this could be at approximately 100 to 150 engine operating hours When this time limit is reached perform the following 1 Check the collector ring and brush assembly for any corrosion pitting arcing and wear TM 10 3950 672 24 1 2 If the swivel has a grease fitting instead of a nylon bushing grease it Use no more than about 1 ounce 0 028 kg of a good quality bearing grease 3 Check the collector ring setscrews and ensure they are tight 4 Check the brush and arm assembly springs Ensure they are holding the brushes firmly against the collector rings 3 181 Section 10 Subject HOISE aana TM Description Theory of Operation Removal Hoist Installation and Alignment Functional Check Servicing Adjustment of Motor Control Valve Cable Follower Description Removal Disassembly Cleaning and Inspection Assembly Installation Vane Type Motor Description Removal Installation Hoist to Boom Alignment TM 10 3950 672 24 1 Hoist Para Page 3 183 EO
384. mbly NOTE The boom may be disassembled with the base section remaining on the crane if repair of the base section is not required If the base section is not being removed from the crane for disassembly start with step b a b j Remove the boom in accordance with removal procedures paragraph 3 60 1 Place the boom in a horizontal position Remove the bolts washers and plates securing the pins which connect the telescope cylinder to the base section Remove the pins Back off the setscrews of the base section adjustable wear pads to provide additional clearance Remove the upper front base section plate Remove the capscrews washers and plates securing the lower base section wear pads Remove the wear pads Remove the upper rear wear pads Remove the telescope section from the base section and place in a horizontal position Remove the capscrews washers and stop blocks securing the telescope cylinder assembly to the fly section Remove the cylinder assembly If necessary remove the wear pads from the cylinder 3 60 4 Assembly NOTE The following thread locking adhesive sealant procedure should be used for all bolts and fasteners Apply a light coat of Locquic Primer T to the threads and allow to dry Apply several stringer beads of Loctite 242 perpendicular to the threads and several beads parallel to the threads Allow to cure before installation a b If removed install the wear pads to the cylinder
385. mbly and Assembly Pressing Pars 1 Locks Wires and Cables 4 2 04 0 Shims 2 00404 0 u uu uuu Bearings 2 Gaskets 2 04 00000 0 qug we 2 2 2 0 0 ggg WW Hydraulic Systems Fatigue of Welded Structures Loctite 00 0 Fasteners and Torque Values TM10 3950 672 24 1 GENERAL MAINTENANCE MAINTENANCE These general suggestions should be helpful in following the instructions in this manual In analyzing a system malfunction use a systematic procedure to locate and correct the problem 1 Determine the problem 2 List possible causes 3 Devise checks 4 Conduct checks in a logical order to determine the cause 5 Consider the remaining service life of components against the cost of parts and labor necessary to replace them 6 Make the necessary repair 7 Recheck to ensure that nothing has been overlooked 8 Functionally test the failed part in its system NOTE Your safety and that of others
386. ment required to perform the designated function f Column 6 Remarks Column 6 identifies remarks defined in Section IV of the MAC B 4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS SECTION Ill a Column 1 Reference Code The tool and test equipment reference code correlates with a code used in the MAC Section column 5 b Column 2 Nomenclature This column lists the name and nomenclature of the tools and test equipment required to perform the maintenance function c Column 3 Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment 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 Federal Supply Code For Manufacturers code five digit in parenthesis B 3 TM10 3950 672 24 1 B 5 EXPLANATION OF COLUMNS IN REMARKS SECTION IV a Column 1 Reference Code This code refers to the appropriate item in Section Il Column 6 of the MAC b Column 2 Remarks This column provides the required explanatory information necessary to clarify items appearing in Section Il of the MAC B 4 Component Assembly ENGINE Engine Assembly Crankcase Block Cylinder Head Cylinder Head Crankshaft Crankshaft Section MAINTENANCE ALLOCATION CHART FOR CRANE WA
387. move the cover piston spring and gasket from the case screwing the band adjusting screw inward as the piston is removed This places enough tension on the band to keep the struts properly engaged in the band end notches while the piston is removed 3 Apply air pressure to the port in the servo cover to remove the piston and If the piston or piston sealing lips are damaged the complete piston and rod assembly should be replaced at assembly 4 Remove the seal from the cover Extension Housing Bushing and Rear Seal 1 If only the rear seal needs replaced carefully remove it with a tapered chisel or special tools T50T100 A and 1175 AC NOTE If using special tool T77L 7697D bushing remover to remove the bushing ensure the spline seal is not damaged 2 Remove the bushing tool T77L7697 D or equivalent using special TM 10 3950 672 24 1 TORQUE SPECIFICATIONS ltem Ib ft Converter to Flywheel Front Pump to Transmission Case Overrunning Clutch Race to Case Oil Pan to Case Stator Support to Pump Converter Cover to Converter Housing Guide Plate to Case Intermediate Servo Cover to Case Diaphragm Assembly to Case Distributor Sleeve to Case Extension Assembly to Transmission Case Plug Case Front Pump or Line Pressure Pressure Gauge Tap Band Adjusting Screw Locknut to Case Converter Drain Plug Manual Valve Inner Lever to Shaft Downshift Lever to Shaft Transmission to Engine Rear Engine Support
388. moved far enough the piston will unseat the poppet and increase flow When this happens there is little or no flow through port B around the check valve seat MAINTENANCE REMOVAL 1 To remove the check valve unscrew the check valve from the stabilizer port block INSTALLATION 1 Check the inside of the port block for any sharp edges or burrs and remove as necessary with emery cloth 2 Install new O rings onto the check valve 3 Lubricate the check valve and O rings with clean hydraulic oil 3 114 CAUTION DO NOT DAMAGE THE O RINGS DURING INSTALLATION OF THE CHECK VALVE IF THE CHECK VALVE TURNS FREELY THEN GETS HARD TO TURN THEN EASY TO TURN REMOVE THE CHECK VALVE AND CHECK THE O RINGS THEY HAVE PROBABLY BEEN DAMAGED BY A SHARP EDGE OF A PORT NOTE The check valve should turn by hand until compression of the O rings begins 4 Carefully install the check valve into the port block until fully seated 3 47 OUTRIGGER SELECTOR VALVE TM 10 3950 672 24 1 DESCRIPTION The OUTRIGGER SELECTOR valve is located in the cab to the left of the seat It is an eight position hydraulic selector valve marked FRONT RIGHT LEFT and REAR RIGHT LEFT The selector valve directs the flow of hydraulic oil from the outrigger directional control valve to the appropriate outrigger s To operate one outrigger only position the selector valve lever to one of four positions FRONT RIGHT FRONT LEFT REAR RIGHT or REA
389. mperatures demand regardless of vehicle mileage accumulated hours of operation or established change schedule DRIVE UNITS If it is desirable to select an arbitrary lubricant change schedule we recommend changing the lubricant at 25 000 to 30 000 mile 40 234 to 48 280 kilometers intervals or at 2000 hours of operation when the yearly usage is in excess of 60 000 miles 96 561 kilometers or 4000 hours When yearly usage is less than 60 000 miles 96 561 kilometers or 4000 hours the lubricant should be changed twice yearly spring and fall irrespective of mileage or hours of operation HIGH TEMPERATURE OPERATION The normal operating temperature of compounded lubricants during the summer season is approximately E 76 TM 10 3950 672 24 1 160 degrees to 220 degrees F 71 degrees to 104 degrees C The chemicals and additives that give _ these lubricants increased load carrying capacity oxidize faster at temperatures above 220 degrees F 104 degrees C contributing to more rapid lubricant deterioration For this reason lubricants of this type that operate continuously at high temperatures must be changed more frequently to realize the inherent advantages they offer Oil Viscosities For service purposes and the convenience of description the term Standard indicates a lubricant of proper viscosity for average temperature conditions during the spring summer and fall in the continental United States except for Alas
390. n entire set 11 Do not paint or coat wire ropes with any substance except approved lubricants WIRE ROPE INSPECTION RUNNING ROPES AND PENDANT CABLES Wire rope should be inspected frequently dally and periodically yearly in accordance with the following information excerpted from a National Consensus Standard as referenced by Federal Government Agencies Recommended inspection intervals may vary from machine to machine and may vary based on environmental conditions frequency of lifts and exposure to shock loads The inspection time intervals may also be predetermined by state and local regulatory agencies Any deterioration observed in the wire rope should be noted in the equipment inspection log and an assessment concerning wire rope replacement should be made by a qualified person Frequent Inspection A frequent daily visual inspection is recommended for all running ropes in service This inspection should be made on all wire rope which can be expected to be in use during the day s operation This inspection should be used to monitor progressive degradation and to discover severe damages necessitating wire rope replacement such as a Distortion Kinking Crushing Un stranding Bird caging Reduction of diameter etc General corrosion Broken or cut strands Number distribution and type of broken wires Evidence of core failure f End fitting wear abrasion Periodic Inspection ooo 8 Wire rope should be inspected
391. n line Wrong kind of oil 3 105 a Fill the hydraulic reservoir b Tighten all fittings c Drain and fill reservoir with non foaming oil a Fill the reservoir b Drain the reservoir and refill with clean oil c Drain the reservoir and refill with proper viscosity oil a Replace the seal a Fill the reservoir b Tighten the fittings c Drain and fill reservoir with non foaming oil REMOVAL 1 Tag and disconnect the hydraulic lines from the pump Cap or plug all openings 2 Remove the bolts and washers securing the pump and slide the pump shaft from the drive adapter 3 42 VALVES TM 10 3950 672 24 1 INSTALLATION 1 Slide the pump shaft into the drive adapter Install the bolts and washers and secure the pump If a Cummins engine is installed torque the bolts to 58 Ib ft 79 Nem 2 Connect the hydraulic lines to the pump as tagged during removal GENERAL This subsection provides descriptive information for all the hydraulic valves used on this crane For a listing of all valves the circuit they are used in and their physical location refer to the Valve Usage Table The description of the valves given here is for the valve itself For information on how the valve functions in the individual circuits refer to the Description and Operation of that circuit Valve Name Directional Control Valves Open Spool Hoist Closed Spool Boom Lift Outrigger Double Selector Valve Hol
392. n nnnnnen isset E 20 Transmission Shift Modulator 3 57 Transmission Shifting Lever 3 62 Transmission Shifting Lever senes sn 3 62 Transmission 0 1 ee eee een aan ener eee eee eee E 20 Transportation Discrepancy 00 00 1 1 Troubleshooting Symptoms 5 9 Turnsignal Light Front 000 0 eee eee ener reread eee nnn 3 229 Turnsignal Light Front 1 3 229 Typical External Circuit Description Operation 5 144 Index 14 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page U U Joint Bearing eee aeee ss snnt nnn 3 72 JOM installations ioter CIE UE SE E EM 3 72 Unpacking of Equipment Stute 2 1 V Valve Grinding 5 360 Valve Guide SpecifiCatlons 9 d da ada aa da aad dudes 5 358 Valve Seat Grinding
393. nclude replacement of all cylinder seals 1 Drain all hydraulic oil from the cylinder 2 Remove the setscrews securing the barrel to the head WARNING DO NOT USE AIR PRESSURE TO REMOVE THE CYLINDER ROD ASSEMBLY USE ONLY A SOURCE OF CONTROLLED HYDRAULIC OIL PRESSURE IF THE ROD ASSEMBLY IS HARD TO MOVE CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD DAMAGE TO THE ROD SURFACE MAY CAUSE UNNECESSARY MAINTENANCE AND EXPENSE 3 Remove the cylinder rod assembly from the cylinder barrel and move it to a clean work area 3 131 NOTE It is advisable to cover the cylinder barrel opening to avoid contamination 4 Secure the cylinder rod to prevent it from moving CAUTION WHEN REMOVING THE SEALS AND RINGS AVOID SCRATCHING THE GROOVED AND GLAND SURFACES NOTE Aligning discarded seals and rings in the order of disassembly will facilitate installation of new items 5 Remove the seal assembly from the outside of the piston 6 Remove the head from the rod NOTE Note the sequence of each seal making up the rod seal and its location on the rod to ensure proper assembly 7 Remove the wear ring buffer seal assembly rod seal and wiper ring from the inside of the head Remove the O ring and backup ring from the outside of the head TM 10 3950 672 24 1 Barrel Wear Ring Seal Assembly Buffer Seal Rod 9 Setscrew Head Rod Seal O Ring Wiper Ring Backup Ring
394. nd clamp the gun nozzle to the hose attached to the radiator outlet opening 4 With the radiator cap on tight fill the core with water Turn on air pressure in short blasts to prevent core damage 5 Continue filling the radiator with water and applying air pressure as above until the water comes out Clear 6 Clamp the flushing gun nozzle firmly to a hose attached securely to the engine water outlet opening Fill the engine block with water partly covering the water inlet opening to permit complete filing 7 Turn on compressed air to blow out water and loose sediment Continue filling with water and blowing out with air until flushing stream comes out clear 8 For badly clogged water jackets that do not respond to regular pressure flushing remove the engine cylinder head and core hole plugs and with a suitable length of small copper tubing attached to the flushing gun nozzle flush the water jackets through the openings 9 When the vehicle is equipped with a water heater connected to the cooling system flush the heater following the same procedure as for the radiator core E 16 TM 10 3950 672 24 1 10 After completing the flushing operation clean out the radiator overflow pipe inspect the water pump clean the thermostat and the radiator cap control valves Check the thermostat for proper operation before installation 11 Blow insects and dirt from the radiator core air passages using water if necessary to soften
395. ndle Tighten the adjusting nut to 50 Ib ft 69 N m while rotating the wheel In both directions to ensure all bearing surfaces are In contact Backoff the adjusting nut 1 16 to 1 4 turn NOTE Ensure the pin is installed between the washer and jam nut 3 71 TM 10 3950 672 24 1 5 Install the washer pin and jam nut onto the end of the spindle Torque the jam nut to 250 Ib ft 339 Nem End play must be within 0 001 to 0 010 inches 0 025 to 0 254 mm 6 Install the cover on the hub and secure with the bolts and washers Installation 1 Using an adequate lifting device position the hub brake and spindle assembly to the frame 2 Install the bronze busing and pin weld 3 Secure the pin weld to the hub brake and spindle assembly with the bolts and washers Torque the bolts to 75 Ib ft 102 N m 4 Install the tire and wheel assembly on the hub and secure with the nuts Torque the nuts to 300 Ib ft 407 Nem 5 Remove the cribbing and blocking and lower the wheels to the ground TM 10 3950 672 24 1 3 28 U JOINT BEARING ASSEMBLY 3 28 1 Removal a Remove drive line shaft 3 Figure 3 14 refer to paragraph 3 22 1 Remove snap ring 1 securing cross bearing 2 in drive line shaft 3 yoke Secure exposed bearings to cross bearing assembly 2 with tape Press cross bearing 2 out of drive line shaft 3 yoke 3 28 2 Installation Press cross bearing 2 Figure 3 14 into drive line
396. nds inch 63 3 to 86 4 kgcm Remove the gauge pin from the switch 7 Install a new downshift lever seal in the recess of the outer lever shaft Slide the downshift lever and shaft into Position 8 Install the outer downshift lever on the shaft and secure with the lockwasher and nut Torque the nut 12 to 16 Ib ft 16 to 22 Nom Disassembly of the Parking Pawl Linkage 1 Remove the bolts securing the parking pawl guide plate to the case Remove the plate 2 Remove the spring parking pawl and shaft from the case 3 Working from the pan mounting surface drill a 0 1 25 inch 3 1 mm diameter hole through the center of the cupped plug Pull the plug from the case with a wire hook 4 Unhook the end of the spring from the park plate Slot to relieve the tension 5 Thread a 1 4 20 inch or 8 32 x 1 1 4 inch screw into the park plate shaft the shaft from the case with the screw Remove tl 3 spring and park plate Assembly of the Parking Pawl Linkage 1 Install the spring and park plate in the case and install the shaft Install the end of the spring into the Slot of the park plate 2 Install a new cupped plug to retain the shaft 3 Install the parking pawl shaft in the case Install the parking pawl and spring into place on the shaft 4 Install the guide plate on the case ensuring the actuating rod is seated in the slot of the plate Secure the plate with the two bolts and lockwashers Torque the bolt
397. ng 13 into the spool 12 Install spool 12 into the valve body 5 Install washer 6 onto the spool onto plug 9 Install the O ring 6 Install spring 8 and secure to the spool with plug 9 7 Install poppet 5 spring 4 O ring 2 and plug 17 into the valve body 8 Install the remaining plugs into the valve body TM 10 3950 672 24 1 PILOT OPERATED CHECK VALVE DESCRIPTION The pilot operated check valve is usually located in the port block on the outrigger stabilizer cylinder The valve is normally closed and is opened by pilot pressure MAINTENANCE DISASSEMBLY 1 Remove the backup rings 13 and 15 and Orings 2 4 and 11 from the body 1 2 Remove the bottom plug from the body 1 remove the O ring 16 orifice 18 O ring 17 piston 14 spring 3 piston 19 and stem 20 NOTE Some valves will not have a seal ring 24 or a retaining ring 25 3 Remove the plug 8 O ring 7 springs 6 and 10 spring end 9 ball 5 poppet 12 seal ring 24 and retaining ring 25 CLEANING AND INSPECTION 1 Clean all parts with solvent and dry with compressed air Check all parts for serviceability E 103 ASSEMBLY NOTE Coat all parts with clean hydraulic oil prior to assembly It is recommended O rings and backup rings be replaced at assembly 1 Install the stem 20 piston 14 spring 3 piston 19 O ring 17 orifice 18 into the bottom of the va
398. ng brake c Improperly adjusted crossover relief valve d Improperly lubricated swingbear ing e Improper size hose and or fit tings installed f Clogged or restricted hydraulic hoses or fittings g Worn or damaged output shaft bearings h Worn or damaged swing mo tor i Worn or damaged hydraulic pump section 3 139 TM10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION e Replace crossover relief valve f Replace pinion a Remove clean and repair or replace relief valve Repair or replace swing motor Repair as necessary Replace crossover relief valve Remove swing box and repair Replace pump section Adjust repair or replace valve Readjust c Adjust valve Refer to VALVES in Section 6 d Lubricate bearing per recom mendations e Replace with correct hose fitting f Clean or replace damaged parts g Replace bearings h Repair or replace motor i Repair or replace pump section TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 5 Swing operation slow in one direction only Boom swings slowly 7 Swing motor continues to op erate when swing control is in neu ral position 8 Swing motor turning in wrong direction 9 Swing motor noisy a Crane not level If equipped b Damaged relief valve c Improperly adjusted crossover relief valve d Clogged or restricted hose e Improperly torqued turntable bear
399. ng operation During extension oil unseats the poppet check valve in the holding valve when pressure is 6 4 psi 41 37 27 58 kPa 0 414 0 276 bar This oil is routed to the piston side of the cylinder which forces the rod out of the cylinder causing the boom section to extend During retraction oil enters the retract port and flows to the rod side of the cylinder when pilot pressure reaches a pre determined value the main poppet unseats and oil flows from the piston side of the cylinder to the reservoir causing the boom section to retract When holding the boom section at a given length oil is trapped in the cylinder by the holding valve Refer to for a complete description of the holding valve operation MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Erratic operation of extending a Low hydraulic oil level a Replenish hydraulic oil to elescoping cylinder proper level b Damaged relief valve b Repair or replace relief valve c Airin telescope cylinder c Bleed by lowering telescope cy linder below horizontal d Low engine rpm d Increase engine rpm to recom mended setting e Lack of lubrication on boom e Properly lubricate all boom sec sections tions f Extremely tight boom nose f Inspect and properly lubricate sheaves boom nose sheaves 3 155 1 Erratic operation of extending elescoping cylinder continued 2 Erratic operation of retracting telescoping cylinder g
400. ng with clutch spring compressor tool T65L77515 A or equivalent Remove the snap ring Remove the tool and the springs and retainer assembly 22 Remove the one way clutch inner race attaching bolts from the rear of the case Remove the inner race from inside of the case 23 Remove the low reverse clutch piston from the case using air nozzle tool 7000 DE or equivalent Disassembly of the Control Valve Body NOTE The valve body to screen gasket should not be cleaned in a degreaser solvent or any type of detergent solution when disassembling the main control To clean the gasket wipe it off with a lint free cloth 1 Remove the nine screws that attach the screen to the lower valve body and remove the screen and gasket 2 Remove the five upper to lower valve body and hold down plate attaching screws Remove the seven attaching screws from the underside of the lower valve body E 46 TM 10 3950 672 24 1 NOTE When removing the separator plate and gasket be careful not to lose the check valves and springs 3 Separate the bodies and remove the separator plate and gasket Remove and clean the separator plate screen if necessary 4 Remove the manual valve retaining pin from the upper valve body 5 Slide the manual valve out of the valve body 6 Cover the downshift bore with a finger then working from the underside of the body remove the downshift valve retainer Remove the spring and downshift valve 7 Apply hand p
401. not smooth polish with a fine crocus cloth If components show unusual wear replace the entire pump 2 Replace all seals and plates ASSEMBLY NOTE Lubricate all internal components and the lips of the shaft seal before assembly 1 Install the shaft seal 3 into the front housing 4 to a depth of 1 4 inch from the pilot face NOTE Do not push the pressure seal 5 to the bottom of the groove The seal must be in the wear plate groove and stick above the plate surface 0 005 inch 0 127 mm minimum 2 Invert the housing 4 with the bores facing up and install the wear plate 7 spacer 6 and pressure seal 5 into the bottom of the gear pocket in the Bolt Washer Shaft Seal Front Housing Pressure Seal Spacer Wear Plate Drive Gear Driven Gear Thrust Plate Gasket Dowel Pin Rear Housing Drive Gear E 110 TM 10 3950 672 24 1 Driven Gear Cover Washer Bolt O Ring Plug housing Ensure the pressure seal 5 is installed with the flat face down and the legs of the seal toward the inlet of the pump 3 Install the drive gear 8 through the shaft seal 3 being careful not to cut the shaft seal 4 Install the driven gear 9 with the short journal up 5 Install the thrust plate 10 toward the gears 6 Install two dowel pins 12 and the gasket 11 in the housing 4 groove 7 Install the rear housing 13 over the dowel pins 12 in the front housing 4 8 Follow the proced
402. ns 31 into the planet shafts 32 of the primary planetary assembly 20 21 Press out the planet shafts 32 and remove the gears 33 bearings 34 and thrust races 35 22 Remove the spacer 36 from the planet carrier housing 23 Repeat steps 20 through 22 for the secondary planetary assembly 23 CLEANING AND INSPECTION 1 Clean all parts with a suitable cleaning solvent and dry with compressed air or a lint free clean cloth TM 10 3950 672 24 1 Bolt Washer Brake Housing End Cover Piston Cylinder Head O ring Backup Ring Brake Disc 10 Stator 11 Bolt 12 Internal Gear 13 O ring 14 Bearing 15 Bearing Race 16 Spring 17 Primary Sun Gear 18 Spacer 19 Oil Seal 20 Primary Planetary Assembly 21 Bearing Race 22 Bearing 23 Secondary Planetary Assembly 24 O ring 25 Lockwasher 26 Locknut 27 Output Shaft 28 Hub 29 Bearing 30 01 Seal 31 Roll Pin 32 Planet Shaft 33 Gear 34 Bearing 35 Thrust Washer 36 Spacer 37 Secondary Sun Gear 38 End Cap Not Shown 39 Screw Not Shown 40 Pinion Not Shown Gear Reduction Assembly Exploded View E 129 2 Inspect all bearings for damage to the rolls cages or quills 3 Inspect all gear teeth for cracks pitting or other damage 4 Inspect all bearing surfaces for scoring scratches or other damage ASSEMBLY NOTE Prior to assembly all bearings must be packed w
403. nspect 15 21 23 Replace 24 Repair Selector Valve Inspect Replace Test BODY CAB HOOD amp HULL Door Assembly with Inspect 21 23 24 Latch Handle Replace Access Covers Engine Inspect Battery amp Tool Box Replace TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTE NANCE LEVEL Direct General Tools and Component i Support T ELE Equipment Remarks Assembly Function ejoj F Ref Code Code Upholstery Seat Seat Assembly Inspect 21 23 24 Replace BODY CHASSIS OR HULL amp ACCESSORY ITEMS Mirrors Windshield Inspect 24 Wiper amp Cab Fan Replace Cab Heater amp Inspect 12 13 24 Defroster Assembly Replace 20 HYDRAULIC amp FLUID SYSTEM Hydraulic Pump Inspect 12 13 15 Replace Repair Hydraulic Control Inspect Valve Replace Repair Strainers Filters Lines Inspect and Fittings Replace TM10 3950 672 24 1 Section Il MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct Genera Tools and Component i Suppo EE Equipment Remarks Assembly Function c o Ref Code Code Hydraulic Cylinders Lift Cylinder Inspect 12 13 15 Replace 24 Repair Tele Cylinder Inspect 12 13 15 Replace 24 Repair Hydraulic Reservoir Inspect 2 12 13 Service 24 21 23 Replace WARNING SCANNING AND SIGNALING DEVICES A
404. nsure the retainer lays flat in the housing and Is not tilted on edge 2 Install the check ball into the housing 3 Lubricate both seals and install the 5 8 inch diameter seal on the large diameter end of the check ball seat Install the 7 16 inch diameter seal on the small diameter end of the check ball seat CAUTION WHEN INSTALLING THE SEAL DO NOT TWIST OR DAMAGE THE SEALS 4 Lubricate and install the check ball seat in housing insert open end of seat first Do not damage seals when installing check ball seat Push the check ball seat to the bottom of the hole 5 Install the setscrew Use a 0 3124 in Allen wrench to torque the setscrew to 100 Ib in 11 Nem To prevent interference the top of the setscrew must be slightly below the housing mounting surface SPRING SLOT CONTROL SLEEVE SPRING SLOT CONTROL SPOOL IDENTIFICATION MARKS 0868 13 6 Assemble the spool and sleeve carefully so the spring slots line up at the same end Rotate the spool while sliding the parts together Test for free rotation The spool should rotate smoothly in the sleeve with fingertip force applied at the splined end NOTE Some spool and sleeve sets have identification marks align these marks as shown TM 10 3950 672 24 1 0866 14 7 Bring the spring slots of both parts in line and stand the parts on the end of the bench insert the spring installation tool through the spring slots of both parts A tool is avail
405. ntermediate band Control pressure test Note results Perform governor test Service as required Check engine vacuum lines Service as necessary Check vac uum diaphragm unit Service as necessary Perform vacuum supply and diaphragm tests Tighten bolts Determine source of contami nation Service as required Perform fluid level check Tune adjust engine idle as re quired Adjust intermediate band Control pressure test Note re sults Tighten bolts Determine source of contami nation Service as required Perform governor test Service as required Perform air pressure test Ser vice as required Service or replace as required SYMPTOM PROBABLE CAUSE 18 No 2 3 upshift 19 Harsh delayed 2 3 upshift 20 Soft early mushy 2 3 up shift 1 Erratic shifts Low fluid level Throttle valve linkage misad justed long sticking or damaged Low main control pressure to direct clutch Valve body bolts loose or too tight Valve body dirty sticking valves Incorrect engine performance Engine vacuum leak Damaged or worn intermediate servo release and high clutch pis ton check ball Valve body bolts loose or too tight Vacuum diaphragm or throttle valve control rod bent sticking or leaking Valve body bolts loose or too tight Valve body dirty sticking valves Vacuum diaphragm or throttle valve control rod
406. ntrol Valve Ball Bearing Spacer Retaining Ring Spacer Spring O Ring O Ring O Ring Seal 26 Oil Seal 27 Ball Bearing 28 Spacer 29 Capscrew 30 Lockwasher 31 Capscrew 32 Washer 33 Capscrew 34 Lockwasher 35 O Ring 36 O Ring 37 Capscrew 38 Washer 39 Oil Seal HO 12 Grove moist cutaway E 138 TM 10 3950 672 24 1 Circlip Pin Gear Spacer Cable Deflector Screw Flatwasher Washer Hoist Housing Planet Gear Collar Needle Bearings Thrust Washer O Ring Hoist 1 Remove the screws 45 flatwashers 46 and washers 47 securing the cable deflector 44 and the hoist housing collars 48 Remove the deflector 44 and collars 48 2 Remove the capscrews 37 and washers 38 from the motor end housing 4 Remove the housing 3 Remove the capscrews 31 and washers 32 from the brake end housing 5 and remove the housing Remove the seals 26 from the housing NOTE Photos of the right hand drum end 3 show eight bolt holes Quantity of bolts has been increased to sixteen 4 Remove the capscrews 33 and washers 34 from the right hand drum end 3 5 Pull the drum 2 from the housing 1 TM 10 3950 672 24 1 6 Remove the right hand drum end 3 from the housing 7 Remove the spacer 28 from the right hand drum end 3 TM 10 3950 672 24 1 2 Use a brass drift to drive
407. o tight f Valve body dirty or sticking valves g Transmission filter plugged h Pump damaged or leaking 3 49 Perform fluid level check Adjust idle Service as required Perform control pressure test Clean service or replace valve Perform fluid level check Adjust throttle valve linkage c Tighten bolts d Determine source of contami nation Service as required a Perform fluid level check b Check and adjust or service as required c Control pressure test note results d Perform air pressure test e Tighten bolts f Determine source of contami nation Service as required g Replace filter h Visually Inspect pump gears Replace pump if necessary TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 5 No delayed reverse engage ment forward OK 6 No delayed reverse engage ment and or no engine breaking in manual low 1 7 No engine braking in manual second gear 8 Forward engagement slips ishudders chatters a Improper fluid level b Manual linkage misadjusted damaged c Low main control pressure in reverse Reverse clutch stator sup port seal rings leaking 1 2 a Improper fluid level b Low reverse servo piston seal leaking c Planetary low one way clutch damaged a Intermediate band out of ad justment b Improper band or clutch appli cation or oil pressure control system c Intermediate servo leaking d
408. o change plugs one or more times between complete lubrication changes The removed plugs can be cleaned and reused NOTE For maximum protection against wear particles it is desirable that magnetic plugs be employed at any drain fill or level hole location of the drive unit Lubricant Change Schedule There are very practical reasons for recommending lubricant changes Fluid lubricants serve more than one purpose They not only lubricate but they transport chemically reactive additives they wash away minute wear particles serve as a corrosion inhibitor and also act as a heat transfer medium Draining and refilling with a fresh supply assists in eliminating both magnetic and nonmagnetic wear particles which may not have been trapped by a magnetic plug Exposure to heat and use may also alter the desirable performance properties which are reassured through a lubricant change A regular schedule for changing the lubricant in a particular vehicle and operation can be accurately determined by analysis of samples taken from the assembly at specified intervals or mileages The lubricant supplier frequently makes available his laboratory facilities for determining the useful life of his product under actual service conditions The finally recommended schedule may be correlated for economic reasons with lubricant changes governed by climatic conditions and magnetic drain plug maintenance Lubricant changes should be made as climatic te
409. o could result in death or injury to personnel i Position the outrigger beam on blocking material j Remove the cylinder support NOTE For Removal and Installation of the cylinder refer to OUTRIGGER STABILIZER CYLINDER in this Section NOTE For Removal and Installation of the double selector valve used when the optional tow winch is installed refer to Section 6 VALVES 3 75 4 Inspection Inspect the outrigger beams for bends evidence of cracks or other damage Check the outrigger beam internally for hydraulic fluid which may indicate a leaking cylinder loose connection or damaged hydraulic line 3 75 5 Installation a Place a soft wood support between the outrigger beam and the port block of the cylinder b Attach a suitable lifting device to the outrigger beam c Slide the beam into the outrigger housing being careful not to let the cylinder slide or tilt Align the cylinder barrel with the frame mount d Install the cylinder barrel to the frame mount Apply anti seize to the pin and secure the cylinder barrel to the frame mount with the pin cotter pin flatwasher washers and capscrew e Connect the hydraulic lines to the cylinder as tagged prior to removal Remove any blocking material in the outrigger assembly g Activate the system and check for proper operation and any leaks 3 195 3 76 OUTRIGGER STABILIZER CYLINDER TM 10 3950 672 24 1 DESCRIPTION The 3 inch 7 62 cm stabilizer cylinder is 40 19 inches
410. o the other This means of steering is very difficult and sleeve rotates to the same position as the spool the requires a great amount of force to be applied to the metered flow of hydraulic oil stops and oil flows from the steering wheel IN port to the OUT port and back to the return manifold It is the action between the spool and sleeve that MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL Control Valve 1 To gain access to the steering control valve 3 Tag and disconnect the hydraulic hoses from remove the screws securing the cover to the front of the the steering control valve Cap or plug each hose and cab Pull the cover off far enough to disconnect any the ports of the valve wiring necessary to remove the cover Remove the cover 4 Remove the bolts and washers securing the valve to the steering column Remove the control 2 Thoroughly clean the steering control valve and valve surrounding area of all dirt and contamination before disconnecting the hydraulic hoses from the valve 3 85 Integral Column Bearing Spring 0868 27 1 Remove the four capscrews from the column 2 Remove the column and spring 3 Remove the bearing locator 4 Remove the quad ring seal and 1 15 16 inch diameter seal from the column Control Shaft and Bearing Ass y Retaining Ring Bore Control Column 0868 26 3 86 10 3950 672 24 1 5 Using a thin bladed screwdriver pry the retain ing rin
411. oad capacity exceeded d Hydraulic oil low e Broken hydraulic lines of fit tings f Damaged relief valve g Damaged hoist control valve h Damaged primary drive assem bly i Sheared shaft on pump or dam aged pump j Motor control valve out of adjustment E 133 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION Hoist will not raise load a Each layer of cable on the drum reduces the line pull By reducing the amount of cable on the drum the pull will increase b Multiply the line pull times the number of lines used adjusting for the amount of cable on the drum compare with load Add parts of line if load exceeds results c Reduces load Refer to applica ble Load Chart Replenish system Replace lines or fittings Repair or replace valve Repair or replace valve h Repair or replace primary drive assembly i Install a O to 5000 psi 0 to 34 475 kPa 344 8 bar guage in the inlet line of the hoist valve bank Activate the system No pressure or excessively low pressure indicates a damaged pump or drive shaft Re pair or replace j Refer to Adjustment of the Motor Control Valve in this Section and adjust the valve TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 2 Hoist will not lower Broken lines or fittings Replace lines or fittings Damaged relief valve Repair or replace valve Damaged hoist control valve Repair or replace valve d Damag
412. ockwire 5 16 inch 18 2030 284 11 PINION BEARING CAGE TO CARRIER CAPSCREW Fastener Size Torque Pounds Foot Grade 5 Grade Grade B 3 8 inch 16 25 3513548 40 4 15 5 35 50 3 56 9 7 16 inch 4 40 55 5 5 7 6 50 65 6 9 9 0 60 75 8 3 103 1 2inch 13 65 85 9 0 11 8 75 100 10 4 138 85 115 11 8 15 9 5 B inch 11 130 165 18 0 22 8 150 190 20 7 26 3 180 230 24 9 31 8 DIFF CASE CAPSCREWS OR BOLTS AND DIFF BEARING CAP TO Nap NUTS LONG amp SHORT CARRIER CAPSCREWS Fastener Size Torque Lbs Ft Fastenar Size Torque Lbs Fr Capscrews 3 8 inch 16 35 50 4 8 6 9 9 16 inch 12 115 140 15 9 19 4 7 16 inch 14 60 75 18 3 1041 5 8 inch 11 160 190 22 1 26 3 1 2 inch 13 B5 115 11 8 15 9 3 4 inch 10 290 350 40 1 48 4 9 16 inch 12 130 165 19 0 22 81 3 8 inch 9 470 550 65 0 76 00 IN 5 8 inch 11 180 230 249318 7 8 inch 14 375 435 151 8 60 1 2 Bolts and Nuts 1 2 inch 13 B5 115 118 15 91 1 2 inch 20 100 130 13 8 18 0 THRUST SCREW JAM NUT 5 B inch 11 150 190 20 26 31 5 8 inch 18 210 270 29 0 37 3 Fastener Size Torque Lbs Ft Kam i GEAR TO DIFF CASE BOLT NUTS 3 4 inch 16 150 190 20 7 26 3 4 7 8 inch 14 150 190 20 7 26 3 Fastener Size Torque Lbs F 1 Kgm All torques given apply to parts lightly 11 Binch 16 150 190 20 2 26 3 coated with rust preventative type oil 1 2 inch 20 85 115 11 8 15 9 M 5 Binch 18 180230 249318 For dry 1
413. omply could result in scalding or serious burns NOTE This switch closes when engine coolant temperature is above 210 F illuminating the low oil pressure high engine temperature indicator 3 10 1 Testing Open engine access door Set multimeter to ohms attach positive lead of multimeter to switch terminal and negative lead to switch body If continuity is indicated replace switch Close and secure engine access door 3 10 2 Removal 3 10 3 a Disconnect negative battery cable and two electrical leads from battery b Open engine access door c Drain engine coolant to a level below coolant temperature switch 3 Figure 3 6 d Tag and disconnect electrical lead to coolant temperature switch 3 e Remove coolant temperature switch 3 from engine Installation a Install coolant temperature switch Figure 3 6 in engine b Connect electrical lead to coolant temperature switch 3 and remove tag c Service engine coolant system d Close and secure engine access door e Connect negative battery cable and two electrical leads to battery 3 22 TM 10 3950 672 24 1 1 LEGEND Engine Oil Pressure Switch Engine Oil Pressure Sender Engine Coolant Temperature Switch Engine Coolant Temperature Sender pg Figure 3 6 Engine Senders and Switches 3 23 TM 10 3950 672 24 1 3 11 ENGINE COOLANT TEMPERATURE SENDER WARNING Engine must be cool to the touch prior to working on coolant system components
414. on does not reveal the cause of the trouble and the crane is operational further troubleshooting is necessary Do not remove the transmission from the crane until the mechanical hydraulic and air pressure tests are performed and the causes of trouble are checked against the troubleshooting chart Mechanical Checks LINKAGE CHECK 1 A check should be made to ensure the linkage is free and returns to idle when released 2 Ensure the D detent in the transmission corresponds exactly with the stop in the console Leakage at the manual valve can cause delay in engagements and or slipping while operating if the linkage is not correctly adjusted ENGINE IDLE SPEED CHECK Check the engine idle speed If the idle speed is too low the engine will run roughly An idle speed that is E 20 too high will cause the crane to creep have harsh transmission engagements and harsh closed throttle downshift CONTROL PRESSURE TEST There are two methods of performing the control pressure test One is to perform the test using the engine vacuum The second method is to use a hand operated vacuum pump 1 To perform the control pressure test using the engine vacuum perform the following a Attach a tachometer to the engine and a vacuum gauge to the transmission vacuum line at the manifold vacuum port CAUTION PRESSURE GAUGES AFFECT THE SHIFT QUALITY OF THE TRANSMISSION CARE SHOULD BE TAKEN NOT TO ACCELERATE OR DECELERATE RAPIDLY
415. on each end of the cylinder WARNING DO NOT USE AIR PRESSURE TO REMOVE THE CYLINDER ROD ASSEMBLY USE ONLY A SOURCE OF CONTROLLED HYDRAULIC OIL PRESSURE IF THE ROD ASSEMBLY IS HARD TO MOVE CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD 3 Withdraw the cylinder rod assembly from the barrel and move it to a clean work area Cap or plug the ends of the rod to protect the threads NOTE It is advisable to cover the cylinder barrel opening to avoid contamination 4 Secure the cylinder rod to prevent it from moving 5 Remove the piston from the rod 6 Remove the spacers and heads from each end of the head CAUTION WHEN REMOVING THE SEALS AND RINGS AVOID SCRATCHING THE GROOVED AND GLAND SURFACES NOTE Aligning discarded seals and rings in the order of disassembly will facilitate installation of new seals and rings 7 Remove the crown seal and wear rings from the outside of the piston NOTE Note the sequence of each seal making up the rod seal and its location on the rod to ensure proper assembly 8 Remove the O ring and backup ring from the outside of the heads and the rod seal buffer seal assembly and wear ring from the inside of the heads 9 Remove the wiper ring from each head plate CLEANING AND INSPECTION 1 Clean all parts with solvent and dry with compressed air Inspect all parts for serviceability TM 10 3950 672 24 1 E T
416. onent parts 2 Inspect the hypoid gears for wear or damage Gears which are worn ridged pitted or scored should be replaced When necessary to replace either the pinion or gear of hypoid set the entire gear set should be replaced for the 3 Inspect the differential following assembly a Pitted scored or worn thrust surfaces of the differential case halves thrust washers spider trunnions and differential gears Thrust washers must be replaced in sets The use of a combination of old and new washers will result in premature failure b Wear or damage to the differential pinion and side gear teeth Always replace differential pinions and side gears in sets E 74 TM 10 3950 672 24 1 4 Inspect the axle shafts for signs of torsional fractures or other indication of impending failure 5 When servicing drive units assembled with Dri Loc or Loctite No 277 in threaded case holes where the bolts do not require removal check each bolt for tightness by applying the minimum amount of torque specified for that fastener If the bolt does not rotate it is satisfactory If the bolt rotates to any degree it must be removed from the case halves and Loctite No 277 must be applied to the threaded hole INSPECTION OF DRIVE UNIT HOUSING 1 Remove any accumulation of dirt grit or gum from housing bowl and sleeves Clean housing thoroughly with solvent and blow dry with compressed air 2 Inspect housing for cracks lo
417. oper attachment Tighten repair or replace components as necessary d Repair or replace pump Drain flush and refill system with re commended oil a Use adequate pressure gauge and adjust system relief valve as necessary b Clean repair or replace line as necessary a Check all lines for security and proper attachment Tighten repair or replace components as necessary Ensure that oil level in reservoir is adequate Fill to HIGH mark on sight gauge b Regulate engine speed 3 40 HYDRAULIC FILTER Removal and Disassembly WARNING ENSURE ALL HYDRAULIC SYSTEMS ARE SHUT DOWN AND THE PRESSURE IS RELIEVED 1 Shut down all hydraulic systems 2 Wipe any dirt from the filter housing and filter head 3 Remove the screws from the filter cover and remove the cover Inspect the cover O ring and replace it if there is any evidence of damage 4 Remove the screws securing the head to filter bowl Remove the head Inspect the bowl O ring and replace It If there is any evidence of damage 5 Remove the hitch clip pin from the diverter handle and remove the diverter and poppet valve assembly Inspect the diverter O ring and replace it if there is any evidence of damage 6 Remove the elements 3 104 TM 10 3950 672 24 1 7 f necessary remove the screws and lockwashers securing the indicator to the head Inspect the indicator O ring seals and gasket sponges for damage Replace if necessary 8 Ensu
418. or switch and remove tag Connect wires 82 84 and 38D to left outrigger selector switch and remove tag Connect wires 372A 372B and 371 to gearshift switch and remove tag Connect connector to gearshift solenoid and remove tag Connect wires 1 37 and 1 36 to oil cooler temperature switch and remove tag Connect wire 1 96A to battery connector and remove tag Connect wires 156 157 and 2A to starter relay and remove tag Connect wires 51L 73A 51 M 73B 51N and 73C to two block override solenoid and remove tag Connect wires 73 70 67 52A 41 5 38A 32 25A 18 17 16 15 14 13D 12D 10 9 7A 372A 1 3 4 99 371 1 69A and 1 36 to crane relay panel and remove tag Connect wires 38 and 41 to brake switch and remove tag Connect wire 715 to alternator discharging light and remove tag Connect wires 137 and 51 H to oil cooler fan motor and remove tag Connect wire 99 to horn and remove tag Connect wire 15 to left front turn signal light and remove tag Connect wire 12B to left front side marker light and remove tag Connect wire 12A to left headlight and remove tag Connect wire 14 to right front turn signal light and remove tag Connect wire 1 3B to right front side marker light and remove tag 3 241 TM 10 3950 672 24 1 qq Connect wire 1 3A to right headlight and remove tag rr Secure harness to chassis with wire ties as necessary to prevent chafing and interference with other
419. orm steps 1 and 2 if not done during Transmission Assembly 1 Install the valve body on the case ensuring the selector and downshift levers engage the valves properly and secure with the attaching bolts Torque the bolts 95 to 125 Ib in 11 to 14 Nem 2 Clean the transmission pan and gasket surfaces thoroughly Install a new pan gasket and the pan Secure the pan to the transmission case with the attaching bolts Torque the bolts 8 to 12 Ib ft 11 to 16 Nem LUBRICATION The fluid level indicator should be used to determine actual fluid requirements Check the oil level at normal operating temperature Refer to TROUBLESHOOTING Hydraulic Checks If it is necessary to add or replace fluid use DEXRON Il or equivalent If a partial drain was done add 5 quarts 4 7 liters shallow pan or 6 quarts 5 6 liters deep pan of fluid to the transmission through the filler tube Check the fluid level If a complete drain was done the approximate refill capacity is 11 75 quarts 11 2 liters The approximate dry capacity includes cooler and lines TM 10 3950 672 24 1 FRONT DRIVE AXLE DESCRIPTION The front drive axle is a F 146 FSHX axle manufactured The straddle mounted pinion has two tapered roller by Rockwell The axle incorporates a single reduction bearings in front of the pinion teeth which take the carrier with a heavy duty hypoid drive pinion and ring forward and reverse thrust and a third bearing behind gear The differenti
420. ort RES EUN Equipment Remarks Assembly Function F Ref Code Code Batteries Storage Inspect Replace 5 Battery Tie Down Inspect Battery Cables Inspect 7 Replace Repair Hull or Chassis Wiring Harness Wiring Harnesses Test 23 Replace Repair TRANSMISSION Gear Shift Shift Adjust 0 5 Modulator Replace Torque Converter Replace 14 15 24 Transmission Service 2 4 6 8 Assembly Inspect 9 10 12 Test 13 14 15 Replace 24 Repair 24 0 TM10 3950 672 24 1 Section MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 5 4 MAINTENANCE LEVEL Direct General Tools and Component Maint Support Support Depot Equipment Remarks Assembly Function DY Ref Code Code Coolers Pumps Motors Trans Front Pump Inspect 21 23 24 Replace 0 2 Repair PROPELLER amp PROPELLER SHAFTS Drive Line Assembly Inspect Service Replace Repair FRONT AXLE Front Axle Assembly Service 2 4 12 Inspect 13 17 24 Replace 6 Repair Differential Front Inspect 13 14 2 Spin or No Spin Service Replace Repair TM10 3950 672 24 1 Section MAINTENANCE ALLOCATION CHART Continued FOR CRANE WAREHOUSE M469 4 5 MAINTENANCE LEVEL Direct General Tools and Component i Support RES NUN Equipment Remarks Assembly Function F Ref Code Code Planetary Drive Inspect Service
421. ose studs nicks and burrs at machined surfaces Remove nicks and burrs with stone or file Make all necessary repairs or parts replacement before installing drive unit in housing Repair 1 Replace all worn or damaged parts Replace trunnion sockets if scratched Replace all hex nuts with rounded corners washers distorted snap rings oil seals gaskets and socket felts at a time of overhaul 2 Use only genuine Rockwell Standard parts for satisfactory service For example using gaskets of improper material generally leads to mechanical trouble due to variations in thickness and the inability of certain materials to withstand compression oil etc 3 Remove nicks mars and burrs from machined or ground surfaces Threads must be clean and free to obtain accurate adjustment and correct torque A fine mill file or India stone is suitable for this purpose Studs must be tight prior to assembling the parts 4 The burrs caused by lockwashers at the spot face of stud holes of knuckle flanges spider flange or hub cover should be removed to assure easy assembly of these parts 5 When assembling component parts use a press where possible LUBRICATION General The efficiency and life of mechanical equipment is as dependent proper lubrication as proper engineering design The importance of proper lubrication is increased because of greater gear tooth and bearing pressures and higher speeds in present day vehicles
422. ot dropped when the side plate is removed 4 Remove the capscrews securing the side plates to the hoist and lift the follower assembly from the crane DISASSEMBLY NOTE The cable follower should be disassembled in a clean work area 1 Remove the capscrews and washers securing the angle to the cable follower shaft 2 Remove the angle and shim washer from the end of the cable follower shaft and slide the roller assembly off the shaft 3 Remove the shaft bearings and the other shim washer from the roller assembly CLEANING AND INSPECTION 1 Clean all grease from the shaft and bearings 2 Check the inner shaft the roller and the shaft bearings for cracks scoring or grooving Replace if necessary 3 Check the spring tension If the springs will not provide sufficient tension when adjusted replace them ASSEMBLY 1 Install the inner shaft bearings into the roller assembly 2 Install on e shim washer on the inner shaft NOTE Locate the roller assembly as parallel as possible 0 625 inches 15 8 mm from the hoist drum and 0 125 inches 3 1 mm from the left flange 3 Install the roller assembly on the inner shaft and install a shim washer on the end 4 Ensure the roller assembly and bearings are fully seated and install the angle on the cable follower shaft 5 Apply medium strength threadlocking adhesive sealant and primer to the capscrews Install the capscrews and washers and secure the angle to the
423. otate the spool slowly when removing it from the sleeve 20 Remove the seal from the housing ee BALL RETAINER CHECK BALL 5 8 SEAL 43 7 16 SEAL CHECK BALL SEAT 0868 11 21 Remove the setscrew from the housing 22 Screw a 1 8 24 machine screw into the end of the check ball seat Then by pulling on the screw with pliers lift the seat out of the housing E 83 TM 10 3950 672 24 1 23 Remove the two seals from the check valve seat 24 Tip the housing to remove the check ball and the check ball retainer ASSEMBLY Check all mating surfaces Replace any parts that have scratches or burrs that could cause leakage Clean all metal parts in clean solvent Blow dry with air Do not wipe dry with a cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage Do not use a coarse grit or try to file or grind these parts NOTE Lubricate seals with the exception of the quad ring seal with a petroleum jelly such as Vaseline Do not use excessive lubricant on the seals for the gerotor section Refer to the parts listings covering your steering control unit when ordering replacement parts Replace all old seals with new seals during assembly Control End SETSCREW HECK BALL SEAT 8 8 m 7 16 CHECK BALL CHECK BALL RETAINER 1 Use needle nose pliers to lower the check ball retainer into the check valve hole of the housing E
424. oth internal and external leaks If there are external leaks around gaskets there may also be internal leaks into the engine Proper tightening of the head bolts with a torque wrench is essential for preventing leaks around the head gasket TM 10 3950 672 24 1 Water Pump The pump should be checked carefully for leaks and proper lubrication and if leaking cracked or worn it should be rebuilt or replaced promptly Fans and Belts The fan should be checked for loose or bent blades A loose blade might work free during operation and cause damage A bent blade could cause an imbalance and cause the water pump to fail prematurely and it will reduce the fan s efficiency Refer to the engine manual for your particular engine for fan and other belt adjustment specifications When one belt of dual drives is damaged or worn they must both be changed as a matched pair Thermostat Thermostats used in these carriers are of the non adjustable type and are incorporated in the cooling system for the purpose of retarding or restricting the circulation of coolant during engine warm up Engine overheating and loss of coolant is sometimes due to an inoperative thermostat To check for this condition remove the thermostat and test by submerging it in hot water and noting the temperature at which the thermostat opens and closes Use an accurate high temperature thermometer for making this test Hose and Clamps Hoses and their connec
425. ove tag Connect wire 1 3G to right rear side marker light and remove tag Connect wires 1 3F and 16 to right tail stoplight and remove tag Connect wire 25C to transmission oil temperature switch and remove tag Connect wires 18 and 51Y to quick start solenoid and remove tag Connect wire 32 to fuel level switch and remove tag Connect wires 3 and 1 69C to engine water temperature sensor and remove tag Connect wires 1 96B 5 and 1 96A to alternator terminal B and connect multi pin connector to alternator and remove tag Connect wires 157 and 156 to starter and remove tag Connect wire 1 to fuel solenoid and remove tag Connect wire 51X to engine oil pressure switch and remove tag Connect wires 4 and 169B to engine oil pressure sender and remove tag Connect wires 10 and 51V to tachometer sender and remove tag Connect wires 2C and 52C and connector to neutral safety switch and remove tag Connect wire 25B to transmission oil temperature switch and remove tag 3 240 TM 10 3950 672 24 1 Connect wires 7C 8D 7B and 8B to backup switch and remove tag Connect wires 83 51 AB and 51 AC to right rear outrigger solenoid and remove tag Connect wires 82 and 51AD to left front outrigger solenoid and remove tag Connect wires 84 51 AC and 51AD to left rear outrigger solenoid and remove tag Connect wires 81 51 AA and 51 AB to right front outrigger solenoid and remove tag Connect wires 81 83 38C and 38D to right outrigger select
426. p ring and re check the clearance E 53 TM 10 3950 672 24 1 Disassembly of the Input Shell and Sun Gear 1 Remove the rear snap ring from the sun gear 2 Remove the thrust washer wear plate from the input shell and sun gear 3 Working from inside the input shell remove the sun gear Remove the snap ring from the gear Assembly of the Input Shell and Sun Gear 1 Install the forward snap ring on the forward end short end of the sun gear Working from inside the input shell slide the sun gear and snap ring into place ensuring the longer end is at the rear 2 Install the thrust washer wear plate on the sun gear and install the rear snap ring Disassembly of the Output Shaft Hub and Ring Gear 1 Remove the hub snap ring from the ring gear 2 Lift the hub from the ring gear Assembly of the Output Shaft Hub and Ring Gear 1 Position the hub in the ring gear 2 Secure the hub with the snap ring Ensure the snap ring is fully engaged with the groove Disassembly of the One Way Clutch 1 Remove the snap ring and bushing from the rear of the low reverse clutch hub 2 Remove the rollers from the spring assembly and lift the spring assembly from the hub 3 Remove the remaining snap ring from the hub Assembly of the One Way Clutch 1 Install a snap ring in the forward snap ring groove of the low reverse clutch hub 2 Install the low reverse clutch hub on the bench with the forward end down 3 Install
427. pecial lubrications applied to them and or for those using flat or split ring types of washers Discount the residual lubricant present that was applied at the time of manufacture Figure D 1 Torque Values Sheet 1 of 3 D 2 TM10 3950 672 24 1 P TORQUE POUNDS FOOT TENSILE STRENGTH MINIMUM FINE OR COURSE THREAD FASTENER SA 3 100 000 STEEL PSI A S T M A449 S A E 5 A S T M 35488 CAPSCREW STEEL 5 A 325 GRADE MATERIAL DESIGNATION Medium Carbon Stee Quenched Med Carbon Steel SOCKET HEAD CAPSCREW ALSONAS AIRCRAFT STD High Carbon Alley Quenched SOCKET CAPSCREW CAPSCREW NAS 144 AIRCRAFT STO MS20000 MIL STD N A S 624 High Carbon NATIONAL Alloy AIRCRAFT Quenched CAPSCREW STANDARD Tempered STEEL Torque values as shown are for nut bolt combinations that have been plated or have had lubrication applied Figure D 1 Torque Values Sheet 2 of 3 D 3 TM10 3950 672 24 1 FINE OR COURSE THREAD FASTENER GRADE DESIGNATION Torque values as shown are for nut bolt combinations that have not been plated and have not had special lubrications applied to them and or for those using flat or split ring types of washers discount the residual lubricant present that was applied at the time of manufacture Metric Torq
428. pel loose dust and dirt accumulations from the air cleaner body automatically thus lengthening the element service life The valve lips must point straight down to operate effectively and must be kept free from debris Mud and chaff can lodge in these lips periodically and hold them open during engine operation E 11 TM 10 3950 672 24 1 Check the condition of the valve and lips frequently and keep them clean The valve lips should be open only when the engine is shut down or running at low idle speed If the valve is turned inside out check for a clogged air cleaner inlet Malfunction of this valve does not reduce the air cleaner effectiveness but does allow the element to get dirty faster and reduces serviceable life If a valve is lost or damaged replace it with a new valve of the same part number Duct Work 1 Check the intake pipe cap and screen for accumulation of leaves trash and other debris that could restrict air flow Repair the screen or replace the cap if any large holes are found in the screen 2 Check all mounting hardware for security to eliminate possible vibration of intake piping Such vibration leads to early failure of hoses clamps and mounting parts and can cause hoses to slip off the connecting pipes allowing unfiltered air into the engine air intake 3 Check hoses for cracks chafing deterioration and replace at the first sign of probable failure TM 10 3950 672 24 1 WATER CO
429. periodically annually or at a shorter time interval if necessitated by environmental or other adverse conditions and shall cover the entire length of the wire rope Only the outer 3 166 TM 10 3950 672 24 1 surface of the wire rope need be inspected and no attempt should be made to open the rope Periodic inspection should include all items listed under frequent inspection plus the following a Inspect for reduction of rope diameter below nominal diameter b Inspect for severely corroded or broken wires at end connections c Inspect for severely corroded cracked bent worn or improperly applied end connections d Inspect wire rope in areas subjected to rapid deterioration such as 1 Sections in contact with saddles equalizer sheaves or other sheaves where wire rope travel is limited 2 Sections of wire rope at or near terminal ends where corroded or broken wires may protrude e Inspect boom nose sheaves hook block sheaves boom extension jib sheaves auxiliary boom nose sheaves and hoist drums for wear Damaged sheaves or hoist drums can accelerate wear and cause rapid deterioration of the wire rope WIRE ROPE REPLACEMENT ALL WIRE ROPE No precise rules can be given for determination of the exact time for replacement of wire rope since many variable factors are involved Determination regarding continued use or replacement of wire rope depends largely upon the good judgment of an appointed and qualified per
430. ppet valve closes and the gerotor set becomes a hydraulic pump Turning the steering wheel mechanically actuates the gerotor set pumping hydraulic oil from one side of the steer cylinders to the other This means of steering is very difficult and requires a great amount of force to be applied to the steering wheel MAINTENANCE PRIOR TO DISASSEMBLY 1 Observe the shaft area of the unit immediately upon removal f it shows an appreciably oil wetted appearance this indicates the shaft seal may have been leaking 2 If there is a functional problem or leakage at the control end of the unit the disassembly of the control end of the unit only will be required and it is generally advisable to leave the gerotor end assembled 3 If a complete teardown and assembly of the unit is planned clean all paint and surface contamination from the unit at points of separation This is extremely important at the meter end of the unit so no paint flakes or particles will enter these closely fitted E 79 parts as they are being assembled To clean the unit adequately first plug all four ports then wire brush around the meter area ringing and blowing away all surface contamination before any disassembly is begun 4 For any disassembly an extremely clean bench area is necessary Do not use shop cloths or cotton waste to wipe or clean the parts The lint deposited by these cloths can disrupt the function or cause leaks The clean inside surface
431. pressure and return hydraulic circuit hydraulic pumps hydraulic cylinders and all hydraulic valves Description and operation of individual hydraulic circuits are discussed in their individual Sections A complete hydraulic system schematic showing all options is at the back of this Manual and an A N S I Graphical Symbols chart is provided in this Section A hydraulic test panel for checking relief valve settings is located at the front right side of the engine compartment The test panel contains three fittings sealed with pipe plugs By removing the pipe plugs and connecting a pressure gauge to the fittings the pressure setting of the relief valves can be checked SWING AND TELESCOPE HYDRAULIC TEST PANEL REFER TO SERVICE MANUAL FOR PRESSURE TEST PROCEDURE O R LIFT AND MAIN HOIST o D STEER Hydraulic Test Panel Decal MAINTENANCE HYDRAULIC OIL RECOMMENDATIONS For the hydraulic oil specifications refer to Section 13 LUBRICATION DRAINING AND FLUSHING If component has been changed because of a failure that might allow metal or abrasive particles to enter the system all systems must be thoroughly checked drained and flushed 3 92 1 Remove the reservoir drain plug Allow approximately three minutes after oil stops flowing from the drain port for the side walls to drain 2 Clean and install the reservoir plug and fill the reservoir with a 50 50 mixture of fuel oi
432. r seals Damaged piston seals i Replace all cylinder seals Bent boom section j Replace damaged boom sec tion k Broken hydraulic pump cou k Replace broken hydraulic pling pump coupling Worn or damaged hydraulic Repair or replace pump pump m Broken hydraulic pump shaft m Replace pump shaft 3 157 REMOVAL AND INSTALLATION Removal and installation of the telescope cylinder from the boom is described under disassembly and assembly of the boom Refer to BOOM MAINTENANCE in this Section 3 62 LIFT CIRCUIT TM 10 3950 672 24 1 DISASSEMBLY AND ASSEMBLY Disassembly and assembly procedures of the telescope cylinder and control valve are provided in Section 6 under CYLINDERS and VALVES respectively DESCRIPTION The boom lift circuit consists of the lift cylinder holding valve lift control valve thermal relief valve swivel and lockout solenoid valve if the hydraulic lockout option is provided The holding valve is located in the port block which is welded to the outside of the cylinder barrel The lift control valve is located in the valve compartment behind the front console in the cab Movement of the control lever forward DOWN or rearward UP from center neutral shifts a spool within the lift control valve Appropriate passages in the control valve route oil to the holding valve The holding valve passes oil to and from the cylinder as required Boom elevation is 0 degrees to 70 deg
433. r to provide rotation MAINTENANCE GENERAL Proper identification of bolt grade is important When The swing bearing is the most critical maintenance point marked as a high strength bolt grade 8 the of the crane It is here at the centerline of rotation that serviceman must be aware of bolt classifications and stresses of loads are concentrated addition the that he is installing a high strength heat treated bearing provides the only attachment between the tempered component and the bolt must be installed superstructure and carrier Therefore proper care of the according to specifications Special attention should be bearing and periodic maintenance of the turntable to given to the existence of lubricant and plating that will bearing attach bolts IS A MUST to ensure safe and cause variation from dry torque values When a high efficient operation strength bolt is removed or untorqued the bolt must be replaced with a new bolt of the same classification along with a new grade 8 nut TORQUING TURNTABLE BOLTS WARNING General IT IS MANDATORY THAT BEARING WARNING ATTACHING BOLTS BE INSPECTED FOR LACK OFTORQUE AND FAILURE TO MAINTAIN PROPER RETORQUED AS REQUIRED AFTER TORQUE OF THE TURNTABLE THE FIRST 300 HOURS OF CRANE BEARING ATTACHING BOLTS WILL OPERATION THE BOLTS MAY RESULT IN DAMAGE TO THE CRANE LOOSEN IN SERVICE DUE TO AND POSSIBLE INJURY VIBRATION SHOCK LOADS AND PERSONNEL TEMPERATURE CHANGES THEREFORE PE
434. r valve in the valve body 10 Install the one spring DR 2 shift valve and the 1 2 shift valve in the body 11 Install the throttle modulator valve and spring and the 2 3 shift valve in the valve body 12 Install the spring and the 2 3 backout valve in the valve body 13 Install the two springs and the intermediate servo accumulator valve in the valve body 14 Install the intermediate servo modulator valve and spring in the body 15 Carefully install the valve retaining plate on the body and secure with the eight attaching screws Torque the two hex washer head screws 20 to 45 Ib in 2to 5 Nom Torque the remaining six screws 20 to 40 Ib in 2 to 5 Nem 16 Install the throttle pressure boost valve and spring in the valve body Install the manual low 2 1 scheduling valve and spring In the valve body and install the retaining plate Torque the attaching screws 20 to 45 Ib in 2 to 5 Nem 17 Install the spring retainer on the stem of the main regulator valve so that the retainer flange is next to the valve shoulder Install the main regulator valve spring retainer two springs pressure boost valve and sleeve in the bore Apply hand pressure on the end of the pressure boost valve sleeve and install the spring clip retainer in the groove on the under side of the body so that the clip is inserted into the end groove in the sleeve Ensure the pressure boost valve sleeve is free in its bore 18 Install the manual valve in the
435. ract Installation Lubricate new or used bearings before installation Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate preloading When installing a bearing spacer or washer against a shoulder on a shaft be sure the chamfered side is toward the shoulder When pressing bearings into a retainer or bore uniformly apply pressure to the outer race If the bearing is pressed on the shaft uniformly apply pressure on the inner race Preload Preload is an initial load placed on the bearing at the time of assembly Whether a tapered roller bearing should have preload could depend on any of several conditions rigidity of the housings and shaft bearing spread speed of operation etc To determine whether a bearing requires preload or end clearance consult the disassembly and assembly instructions pertaining to that bearing Care should be exercised in applying preload Misapplication of preload to bearings requiring end clearance can result in bearing failure Sleeve Bearings Do not install sleeve bearings with a hammer Use a press and be sure to apply the pressure directly in line with the bore If it is necessary to drive on a bearing use a bearing driver or a bar with a smooth flat end If a sleeve bearing has an oil hole align it with the oil hole in the mating part GASKETS Be sure the holes in the gaskets correspond with the lubricant passages in the mating p
436. ransportation Discrepancy Report TDR SF 361 Fill out and forward SF 361 Transportation Discrepancy Report TDR SF361 as prescribed in AR 55 38 NAVSUPINST 4610 33C AFR 75 1 8 MCO P4610 19D DLAR 4500 15 1 3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Destruction of Army materiel to prevent enemy use shall be in accordance with TM 750 244 3 1 1 TM10 3950 672 24 1 1 4 ADMINISTRATIVE STORAGE Equipment issued to and by the Army activities will have preventive maintenance in accordance with Preventive Maintenance Checks and Services PMCS performed before being placed into storage When removing the equipment from administrative storage the PMCS checks should be performed to ensure operational readiness 1 5 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRs If your equipment needs improvement let us know Send us an EIR You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance Put it on an SF 368 Product Quality Deficiency Report Mail it to Commander U S Army Tank automotive and Armaments Command Attn AMSTA IM JM Warren MI 48397 5000 We ll send you a reply 1 2 TM10 3950 672 24 1 Section 2 General Maintenance Subject Para Page Maintenance EE GleanlineSS D M D Aeon c D n 1 4 Removal and Installation 00 Disasse
437. re reinstalled BEARINGS Antifriction Bearings When an antifriction bearing is removed cover it to keep out dirt and abrasives Wash bearings in nonflammable cleaning solution and allow them to drain dry The bearing may be dried with compressed air BUT do not spin the bearing Discard the bearings if the races and balls or rollers are pitted scored or burned If the bearing is serviceable coat it with oil and wrap it in clean waxed paper Do not unwrap new bearings until time of installation The life of an antifriction bearing will be shortened if not properly lubricated Dirt in an antifriction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage Double Row Tapered Roller Double row tapered roller bearings are precision fit during manufacture and components not interchangeable The cups cones and spacers are usually etched with the same serial number and letter designator If no letter designators are found wire the components together to assure correct installation Reusable bearing components should be installed in their original positions Heating Bearings Bearings which require expansion for installation should be heated in oil not to exceed 250 degrees F 121 degrees C When more than one part is heated to aid in assembly they must be allowed to cool and then pressed together again Parts often separate as they cool and cont
438. re the new filter element s is correct by comparing the part number with that of the used filter element s 9 Discard the used filter element s Assembly and Installation 1 If removed install the indicator to the head and secure with the lockwashers and screws 2 Install the filter elements s into the filter bowl 3 Install the diverter and poppet valve assembly into the head and secure with the diverter handle and hitch clip pin 4 Install the head to the filter bowl and secure with the screws 5 Install the filter cover and secure with the screws 6 Start up the hydraulic system and check for leaks 3 41 HYDRAULIC PUMP DESCRIPTION TM 10 3950 672 24 1 The hydraulic pump is mounted on and is driven by the diesel engine through an adapter and coupling on the crankshaft The pump is a gear type unit and consists of two section The first section has an output of 27 4 103 7 Ipm and the second section has an output of 18 9 71 5 Ipm 2400 rpm MAINTENANCE NOTE For more detailed information refer to Appendix TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Noisy pump caused by cavitation 2 Oil heating 3 Shaft seal leakage 4 Foaming Oil Oil supply low Air leaking into the suction line Incorrect oil in reservoir Oil supply is low Contaminated oil Oil in system too light Worn shaft seal Low oil level Air leaking into the suctio
439. reducer to rotate the superstructure to the left shuttle valve in the crossover relief valve installed between the swing left and swing right lines provides pressurized oil to the swing brake assembly to release the swing brake MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Boom swing operation erratic In either direction b Swing brake dragging not re leasing properly a Damaged relief valve a Replace relief valve b Readjust and or replace neces sary parts TM 10 3950 672 24 1 PINION END COVER DIPSTICK GEAR REDUCER SWING MOTOR Swing System Components 3 137 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 1 Boom swing operation erratic in either direction continued 2 Boom swing operation erratic in one direction only c Low engine rpm d Low hydraulic oil e Improper movement of control lever to neutral f Insufficient lubricant on swing bearing g Crane not level h Damaged swing motor i Excessive overload j Restricted or partly clogged hy draulic hose or fitting k Pump cavitation in swing sec tion I Improperly torqued turntable bolts m Excessive preload on upper and lower pinion shaft bearing n Improperly torqued swing mo tor attachment bolts o Malfunction of the swing box p Worn or damaged pump sec tion a Relief valve inoperative b Crane not level c Turntable bearing binding due
440. rees from horizontal The lift control valve is the closed spool type and is described under VALVES in Section 6 The holding valve is threaded into the cylinder port block The holding valve functions when booming up cylinder rod extended booming down cylinder rod retracted or holding cylinder rod stationary When booming up oil unseats the poppet check valve in the holding valve letting oil flow to the piston side of the cylinder Pressure is applied to the piston forcing the rod to extend raising the boom When booming down oil enters the retract port of the port block and flows to the cylinder rod side When pilot pressure reaches a pre determined value the main poppet unseats and oil flows from the piston side of the cylinder to the reservoir When holding the boom oil is trapped in the cylinders by the holding valve Refer to the applicable SM package for a complete description of holding valve operation The lift cylinder is the double acting type with a cylinder bore of 7 inches 17 8 cm For a detailed description of the lift cylinder refer to Lift Cylinder in Section 6 HYDRAULIC SYSTEM MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Boom raises erratically Lowengine rpm Main relief valve damaged Air in cylinder rods Bent boom pivot shaft Low hydraulic oil a Replenish hydraulic oil to pro per level b Increase engine rpm to recom mended setting
441. remove the wheel cylinder attaching capscrews and wheel cylinder CLEANING AND INSPECTION Cleaning E 96 CAUTION DO NOT USE CLEANING SOLVENTS ON THE HYDRAULIC SEALS BOOTS OR PISTONS CLEANING SOLVENTS CAN DAMAGE THESE COMPONENTS PROTECT THE BRAKE LINING FROM SOLVENTS LUBRICANTS RUST INHIBITORS OR OTHER CONTAMINANTS THAT CHANGE THE FRICTION PROPERTIES THE LINING CONTAMINATED LININGS MUST BE REPLACED 1 Using a cleaning solvent clean ground or polished parts and surfaces Kerosene or diesel fuel can be used for this purpose do not use gasoline Do not clean ground or polished parts in a hot solution tank or with water steam or alkaline solutions These solutions will cause corrosion of the parts WARNING USE CARE WHEN USING CLEANING SOLVENTS FOLLOW THE INSTRUCTIONS SUPPLIED BY THE SOLVENTMANUFACTURERTO PREVENT INJURY WARNING USE CARE WHEN USING HOT SOLUTION TANKS AND ALKALINE SOLUTIONS FOLLOW THE INSTRUCTIONS SUPPLIED BY THE ALKALINE MANUFACTURER TO PREVENT INJURY RETAINER NUT SPRING WASHER LOCK BRAKE SHOE SET PLATE CYLINDER ASSY WHEEL SCREW CAP HEX HEAD PIN STRAIGHT HEAD SPRING BOLT CLIP RETAINING WASHER LOCK BRAKE ASSEMBLY E 97 TM 10 3950 672 24 1 2 Rough parts can be cleaned with the ground or polished parts or in hot solution tanks with a weak alkaline solution Parts must remain in the hot solution tanks until they are completely c
442. ressure on the pressure boost valve sleeve end and remove the sleeve retaining clip from the under side of the body Slowly release hand pressure and remove the sleeve and the pressure boost valve Remove the two springs the spring retainer and the main regulator valve from the bore 8 Apply pressure on the throttle boost valve retaining plate and remove the two attaching screws Slowly release the pressure and remove the plate throttle pressure boost valve and spring and the manual low 2 1 scheduling valve and spring from the body 9 Apply pressure on the remaining valve retaining plate and remove the eight attaching screws 10 Hold the valve body so that the plate is facing upward Slowly release the pressure and remove the plate 11 Remove the spring and the intermediate servo modulator valve from the valve body 12 Remove the intermediate servo accumulator valve and springs 13 Remove the 2 3 back out valve and spring 14 Remove the 2 3 shift valve spring and the throttle modulator valve 15 Remove the 1 2 shift valve DR 2 shift valve and the spring from the valve body 16 Remove the line pressure coasting regulator valve from the body 17 Remove the cutback control valve to complete the disassembly of the control valve Assembly of the Control Valve Body 1 Install the downshift valve and spring in the valve body Compress the spring and install the retainer from the underside of the body 2 Install the va
443. rface for scores and check gear teeth for burrs 3 Inspect the front pump seal for cuts or nicks and the pump bushing for scoring 4 Check the fluid passages for obstructions 5 f any parts are found damaged or worn replace the pump as a unit Minor burrs and scores may be removed with crocus cloth 6 Check the large seal ring groove of the pump body for damage Check the gasket mating surface of the pump body for damage Reverse High Clutch 1 Inspect the drum band surface the bushing and thrust surfaces for scores Minor scores may be removed with crocus cloth Badly scored parts must be replaced 2 Inspect the clutch piston bore and the piston inner and outer bearing surfaces for scores Check the air bleed ball valve in the clutch piston for free movement Check the orifice to ensure it is not plugged 3 Check the fluid passages for obstructions fluid passages must be clean and free of obstructions All 4 Inspect the clutch plates for wear scoring and fit on the clutch hub serrations Replace all plates that are badly scored worn or do not fit freely in the hub serrations 5 Inspect the Clutch pressure plate for scores on the clutch plate bearing surface Check the clutch release spring s for distortion 6 Inspect the clutch piston check ball for freedom of movement and proper seating E 42 TM 10 3950 672 24 1 Forward Clutch 1 Inspect the clutch cylinder thrust surfaces pis ton bore and
444. rict back flow when the directional control valve is closed The restriction prevents the pilot operated poppet from chattering on its seat A vent is provided that vents the area between the pilot piston seal and the free flow poppet and pilot operated poppet seals to prevent a hydraulic lock should weepage around the seals occur O Ring Spring Adjusting Spring Nut Plug Spool E 101 O Ring Orifice Plug Plug Plug TM 10 3950 672 24 1 TM 10 3950 672 24 1 MAINTENANCE ASSEMBLY DISASSEMBLY NOTE 1 Remove O ring 3 from the valve body 1 It is recommended O rings be 2 Remove the plug 17 and O ring 2 spring 4 and replaced with new O rings at poppet 5 from the valve body assembly 3 Remove nut 10 spring 8 O ring 7 and washer 5 from the valve body 4 Remove the spool 12 from the valve body Remove the O ring 13 from the spool Remove plug 15 from the spool 5 Remove plug 11 and orifice 14 6 Remove plug 16 and O ring Remove all of the remaining plugs from the valve body CLEANING AND INSPECTION 1 Clean all parts in a suitable solvent and dry with air 2 Inspect the spool and poppet for nicks and scratches Minor nicks and scratches may be removed with crocus cloth E 102 1 Prior to assembly coat all parts with clean hydraulic oil 2 Install O ring and plug 16 into the valve body 3 Install plug 11 and orifice 14 4 Install plug 15 and O ri
445. rive Belt Removal in Index of this TM Disconnect 3 wire plug from 3 wire socket at rear of alternator Blue Yellow Black leads Remove terminal nut 1 Figure 3 28 and washer 2 from terminal B Tag and remove Blue No 196 and No 5 wire and blue condenser wire 196 from terminal B Tag and disconnect Black No 174 and Blue 196 from B terminal Leave condenser in place on B terminal Remove two capscrews 26 from alternator brace Remove alternator brace 27 from alternator Remove one pivot hex flange screw 23 from alternator support bracket 24 Leave bracket 24 attached to engine block Remove alternator from engine Disassembly Remove two terminal nuts 1 and 21 Figure 3 26 two washers 2 and 22 and two screws 3 Move voltage regulator 4 away from rear housing 8 disconnect electrical connector from brush assembly 6 and remove voltage regulator 4 Remove two screws 5 and brush assembly 6 from rear housing 8 CAUTION Do not insert screwdriver blades deeper than 1 16 inch 1 587 mm to avoid damaging stator winding Match mark front and rear housings and remove four screws 7 Insert two flat tip screwdrivers in opposite openings between stator 10 and rear housing 8 refer to Figure 3 27 NOTE Mark stator 10 location prior to prying apart and removing from front housing 15 Pry units apart and remove rear housing 8 Figure 3 26 and stator 10 from front housing 15
446. rmation of rust in the cooling system is a result of the interaction of water iron and oxygen and can only be prevented by maintaining full strength corrosion protection at all times For rust protection during the winter months an antifreeze having a corrosion preventive should be installed in the fall When spring arrives drain the old antifreeze solution from the cooling system as all corrosion inhibitors are weakened and may be entirely exhausted by this time depending on how the engine has been taken care of and how many operating hours have been put on it To rustproof the cooling system for summer driving add a good rust inhibitor with the first fill of clean water if water is to be used in the spring This solution should then be drained in the fall and a fresh filling of chemically treated anti freeze installed A good quick test to determine if the cooling system needs cleaning or flushing due to rust scale or grease is to wipe the inside of the filler neck and header tank with the finger If any sludge or excessive rust and scale are present and evidence by this test the system needs a thorough cleaning SEASONAL CARE The cooling system of any vehicle should be drained and flushed out at least once a year Unless the coolant has a corrosion preventive in it rust and scale will eventually clog up the cooling system Any effective commercially available flushing agent should be used at least once a year and preferably tw
447. roller assembly INSTALLATION 1 Using a suitable lifting device install the follower assembly on the hoist 2 Install the side plates to the hoist and secure with the capscrews Torque the capscrews to 31 Ib ft 42 Nem Fill the side plate assemblies with grease through the grease fittings on each side plate weld 3 186 Cable Follower Assembly 3 187 TM 10 3950 672 24 1 L H Side Plate Weld Side Plate Weld Lever Weld Nut dam Nut Spring Adjusting Rod Extension Spring Capscrew Lever Weld Rotter Assembly Grease Fitting Angle Angle Washer Capecrew Lockwesher Angle Bearing Shatt 1941 3 Install the lever welds to the side plate welds and secure with bolts washers and nuts Torque the bolts 10 to 12 Ib ft 14 to 16 Nem 4 Install the extension springs adjusting rod to extend the Adjust the spring extension spring TM 10 3950 672 24 1 approximately 1 inch 25 4 mm Tighten the adjusting nuts 5 Refer to operators manual TM 10 3950 672 10 and lubricate the cable follower as specified 3 188 3 73 VANE TYPE MOTOR TM 10 3950 672 24 1 DESCRIPTION The vane type motor is a fixed displacement rotary balanced motor that converts hydraulic oil flow into rotary mechanical motion The motor consists of four basic sub assemblies a body or housing and shaft with a permanently lubricated bearing a front port plate assembly consisting of the port plate with a built in
448. rom the housing n RADIUS BEND TIP RADIUS ON ENO 50 Q S o MOUNTING FLANGE 2187 9 OUST SEAL PRESSURE SEAL FLANGE INNER SIDE PRESSURE SEAL DUST SEAL OUTER SIDE 2187 11 L REMOVAL TOOL E 122 TM 10 3950 672 24 1 NOTE The dust seal pressure seals and seal will come off with the flange 15 Use a seal remover tool like the one shown above to remove the dust seal and pressure seal Work from the outer side to remove each seal Work the nose of the tool between the pressure seal and the flange Pry the seal partway Remove the tool and repeat at a point 180 degrees away Push the seal completely out of the cavity 2187 12 16 Remove the output shaft from the housing 17 Remove the bearing race and needle thrust bearing from the shaft SEAL PLUG 2187 13 18 A metal plug and seal is used to plug a machining hole in the housing It is not necessary to remove the plug and replace the seal unless leakage is occurring around the plug To remove the plug insert an so Allen wrench through the port opening and push it out CLEANING AND INSPECTION 1 Check all mating surfaces and replace any parts having scratches or burrs that could cause leakage or damage 2 Clean all metal parts in clean solvent Blow dry with air Do not wipe them with a cloth or paper towel because lint or other matter can get into the hydraulic System and cause damage 3 Ch
449. rom the old engine and install them on the new engine in the same locations Ensure the same grade hardware torque valves and loctite as were installed by the factory are used Refer to Section 3 DRIVE TRAIN and remove the transmission from the engine if necessary 3 7 3 Installation o 7 If the transmission was removed from the engine refer to Section 3 DRIVE TRAIN and install the engine to the transmission With all the components and fittings installed on the new engine lift the engine into the crane With the engine in position secure the transmission to the frame with the bolts nuts and washers Torque the bolts to 75 Ib ft 101 7 Nem Secure the engine to the mounting bracket with the bolts nuts and washers Torque the bolts to 75 Ib ft 101 7 Nem Remove the lifting device Connect the transmission shifting linkage to the transmission refer to paragraph 3 23 Connect the throttle cable to the throttle linkage If removed install the steering pump and secure with the bolts and washers Torque the bolts to 165 Ib ft 223 7 N m refer to paragraph 3 33 Connect all lines and tubing to the engine transmission and other components as tagged during removal Install the hydraulic pump and secure with the bolts and washers Torque the bolts to 165 Ib ft 223 7 Nem Connect the lines as tagged during removal refer paragraph 3 41 3 18 10 3950 672 24 1 Connect all electrical
450. rotor 7 Inspect the vanes for excessive wear marks burrs nicks and scoring Replace any defective vanes E 151 8 Inspect the wear surfaces of the port plate and end cap for deep scratches Replace if defective 9 Inspect the housing and end cap for cracks or other casting damage Replace all damaged castings 10 Inspect the shaft for excessive wear internal spline bearing surface and drive end Replace if defective CAUTION DIRT IS A MAJOR CAUSE OF WEAR AND MOTOR FAILURE COVER ALL PARTS AFTER CLEANING TO PREVENT DUST AND DIRT FROM SETTLING ON THEM ALL SURFACES SHOULD BE COATED WITH A FILM OF HYDRAULIC LUBRICATING OIL AFTER THEY HAVE BEEN CLEANED ASSEMBLY Immerse the seals and bearings in clean hydraulic fluid to make the assembly easier and to provide initial lubrication NOTE Do not install the retaining ring over the external drive end of the shaft as damage may be done to the seal surface next to the groove 1 Install one retaining ring 19 in the groove nearest the external drive end of the shaft 21 NOTE There is an intentional interference fit between the ball bearing inner race and the shaft OD 2 Press on the ball bearing inner race only and press the ball bearing 20 on the shaft 21 and against the retaining ring 19 Install the other retaining ring 19 into the groove provided NOTE Two special tools must be fabricated to accomplish the following steps See the figure
451. rrect fasteners can result in damage malfunction or injury to personnel SAFT 4 TM10 3950 672 24 1 SAFETY SUMMARY Continued WARNING Never crawl under the crane when performing maintenance unless the crane is securely blocked and or on jack stands Do not work on equipment that is only supported by a jack or hoist Equipment may fall and cause serious injury or DEATH to personnel Keep clear of the crane or its components as they are being raised or lowered Do not allow components suspended in the air to swing Equipment may fall or strike personnel and cause serious injury or DEATH to personnel Extreme care must be taken when working on cable or chain under tension A snapped cable or swinging load may result in injury or DEATH to personnel WARNING Starting fluid is toxic and highly flammable NEVER heat the container and NEVER discharge starting fluid in a confined area or near an open flame Severe injury to personnel may result WARNING When using steam cleaners avoid contact with the steam which can cause burns blindness and other serious injuries Wear protective apron gloves and safety goggles when using live steam WARNING The wire rope can become frayed or contain broken wires Wear heavy leather palmed work gloves when handling the wire rope Frayed or broken wires can injure the hands Never let moving wire rope slide through hands even when wearing gloves as a broke wire strand could penetrate the gloves and
452. rting the engine and normal during normal check check the following 1 Check for correct operation of the drainback valve in the stator support 2 Check the pump bushing 3 Repair or replace pump if required TRANSMISSION FLUID LEAKAGE CHECKS 1 Leakage at the oil pan gasket often can be stopped by tightening the attaching bolts to the proper torque If necessary replace the gasket 2 Check the fluid filler tube connection at the transmission case If leakage is found install a new O ring The filler tube bracket should align properly 3 If leakage is found at either the downshift control lever shaft or the manual lever shaft replace either or both seals FLUID LEAKAGE IN CONVERTER AND FRONT PUMP AREA Leakage at the front of the transmission is evidenced Troubleshooting Chart SYMPTOM PROBABLE CAUSE SOLUTION 1 Slow initial engagement a Improper fluid level b Damaged or improperly adjust ed linkage c Contaminated fluid d Improper clutch and band ap TM 10 3950 672 24 1 by fluid around the converter housing and may have several sources By careful observation it is possible in many instances to pinpoint the source of the leak before removing the transmission 1 Fluid leaking by the front pump seal lip will tend to move along the drive hub and onto the back of the impeller housing Except in the case of a total seal failure fluid leakage by the lip of the seal will be deposited on th
453. s vented shift units and all other openings should be tightly covered or closed to prevent the possibility of water entering the assembly 3 65 TM 10 3950 672 24 1 3 26 3 Installation a b Position the axle under the crane on jacks which are capable of handling the weight of the axle Raise the axle into place and secure to the frame with the eight bolts nuts and washers Torque the bolts to 250 Ib ft 339 Nem Install the wheels onto the axle Refer to WHEELS AND TIRES in this section Connect the hydraulic brake line at each wheel as tagged during removal NOTE To provide proper torque of the capscrews at installation grind a flat on the washers as required to allow clearance for bend radius on the clamps and clamp drives Connect the drive line to the axle differential or gearbox if installed and secure with the clamps capscrews washers and nuts torque the capscrews 27 to 29 Ib ft 37 to 39 Nem Bleed the hydraulic brake system Refer to HYDRAULIC BRAKES in this section Remove the blocking and retract the outriggers to lower the wheels to the ground 3 66 3 27 REAR STEER AXLE TM 10 3950 672 24 1 DESCRIPTION The rear steer axle incorporates a steer cylinder assembly and a left and right hand hub and spindle assembly or a left and right hand hub brake and spindle assembly A single 3 inch 7 62 cm hydraulic cylinder is attached by a rod eye assembly to the link plates that are attached to the
454. s washers and nuts securing the 1 Install the valve to the mounting plate and secure solenoid valve s to the mounting plate Remove the with the bolts washers and nuts valve 3 116 3 49 HOIST MOTOR CONTROL VALVE TM 10 3950 672 24 1 DESCRIPTION The hoist motor control valve is designed to provide an even flow of oil to the hoist motor in both directions To drive the hoist motor in the raise direction hydraulic oil flows through the in port and pushes the free flow poppet off its seat The oil then flows to the out port and on to the hoist drive motor When driving the hoist motor in the lower direction oil from the directional control valve enters the out port The pilot operated poppet is held shut by the adjustment spring until pilot pressure of sufficient force is sensed at the pilot pressure port to move the pilot operated poppet off its seat This allows flow to the return reservoir through the directional control valve An orifice plug is installed in the pilot pressure port to restrict back flow when the directional control valve is closed The restriction prevents the pilot operated poppet from chattering on its seat A vent is provided that vents the area between the pilot piston seal and the free flow poppet and pilot operated poppet seals to prevent a hydraulic lock should weepage around the seals occur MAINTENANCE For more detailed information refer to Appendix E REMOVAL 1 Tag and disconnect
455. s 12 to 16 Ib ft 16 to 22 N m Disassembly of the Servo Apply Lever 1 Working from the inside of the transmission case carefully drive on the servo apply lever shaft to remove the cup plug The shaft can be withdrawn from the case by hand Assembly of the Servo Apply Lever 1 Hold the servo apply lever in position and install the new shaft E 49 TM 10 3950 672 24 1 INSTALL CUP PLUG FLUSH WITH SERVO APPLY LEVER SHOULDER OF COUNTERBORE 1 2 IN DIA 12 7 MM 13 32 IN DIA rj 10 32 MM 101 6 152 4 MM 0923 INSTALLING TOOL MAKE FROM 1 2 IN 12 7 MM DIA DRILL ROD Servo Apply Lever installation 2 Coat the cup plug with threadlock and sealer Using the fabricated tool shown in the illustration titled Servo Apply Lever Installation drive the cup plug into position in the case Ensure the plug is flush with the shoulder of the counterbore Disassembly of the Front Pump 1 Remove the two seal rings and the selective thrust washer 2 Remove the large square seal from the outside diameter of the pump housing 3 Remove the five bolts that secure the stator support to the pump housing Lift the support from the housing 4 Remove the drive and the driven gear from the housing 5 If the pump housing bushing is worn or damaged it must be replaced Install the new bushing in position ensuring the half moon slot in the bushing is on top and in line with the oil lube hole near the seal bore
456. s 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 intermediate direct support refer to the Maintenance Allocation Chart WARNING The cooling system is pressurized Personal injury may result when removing the radiator cap after operating temperature is reached Do not remove radiator cap when radiator is hot to touch WARNING Do not smoke or allow flame or spark in the vicinity while checking or filling the batteries The batteries generate hydrogen a highly explosive gas Wear safety goggles when adding distilled water CAUTION Turntable bearing bolts cannot be retorqued more than one time Stretching takes place each time they are torqued If torque is lost replace bolts CAUTION In cold operation charge batteries immediately after water has been added to prevent freezing and damage to batteries run crane engine for one hour at 1500 RPMs 2 5 TM10 3950 672 24 1 It is necessary for your to know how fluid leaks affect the status of your equipment The following are definitions of the types classes of leakage you need to know to be able to determine the status of your equipment Learn and be familiar with them and REMEMBER when in doubt notify your supervisor 2 10 LEAKAGE DEFINITIONS FOR ORGANIZATIONAL PMCS CL
457. s from the INSTALLATION 1 Torque the converter drain plug 18 to 28 Ib ft 24 to 30 N m 3 56 TM 10 3950 672 24 1 2 Install the converter on the transmission ensuring the converter drive flats are fully engaged in the pump gear 3 Rotate the converter until the studs and drain plug are in alignment with their holes in the flywheel NOTE When moving the converter and transmission assembly into position with the engine the converter must rest squarely against the flywheel This indicates that the converter pilot is not binding in the engine crankshaft Do not allow the converter drive flats to disengage from the pump gear 4 Move the converter and transmission assembly into position with the engine using care not to damage the flywheel and the converter pilot 5 Install the converter housing to engine attaching bolts Torque the bolts 50to 65 pounds foot 67 to 88 Nm 6 Connect the vacuum line to the vacuum diaphragm ensuring the line is in the retaining clip 7 Connect the oil cooler lines to the transmission 8 Connect the shift cable to the respective lever on the transmission 9 Install the converter to flywheel attaching nuts Torque the nuts 20 to 30 Ib ft 27 to 40 Nem 10 Install the converter housing access cover and secure with the attaching bolts 11 Connect the neutral switch wire to the plug connector 12 Refer to Section 2 ENGINES and install the engine and transmission as an assem
458. s of the cylinder to the spindle link plates 3 Remove the bolts and washers securing the steer cylinder to the frame and remove the steer cylinder from the crane 3 89 and washers and secure the cylinder Torque the bolts to 583 Ib ft 791 Nem 3 Connect the hydraulic lines to the cylinder as tagged during REMOVAL 4 Operate the steering system and check for proper operation and any leakage TM 10 3950 672 24 1 Section 6 Hydraulic System Subject Para Page Hydraulic System rer 3 36 3 92 Description Hydraulic Oil Recommendations Draining and Flushing Removing Air From the Hydraulic System Control Valves Hydraulic Hoses Lines and Fittings Typical Removal d x Installation lt 3 37 2 Hydraulic 3 38 BCLLO UNETE 3 38 1 Installation ee 3 38 2 Supply Pressure and Return 3 39 Description Hydraulic Filter 3 40 Removal and Disassembly Assembly and Installation Hydraulic Pump 3 41 3 105 Description Troubleshooting Removal Installation Valves TEE 3 42 3 10 General Valve Usage Table Relief Valves cccccccsssssscssssesesssscsesesesesesescscsesesesesssseseseseseseseseaceeseseseeseseseseseseseass 3 10 Description General Preparation Main Relief Valve Adjustment Circuit Relief Valve Adjustment Directional Control Valve ssssssssssssss
459. s re quired g Replace seals and service clutch as required Determine cause of condition Service as required TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION Reverse shudder chatters slips 10 No drive slips or chatters in first gear in D All other gears normal 11 No drive slips or chatters in second gear 12 Starts up in 2nd or 3rd a Improper fluid level b Low main control pressure in reverse c Low reverse servo leaking d Low planetary one way clutch damaged e Reverse clutch drum bushing damaged f Reverse clutch stator support seal ring grooves worn or damaged g Reverse clutch piston seals cut or worn h Looseness in the driveshaft U joints or engine mounts a Damaged or worn planetary one way clutch a Intermediate band out of ad justment b Improper band or clutch appli cation or control pressure c Damaged or worn intermediate servo piston seals and or internal leaks d Dirty or sticking valve body body e Polished glazed intermediate band or drum a Improper band and or clutch application or oil pressure control system b Damaged or worn governor Sticking governor c Valve body loose d Dirty or sticking valve body body e Cross leaks between valve body and case mating surface E 35 a Perform fluid level check b Control pressure test c Air pressure test visually In spect seal rings and piston bore
460. sassembly of the Drive E 58 Front Drive Axle Installation RRRRE MMM 3 66 Front Drive Axle Lubrication RM E 75 Front Drive Axle 2 ser nr sisi sins ntn E 57 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page F continued Front Drive Axle Removal RIEN 3 65 Front Drive Axle Wheel End E 57 Front Drive Axle Wheel Ends Disassembly E 57 Front Gear Housing and Gear Train Operation and Description of nnns 5 163 Front Gear Housing and Gear Train Troubleshooting 2 44 40 00000000 000000 5 175 Front Steering Control Valve E 83 Front Steering Control Valve E 79 Front Steering Control Valve Disassembly E 81 Front Steering Control Valve Maintenance erii ii inna E 79 Front Steering Control Valve Prior to Disassembly of enne n nennen nnne nnne nnn E 79 Front Steering Control Valve Theory of 0 00 E 79 Front Support Cleaning and Inspection si
461. sheaves for security and freedom of movement 3 154 TM 10 3950 672 24 1 3 61 TELESCOPE CIRCUIT The boom telescope circuit consists of the telescope cylinder telescope control valve telescope relief valve holding valve boom assembly swivel and lockout solenoid valve The holding valve is located on and threaded into the cylinder The telescope control valve is located in the valve compartment behind the front console in the cab Movement of the telescope control valve lever forward OUT or rearward IN from center neutral shifts a spool within the telescope control valve which aligns appropriate passages in the control valve to route oil to the holding valve The holding valve with its internal makeup of valves and springs passes oil to and from the telescope cylinder The telescope control valve is the closed spool type and is described under VALVES in Section 6 The boom telescope cylinder has a 4 5 in 1 1 4 cm bore The cylinder is internally ported rod ported Oil from the telescope control valve is routed to the cylinder by external lines Foreign material is prevented from entering the cylinder by a wiper seal during rod retraction O ring seals prevent internal and external leakage The cylinder rod is secured to the boom base and the cylinder barrel is attached to the fly section The holding valve is threaded into the rod end of the telescope cylinder The holding valve functions during the retraction extension or holdi
462. sher 2 move console 3 away from mounting bracket 5 and remove serrated washer 4 Remove console 3 from vehicle Installation Position console 3 Figure 3 20 in vehicle Install serrated washer 4 on stud of console 3 and install console 3 on mounting bracket 5 with washer 2 and knob 1 Connect two electrical connectors to console 3 and remove tags Connect negative battery cable and two electrical leads to battery 3 174 TM 10 3950 672 24 1 LEGEND 1 Knob 4 Serrated washer 2 Washer 5 Mounting Bracket 3 Console Figure 3 20 Antitwo Block System Console 3 175 TM 10 3950 672 24 1 Section 9 Swivels Swivels Description 6 Port Hydraulic Swivel Description Theory of Operation Removal Installation Electrical Swivel Description Removal Installation Preventive Maintenance 3 68 SWIVELS Para Page 3 68 3 176 3 69 3 178 3 70 3 180 DESCRIPTION The swivel installation consists of a hydraulic swivel and an optional electrical swivel Solid connections cannot be used to transfer oil or electricity between the carrier and superstructure due to the continuous 360 degree swing The use of swivels efficiently accomplishes this function The spool portion of the hydraulic swivel is mounted on a spool mounting plate bolted to the carrier bearing plate The barrel portion of the hydraulic swivel has a lug welded to the barrel case that fits in a slot on the turntable bearing plate
463. shoes in position so that the push rod ends of the shoes are engaged with the wheel cylinder or push rods 5 Assemble the retainer nails springs and retainers Lock the nails in position by pushing down on the retainers while twisting the nails 1 4 turn with pliers 6 To assemble the shoe return spring put one hook in position in a brake shoe Pull the spring open to install the opposite hook in the other shoe 7 Assemble the retainer spring clip into the brake shoes 8 Bleed the hydraulic system after all the brakes are assembled and perform a brake adjustment Refer to Section 3 TM 10 3950 672 24 1 HOIST MOTOR CONTROL VALVE GROVE 15B HOIST DESCRIPTION The hoist motor control valve is designed to provide an even flow of oil to the hoist motor in both directions To drive the hoist motor in the raise direction hydraulic oil flows through the in port and pushes the free flow poppet off its seat The oil then flows to the out port and on to the hoist drive motor When driving the hoist motor in the lower direction oil from the directional control valve enters the out port The pilot operated poppet is held shut by the adjustment spring until pilot pressure of sufficient force is sensed at the pilot pressure port to move the E 100 pilot operated poppet off its seat This allows flow to the return reservoir through the directional control valve An orifice plug is installed in the pilot pressure port to rest
464. son who evaluates the remaining strength in a used rope after allowance for any deterioration disclosed by inspection Wire rope replacement should be determined by the following information excerpted from a National Consensus Standard as referenced by Federal Government Agencies and as recommended by Grove All wire rope will eventually deteriorate to a point where it is no longer usable Wire rope shall be taken out of service when any of the following conditions exist a In running ropes six randomly distributed broken wires in one lay or three broken wires in one strand in one lay b Wear of one third the original diameter of outside individual wires Kinking crushing bird caging or any other damage resulting in distortion of the rope structure 3 167 TM 10 3950 672 24 1 c Evidence of any heat damage from any cause d Reductions from nominal diameter of more than 1 64 inch for diameters up to and including 5 16 inch 1 32 inch for diameters 318 and 1 2 inch inclusive 3 64 inch for diameters 9 16 to 3 4 inch inclusive 1 16 inch for diameters 7 8 to 1 1 8 inches inclusive 3 32 inch for diameters 1 14 to 1 1 2 inches inclusive e n standing ropes more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection f Grove recommends that for cable extended booms a single damaged wire rope assembly shall require replacement of the entire set of extension
465. ssary 3 93 TM 10 3950 672 24 1 12 Disconnect the return lines from the steer cylinder and turn the wheels to the extreme right 13 Connect the return lines and turn the wheels to the extreme left and then back to center Replenish the reservoir oil level as necessary CAUTION WHEN OILS ARE CHANGED OR ADDED ENSURE THAT OILS OF DIFFERENT MANUFACTURERS ARE OF THE SAME SPECIFICATIONS HOWEVER DISCOLORATION MILKINESS MAY OCCUR When hydraulic oils are changed recheck the reservoir oil level after brief system operation and add oil as required Reservoir gauge level capacity is 30 0 gallons 113 5 liters and total capacity is 35 0 gallons 132 4 liters Ensure the crane is in the travel mode of operation when the oil system is being filled The system must be filled with all cylinders retracted and the boom at rest Fill the reservoir to the full mark on the reservoir sight gauge After the reservoir is filled operate all circuits and recheck the reservoir sight gauge Add oil as required REMOVING AIR FROM THE HYDRAULIC SYSTEM Due to the manner in which the hydraulic system is designed air entering the hydraulic oil will normally be removed automatically by passage of the oil over the baffles in the hydraulic reservoir However if a component has been replaced the reservoir level is too low or a leak develops in the suction lines to the pumps air can enter the system If air becomes entrapped in the hydraulic
466. sse inni 5 307 Fuel Drain Manifold ee eee aden isis 5 92 Fuel Drain Manifold 5 82 uel Eilter Feplacement ott en stone easter eee ee etus 5 85 Fuel Filter Water eee neta 3 27 Fuel Filter Water Separator Draining 3 27 Fuel Filter Water Separator Installation I IA I nnn 3 27 Fuel Filter Water Separator 3 27 Fuel Injector Replacement 0 2 5 95 Fuel Inlet Fitting Sealing Washer Replacement Injection 5 269 Fuel Lift P mMp Replacement innreise iiei 5 88 Fuel Or Oil Leaking From Exhaust Manifold 5 41 Fuel P mp Dataplate erre rie erected tet SU te oS 5 3 5 101 Fuel Pump Stud 5 304 Fuel Shutoff Valve Troubleshooting
467. ssion e Remove the actuating lever shoe retaining springs and remove the shoes 3 24 2 Inspection a Inspect the drum braking surface for roughness and scoring b Replace the drum if worn or physically damaged Inspect the brake lining and replace if the distance between the braking surface of the lining and the top of the rivet head is less than 0 031 in 0 794 mm 3 24 3 Installation a Install the brake shoe lower retaining spring on the shoes Position the shoes and lower retaining spring on the back of the carrier plate and install the shoe upper retaining springs and the actuating lever b Install the assembly on the transmission with the lever properly positioned at ball socket and shoe ends Install the brake mounting bolts and lockwashers Install the transmission drum and spline flange nut and cotter pin NOTE If the drum mounting bolts are pressed into the companion flange the drum can be mounted later as in step d otherwise the drum and flange should be assembled together and installed as a unit 3 59 3 24 4 TM 10 3950 672 24 1 d Install the brake drum Refer to DRIVE LINE in this section and install the drive shaft e Connect the actuating lever to the parking brake linkage Check the brake operation and adjust if necessary Adjustment a Chock the wheels Release the parking brake lever in the cab b From under the crane remove the cotter pin from the parking brake linkage adjusting cle
468. ssive or improper torque ALWAYS use a slow even movement and STOP when the predetermined value has been reached If it is reported by the crane operator or suspected that the crane has been overloaded beyond the capacities specified above the bold line on the crane s capacity chart then all turntable bolts must be inspected for looseness and retorqued to specifications Turntable bolts should be torqued diametrically opposed working in sequence from one side of the circle to the opposite side rather than tightening adjacent bolts successively Torque first to 5096 then to the final torque value When using step wrenches calculated wrench settings are valid only when the following conditions are met 1 Torque wrenches must be those specified and forces must be applied at the handle grip The use of handle extensions will change applied torque to the bolt 2 All handles must be parallel to the step wrench during final tightening Multiplier reaction bars may be misaligned no more than 30 degrees without causing serious error in torque 3 Multiplier reaction bar handles must be propped or supported within the outer 1 4 of the handle length or serious under or over tightening will occur The inner race of the bearing is secured to the carrier frame by 23 0 75 inch grade 8 bolts The outer race of 3 144 TM10 3950 672 24 1 the bearing is secured to the superstructure by 20 0 75 inch hex socket head capscrews Torque Values
469. standard Army Maintenance System concept b The Maintenance Allocation Chart MAC ih section Il 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 Unit includes two subcolumns C operator crew and 0 organizational maintenance Direct Support includes an F subcolumn General Support includes an H subcolumn Depot includes a D subcolumn c Section Ill lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced fro d Section IV contains supplemental instructions and explanatory notes for a particular maintenance function B 2 MAINTENANCE FUNCTIONS Maintenance functions will be limited to and defined as follows a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel 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 c Service Operations required periodically to keep an item in proper oper
470. sting ring where employed and bearing caps Tighten the capscrews to the proper torque 2 The bearing cups must be a hand push fit in the bores If they are not the bores must be reworked with a scraper or some emery cloth until a hand push fit is obtained Use a blued bearing cup as a gauge and check the fits as work progresses Once the cup fits properly remove the bearing caps 3 Lubricate the differential bearing cones and cups with the recommended axle lubricant 4 Place the cups over the bearings and position the assembly in the carrier housing 5 Insert the bearing adjusting nuts and turn handtight against the bearing cups lt gt CAUTION IF THE BEARING CAPS DO NOT POSITION PROPERLY THE ADJUSTING NUTS MIGHT BE CROSS THREADED REMOVETHE CAPS AND REPOSITION THE ADJUSTING NUTS FORCING THE CAPS INTO POSITION WILL RESULT IRREPARABLE DAMAGE TO THE CARRIER HOUSING OR BEARING CAPS 6 Install the bearing caps in the correct location as marked and tap lightly into position E 70 TM 10 3950 672 24 1 7 Install the carrier leg capscrews and tighten to the required torque Install the adjusting nut lock cotter keys or lock plate If the carrier leg capscrews are drilled or castellated lock wire after final adjustments are made Refer to Torque Values in this Sub Section Adjustment of Differential Bearing Preload 1 Using a dial indicator at the backface of the gear loosen the be
471. t Service as required e Tighten bolts f Determine source of contami nation Service as required g Check vacuum lines to dia phragm unit Service as necessary Perform vacuum supply and dia phragm tests a Control pressure test Note re sults b Tighten bolts c Determine source of contami nation Service as required d Perform governor test Repair as required a Perform fluid level check b Check and adjust or service as required c Perform governor test Service as required Adjust intermediate d Check diaphragm unit Service as necessary e Tighten bolts f Determine source of contami nation Service as required g Perform air pressure test TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 16 Rough harsh delayed 1 2 upshift 17 Mushy early soft slipping 1 2 upshift Improper fluid level Poor engine performance Intermediate band out of adjust ment Main control pressure too high Governor valve sticking Engine vacuum leak Valve body bolts loose or too tight Valve body dirty sticking valves Improper fluid level Incorrect engine performance Intermediate band out of adjust ment Low main control pressure Valve body bolts loose or too tight Valve body dirty sticking valves Governor valve sticking Damaged intermediate servo or band Polished glazed band or drum 3 53 Perform fluid level check Tune engine Adjust i
472. t the primer curing time is approximately 6 hours E 125 TM 10 3950 672 24 1 PLACE TIP OF APPLICATOR OF TOP OF THREADED PORTION APPLY 3 OR 4 DROPS IN EACH HOLE 2147 20 9 Apply three or four drops of Loctite adhesive Loctite number 601 sealant at the top of the threads in each of the 4 holes in the housing as shown above Also apply one drop of Loctite to one side of the threads of each capscrew Do not allow parts with Loctite applied to the surface to contact any metal parts other than their proper assembly Wipe off any excess Loctite from the housing face using a nonpetroleum base solvent Do not apply Loctite to the threads more than fifteen minutes before installation of the capscrews If the housing stands for more than 15 minutes repeat the application additional cleaning or removal of previous Loctite is necessary 10 Before installing the flange and seal assembly over the shaft place a protective sleeve or bullet over the shaft Install the flange Rotate the flange slowly while pushing down over the shaft Be careful not to invert or damage the seals 11 Clamp the motor in a vise as shown in step 11 of DISASSEMBLY Install the capscrews and torque immediately 225 to 250 Ib in 25 to 28 Nem If you use primer allow the Loctite to cure for 10 to 15 minutes without primer allow 6 hours before subjecting the motor to high torque reversals On all other applications you can run the motor immediately
473. tall new O rings onto the holding valve 4 Lubricate the holding valve and O rings with clean hydraulic oil CAUTION DO NOT DAMAGE THE O RINGS DURING INSTALLATION OF THE HOLDING VALVE IFTHE HOLDING VALVE TURNS FREELY THEN GETS HARD TO TURN THEN EASY TO TURN REMOVE THE HOLDING VALVE AND CHECK THE ORINGS THEY HAVE PROBABLY BEEN DAMAGED BY A SHARP EDGE OF A PORT 3 122 TM 10 3950 672 24 1 NOTE The holding valve should turn by hand until compression of the O rings begins 5 Carefully install the holding valve into the port block until fully seated NOTE Coat all seals and rings with clean hydraulic oil CAUTION AVOID STRETCHING THE SEALS AND RINGS ENSURE THE SEALS AND RINGS ARE INSTALLED IN THE PROPER ORDER 6 Install the O ring and backup ring onto the outside of the head NOTE Ensure the rod seal is installed in the sequence as noted during disassembly 7 Install the wiper ring rod seal buffer seal and the wear ring into the inside of the head 8 Install the seal assemblies onto the outside of the piston 9 Install the O ring and backup rings into the inside of the piston Ensure the O ring is between the backup rings 10 Lubricate the rod with clean hydraulic oil 11 Install the head onto the rod Remove the cover from the cylinder barrel 12 Clean all oil from the threads of the cylinder rod and barrel and apply NEVER SEEZ paste type compound 13 Install the piston on
474. tch an outrigger selector valve and a double selector valve The outrigger selector valve is located in the cab to the left of the seat The double selector valve if installed is located in the battery box Each stabilizer cylinder has a port block mounted on its side A pilot operated check valve is threaded into the port block A level is mounted on the right side of the cab The level provides the operator with a visual indication of crane levelness 3 192 TM 10 3950 672 24 1 3 75 2 Theory of Operation Flow from the 32 gpm 121 1 lpm pump section supplies the outrigger circuit Positioning the OUTRIGGER control switch to DOWN OUT positions the spool in the control valve to permit oil to flow to the OUTRIGGER SELECTOR valve Positioning the selector valve switches to one of the eight positions FRONT REAR LEFT RIGHT FRONT RIGHT REAR RIGHT FRONT LEFT or REAR LEFT allows the hydraulic oil to flow to the appropriate cylinder s The oil first unseats the check valve and the pressure on the piston then extends the outrigger Oil from the rod side of the cylinder flows back through the control valve then to the tank Positioning the OUTRIGGER control switch to UP IN positions the spool in the control valve to permit oil to flow to the rod side of the cylinder s The pilot pressure from the pressurized retract line unseats the check valve allowing oil to flow from the piston side of the cylinder s to the SELECTOR valve The oil flows from
475. te as the bolt advances b Apply liquid Loctite No 277 to the threaded holes only by letting four or five drops run down the side of each hole Visually check to ensure the Loctite has contacted the threads 8 Align mating marks position the mating case half and draw the assembly together with three equally spaced bolts 9 Install the remaining bolts and tighten to the correct torque Refer to Torque Values in this Sub Section 10 If the bearings are to be replaced press squarely and firmly on the differential case halves with a suitable sleeve 11 Check the rolling resistance of the differential nest as follows NOTE Use soft metal covers over the vice jaws to protect the ring gear a Place the differential and ring gear assembly in a vise b Insert a checking tool into the differential nest Allow the splines of the tool to engage with the spline of one sidegear only E 69 TM 10 3950 672 24 1 NOTE The checking tool can be made by cutting an axle shaft to appropriate length and welding a nut on the end to accept a wrench socket c Using a suitable socket and torque wrench rotate the differential nest while observing the scale on the torque wrench The correct rolling resistance of the differential assembly is 50 pounds foot 6 91 kgm torque maximum applied to one sidegear Installation of the Differential and Gear Assembly 1 Temporarily install the bearing cups threaded adju
476. th the slot in the case Slide the band off the reverse high clutch drum 11 Remove the forward part of the gear train as an assembly 12 If not already done remove the bolts that attach the servo cover to the transmission case 13 If not already done remove the cover piston spring and gasket from the case 14 Remove the large snap ring that secures the reverse planet carrier in the low reverse clutch hub Lift the thrust washers and planet carrier from the drum 15 Remove the snap ring that secures the reverse ring gear and hub on the output shaft Slide the ring gear and hub off the shaft Remove the thrust washer 16 Rotate the low reverse clutch hub in a clockwise direction and at the same time withdraw it from the case 17 Remove the reverse clutch snap ring from the case then remove the clutch discs plates and pressure plate from the case 18 If not already done remove the extension housing attaching bolts from the case Remove the extension housing and gasket 19 Slide the output shaft assembly from the transmission case 20 Remove the distributor sleeve attaching bolts and remove the sleeve parking pawl gear and the thrust washer lf the thrust washer is staked in place use a sharp chisel and cut off the metal from behind the thrust washer Be sure to clean the rear of the case with air pressure or a suitable solvent to remove any metal particles 21 Compress the reverse clutch piston release spri
477. the 41 out of the carrier and planet gear NOTE Be careful not to lose any of the needle bearings 3 Remove the planet gear 49 thrust washers 51 O ring 52 and needle bearings 50 10 Remove the seal 39 from the cable drum 2 Primary and Secondary Carrier 1 Remove the circlip 40 from the pin 41 securing the gears 49 in the carrier E 140 4 Remove the spacer 43 from the secondary carrier 12 5 Repeat steps 1 2 3 and 4 for the other planet gears CLEANING AND INSPECTION 1 Clean all parts with a suitable solvent and dry with compressed air CAUTION DO NOT ALLOW COMPRESSED AIR TO SPIN THE BEARINGS 2 Clean all tapped holes and threads using taps and dies 3 Check all parts for cracks nicks or other damage Polish out any minor blemishes on the brake piston or cylinder mating surfaces with a fine crocus cloth 4 Examine the bearings for smoothness and freedom of movement 5 Prelubricate all seals O rings and bearings with 90weight EPGL gear lubricant unless otherwise specified ASSEMBLY NOTE Any maintenance involving disassembly of the hoist should include replacement of all gaskets and O rings TM 10 3950 672 24 1 Primary and Secondary Carrier 1 Install the spacer 43 in the secondary carrier NOTE The primary carrier has one row of needle bearings and the secondary carrier has two rows of needle bearings 2 Place a small amount of EP
478. the SELECTOR valve through the control valve and back to the tank 3 75 3 Removal a Extend the outrigger slightly to facilitate attaching a lifting device to the outrigger beam b Using an adequate lifting device lift the frame enough to enable removal of the outrigger beam Install cribbing or blocking which is capable of handling the weight of the crane under the frame for support c Shut down the engine d Tag and disconnect the hydraulic lines to the cylinder Cap or plug all openings CAUTION Use an adequate support to fully support the cylinder e Place a soft wood support between the outrigger beam and the cylinder CAUTION When blocking up the cylinder place the support under the port block f Remove the capscrew washer flatwasher cotter pin and pin securing the cylinder barrel to the frame Attach a suitable lifting device to the outrigger beam Pull the outrigger beam out of the outrigger box readjusting the lifting attachment to prevent the cylinder from sliding or tilting when the outrigger beam clears the outrigger box 2 3 193 1 2 3 4 5 6 Outrigger Beam Stabilizer Cylinder Lockwasher Capscrew Plate Pin Cotter Pin Flatwasher Lockwasher Capscrew Pin Outrigger Installation 3 194 TM 10 3950 672 24 1 TM 10 3950 672 24 1 WARNING 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 s
479. the clutch restrict or stop drum rotation as determined by the action of the hydraulic operated brake Oil from the hoist directional control valve flows to the hoist control valve mounted on the hoist drive motor When hoisting up oil enters the IN Port of the hoist control valve and unseats the free flow poppet Oil then flows from the OUT port of the valve to the up E 132 port of the motor which drives the hoist to wind cable onto the drum When hoisting down oil flows to the down port of the hoist motor the hoist brake and the pilot line of the hoist control valve The pilot operated poppet of the hoist control valve and the hoist brake are controlled by the pressure in the down line Because the poppet in the hoist control valve is closed and oil cannot flow from the raise port of the motor pressure rises in the down line As the pressure rises the hoist brake will release and as pressure continues to rise the pilot pressure in the hoist control valve will open the poppet allowing the hoist to run in a down direction and oil flow to the reservoir If the load drop speed increases the pressure in the down line will decrease This decrease in pressure will cause the poppet in the hoist control valve to close and causes the spring actuated brake to slow or stop the hoist The hoist control valve prevents the load from driving the hoist motor during hoist down operation a Too much cable on drum b Improper reeving C L
480. the differential ring gear onto the differential case half is necessary for correct gear adjustment and longer drive unit service life For correct installation it is recommended the ring gear be heated in water to approximately 160 to 180 degrees F 71 to 82 degrees C for about ten minutes before assembly This will allow an easier fit of the gear over the differential case pilot without the use of a press and without damaging the case and the ring gear mating surfaces The gear should not be pressed or driven on the case as this would cause excessive metal particles to lodge between the gear and case thus resulting in gear runout Proper installation should therefore incorporate preheating the gear as described above to ensure correct interference fit and to eliminate metal pickup 1 Rivet the hypoid gear to the case half with new rivets Rivets should not be heated but always upset cold When the correct rivet is used the head being formed will be at least 0 1 25 inch 3 18 mm larger in diameter then the rivet hole The heat will then be approximately the same height as the preformed head Excessive pressure will cause distortion of the case holes and result in gear eccentricity Tonnage required for squeezing cold rivets These pressures are approximately for annealed steel rivets and pressure may be adjusted to suit individual working conditions DIAMETER TONNAGE OF RIVET REQUIRED 7 16 inch 22 1 2 inch 30 9 16 inch 36
481. the fluid level on the dipstick between ADD and DON T ADD marks and or between the arrows If the transmission is not at an operating temperature of 150 degrees to 170 degrees F 66 degrees to 77 degrees C and it becomes necessary to check the fluid level such as pre delivery the fluid may be checked at room temperature 70 degrees to 95 degrees F 21 degrees to 35 degrees C giving the dipstick a cool feeling The dipstick reading at room temperature should have the fluid level on the dipstick between the middle and top holes FLUID CHECKING PROCEDURE Check the transmission fluid using procedure the following 1 With the transmission in Park engine at curb idle rpm foot brakes applied and crane on level surface move the transmission selector lever through each range Allow time in each range to engage the transmission return to Park and apply parking brake fully Do not turn off the engine during the fluid level check 2 Clean all dirt from the transmission fluid dipstick cap before removing the dipstick from the filler tube E 31 TM 10 3950 672 24 1 3 Pull the dipstick out of the tube wipe it clean and push all the way back into the tube Be sure it is fully seated 4 Pull the dipstick out of the tube again and check the fluid level 5 For correct fluid level reading on the dipstick follow the appropriate instructions started previously for transmission hot and transmission cold check Do not overfill the
482. the inside of the port block for any sharp edges or burrs and remove as necessary with emery cloth 2 Install new O rings onto the holding valve 3 Lubricate the holding valve and O rings with clean hydraulic oil CAUTION DO NOT DAMAGE THE O RINGS DURING INSTALLATION OF THE HOLDING VALVE IFTHE HOLDING VALVETURNS FREELY THEN GETS HARD TO TURN THEN EASY TO TURN REMOVE THE HOLDING VALVE AND CHECK THE O RINGS THEY HAVE PROBABLY BEEN DAMAGED BY A SHARP EDGE OF A PORT NOTE The holding valve should turn by hand until compression of the O rings begins 4 Install the wiper ring into the head retaining plate 5 Install the O ring and backup ring onto the outside of the head NOTE Ensure the buffer seal is installed in the sequence as noted during disassembly 6 Install the rod seal buffer seal assembly and wear rings into the inside of the head 7 Install the seal assemblies onto the outside of the piston 8 Install the O ring and both backup rings into the inside of the piston Ensure the O ring is between the backup rings 9 Lubricate the rod with clean hydraulic oil 10 Install the head retaining plate on the rod 11 Install the head onto the rod Remove the cover from the cylinder barrel 12 Clean all oil from the threads of the cylinder rod and barrel and apply NEVER SEEZ paste type compound 13 Install the spacer and piston on the rod Tighten the piston with a spanner wrench Apply Lo
483. the low reverse clutch by applying air pressure at the clutch pressure apply hole in the case TM 10 3950 672 24 1 SELECTIVE THRUST WASHER THICKNESS IDENTIFICATION THICKNESS COLOR INCH 0 056 0 060 0 073 0 077 0 088 0 092 Blue Natural White Red 19 Install the reverse planet ring gear thrust washer and the ring gear and hub assembly Install the snap ring in the groove on the output shaft 20 Install the front and rear thrust washers onto the reverse planet assembly and retain them with petroleum jelly Install the assembly into the ring gear and install the snap ring 21 Set the reverse high clutch assembly on a bench with the front end facing down Install the thrust washer on the rear end of the reverse high clutch assembly Retain the thrust washer with petroleum jelly and install the splined end of the forward clutch into the open end of the reverse high clutch with splines engaging the direct clutch friction plates 22 Install the thrust washers and retain them with petroleum jelly on the front end of the forward planet ring gear and hub Install the ring gear into the forward clutch 23 Install the thrust washer on the front end of the forward planet assembly Retain the washer with petroleum jelly and install the assembly into the ring gear Install the input shell and sun gear assembly 24 Install the reverse high clutch assembly forward clutch assembly forward planet assembly and drive input shell
484. the one way clutch spring assembly on top of the snap ring 4 Install a roller into teach of the spring assembly compartments 5 Install assembly the bushing on top of the spring 6 Install the remaining snap ring at the rear of the low reverse clutch hub to secure the assembly Disassembly of the Low Reverse Clutch Piston 1 Remove the inner and the outer seal from the low reverse clutch piston Assembly of the Low Reverse Clutch Piston 1 Dip the two new seals in clean transmission fluid 2 Install the seals on the piston TRANSMISSION ASSEMBLY 1 Mount the transmission in a holding fixture 2 Tap the low reverse piston into place in the case with a clean rubber hammer 3 Hold the one way clutch inner race in position and secure with the attaching bolts Torque the bolts 18 to 25 Ib ft 24 to 34 Nem 4 Install the low reverse clutch return spring and retainer assembly in the clutch piston 5 Install the retainer snap ring in place on the one way clutch inner race 6 Install the compressing tool T65L 7751 5 A or equivalent and compress the springs just enough to install the low reverse clutch piston snap ring then the 7 Install the snap remove compressing tool ring E 54 TM 10 3950 672 24 1 8 Place the transmission case on the bench with the front end facing down NOTE Do not re stake the thrust washer 9 Install the parking gear thrust washer and the gear on the case
485. the rod and tighten with a spanner wrench Apply Locquic Primer T to the threads of the setscrew Allow to dry and apply Loctite 271 adhesive sealant to the threads of the setscrew Install the setscrew and secure the piston on the rod CAUTION AVOID SCRATCHING OR DAMAGING THE GROOVED GLAND SURFACES OR THE RINGS AND SEALS CAUTION EXERCISE EXTREME CARE WHEN HANDLING OR SETTING DOWN THE CYLINDER ROD DAMAGE TO THE ROD SURFACE MAY CAUSE UNNECESSARY MAINTENANCE AND EXPENSE 14 Lubricate the piston and head with clean hydraulic oil and install the rod assembly into the barrel with a twisting motion 3 123 TM 10 3950 672 24 1 15 Apply Locquic Primer T to the threads of the setscrew Allow to dry and apply Loctite 271 adhesive sealant to the threads of the setscrew Install the setscrew into the barrel on the rod end of the cylinder WARNING DO NOT USE AIR PRESSURE TO CYCLE PRESSURIZE THE CYLINDER 16 Pressurize and cycle the cylinder Check for proper operation and any leakage 3 53 TELESCOPE CYLINDER The boom telescope cylinder is of the double acting type The cylinder has a bore of 4 5 in 11 4 cm The retracted length from the end of the barrel to the centerline of the holding block is 142 0 in 360 6 cm The extended length from the end of the barrel to the Disassembly NOTE Any maintenance requiring disassembly of the cylinder should include replacement of all cylinder seals 1 Dr
486. the valve bank on the mounting plate and secure with the capscrews and washers 2 Connect the control levers to the valve s and secure with the cotter pins and clevis pins 3 Connect any electrical leads to the valve bank as tagged during removal 4 Connect the hydraulic lines to the valve bank as tagged during removal 5 Install the console assembly to the frame Secure the top of the console assembly with the clamps washers and nuts Secure the sides of the console with the capscrews and washers Torque the capscrews to 31 Ib ft 42 Nem 3 112 TM 10 3950 672 24 1 FUNCTIONAL CHECK 1 Start the engine and check the operation at high and low idle speed with no load applied 2 Set the engine speed to the recommended operating rpm 3 Operate the control lever s of the affected circuit s Check for smooth operation of cylinders and motors Check the valve bank s and lines for leakage 3 45 HOLDING VALVES TM 10 3950 672 24 1 DESCRIPTION Two different holding valves are utilized on the crane one in the lift cylinder and one in the telescope cylinder Both valves are installed in the port block of their respective cylinder MAINTENANCE NOTE For more detailed information refer to Appendix E REMOVAL 1 To remove the holding valve unscrew it from the port block INSTALLATION 1 Check the inside of the port block for any sharp edges or burrs and remove as necessary with emery cloth 2
487. tional 0 00 3 222 Instruments Main Control Panel 3 222 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page J K continued Instruments Main Control Panel nnn 3 222 Instruments Main Control Panel 3 222 Intake Air Restriction Replacement 40 5 115 Intake Manifold Cover and Gasket 5 112 L Lift Circuit Description Replacement and 3 158 Lift Cylinder Description Replacement and 3 120 Lift Pump Replacement and 5 88 Lift Pump 5 69 List of Troubleshooting Symptoms nnne ennt nsns nnn 5 9 Locking Screw O Ring Replacement Injection 5 264 Locks General Maintenance 0 eene 1 5 Loctite General Maintenance 0 9
488. tions must be checked regularly because they are often the source of hidden trouble Hoses may often times appear in good condition on the outside while the inside will be partially deteriorated If there are any doubts about a hose doing its job replacement should be made The clamps should be inspected to make sure they are strong enough to hold a tight connection TEST EQUIPMENT The hydrometer is a primary aid in maintaining the cooling system at top efficiency Hydrometers which are used to test the freezing protection of an anti freeze solution work on the principle of specific gravity or weight of the antifreeze solution They are simple to use provided they are used in the proper manner When using the temperature sensitive hydrometer the solution must be warm at least 110 degrees F 43 degrees C the temperature and level must be noted correctly and the float must be able to move freely Read only the hydrometer scale corresponding to the type antifreeze solution in the radiator Keep the hydrometer clean inside and out and treat it with the same care as given any other precision instrument NOTE Hydrometers correctly register the freezing protection of a mixture of methanol and glycol base antifreeze Therefore always flush the cooling system with the thermostat removed before adding antifreeze for the winter ANTIFREEZE When freeze protection is required an ethylene glycol base permanent anti
489. tment Torque Wrench Set T65L 77515 A Clutch Spring Compressor T77L 77548 A Lip Seal Protector T63L 77837 A Front Pump Seal Replacer T83T 7B200 AH VRV Gage Block T69L 7D044 A Clutch Housing Bushing Tool T74P 77247 A Neutral Start Switch Socket Tool T82L 7006 A Air Pressure Check Plate T82P 7006 C Capscrews for Air Pressure Check Plate T83L 7902 A1 Torque Adapter Turning Tool T83L 7902 A2 Pilot Guide T80L 77030 B Servo Piston Remover T83L 7902 A3 Holding Fixture ROTUNDA EQUIPMENT 014 00028 Torque Converter Cleaner 072 00004 Torque Converter Leak Tester 019 00027 Automatic Transmission Tester E 40 CLEANING AND INSPECTION Transmission It is important to completely clean all transmission components including converter main control valve body governor all clutches and all check balls after any transmission servicing that generates contamination These contaminants are a major cause for recurring transmission troubles and must be removed from the system before the transmission is put back into service The cleaning of debris from the direct Clutch check ball is often omitted This omission can lead to a repeat servicing of the transmission Clean all parts with suitable solvent and use moisture free air to dry off all parts and clean out fluid passages The composition clutch plates bands and synthetic seals should not be cleaned in a vapor degreaser or with any type of detergent solution To clean these parts wipe the
490. to abnormal loads beyond the endurance limit will shorten the wire ropes life expectancy Examples of this type of loading are listed below 1 High velocity movement e g hoisting or swinging of a load followed by abrupt stops 2 Suspending loads while traveling over irregular surfaces such as railroad tracks potholes and rough terrain 3 Moving a load that is beyond the rated capacity of the lifting mechanism i e overloading LUBRICATION A wire rope cannot be lubricated sufficiently during manufacture to last it s entire life Therefore new lubricant must be added throughout the life of a rope to replace factory lubricant which is used or lost t is important that lubricant applied as part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted Lubricant applied shall be of the type which does not hinder visual inspection Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope The object of rope lubrication is to reduce internal friction and to prevent corrosion Wire Rope Lubrication 3 164 During fabrication ropes receive lubrication the kind and amount depends on the rope s size type and anticipated use This in process treatment will provide the finished rope with ample protection for a reasonable time if it is stored
491. to continuous limited swing Ex ample concrete pourer d Restricted hose or fitting 3 138 c Increase engine rpm to obtain smooth swing operation d Replenish hydraulic oil to pro per level e Feather controls to neutral to maintain smooth stopping action f Lubricate bearing properly g Level crane using outriggers If equipped h Repair or replace swing motor i Reduce load j Replace hose or fittings k Retighten suction hose or re place any damaged fitting l torque turntable bolts evenly m Adjust as necessary n Torque swing motor attach ment bolts o Remove swing box and make necessary repairs p Repair or replace damaged sec tion a Clean readjust and or replace relief valve b Level crane using outriggers If equipped c Rotate machine 360 degrees in both directions several times and lubricate turntable bearing d Replace hose or fitting 2 Boom swing operation erratic in one direction only continued 3 Boom will not swing in either direction 4 Swing operation slow in either direction e Crossover relief valve malfunc tioning f Damaged swing pinion a Damaged relief valve b Damaged swing motor c Swing brake not releasing prop erly d Completely inoperative cross over relief valve e Internal damage to swing box f Worn or damaged hydraulic pump section a Damaged relief valve b Improperly adjusted swi
492. to eliminate damage to the rubber portion or distortion of the metal container 6 Lubricate the outside diameter of the pressure seal with petroleum jelly Place the seal in the flange and press into place as shown in the Seal Installation figure This seal has a metal case with rubber molded around it Install it carefully to prevent damage to the seal especially distortion to the metal case The preferred method of installation is to use a press and a seal installation tool If a press is not available use the following method After lubrication insert the seal into the flange with the lip up as shown in the Seal Installation figure 1 1 4 INCH SOCKET FLANGE 2187 19 Use a 1 25 inch socket or equivalent tool that has the same outside diameter as that of the seal Carefully tap the socket until the seal is completely seated It is extremely important that the seal is installed straight Liberally fill the space between the dust seal and pressure seal as well as the lips of both seals with petroleum jelly as shown in the Seal Installation figure 7 Install the 1 9375 inch 4 92 cm diameter seal in the flange 8 Apply a light coat of Loctite Primer NF on the bolts and in the tapped holes of the housing Allow primer to air dry for at least one minute Do not force dry with air jet as the primer will blow away Use of the primer is optional With the primer curing time with Loctite is approximately 15 minutes Withou
493. to the gauge then tape the lead ends Instrument Removal and Installation 3 88 2 Inspection a Examine gauges for cracked and broken lenses Check gauge terminals and mounting studs for damage b Check wiring for damaged insulation or damaged terminals 3 88 3 Installation Connect the electrical leads as marked prior to removal Place the gauge into position on the panel and secure it with the attaching hardware Position the cab front cover plate and secure with the screws washers and nuts Connect negative leads to battery negative post 3 88 4 Functional Check Start the engine and observe for proper functioning of the repaired indicator Refer to operators manual TM 10 3950 672 10 Troubleshoot further as necessary any system malfunction not corrected by repair or replacement of the indicator or associated wiring 3 222 TM 10 3950 672 24 1 3 89 ELECTRICAL SWITCHES 3 89 1 Removal Disconnect negative leads to negative battery post Gain access to the front console as described under Instrument Removal Remove the hardware securing the switch to the console then remove the switch Tag and disconnect the leads from the switch then tape the lead ends ao oc p 3 89 2 Inspection Visually check the switch for evidence of cracks damaged connections or other damage Check wiring for damaged insulation or damaged terminals c Perform the following check to determine switch serviceability 1
494. tor 3 Remove nut 4 collar 5 and felt washer 6 from shaft of wiper motor 3 Remove nut 7 lockwasher 8 flat washer 9 wiper motor 3 and bushing 10 from cab frame Tag and disconnect three electrical leads from wiper motor 3 NOTE Nut 11 is factory positioned so that motor is parallel to windshield Do not disturb setting f Tag and disconnect electrical lead 23 from pump of pump canister 14 g h j Position suitable container under pump canister 14 disconnect hose 1 5 from pump and drain fluid Remove four nuts 16 four lockwashers 17 four washers ground wire 24 from lower left mounting stud 25 and pump canister 14 from left front wheel well Disconnect hose 15 from nozzle 21 Remove nut 19 lockwasher 20 nozzle 21 and rubber seal 22 from cab frame 3 3 2 Installation a b Install rubber seal 22 Figure 3 3 and nozzle 21 in cab frame with lockwasher 20 and nut 19 Connect hose 15 to nozzle 21 NOTE Ensure ground wire is positioned on lower left mounting stud Position pump canister 14 and ground wire on mounting studs in left front wheel well Secure pump canister 14 with four washers 18 four lockwashers 17 and four nuts 16 Connect hose 15 to pump of pump canister 14 Connect electrical lead to pump of pump canister 14 and remove tag 3 6 Wiper Arm Wiper Blade Wiper Motor N
495. torque If necessary replace the gasket 2 Check the fluid filler tube connection at the transmission case If leakage is found install a new O ring The filler tube bracket should align properly 3 If leakage is found at either the downshift control lever shaft or the manual lever shaft replace either or both seals FLUID LEAKAGE IN CONVERTER AND FRONT PUMP AREA Leakage at the front of the transmission is evidenced Troubleshooting Chart TM 10 3950 672 24 1 by fluid around the converter housing and may have several sources By careful observation it Is possible in many instances to pinpoint the source of the leak before removing the transmission 1 Fluid leaking by the front pump seal lip will tend to move along the drive hub and onto the back of the impeller housing Except in the case of a total seal failure fluid leakage by the lip of the seal will be deposited on the inside of the converter housing only near the outside diameter of the housing 2 Fluid leakage by the outside diameter of the seal and front pump body will follow the same path which the leaks by the front pump seal follow 3 Fluid that leaks by a front pump to case bolt will be deposited on the Inside of the converter housing only Fluid will not be deposited on the back of the converter 4 Leakage by the front pump to case gasket may cause fluid to be deposited inside the converter housing or it may seep down between the front of the case and
496. triggers lift the frame until the wheels are at least two inches off the ground Install cribbing or blocking which is capable of handling the weight of the crane under the frame for support NOTE The tire and wheel assembly weighs approximately 114 pounds 51 7 kg 5 Remove the wheel lug nuts and remove the tire and wheel assembly 6 Support the hub and spindle assembly with a suitable lifting device 7 Remove the bolts washers and pin weld securing the hub and spindle assembly to the frame 8 Remove the pin weld and bronze bushing from the hub and spindle assembly 9 Remove the hub and spindle assembly from the frame Disassembly 1 Remove the bolts and washers securing the cover to the hub Remove the cover CAUTION ENSURE THE ROLLER BEARINGS AND OTHER COMPONENTS ARE KEPT FREE OF DIRT spindle NOTE The bearings may not release themselves when pulling the hub It is not necessary to remove them if inspection reveals no damage 4 If necessary remove the bearings 5 Remove the seal from the hub Assembly 1 Install the seal in the hub 2 If removed clean repack and install the bearings 3 Install the hub onto the spindle 4 Install the adjust nut on the spindle Tighten the adjusting nut to 50 Ib ft 69 N m while rotating the wheel in both directions to ensure all bearing surfaces are In contact Backoff the adjusting nut 1 16 to 1 4 turn NOTE Ensure the pin is installed
497. ts efficient operating temperature The following paragraphs point out several facts about cooling system components the effects of cooling system neglect and procedures to be followed for cooling system maintenance EFFECTS OF COOLING SYSTEM NEGLECT Whenever an engine does not perform at top efficiency neglected cooling system may be at fault even though the engine part directly responsible is not even a part of the cooling system Most of these problems will be Thermostat not installed a TM 10 3950 672 24 1 SOLUTION g Operate engine in proper load range h Break in engine properly Install thermostat Replace thermostat Warm up engine properly traced to overheating however an engine that is running too cold can be just as troublesome Overheating An engine that is overheating may lead to troubles such as the following 1 Burned valves 2 Pinging or knocking 3 Excessive fuel consumption 4 Poor lubrication increased engine wear 5 Sticking valves 6 Short injector life 7 Engine hot spots 8 Need for higher grade fuel Overcooling The following engine troubles result when an engine is overcooled 1 Excessive fuel consumption 2 Sludge formation in crankcase 3 Corrosive acids formed in crankcase 4 Excessive fuel deposits in the exhaust system RUST PREVENTION To keep engines operating at newness efficiency all forms of rust formation must be prevented The fo
498. tuds into position ensure that the stud serrations the corresponding holes of the hub and drum and serrations of the wheel studs align correctly otherwise as studs are being pressed through a larger hole will develop causing loose wheel studs NOTE If a press is not available a brass hammer or drift may be used to seat the wheel studs Installation of the Wheel Hub and Drum Assembly 1 Install the hub and drum assembly onto the spindle being careful not to damage the oil seal in the hub Press the hub until the inner bearing is seated flush on the spindle 2 Place the outer bearing cone into position on the spindle and against its cup in the hub NOTE After completing steps 3 and 4 adjust the bearing following the procedure under Wheel Bearing Adjustment in this package 3 Install the inner wheel bearing adjusting nut onto the spindle against the outer bearing 4 Install the outer wheel bearing lock washer and lock nut onto the spindle and against the adjusting nut 5 Coat the inside hub mating surface of the drive shaft with silicone RTV gasket material following the procedure under Silicone RTV Gasket Application in this package 6 Apply a small amount of wheel bearing grease to the internal splines of the drive shaft 7 Install the axle drive shaft and secure with the axle shaft to hub nuts washers dowels and studs Wheel Bearing Adjustment 1 Tighten the bearing adjusting nut to 50 Ib ft
499. turns cable is wrapped on boom nose shaft c Remove strap 3 unwrap cable from shaft on boom nose and allow cable to rewind onto cable reel assembly 7 d Disconnect electrical connector from box on outside of cable reel assembly 7 e Remove four screws 4 four lockwashers 5 four washers 6 and cable reel assembly 7 from boom mounting plate 3 67 2 Installation a Install cable reel assembly 7 Figure 3 19 on boom mounting plate with four washers 6 four lockwashers 5 and four screws 4 b Connect electrical connector to box on cable reel assembly 7 c Route cable through roller guide assembly under roller wrap cable around end of boom nose shaft same number of turns as recorded during removal and connect cable connector 1 to junction box 2 d Secure cable wraps around boom nose shaft together with strap 3 e Connect negative battery cable and two electrical leads to negative battery post 3 172 TM 10 3950 672 24 1 BOOM NOSE SHAFT ROLLER GUIDE LEGEND 1 Cable Connector 2 Junction Box 3 Strap 4 Screw 5 Lockwasher 6 Washer 7 Cable Reel Assembly Figure 3 19 Antitwo Block System Cable Reel 3 173 TM 10 3950 672 24 1 3 68 ANTITWO BLOCK SYSTEM CONSOLE 3 68 1 Removal Disconnect negative battery cable and two electrical leads from battery Tag and disconnect two electrical connectors from console 3 Figure 3 20 Unscrew knob 1 remove wa
500. ue Values Figure D 1 Torque Values Sheet 3 of 3 D 4 TM10 3950 672 24 1 APPENDIX E SERVICE MAINTENANCE PACKAGES TABLE OF CONTENTS Subject Page Airinake System IUE Md dI ONUS MINIM eee aa Mee aaa eet 7 Bre TR e Nm E 7 Maintenant e EET E 7 Troubleshooting sarearena aa O 7 Filter Element Replacement RED 8 Element Cleaning oreet edt be ad dau E Inspector IM M E 10 Water Cooling System EM E 12 Description nn nn nn UU nn E 12 12 eee 14 Effects of Cooling System Neglect E 14 Rust Prevention MM E 15 Seasonal ou ee eeececce cece eect eee E 15 OTe Talla TO METTETE E 15 Pressure Flushing RR E 16 Component 16 Test 17 Antifreeze 1 7 18 Coolant Recommendations cccccseccsssscsecsesecsessssessesassessssessesassessssessssassesassassesassesaesassesassessesacse
501. umulation on the spool Damaged seals must be replaced A component functioning at reduced efficiency may indicate that the control valve for that component is leaking internally _ Assuming preliminary check out reveals that adequate volume is being supplied to the affected valve bank relief valves are properly adjusted and the component is not at fault check the valve for scored or worn parts Scoring is a sign of the number one problem in hydraulics contamination external contamination by dust or internal contamination by debris from deteriorating components or oxidized oil Scored or severely worn valve components must be replaced Warped mounting surfaces can distort the assembly and cause leakage and binding To check for valve distortion loosen the mounting bolts slightly If the leakage stops when the bolts have been backed off slightly distortion was the problem To correct this condition shim the valve assembly to level and retighten the mounting bolts 3 96 TM 10 3950 672 24 1 Check valves in the control valves are designed to permit a flow of oil in one direction only If a piece of dirt or rust has worked its way into the check valve and lodges between the poppet and seat it will keep the valve open and allow a return flow of oil The remedy is to clean the valve but it is also a good idea to follow through and ensure the hydraulic system filters are still serviceable Binding Spools Some of the most common
502. ure in the note preceding step 2 and the procedure in step 2 and install the second E 111 TM 10 3950 672 24 1 wear plate 7 spacer 6 and pressure seal 5 9 Install the drive gear 14 and driven gear 15 with the short journal up on the driven gear 10 Install the second thrust plate 10 11 Install two dowel pins 12 and the second gasket 11 into the cover 16 12 Install the cover 16 and secure with the bolts 18 and washers 17 13 Invert the assembly and install the bolts 1 and washers 2 in the front housing 4 Torque the bolts 28 to 35 Ib ft 38 to 47 Nom 14 Rotate the pump shaft by hand or with pliers The pump will have a small amount of drag but should turn freely after a short period of use TM 10 3950 672 24 1 CROSSOVER RELIEF VALVE DESCRIPTION The crossover relief valve with shuttle valve is designed to protect the system from excessive pressure buildup and to maintain a given pressure in the system The crossover relief valve relieves surge pressure in the swing circuit that could occur if the motor is suddenly stopped It also provides for smooth start ing and stopping of the swing motor The valve consists of a drilled and ported block with two relief valves and two check valves with orifice plugs installed in the block The relief valves relieve pressure from one line to the other and therefore there is no connection to the reservoir MAINTENANCE NOTE Repair is
503. ure switch 1 Figure 3 6 c Remove oil pressure switch 1 from engine Installation a Install oil pressure switch 1 Figure 3 6 in engine b Connect two electrical connectors for oil pressure switch 1 and remove tags c Connect negative battery cable and two electrical leads to battery 3 20 TM 10 3950 672 24 1 3 9 ENGINE OIL PRESSURE SENDER 3 9 1 Testing a Remove engine oil pressure sender b Set multimeter to ohms attach positive lead of multimeter to sender terminal and negative lead to sender body Multimeter should indicate 240 ohms c Using a hand operated vacuum pressure tester apply 50 psi and then 100 psi of pressure to sender while observing multimeter Multimeter should indicate 103 ohms at 49 51 psi and 33 ohms at 99 101 psi d If multimeter indications are not as above replace sender 3 9 2 Removal a Disconnect negative battery cable and two electrical leads from battery b Tag and disconnect electrical lead to engine oil pressure sender 2 Figure 3 6 c Remove oil pressure sender 2 from engine 3 9 3 Installation a Install oil pressure sender 2 Figure 3 6 in engine b Connect electrical lead to oil pressure sender 2 and remove tag c Connect negative battery cable and two electrical leads to battery 3 21 3 10 TM 10 3950 672 24 1 ENGINE COOLANT TEMPERATURE SWITCH WARNING Engine must be cool to the touch prior to working on coolant system components Failure to c
504. urely 3 250 A 1 SCOPE TM 10 3950 672 24 1 APPENDIX A REFERENCES This appendix lists all forms and publications that are referenced in this manual A 2 PAMPHLETS DA Pam 25 30 DA Pam 738 750 A 3 FORMS DA Form 2404 DA Form 2028 DA Form 2028 2 SF 361 SF 364 SF 368 A 4 SUPPLY BULLETINS SB 11 573 A 5 TECHNICAL BULLETINS None A 6 TECHNICAL MANUALS TM 43 0139 TM 1 0 3950 672 24P A 7 FIELD MANUALS FM 21 11 A 8 MISCELLANEOUS PUBLICATIONS CTA 50 970 Consolidated Index of Army Publications and Blank Forms The Army Maintenance Management System TAMMS Equipment Inspection and Maintenance Worksheet Recommended Changes to Publications and Blank Forms Recommended Changes to Equipment Technical Publications Transportation Discrepancy Report Report of Discrepancy ROD Product Quality Deficiency Report Painting and Preservation Supplies Available for Field Use for Electronics Command Equipment Painting Instructions for Field Use Operators Manual Warehouse Crane M469 Repair Parts and Special Tools List Warehouse Crane M469 First Aid for Soldiers Expendable Items Except Medical Class V Repair Parts and Heraldic Items A 1 TM10 3950 672 24 1 APPENDIX B MAINTENANCE ALLOCATION CHART Section INTRODUCTION B 1 THE ARMY MAINTENANCE SYSTEM a This introduction provides a general explanation of all maintenance and repair functions authorized at various maintenance levels under the
505. urrs Minor scores or burrs may be removed with crocus cloth Replace the case if it is badly scored or damaged 2 Check the fluid passage in the case for obstructions Clean out all fluid passages Inspect the clutch piston for scores and replace if necessary 3 Check the piston return springs for distortion Check the piston return spring retainer for flatness 4 Inspect the composition clutch piates steel clutch plates and clutch pressure plate for worn or scored bearing surfaces Replace all parts that are deeply scored 5 Check the clutch hub splines Planetary One Way Clutch 1 Inspect the intermediate outer and inner races for scores or damaged surface areas where rollers contact the races 2 Inspect the rollers and springs for excessive wear or damage 3 Inspect the spring and roller cage for bent or damaged spring retainers Converter and Fluid Cooler When internal wear or damage has occurred in the transmission metal particles clutch plate material or band material may have been carried into the converter and oil cooler These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into service Whenever a transmission has been disassembled to replace worn or damaged parts or because the valve body sticks from foreign material the converter and oil cooler must be cleaned by using the Rotunda Torque Converter Cleaner model
506. using are flush Be careful not to damage the seal BEARING RACE NEEDLE THRUST BEARING 2187 13 NOTE Do not allow oil to get into the tapped holes 2 Lubricate the output shaft with hydraulic oil Install the shaft in the housing 2187 16 3 Install the needle thrust bearing then the bearing race on the shaft Pull the shaft partially out of the housing them push all three parts in the housing together The bearing race must rotate freely when in position INSPECT FOR CRACKS IN THIS 2187 17 4 Clean the mounting flange and output shaft to remove all loose metallic chips particles dirt or other contamination including oil During cleaning visually inspect the seal seat in the mounting flange for scratches or other marks that might damage the seal Check for cracks in the flange that might cause leakage E 124 TM 10 3950 672 24 1 APPLY PETROLEUM JELLY ACROSS THIS AREA OUTPUT SHAFT DUST SEAL 2187 18 Seal Installation NOTE The pressure seals are marked Pressure Seal 9057 1 Check the seals before installing to ensure they are installed in the correct places The dust seal is smaller in diameter than the pressure seal If installed in the wrong place leakage around the shaft will occur 5 Install the dust seal in the flange as shown in the Seal Installation figure Press the seal into place carefully using a tool which will provide proper guiding and positioning
507. ut Collar Felt Washer Nut Lockwasher TM10 3950 672 24 1 DO NOT REMOVE THIS NUT FACTORY SETTING LEGEND 9 Washer 17 Lockwasher 10 Bushing 18 Washer 11 Nut 19 Nut 12 Lockwasher 20 Lockwasher 13 Washer 21 Nozzle 14 Pump canister 22 Rubber Seal 15 Hose 23 Electrical Lead 16 Nut 24 Ground Lead 25 Stud Figure 3 3 Windshield Wiper and Washer Assembly 3 7 TM10 3950 672 24 1 f Connect three electrical leads to wiper motor 3 and remove tags g Install bushing 10 on shaft of wiper motor 3 and position wiper motor 3 through hole in cab frame and onto frame stud h Secure wiper motor 3 to frame stud with flat washer 9 lockwasher 8 and nut 7 i Install felt washer 6 collar 5 and nut 4 on shaft of wiper motor 3 j Press wiper arm 1 with wiper blade 2 onto shaft of wiper motor 3 k Connect negative battery cable and two electrical leads to battery 3 8 TM10 3950 672 24 1 3 4 DOOR AND LATCH ASSEMBLY 3 4 1 Removal a g Open door assembly 1 Figure 3 4 and lift door off cab hinges Remove bolt 2 with hardware and latch extension 6 from latch 7 Remove lockwasher 3 four flat washers 4 bushing 5 and latch extension 6 from bolt 2 Remove two nuts 8 two lockwashers 9 and two screws 10 to loosen handle 13 Remove two pins 11 two washers 12 latch extension 6 and handle 13 from door assembly 1 Drill out four
508. utions to assure normal bearing contact 8 While in the press under pressure check the bearing preload torque Wrap soft wire around the cage and pull on a horizontal line with a pound kilogram scale If a press is not available the pinion nut may be tightened to the correct torque and the preload checked PINION SHAFT THREAD SIZE rs 9 PINION NUT TORQUE required to obtain correct pinion bearing preload 7 8 20 1 20 1 1 4 12 1 1 4 18 1 1 2 12 1 1 2 18 13 4 12 200 275 300 400 700 900 700 900 800 1 100 800 1 100 900 1 200 NOTE Use rotating torque not starting torque If the rotating torque is not within 5 to 25 Ib in 1 to 3 Nem for new bearings or 5 to 15 Ib in 1 to 2 Nem for reused bearings use a thinner spacer to increase or a thicker spacer to decrease preload EXAMPLE Assuming the pinion cage diameter to be 6 in 15 24 cm the radius would be 3 in 7 62 cm and with 5 Ib 2 268 kg pull would equal 15 Ib in 2 Nem preload torque TM 10 3950 672 24 1 PRESS LOAD required to obtain correct pinion bearing preload 271 373 407 542 949 1 220 949 1 220 1 085 1 492 1 085 1 492 1 220 1 627 Pinion Bearing Preload Press the flange or yoke against the forward bearing and install the washer and the pinion shaft nut E 66 10 Place the pinion and cage assembly over the carrier studs Hold the flange and tighten the pinion shaft nut to the correct
509. veral 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 1 Remove the cable from the hoist if applicable 2 Rotate the hoist drum until one drain plug is at the highest point 3 Remove the drain plugs NOTE Drum lubricant capacity is approximately 2 quarts 1 8 liters 4 Fill the drum with EPGL 80W 140 lubricant 5 Install the pipe plugs 3 184 ADJUSTMENT OF THE MOTOR CONTROL VALVE The following adjustment procedures are to be used when unacceptable hoist operating characteristics have been traced to the motor control valve Optimum hoist performance is obtained when hydraulic oil temperature is at 170 to 180 degrees F 77 to 82 degrees C or at 165 degrees 74 degrees C on units with a thermostat controlled oil cooler if environmentally possible NOTE For the following procedures refer to the figure titled Hoist Motor Control Valve Adjustment 1 Hoist will not raise the maximum load If the hoist will not raise the maximum load check the system pressure If the system pressure is low adjust to the proper system pressure 2 Hoist is lowering rough 0 SHIM SUPPLIED WITH VALVE NOTE Some very rough conditions may require as much as 0 060 inch 0 152 mm additional shim to correct the rough lowering condition Remove the cap and spring and add shims in 0 005 inch 0 012
510. vice as required d Perform governor test Service as required e Service as required TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 22 Shifts 1 3 in D 23 Engine over speeds 2 3 Shift 24 No forced downshifts 25 Vehicle will not start a Intermediate band out of adjust ment b Damaged Intermediate servo and or internal leaks c Improper band or clutch appli cation or oil pressure control System Polished glazed band or drum Dirty or sticking valve body Governor valve stuck Linkage out of adjustment b Improper band or clutch appli cation or oil pressure control system c Intermediate servo piston seals cut leaking d Dirty or sticking valve body a Kickdown linkage out of adjust ment b Damaged internal kickdown linkage c Improper clutch or band appli cation or oil pressure control system d Dirty or sticking governor e Dirty or sticking valve body a Misadjusted neutral start switch b Misadjusted linkage c Defective neutral start switch E 39 a Adjust band b Perform air pressure test Ser vice front servo and or Internal leaks c Perform control pressure test d Service or replace band or drum e Clean service or replace valve body f Perform governor test Service as required a Service or adjust linkage b Perform control pressure test c Replace seals Check for leaks d Clean service or r
511. vide sufficient space for the wear plate 7 Install the O ring 11 into the groove provided in the front cover face Oil the O ring and stretch it slightly if necessary so it will remain in its groove 8 Install the wear plate 10 with the bronze surface against the gears and the small vent hole in line with the hole in the heat shield Press the wear plate The wear plate shall be sufficiently within the oval cavity so it is axially retained E 91 TM 10 3950 672 24 1 9 Install the drive gear 13 and driven gear 14 assemblies into the front cover Apply oil to the shaft at the drive end to prevent damage to the shaft seal caused by sharp edges on the drive shaft passing through the shaft seal An oil coated shaft rotated Slowly will usually cause no damage to the seal Check to see the shaft seal lip and spring is not pushed out by the shaft 10 Check the wear plate to ensure it is still seated into its oval cavity and install the center section 12 over the gears until it engages the wear plate The center section must be positioned so the previously scribed lines on the housing exteriors are in line with those scribed on the front cover The small slot located mid way between the bores should align with the small vent hole in the wear plate The face containing the slot must be in contact with the wear plate 11 Install the dowel pins 7 and add a generous amount of clean hydraulic oil into the gear cavities
512. vis pin in the parking brake lever Remove the clevis pin C Lengthen the parking brake adjusting link by turning the clevis Continue to lengthen the adjusting link until the shoes seat against the drum when the clevis pin is installed d Remove the clevis pin and shorten the linkage adjustment until there is a slight clearance between the shoes and the drum approximately 0 01 0 in 0 254 mm per shoe e Install a new cotter pin in the clevis retaining pin and check brake operation LEGEND Figure 3 1 2 1 Nut 26 Brake Assembly 2 Lockwasher 2T Washer 3 Drum 28 Bolt 4 Brake Shoe Assembly 29 Bar 5 Bolt 30 6 Spring 31 Bolt 7 Bolt 32 Washer 8 Mount 33 Washer 9 Nut 34 Bolt 10 Lockwasher 35 Cable Support Bracket 11 Spring 36 Nut 12 Lever 37 Lockclip 13 Drum 38 Bolt 14 Brake Assembly 39 15 Shield 40 Nut 16 Bellcrank 41 Clevis 17 42 Nut 18 Lockwasher 43 Cotter Pin 19 Nut 44 Stud 20 Drum 45 Spacer 21 Cam and Lever Assembly 46 Clevis Pin 22 Clevis Pin 4T Clevis 23 Cotter Pin 48 Cotter Pin 24 Bolt 49 Clevis 25 Washer 50 Clevis Pin 3 60 TM 10 3950 672 24 1 Figure 3 12 Park Brake Automatic Transmission Sheet 1 of 2 3 61 TM 10 3950 672 24 1 3 25 TRANSMISSION SHIFTING LEVER ASSEMBLY 3 25 1 Adjustment a b Set outriggers refer to Operator s Manual TM 10 3950 672 10 Remove hitch pin 1 Figure 3 13 clevis pin 2 and disconnect rod assemb
513. w pattern is applicable in either direction the valve may be positioned If it is necessary to open more than one directional control valve in the same valve bank it may be required to partially close or feather the valves that are located in the bank first in regards to flow from the pump in order to provide sufficient flow to the valves located last in the bank The closed spool directional control valve functions basically the same way as the open spool directional control valve in that the through passage of the valve must be blocked off by the valves spool to divert flow to the dead end parallel passage With flow diverted to the parallel passage pressure then must unseat the load check valve to allow the flow to reach the open work port The load check valve is provided to prevent back sliding of components which support heavy loads as is evidenced by the circuits this valve is used in Return flow from the component is through the return work port to the reservoir return passage MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION 1 Sticking spool ature Dirt in oil Pipe fittings too tight Valve warped from mounting Excessively high pressure in e Excessively high oil temper Eliminate any restriction in pipe line or filtering system Change oil and flush system Check torque Retorque as nec essary Loosen valve and check Check pressure at inlet and at e valve Relie
514. washer 10 Mirror Assy 15 Bracket 20 Screw Figure 3 24 Mirror Assembly Right Side 3 204 TM 10 3950 672 24 1 3 81 MIRROR ASSEMBLY RIGHT SIDE 3 81 1 3 81 2 Removal Remove locknut 1 Figure 3 24 bolt 2 cushion washer 3 nut 4 lockwasher 5 washer 6 screw 7 locking plate 8 star washer 9 and mirror assembly 10 from bracket 11 Remove hex nut 12 lockwasher 13 carriage bolt 14 and bracket 15 with mirror 18 from bracket 11 Remove nut 16 lockwasher 17 and mirror 18 from bracket 15 Loosen jam nut 19 and screw 20 and remove bracket 11 from socket in crane frame Installation Install bracket 11 Figure 3 24 in socket in crane frame and tighten screw 20 and jam nut 19 Install mirror 18 on bracket 15 with lockwasher 17 and nut 16 Install bracket 15 with mirror 18 on bracket 11 with carriage bolt 14 lockwasher 13 and nut 12 Install mirror assembly 10 on bracket 11 with locking plate 8 star washer 9 screw 7 washer 6 lockwasher 5 nut 4 cushion washer 3 bolt 2 and locknut 1 3 205 Locknut Screw Cushion washer Nut Lockwasher Washer Screw TM 10 3950 672 24 1 LEGEND 8 Locking Plate 9 Star Washer 10 Mirror Assy 11 Bracket 12 Jam Nut 13 Screw Figure 3 25 Mirror Assembly Left Side 3 206 TM 10 3950 672 24 1 3 82 MIRROR AS
515. worn intermediate servo release and high clutch pis ton check ball d Valve body bolts loose or too tight e Vacuum diaphragm or throttle valve control rod bent sticking or leaking e Check diaphragm and rod Re place as necessary a Valve body bolts loose or too b Valve body dirty sticking valves c Vacuum diaphragm or throttle valve control rod bent sticking or leaking a Poor engine performance b Valve body bolts loose or too tight c Valve body dirty sticking valves d Governor valve stuck e Output shaft collector body seal rings damaged E 38 TM 10 3950 672 24 1 SYMPTOM PROBABLE CAUSE SOLUTION 18 No 2 3 upshift a Perform fluid level check b Adjust linkage Service as re quired c Control pressure test Note re sults d Tighten bolts e Determine source of contami nation then service as required a Check engine tune up b Check engine vacuum lines Service as necessary Check vac uum diaphragm unit Service as necessary Perform vacuum Supply and diaphragm tests c Air pressure test the interme diate servo apply and release the high clutch piston check ball Ser vice as required d Tighten bolts a Tighten bolts b Determine source of contami nation Service as required c Check diaphragm and rod Re place as necessary a Check engine tune up b Tighten bolts c Line pressure test note re suits Determine source of contam ination Ser
516. y 118 Directional Control Valve E 115 Directional Control Valve Description Replacement and 3 111 Directional Control Valve Disassembly 2 E 116 Directional Control Valve E 115 Directional Control Valve Troubleshooting E 1 15 Disassembly and Assembly General nnns 1 5 ER REB EORR MAR Taka taka E 3 228 Dome L ightiemiovall 3 228 Door and Latch Assembly 3 9 Door and Latch Assembly Removal 3 9 Drive Belt Replacement 5 59 Prive 3 42 Drive EE 3 43 Drive Line Removal ea a ea a turus usus 3 42 Drive Train Maintenant ennio m 3 42 Index 4 TM 10 3950 672 24 1 ALPHABETICAL INDEX Subject Page E Effects of Cooling System
517. y O Ring Backup Ring Spacer Rod Head Wear Ring O Ring Backup Ring Buffer Seal Assembly Rod Seal Head Retaining Plate Wiper Ring Bolt Holding Valve 4 50 Inch 11 4 cm Telescope Cylinder 3 125 TM 10 3950 672 24 1 NOTE Note the sequence of each seal making up the buffer seal and its location on the rod to ensure proper assembly 9 Remove the O ring and backup ring from the outside of the head and the wear rings buffer seal assembly and rod seal from the inside of the head 10 plate Remove the wiper ring from the head retaining 11 If necessary remove the holding valve from the port block Cleaning and Inspection 1 Clean all parts with solvent and dry with compressed air Inspect all parts for serviceability CAUTION BEFORE INSTALLING NEW SEALS AND RINGS CLEAN ALL SURFACES AND CAREFULLY REMOVE BURRS AND NICKS PARTS DISPLAYING EXCESSIVE WEAR OR DAMAGE SHOULD BE REPLACED 2 Stone out minor blemishes and polish with a fine crocus cloth 3 Clean with solvent and dry with compressed air any parts that have been stoned and polished 4 Inspect the barrel carefully for scoring Assembly NOTE Coat all seals and rings with clean hydraulic oil CAUTION AVOID STRETCHING THE SEALS AND RINGS ENSURE THE SEALS AND RINGS ARE INSTALLED IN THE PROPER ORDER 3 126 TM 10 3950 672 24 1 NOTE Steps 1 2 3 and 4 are used only if the holding valve has been removed 1 Check
518. y quantity by 0 113 NOTE When multipliers and or special tools are used to reach hard to get at spots ensure torque readings are precisely calculated Grade Grades 060006 3 Lines 1 Line 2 3 Radiai Markings Spaced 1 Dot Lines Heat 120 proa Treated 7 7 6 Lines 1 Line 6 Radial 6 Dots 1 Radial Spaced 1 Dot Lines Spaced Line 60 60 1 Dot Nut identification i ae Y Oot Corners TD Notched Corners 0334 TM10 3950 672 24 1 CHAPTER 2 CRANE MAINTENANCE INSTRUCTIONS Subject Section Page Repair Parts Special Tools TMDE and Support Equipment 2 1 Service Upon Receipt MERO eats eee ee ee ee 2 1 Organizational Preventive Maintenance Checks and Services 2 3 Section 1 Repair Parts Special Tools TMDE and Support Equipment Subject Para Page Common Tools and Equipment 2 1 2 1 Special Tools Repair Parts TMDE and Support Equipment 2 2 2 1 2 1 COMMON TOOLS AND EQUIPMENT For authorized common tools and equipment refer to Modified Table of Organization and Equipment MTOE applicable to your unit 2 2 SPECIAL TOOLS REPAIR PARTS TMDE AND SUPPORT EQUIPMENT Reference Section IIl of Appendix B Maintenance Allocation Chart for a list of all special tools and test equipment needed to maintain the crane Repair parts and special tools
519. y lift is provided by a 7 in 1 7 8 cm diameter bore lift cylinder Boom elevation is from 0 to 70 from horizontal 3 60 1 Removal a b Extend and set the outriggers and fully retract the boom Remove the hook block and wind all the wire rope onto the hoist drum Elevate the boom slightly to allow for withdraw of the lift cylinder rod end from the lift cylinder attach fitting WARNING Ensure the blocking and lifting devices are capable of supporting the boom assembly Attach a suitable lifting device to the boom to provide equal weight distribution Place a safety block in position under the boom and rest the boom on the safety block Disconnect electrical wiring from the boom 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 Block the lift cylinder Remove the bolts washers nuts and plates securing the rod end pivot shaft to the lift cylinder attach fitting Remove the rod end pivot shaft Activate the hydraulic system and withdraw the lift cylinder rod enough to clear the attach fitting WARNING Shut down the crane before proceeding 3 150 m TM 10 3950 672 24 1 Take up the clack on the boom lifting device Remove the retainer plates bolts and washers securing the boom pivot shaft to the boom and turntable assemblies Remove the boom pivot shaft Rais
520. y of oil is available on the suction side of the pump 3 84 TM 10 3950 672 24 1 3 34 STEERING CONTROL VALVE DESCRIPTION The orbitrol steering control valve is located under the precise full hydraulic steering which is accomplished by front console and is actuated by an orbitrol steering a metering system within the valve that is directly column and a steering wheel which are integral parts of connected to the steering column and wheel the steering control valve The steering valve provides THEORY OF OPERATION Turning the steering wheel to the left or right causes a permits incremental steering left or right If hydraulic oil spool enclosed in a precision sleeve to rotate As the flow to the IN port is lost due to failure of the engine spool is rotated a set of lateral springs tend to move the torque converter or steering pump rear wheel steering sleeve in the same direction Due to the springs there can still be accomplished with the steer control valve is a time lag between the movement of the spool and When pressure is lost a poppet valve closes and the sleeve During this time lag hydraulic oil from the IN gerotor set becomes a hydraulic pump Turning the port of the valve is permitted to flow to the gerotor set steering wheel mechanically actuates the gerotor set which meters hydraulic oil to the steer cylinder through pumping hydraulic oil from one side of the steer cylinder the appropriate L or R port of the valve When the t

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