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TM 10-3930-641-10 - Liberated Manuals

1. A Additional Authorization List Blaster Basic Issue Items da A PEE CARO cremari aa a kk Chemical Agent Resistant Coating A A M Cubic Inch Displacement ee O Centimeter dete OE Components of End Items aries AAA A aa Corrosion Prevention and Control A Diesel Engine Driven cane Et ped Equipment Improvement Recommendation pureza orar daras um SA ri Electromagnetic Pulse d ai Gross Combination Weight Rating A O Gross Vehicle Weight Rating ISO ee A ee eos ews International Organization for Standardization se etwas Kilogram A E E NR A S ete Kilometer A P UP DLP ane Kilopascal Ml it as io iia ia ada Kilometers per Hour a MP WE ne ne Kilowatt A II AI Liter A are ie e Baek Pound Foot MPa aa ENN a rada
2. 0011 00 3 M Machine Mounting and Dismoununs 3 o tate ee iii 0005 00 1 Operate ipod ad E ARA AAA era 0005 00 6 mus 0005 00 6 Main Disconnect Switch unter pisa ee ee ee rn 0004 00 14 Maintenance Forms Records and Reports 0001 00 1 Major Components Location and Description of 0002 00 2 Mast Cono Ed at 0004 00 3 Mast Hydraulic System Theory of Operation 0003 00 5 Mounting and Dismounting Machine 0005 00 1 N Nuclear Biological and Chemical NBC Contamination Threat of 0001 00 1 Index 2 Subject Operate TM 10 3930 641 10 INDEX Continued At High Altitudes 1 4 MD A A A A In ExXtreme Hleat Ai ee Ine Mind OF Surlaces Son 4er a eu er Eee een AT an tek Nod ad In Sandy Or Dusy Conditions Lunar ot east ee Kirsten s iia ICE ee hee da Seah a tate eas aoe el decer ale eae Machine Operation Unusual vos A Sk A RR S oc en s es ee eas Dts ee Operation Under Unusual Conditions Operation Unde
3. 0015 00 1 Air Inlet and Exhaust System Theory of Operation 0003 00 2 B Bas e Issu amp Iems BIDASOA ASA a SNE DEERE SER 0014 00 1 Brake System Theory of Operation 0003 00 3 Components of End COED List te ua A ae be 0014 00 1 Container Lock Indicator Panel lt lt RR A 0004 00 13 Controls Dom EIBBb enc os ran ares 0004 00 4 Foot Operated a A ESA AA EA Uu de dus 0004 00 2 PPP O QT TI REN 0004 00 4 ane ada dieu mma dd Eee met ador t 0004 00 3 Seal ODePatOE S 2534 0 da eed des 0004 00 5 oteerme C olumn Mounted o essi Eee ei or einen 0004 00 1 Corrosion Prevention and Control CPC 0001 00 1 D qe cC PEPERIT 0007 00 1 Deealiand DaB Plate sn A n UE ed 0007 00 1 AA ECCE 0007 00 1 Description and Use of Operator Controls and Indicators 0004 00 1 Destruction of Army Materiel to Prevent Enemy 0001 00 2 E Electrical System Theory of Operation 0003 00 4 Electromagnetic Pulse EMP Exposure 0001 00 1 Engine vr pcnc 0005 00 4 Equipment Characteristics Capabilities and Fea
4. Transmission Reduction Ratio in First Transmission Reduction Ratio in Second Transmission Reduction Ratio in Second Reverse Transmission Reduction Ratio in Transmission Reduction Ratio in Third Transmission Reduction Ratio in Fourth Transmission Reduction Ratio in Fourth NV eIS lanas a peas Ea Led LS ated as Transfer Case Transfer Case Reduction Ratio Input Transfer Case Reduction Ratio Output pau eb EIUS os bata ias defi a ce aes Final Drive Reduction Bevel Gear Reduction Ratio Axles Axle Oscillation Front o einen alii Axle Oscillation Diktat Type Braking Surface Pump Type Output Relief Valve Setting Weight 0002 00 6 Caterpillar Inc Direct injection 65 degree V 8 turbo diesel 3308T 393 HP 293 kW 1 210 16 6 1 640 Nm 700 RPM 2 320 RPM 28 degrees BTC 5 4 in 137 mm 6 in 152 mm 1 099 CID 18 L
5. 0010 00 3 ENGINE 1 Engine Cranks but Fails to Start Operating Temperature Above 32 F 0 0010 00 4 2 Engine Cranks but Fails to Start Operating Temperature Below 32 F 0 0010 00 4 3 Engine Misfires Runs Rough or Stalls at Low RPM 0010 00 5 4 Engine Does Not Develop Full Power 1 0010 00 5 5 Engine Does Not Idle 4 0010 00 5 o me Vioralon 22262205466 X eb sees eae aprisa 0010 00 5 7 in 0010 00 5 8 Black or Gray Smoke from 1 0010 00 5 9 White or Blue Smoke from EXxlHaust o uu usce do eq ka erisa eier 0010 00 5 10 Engine Overheats Water Temperature Gage Indicates in Red Area 0010 00 6 11 Engine Fails to Crank When Power Switch Is Turned to 0010 00 6 I2 Alternator IS NOISY 223242 kian Ea dE aH Rad do RA d d Ha RU Seed det es been 0010 00 6 13 Excessive Exhaust Smoke at Normal Operating 0010 00 7 HYDRAULIC SYSTEM 1 Hydraulic System Will Not Lift Load or Will
6. 25 degrees Maximum Departure isses a Fam I ERES GE 20 degrees Maximum Ground CIeardBce Sce ex ark sok Ee Dakar 16 in 40 Clearance ite tee rt 70 ft 21 m Jit vclinb Time Bach Direction dA SE dg b wees Rios 9 seconds Hino Capac putada dai di 50 000 lb 22 679 kg Tophandler with container raised 1 ft 30 cm full back tilt Tophandler with container raised 1 ft 30 cm 0002 00 5 10 3930 641 10 0002 00 EQUIPMENT DESCRIPTION AND DATA CONTINUED EQUIPMENT DATA CONTINUED Engine Manufacturer Idywheel Powerat A E ow ces ee A TForquesat 2300 ade Ensi e RPM Low Idle 32 te Engine RPM High Idle a Da ee o AE AEREE EAEE TEREST EE EEE hd ET Displaco mentada eta en Compression boots tido Keg Moe en bla ke 22 etu DI Melo b acres cds RENE PES IERI E term tet eee nasa Transmission and Powertrain IC A ssh oec dax ee cett trf E dios bai UE ads ei Transmission Reduction Ratio in
7. db onc t 165 625 1 IRAGTALON ute oes 28 gal 106 L Ensmelrankessen errar adi fer A e 11 gal 41 6 L Hydraulic System ipe ene aad 78 gal 295 3 L Transmission and Differential 24 gal 91 L Electrical System Battenes coo les E EL bete nee bibe Lead acid bt d Tob EC DD E 4 D 8D Voltage Bach Battery oneri PSU A II ada 12V Moltape ys sus omia eon eb 24V All O ON Integral regulator A A eee eee Solid state APNEA E a dc 50 Hydraulic System ADS Ns E E a EAT Closed with vacuum relief Pump PYPE OUMU REI Bes Bele a bas bee bed bee Ried Gear single stage 71 gpm 4 5 L sec Rehe Valve Seine pea Ewa 2 500 psi 17 236 kPa Operating Pressure Max usce es POSER med ieee 2 500 psi 17 236 kPa NV CUM 25256 E eeu ion BO OB ee Go A oe PAS pe eae GEL 110 lb 50 kg Cylinders Lift Bore x SMOKE cota oda ke da sc eevee eee ees 10 x 69 in 25 4 x 175 cm Eilt BoreE x UTOR canted ER EU eee eS ES eS
8. 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic 5 CTA 50 970 END OF WORK PACKAGE 0013 00 2 10 3930 641 10 COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS 0014 00 SCOPE This work package lists and for the RTCH to help you inventory items required for safe and efficient opera tion GENERAL The and information 15 divided into the following tabular lists 1 Table 1 Components of End Item List This listing 15 for informational purposes only and is not authority to requisi tion replacements These items are part of the end item but are removed and separately packaged for transportation or shipment As part of the end item these items must be with the end item whenever 1t 1s issued or transferred between property accounts Illustrations are furnished to assist you in identifying the items 2 Table 2 Basic Issue Items List These are the minimum essential items required to place the RTCH in operation to operate it and to perform emergency repairs Although shipped separately packaged BII must be with the RTCH during operation and whenever it is transferred between property accounts This manual is your authority to request requisition replacement BII based on TOE MTOE authorization of end item Illustrations are furnished to assist you in identifying the items EXPLANATION OF COLUMNS Below is an explanat
9. 31 71 Nuelear Contamination Aysldance aan TA urn 3 3 1 Operation and Maintenance of Ordnance Materiel in Cold FM 9 207 TECHNICAL BULLETINS Color Marking and Camouflage Painting of Military Vehicles Construction Equipment and Materials Handling 1 TB 43 0209 Use of Antifreeze Solutions Antifreeze Extender Cleaning Compounds and Test Kit in Engine S tem leds bi ber ie ls e beds re ee TM 750 651 TECHNICAL MANUALS Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including Chemicals TM 9 247 Operator s Unit Direct Support and General Support Maintenance Manual for Lead Ac d Storage Bateries 2 ana tu bU ar RE CETTE PED ENS LEE PEE TM 9 6140 200 14 Procedures for Destruction of Equipment to Prevent Enemy Use Mobility Equipment Command ves bea be xo RE Live p we digas TM 750 244 3 0013 00 1 10 3930 641 10 REFERENCES CONTINUED 0013 00 OTHER PUBLICATIONS Abbreviations and Acronyms AA AS AAA G ASME Y 14 38 1999 Army Acquisition Policy A A A A UR CA ERR A RR ee A AR 70 1 Army Medical Department Expendable Durable
10. END OF WORK PACKAGE 0010 00 8 10 3930 641 10 4 OPERATOR MAINTENANCE INSTRUCTIONS 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION 0011 00 GENERAL To ensure that the machine is ready for operation at all times it must be inspected on a regular basis so that defects may be found and corrected before they result in serious damage equipment failure or injury to personnel This PMCS contains systematic instructions on inspections lubrications adjustments and corrections to be performed by the operator to keep your equipment in good operating condition and ready for 1ts primary mission EXPLANATION OF TABLE ENTRIES 1 Number Item No Column Numbers in this column are for reference When completing DA Form 2404 DA Form 5988 E Equipment Inspection and Maintenance Worksheet include the item number for the check service indi cating a fault Item numbers also appear in the order that you must perform checks and services for the interval listed 2 Interval Column This column tells you when you must perform the procedure in the procedure column a Before procedures must be done immediately before you operate the machine b During procedures must be done while you are operating the machine c After procedures must be done immediately after you have operated the machine d Weekly procedures must be done once each week e Monthly procedures must be done onc
11. Ee C 0005 00 3 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 START ENGINE WARNING DO NOT operate engine in enclosed areas due to the dangers of carbon monoxide poisoning from exhaust fumes Always start and operate engine in a well ventilated area and if in an enclosed area vent exhaust to the outside Failure to follow this warning may cause injury or death to personnel Hearing protection 1s required when operating machine with cab windows open Anyone within 50 ft 15 m of an operating machine must also wear hearing protection Failure to wear hearing protection may cause hearing loss Be ALERT for personnel in the area while operating machine Always check to ensure area 1s clear of personnel before starting engine Failure to follow this warning may cause injury or death to personnel NOTE Refer to WP 0004 00 for the location and operation of controls and indicators Starting Engine Above 32 0 C gt mo Ensure transmission is in N Neutral Ensure parking brake 15 applied by pulling parking brake control knob out Ensure all hydraulic control levers are in a neutral position Ensure all accessories are off Ensure all personnel are clear of machine Press and hold accelerator pedal 1 4 way down CAUTION DO NOT crank starter motor for more than 30 seconds at a time After 30 seconds allow starter motor to cool for at least 2 minutes bef
12. unlock tophandler container locks d Observe LOAD LOCKS UNLOCKED red light LOCKED UNLOCKED on Two yellow READY TO LOCK lights will stay On CONTAINER LOCK 422 0042 INDICATOR PANEL e Pull lift control lever to clear tophandler from container Two yellow READY TO LOCK lights will go off f Carefully back away from drop off point g Use side shift control lever tilt control lever and SIDE SIDE side tilt control lever to center and level tophan SHIFT TILT CONT dler LOCKS a Pee SIDE conr 9 4 N SHIFT TILT LOCKS b LIFT o lt 2 e Lo 422 0037 0005 00 12 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 TOPHANDLER REMOVAL AND INSTALLATION WARNING Be ALERT for personnel in the area while operating machine Always check to ensure area 15 clear of per sonnel and obstructions before moving machine or raising or lowering container handler forks Failure to follow this warning may cause injury or death to personnel or damage to equipment NOTE It will be necessary to change tophandlers to accommodate different size containers 35 ft and 40 ft tophan dlers are available as AAL items WP 0015 00 1 Removal NOTE Tophandler can only be lowered to 7 ft 2 1 m above ground level a Lower tophandler to rest on an elevated support such as a container WARNING DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic sys
13. Miles per Hour m A E EE UA e Mer Millimeter a ee Ate Sele ad aio ida vecs Sd da North Atlantic Treaty Organization noie D O E Nuclear Biological and Chemical pc E rra tiraron traca Newton Meter INS Neen PP ee National Stock Number O oa en Preventive Maintenance Checks and Services A E E O A Pneumatic Tires ROPS re Rollover Protective Structure IET Rough Terrain Container Handler Tables of Organization and Equipment Modified Tables of Organization and Equipment END OF WORK PACKAGE 0001 00 3 10 3930 641 10 EQUIPMENT DESCRIPTION AND DATA 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES Characteristics C Handles and stacks ISO International Organization for Standardization designation 1A or 1C cargo containers or Sealand containers Loads and unloads flatbed trailers and rail cars Makes over the shore landings p Capabilities and Features NOTE Refer to Equipment Data at the end of this work package for machine dimensions weights fluid capac ities and other miscellaneous equipment data DO NOT transport RTCH by self propulsion The RTCH can be transported b
14. oil coolant or hydraulic oil leaks are evi dent Any fuel leak 15 evident Pedal binds or does not oper ate properly Brakes pull grab or do not operate properly Steering 15 erratic Mast does not respond to con trol lever movements 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 32 33 34 NOTE Do not shift from forward to reverse or reverse to forward without stopping Transmis Monitor transmission functioning as Transmission does not operate sion transmission range selector is moved correctly through all ranges Cab Heater Check operation of cab heater and defroster if weather warrants use ENGINE IDLING WARNING With engine running drivetrain components are hot to the touch Use caution to safeguard against burns Failure to fol low this warning may result in injury to personnel NOTE To ensure accurate engine and transmission oil level checks machine must be stopped on level ground 0 1 Hours Engine Oil a With engine running at low idle and Level Hot warm release retainer and open Check left side engine compartment access doors b Wipe area around dipstick and filler tube with a clean rag Item 12 WP 0016 00 c Remove dipstick and read oil level on dipstick Level must be between LOW and FULL marks on LOW IDLE side of dipst
15. 9 White or Blue Smoke from Exhaust 0010 00 CAUTION DO NOT crank starter motor for more than 30 sec onds at a time After 30 seconds allow starter motor to cool for at least 2 minutes before attempt ing to start engine again Excessive heating of starter motor may result in damage or premature starter failure 3 While cranking engine press ether starting aid switch Wait approximately 2 seconds between injections 1 DW fuel level 00 2 Inspect fuel lines between fuel tanks and fuel transfer pump for leaks crimps and bends Check air cleaner indicator on instrument panel Check air cleaner indicator on instrument panel Check air cleaner service indicator Check for water sediment and cloudiness in fuel Check air cleaner service indicator Inspect for overfilled engine oil crankcase WP 0012 00 0010 00 5 If engine still will not start notify Organizational Maintenance Add fuel as necessary WP 0012 00 If problem still exists go to test step 2 Notify Organizational Maintenance If indicator is illuminated service precleaner WP 0012 00 and retest If problem still exists notify Organizational Maintenance If indicator is illuminated service precleaner WP 0012 00 and retest If problem still exists notify Organizational Maintenance If indicator is illuminated service precleaner WP 0012 00 and retest If problem still exists notify Organizational
16. ment for damage or leaks 0012 00 13 0012 00 NOT FULLY MISSION CAPABLE IF a Cracks or distortion in steering linkage that would impair operation are dent Class leaks or damage that would impair opera tion are evident Class III leaks or damage that would impair operation are evident Components are missing or damaged if required for mis sion Components are missing or damaged if required for mis sion Class III leaks or damage that would impair operation are evident 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 45 After Fuel Tank WARNING DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity Failure to follow this warning may cause injury to personnel or equipment damage Operating personnel must wear fuel resistant gloves when han dling fuels If exposed to fuel promptly wash exposed skin and change fuel soaked clothing NOTE Place portable fire extinguisher within reach prior to refueling DO NOT overfill fuel tank If fuel starts foaming from fuel tank stop IMMEDIATELY to avoid fuel spillage a Check fuel tank filler tube and cap a Class HI fuel leaks or
17. Become familiar with steering characteristics of machine before attempting maneuvers in limited space Avoid oversteering c Inthe event of steering system failure perform the following 1 Stop machine in a safe location 2 Apply parking emergency brake 3 Shut down engine and troubleshoot malfunction 4 DO NOT operate machine until problem has been corrected 0005 00 7 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE MACHINE CONTINUED 4 Stopping Parking RTCH a Release accelerator pedal to reduce engine speed WARNING e DO NOT use parking brake to stop moving machine under usual conditions e Only if service brakes fail apply parking brake Failure to follow these warnings may result in injury or death to personnel or damage to equipment b Apply right brake pedal to stop machine Select a level surface to stop park 1f possible c Move transmission range selector to neutral WARNING NEVER leave operator compartment without applying parking brake Failure to follow this warning may cause injury or death to personnel in the event machine moves inadvertently when parked d Apply parking brake by pulling out on parking brake control knob e Lower forks tophandler to the ground by pushing lift control lever forward ENGINE SHUTDOWN CAUTION e Stopping engine immediately after it has been operating under a load can result in overheating and accelerated wear of en
18. GENERAL Do not attempt to operate RTCH until becoming familiar with the location and use of all controls and indicators This work package describes all operator controls and indicators STEERING COLUMN MOUNTED CONTROLS 422 0035 Transmission Range Selector To control direction of travel push lever forward to select forward and pull back to select reverse Center position 15 neutral In either forward or reverse rotate lever to select one of four forward or four reverse gears Lower ranges yield higher power and lower speed Higher ranges yield lower power and higher speed Steering Column Release Knob While holding steering wheel pull knob out to release steering column Move column to desired position and release knob to lock column in place Steering column release knob will not function unless steering column lock is unlocked Steering Column Lock In locked position key 1s straight up and steering column release knob is disabled Turn key clockwise right to unlock and enable steering column release knob Parking Brake Control Knob Pull knob out to engage parking brake Push knob in to release parking brake 0004 00 1 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 FOOT OPERATED CONTROLS 422 0031 5 Horn Switch Push down to sound horn 6 Accelerator Pedal Press pedal to increase engine speed Release to decrease engine speed 7 Right Brake Pedal Press to a
19. Maintenance b Start engine Run engine at half speed for two minutes to increase accumulator pressure then shut down engine c Apply service brakes It should take c Low brake pressure indi at least five brake applications cator comes on with less before low brake pressure indicator than five brake applica comes on Emergency brake should tions Emergency brake come on at the same time does not come on d If brakes do not pass this test notify Organizational Maintenance 66 Monthly Upper And Check pivots for obvious cracks Pivots contain cracks Lower Frame Pivot and Bearings 67 Monthly 0 2 Hours Mast Slider Raise inner channel 2 ft 61 cm Blocks Apply GAA grease Item 6 WP 0016 to mast sliders Lower and raise channel a few times to spread lubri cant 0012 00 26 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 68 Monthly 0 2 Hours Mast Rollers Lower carriage to bottom Apply GAA grease Item 6 WP 0016 00 to four fittings T E 4 PLACES BOTTOM TOP apr smi pe 69 Monthly 0 3 Hours Carriage a With carriage lowered apply GAA Rollers grease Item 6 to two upper fittings through holes in car raige 0012 00 27 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES
20. PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED LUBRICANT INTERVAL INTERVAL LUBRICANT Engine Check Level Add HDO D OE Transmission HDO Check Level Add Container Lock M GAA Operating Shaft Housing Lubricate Bearings Fittings 4 Places Lubricate Bearings 6 Places Force Limiter Guide M 39 Rods Coat Sliding Surfaces with Light Coat of Grease 6 Places Operating Shaft GAA Bearings Lubricate Bearings 2 Places Container Lock Housing Lubricate Fittings Force Limiter Guide Rods Coat Sliding Surfaces with Light 4 Places Coat of Grease 3 20 FT TOPHANDLER Places CARRIER SIDE m END OF WORK PACKAGE 0011 00 9 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 0012 00 LOCATION ITEM TO ITEM INTERVAL HOURS SERVICE NOT FULLY MISSION CAPABLE IF PROCEDURE NOTE e Review WARNINGs CAUTIONS and NOTEs before per forming PMCS and operating the machine Perform all PMCS checks if a You are the assigned operator but have not operated the machine since the last weekly checks b You are operating the machine for the first time Unless otherwise indicated perform PMCS with machine parked on level ground parking brake applied transmission in N Neutral container hand
21. Remove wheel chocks Tow machine slowly at no more than 5 mph 8 kph After towing have Organizational Maintenance reconnect steering cylinder hoses and restore parking brake 422 0054 0006 00 7 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY BRAKE OPERATIONS WARNING Machine will stop suddenly during emergency brake engagement Use caution to guide machine to a stop as quickly and safely as possible Failure to follow this warning may result in injury to personnel 1 When service brake oil pressure is below safe operat pressure LOW PRESS BRAKE indicator will flash PARK BRAKE ON indicator will come on and emergency parking brake will automatically engage LOW PRESS DOO BRAKE 009000 E HEAD an ne AJA PARK BRAKE pc 06 y b A 422 0041 2 If machine has load a horn will keep sounding After machine makes an emergency stop do the fol lowing a Shift transmission into neutral b Run engine at high idle for three minutes to increase brake oil pressure c Try to release parking emergency brake by push ing in parking brake control knob PARKING BRAKE CONTROL _ 422 0035 0006 00 8 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY BRAKE OPERATIONS CONTINUED d LOW PRESS BRAKE indicator should stop flashing If it does not park machine stop engine and lower load or mast N
22. Shipping Weight 70 Fuel Without 105 120 lb 47 768 kg Operational Weight Without 103 230 lb 46 824 kg Operational Weight with 20 107 030 lb 48 558 kg Operational Weight with 35 Ft 112 350 lb 50 961 kg Operational Weight with 40 Ft 113 160 lb 51 329 kg ZO BE Tophandler zn criba road beh ca ond et ies 3 800 lb 1 724 kg 3 bt Tophandler ddr airada ee 9 120 lb 4 137 kg AUFL Tophandler 5 424 051 65 5 3 daa a ib paa 9 930 lb 4 504 kg Maximum Speed With Rated Load ai ds eros 14 5 mph 23 3 kph With Rated Load Reverse 14 9 mph 24 kph Without Rated Load 18 5 mph 29 8 kph Without Rated Load Reverse wer ee tada 19 4 mph 31 2 kph TOWING esee O wh ee ets ea A EN E 5 mph 8 kph for 10 miles 16 km max MAMA e es A Ls 15 at 2 mph 3 2 kph Maximum Depilador Vales Daran 60 in 150 cm Maximum Side ii cues pne IA di ect AAA die p ad pon te A 15 degrees Maximum Breakover Angle asa XD ERI iii Sk exe 148 degrees Maximum Approach
23. THEORY OF OPERATION CONTINUED 0003 00 MAST HYDRAULIC SYSTEM 1 Lift Cylinder The lift cylinder is a ram type cylinder that moves up by oil pressure and moves down by gravity extended part of the cylinder is completely filled with oil 2 Tilt Cylinders Two double acting tilt cylinders both extend and retract by hydraulic pressure These cylinders control the forward and back ward tilt angle of the mast TILT CYLINDERS LIFT CYLINDER 422 0032 3 Side Shift Cylinder A double acting side shift cylinder controls the side shift of the forks and tophandler with respect to the center line of the machine 4 Side Tilt Cylinder This double acting cylinder rotates the forks and tophandler SIDE SHIFT CYLINDER AIR 2 A 7 SIDE TILT u CYLINDER 422 0001 0003 00 5 10 3930 641 10 THEORY OF OPERATION CONTINUED MAST HYDRAULIC SYSTEM CONTINUED 5 0003 00 Container Lock Cylinders There 15 one container lock cylinder on the 20 ft tophandler and two on the 35 ft and 40 ft container tophandlers The cylinder extends to lock the tophandler to the container and retracts to release the tophandler from the CONTAINER 20 FT TOPHANDLER LOCK CYLINDERS 100 N END OF WORK PACKAGE 422 0021 0003 00 6 10 3930 641 10 2 OPERATION INSTRUCTIONS 10 3930 641 10 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS 0004 00
24. and change fuel soaked clothing l Check fuel level WP 0012 Add fuel as necessary WP 0012 00 If problem still exists go to test step 2 2 Check for water sediment and If fuel is unsatisfactory notify cloudiness in fuel Organizational Maintenance 2 Engine Cranks but Fails to Start Operating Temperature Below 32 F 09 C WARNING DO NOT perform fuel system checks inspections or mainte nance while smoking or near fire flames or sparks Fuel may ignite causing damage to machine and injury or death to per sonnel Operating personnel must wear fuel resistant gloves when handling fuels If exposed to fuel promptly wash exposed skin and change fuel soaked clothing 1 Check fuel level WP 0012 Add fuel as necessary WP 0012 00 o0 If problem still exists go to test step 2 2 Check for water sediment and If fuel is unsatisfactory notify cloudiness in fuel Organizational Maintenance If problem still exists go to test step 3 0010 00 4 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 2 Engine Cranks but Fails to Start Operating Temperature Below 32 F 0 C Continued 3 Engine Misfires Runs Rough or Stalls at Low RPM 4 Engine Does Not Develop Full Power 5 Engine Does Not Idle Properly 6 Unusual Engine Vibration 7 Engine Knocks 8 Black or Gray Smoke from Exhaust
25. 0006 00 1 0005 00 4 0004 00 1 0003 00 2 0003 00 1 0003 00 2 0003 00 3 0003 00 1 0003 00 5 0003 00 5 0003 00 2 10 3930 641 10 INDEX Continued Subject Work Package Page T Continued Theory of Operation Exhaust System Ad aka u 0003 00 2 Theory of Operation Electrical System 0003 00 4 Theory ot Operation Fuel Systemi zones a A 0003 00 1 Threat of Nuclear Biological and Chemical NBC Contamination 0001 00 1 Troubleshooti o Introduction eased eee creara erronea abes 0008 00 1 Troubleshootins Procedures sua an ce a REN er AIRE 0010 00 1 Troubleshooting Symptom Index 0009 00 1 W Warranty A 0001 00 2 Index 4 By Order of the Secretary of the Army PETER SCHOOMAKER General United States Army Official Chief of Staff E JOYCE E MORROW Administrative Assistant to the Secretary of the Army 0606902 Distribution To be distributed in accordance with the initial distribution number IDN 252284 requirements for TM 10 3930 641 10 Use Part reverse for Repair Parts and DATE RECOMMENDED CHANGES TO PUBLICATIONS AND aa Tool Lita RESTO and Samo BLANK FORMS Catalogs Supply Manuals SC SM 1 October 2005 For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of
26. 1 Remove slave receptacle cover on disabled machine and booster machine 2 Connect slave cable to booster machine slave receptacle 3 Connect other end of slave cable to slave receptacle of disabled machine located on right side of engine compartment 4 Turn main disconnect switch of disabled machine to ON position 5 Start booster machine and run at a speed just above idle 6 Wait approximately five minutes then start disabled machine If engine fails to start notify Organizational Maintenance 7 After starting disabled machine return booster machine to idle 8 Remove slave cable from disabled machine then from booster machine NATO SLAVE RECEPTACLE 422 0044 0006 00 1 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME COLD 1 General Extreme cold causes many problems a Lubricants thicken or congeal b Batteries may freeze or lose their electrical efficiency c Electrical insulation may crack and cause short circuits d Fuel may not readily atomize for combustion e _ Various materials will become hard brittle and easily damaged f Thecooling system requires adequate protection from extreme cold g Fuels lubricants and antifreeze compounds require special storage handling and use Refer to FM 9 207 for additional information Cooling System a Inspect for leaks and general condition b Make sure clamps are tight c Check fluid le
27. Army forms and procedures used for the equipment will be those prescribed by DA PAM 750 8 Functional User s Manual for The Army Maintenance Management System TAMMS as contained in the Maintenance Man agement Update REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRS If your RTCH 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 Form 368 Product Quality Deficiency Report Mail 1t to us at Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island Illinois 61299 7630 We ll send you a reply CORROSION PREVENTION AND CONTROL CPC 1 of Army materiel is continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items 2 corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem If a corrosion problem is identified it can be reported using SF Form 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as
28. E If you find something seriously wrong IMMEDIATELY report 1t to your supervisor Ze Before performing preventive maintenance read all the checks required for the applicable interval and prepare every thing needed to make all the checks For example you ll always need rag Item 12 0016 00 or two 0011 00 1 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL PMCS PROCEDURES CONTINUED mb 5 En WARNING m Solvent cleaning compound MIL PRF 680 Type 15 an environmentally compliant and low toxic material However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ventilated areas Keep away from open flames and other sources of ignition Failure to do so may cause injury or death to personnel a Keep It Clean Dirt grease oil and debris get in the way and may cover up a serious problem Clean as you work and as needed Use solvent cleaning compound Item 2 WP 0016 00 on all metal surfaces Use detergent Item 4 WP 0016 00 and water when you clean rubber plastic and painted surfaces Es WARNING When servicing this machine performing maintenance or disposing of materials such as engine coolant hydraulic oil lubricants battery acids or batteries and CARC paint consult your unit local hazardous waste disposal center or safety office for local regulatory guidance If further information is needed ple
29. Lock Hous ings 9 GAA 4 PLACES eem 422 0016 83 Monthly 0 3 Hours Tophandler Coat three sliding surfaces 20 ft Force Lim tophandler and six sliding surfaces iter Guide 35 and 40 ft tophandlers with a light Rods coat of GAA grease Item 6 WP 0016 00 GAA 20 FT 3 PLACES Zw 1 35 AND 40 FT 6 PLACES GAA 20 FT 3 PLACES 39 AND 40 FT 6 PLACES 422 0025 0012 00 34 10 3930 641 10 PREVENTIVE MAINTENANCE 5 AND SERVICES PMCS CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 84 Monthly 0 3 Hours Tophandler Apply GAA grease Item 6 WP 0016 Operating o0 to two fittings 20 ft tophandler Shaft Bear and six fittings 35 and 40 ft tophan ings dlers GAA 20 FT 2 PLACES 39 AND 40 FT 6 PLACES 422 0026 85 Monthly Systems CAUTION Pace DO NOT perform this PMCS exercise when temperature is Exercise below 0 F 18 C NOTE DO NOT exercise machine if it has been operated within the past month a Perform Before operation PMCS b Start and warm up engine 0005 00 c While machine 15 warming up per c Class III oil coolant or form a walkaround inspection hydraulic oil leaks are evi checking for evidence of leaks dent Any fuel leak 15 evi dent 0012 00 35 10 3930 641 10 PREVENTIVE MAINTENANCE CHE
30. M and high H settings to control heater fan speed 0004 00 4 10 3930 641 10 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 OPERATOR S SEAT CONTROLS 422 0039 CONTROL OR INDICATOR FUNCTION 18 Vertical Height Adjustment Push down to adjust seat up or down Lever 19 Seat Cushion Tilt Adjustment Pull up to tilt seat cushion Lever 20 Damper Control Lever Pull out crank handle and rotate knob for desired amount of dampening firm or soft 21 Fore Aft Adjustment Lever Lift up and slide seat forward or back Release lever to lock seat in desired position 0004 00 5 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 RIGHT HAND INSTRUMENT PANEL 422 0040 CONTROL OR INDICATOR FUNCTION Water Temperature Gauge Converter Temperature Gauge Alternator Indicator Fuel Pressure Gauge Panel Light Starting Aid Switch Indicates engine coolant temperature WHITE COLD GREEN NORMAL RED HOT Indicates torque converter and transmission oil temperature GREEN NORMAL RED Indicates state of charging system When engine 15 running light comes on when there 15 a charging system malfunction With main disconnect switch in ON position amber indicator should be ON during panel test ON when engine is not running OFF when engine is running Indicates primary fuel pump delivery press
31. Maintenance Notify Organizational Maintenance Add hydraulic oil if needed WP 0011 00 arid WP 0012 00 If problem still exists go to test step 2 If damage is found notify Organizational Maintenance If damage is found notify Organizational Maintenance Notify Organizational Maintenance If problem still exists go to test step 2 Notify Organizational Maintenance Add engine d 0011 00 WP 0012 00 If problem still exists notify Organizational Maintenance 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL INDICATORS CONTINUED 5 Implement Plugged Filter Light Comes On 1 Inspect hydraulic oil level 0012 00 2 Inspect implement filter for dirt 6 Transmission Plugged Oil Filter Light 1 Check transmission oil level Comes On During Operation WP 0012 00 ELECTRICAL SYSTEM 1 Floodlights Auxiliary Floodlights 1 Ensure main disconnect Inoperative switch power switch and floodlight switch are in ON position 2 Check for blown fuse 2 or 3 in left hand instrument panel 3 Check light s for separated connection or damage 2 Horn Will Not Sound When Button Is 1 Check for blown fuse 15 at Pressed right hand instrument panel 2 Check horn for separated connections or damage 0010 00 2 Add hydraulic oil as needed WP 0011 00 arid WP 0012 00 If problem still exists go to t
32. Maintenance Notify Organizational Maintenance If indicator is illuminated service precleaner WP 0012 00 and retest If problem still exists notify Organizational Maintenance Notify Organizational Maintenance 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 10 Engine Overheats Water Temperature Gage Indicates in Red Area WARNING DO NOT service cooling system unless engine has been allowed to cool down This is a pressurized cooling system and escaping steam or hot coolant may cause serious burns e DO NOT remove cooling system radiator cap when engine 15 hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause serious burns e Wear effective eye glove and skin protection when handling coolants Failure to do so may cause injury 1 Check coolant level WP 0012 Add coolant as necessary WP 00 0011 00 add WP 0012 00 If problem still exists go to test step 2 2 Inspect radiator for debris Remove debris blocking the air flow through the core 11 Engine Fails to Crank When Power Switch 1 Check position of main Place main disconnect switch in Is Turned to Start disconnect switch ON position If problem still exists go to test step 2 2 Check position oftransmission Place transmission ra
33. Not Lower Load 0010 00 7 2 Lift or Tilt Cylinders Do Not Hold Position with Hydraulic Control Levers in Neutral Position 0010 00 7 3 Oil Temperature Is Too High Hydraulic Oil High Temperature Indicator Light Comes On 0010 00 7 4 Noisy Hydraulic REOS te ER Pg eg 0010 00 7 0009 00 1 10 3930 641 10 TROUBLESHOOTING SYMPTOM INDEX CONTINUED 0009 00 Malfunction Symptom Troubleshooting Procedure Page STEERING 1 Machine Doesn t Turn When Steering Wheel Is Turned 0010 00 7 2 Steering Wheel Is Hard Tun 0010 00 7 3 Steering Wheel Can Still Be Turned When Vehicle Is at Full 0010 00 8 TRANSMISSION 1 Transmission Will Not Shift from One Speed or Direction to Another or Shifts Rough 0010 00 8 2 Transmission Shits zur 4 od debe 0010 00 8 3 Transmission Doesn t Work When Speed Selection Lever Is Placed in Any Speed 0010 00 8 TRANSFER CASES System Loses Ol 422534405 Geer Ersan sees arrestada eater 0010 00 8 Za NOISY gt Larva Bere ey ia waters ede ron Gaus bs 0010 00 8 END OF WORK PACKAGE 0009 00 2 TROUBLESHOOTING PROCEDURES MALFUNCTION TEST OR INSPECTIO
34. Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s Manual for Truck Container Handler Rough TM 10 3930 641 10 15 May 2006 Terrain 50 000 Lb Capacity Diesel Engine Driven DED Pneumatic Tires PT Model DV43 TABLE RECOMMENDED CHANGES AND REASON ITEM PAGE PARA FIGURE NO TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to addressee listed in publication FROM Activity and location Include ZIP Code DATE PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE TOTAL NO PAGE COLM LINE REFERENCE FIGURE ITEM OF MAJOR NO NO NO NO NO NO ITEMS RECOMMENDED ACTION SUPPORTED NATIONAL STOCK NUMBER PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank
35. UNLOCKED light will go INDICATOR PANEL out 0005 00 10 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 LOADING AND UNLOADING CONTAINER CONTINUED 1 Loading Continued WARNING DO NOT lift container unless green LOAD LOCKS LOCKED light is on Failure to follow this warning may result in injury or death to personnel or damage to equipment NOTE Left brake pedal disengages transmission to provide higher engine speed during lifting g Press left brake pedal while accelerating and pull lift control lever to lift container to minimum traveling height of 12 in 30 cm from ground h Use side shift control lever to center load for carrying i Use tilt control lever to tilt load full back for carrying SIDE SIDE so conr S N COCKS i b LIFT TUT o TILT LEFT BRAKE PEDAL 0005 00 11 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 LOADING AND UNLOADING CONTAINER CONTINUED 2 Unloading a Use side shift control lever control lever and side tilt control lever to position container at drop off point READY TO LOCK b If stacking container on another container on ground use lift control lever to position loaded container over container on ground c When container to be unloaded is in full contact with the ground or with other container when LOAD stacking push container locks control lever to
36. and turn main connect disconnect switch clockwise right to Switch ON position 0012 00 3 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 11 Before 0 1 Hours Transmis a Access transmission under floor sion Oil panel behind cab Level Cold Check b Wipe area around dipstick and fill cap with a clean rag Item 12 WP 0016 00 c Remove dipstick and read oil level on dipstick Level must be between LOW and FULL marks on dipstick d If level 15 low add oil Item 7 8 or 11 WP 0016 00 through filler tube opening until level on dipstick reads between LOW and FULL marks DIPSTICK TRANSMISSION 011 FILLER TUBE 422 0062 12 Before Radiator Visually check that radiator cap is Radiator cap is missing present 0012 00 4 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 13 Before 0 1 Hours Hydraulic Check level of hydraulic oil in sight Tank gage With oil cold and engine not running oil level must be at FULL COLD mark in sight gage If level is low unlock and raise floor plate remove filler cap and add oil Item 7 8 or 11 WP 0015 00 until level is at FULL COLD mark o
37. clean rag Item 12 We Check 0016 00 b Remove dipstick and read oil level on dipstick Level must be between LOW FULL mars ENGINE STOPPED side of dip stick c If level is low add oil Item 7 9 or 10 through filler tube opening until level on dipstick reads between LOW and FULL marks DIPSTICK ey ENGINE OIL FILLER TUBE 422 0058 7 Before Rear Lights Check rear floodlights taillights and Missing or damaged compo stoplights for missing or damaged nents are evident if required components for mission 0012 00 2 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF RIGHT SIDE AND FRONT 8 Overall View Visually check for leakage on or under Class oil coolant or machine oil fuel coolant and hydraulic oil leaks are evi hydraulic oil dent Any fuel leak 15 evident 9 Right Engine a Release retainer and open right side Compart engine compartment access doors ment b Check right engine compartment for b Missing or damaged com damaged or missing drive belts and ponents are evident damaged or leaking coolant hoses c Check for evidence of fluid leakage c Class oil or coolant such as coolant and fuel leaks are evident Any fuel leak 1s evident 10 Before Main Dis Insert key 1f removed
38. coun terclockwise left to OFF position Remove key from switch NATO SLAVE RECEPTACLE MAIN DISCONNECT SWITCH 422 0044 53 After 0 1 Hours Hydraulic a Check level of hydraulic oil at sight Tank gage Level must be at FULL COLD mark in sight gage or com pletely fill sight gage SIGHT GAGE 422 0061 0012 00 19 10 3930 641 10 PREVENTIVE MAINTENANCE 5 AND SERVICES PMCS CONTINUED 0012 00 LOCATION ITEM ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 53 After 0 1 Hours Hydraulic b If level is low access hydraulic tank Cont Tank by unlocking and raising floor plate and removing filler cap from tank Ensure filler cap gasket is present and in good condition FLOOR PLATE FILLER CAP HYDRAULIC TANK 422 0045 c Ensure strainer is present in good condition and free of debris Remove debris from strainer as required d Add oil Item 7 8 or 11 WP 0016 until level is at FULL COLD mark on sight gage or completely fills sight gage e Reinstall filler cap securely Lower floor plate and lock 54 After Below Oper Check hoses cables and connec a Class III leaks or damage ator Com tions below right side of operator that would impair operation partment compartment for damage or leaks are evident b Check cables for fraying or damage b Damage that would impair operation is evident c Check
39. dam for damage or leaks age are evident b Remove fuel tank filler cap Inspect b Fuel cap gasket is missing cap gasket for damage or damaged c If debris is present in filler screen c Filler screen is missing or clean debris from screen damaged d As required fill tank with diesel fuel Item 5 WP 0016 00 e Reinstall filler cap securely FUEL TANK FILLER CAP 422 0060 0012 00 14 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NO INTERVAL HOURS SERVICE 46 After Left Rear Wheel and Tire 47 After Engine Air Precleaner NOT FULLY MISSION PROCEDURE CAPABLE IF WARNING Improperly inflated tires can cause excessive heat buildup resulting in blowouts Failure to follow this warning may cause injury to personnel or damage to equipment a Visually check left rear tire for cuts Tire has cuts abrasions or abrasions or bulges in tread or side bulges in tread or sidewall wall area Check for uneven wear area Other damage that underinflation Look for foreign would impair operation is material embedded in tread or side evident wall area Remove foreign material if found b Check for loose or missing lug nuts b Two or more lug nuts are or valve stem caps missing or valve stem is damaged WARNING If NBC exposure is suspected personnel wearing protective equipment should handle all a
40. each side of machine Tilts mast forward and backward Tilts forward and backward raises and lowers to position container Mount and secure tophandlers Steer and propel machine One on each side of machine Turns machine Articulated for easy steering maneuverability On right side of machine Contains hydraulic oil for front end components On left side of machine Contains diesel fuel for engine operation One on each side ofengine Remove for access to engine compartment Houses and protects two batteries There is a battery box on both sides of machine Provide stability when handling load For towing operations Attaches to tow bar 0002 00 2 10 3930 641 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED 17 18 75 422 0001 COMPONENT DESCRIPTION 17 Lift Cylinder Raises and lowers mast 18 Side Shift Cylinder Shifts forks and tophandler to the side for loading or stacking Rotates forks and tophandler for loading or stacking 19 Side Tilt Cylinder 0002 00 3 10 3930 641 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED A 2 am VA No 20 FT TOPHANDLER 20 39 FT OR 40 FT TOPHANDLER 20 422 0021 KEY COMPONENT DESCRIPTION Container Lock Cylinder Extends to lock tophandler to contai
41. equip ment or injury to personnel may result e Iftire pressure is 0 psi 0 kPa DO NOT inflate Notify Organi zational Maintenance Failure to follow this warning may cause injury or death to personnel b Park machine so that valve stem 15 at 9 o clock or 3 o clock c Clean area around valve stem then remove valve stem cap d Check air pressure in each tire with tire pressure gage Tire inflation should be 70 psi 483 kPa for front tires and 40 psi 276 kPa for rear tires 0012 00 25 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 64 Cont Wheels and WARNING Tires Use a self inflating chuck and stand at tread side of tire at maximum distance allowed by inflation hose Failure to do so could result in injury or death to personnel e Adjust air pressure in tire as required to 70 psi 483 kPa for front tires and 40 psi 276 kPa for rear tires Use pneumatic tire infla tion hose assembly f Install valve stem cap 65 Monthly Brake Accu With main disconnect switch in ON Low brake pressure indica mulator and position turn power switch to ON tor does not come on Emergency and push up and hold panel test Brake Test switch Low brake pressure indica tor should come on If light does not come on notify Organizational
42. fuse box for missing fuses c Missing or damaged com damage or corrosion ponents are evident if required for mission 0012 00 20 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 55 After Rollover Check ROPS for damage and loose or One loose or missing mount Protective missing mounting bolts ing bolt or damage to ROPS Structure are evident ROPS 56 After Right Mirror Check right side mirror and front and Components are missing or and Ladders rear ladders for damage or missing damaged if required for mis components sion 57 After Hydraulic Check all hydraulic cylinders and Class III leaks or damage that Cylinders hoses for damage or leaks would impair operation are evident 58 After Steering Check steering linkage for cracks a Cracks or distortion in distortion or damage steering linkage that would impair operation are dent b Check right front steering cylinder b Class leaks or damage and hoses for damage or leaks that would impair operation are evident 59 After Right Front Visually check right front tire for Tire has cuts abrasions or Wheel and cuts abrasions or bulges in tread or bulges in tread or sidewall Tire sidewall area Check for uneven area Other damage that wear or underinflation Look for w
43. ing may result in injury or death to personnel or damage to equipment e Be ALERT for personnel in the area while operating machine Always check to ensure area is clear of personnel and obstructions before moving machine or raising or lowering container handler forks Fail ure to follow this warning may cause injury or death to personnel or damage to equipment NOTE e During lifting operation do not exceed maximum lifting capacity of 50 000 Ib 22 700 kg Refer to WP 0004 00 for the location and operation of controls and indicators 1 Loading a Center and level tophandler when approaching container b Position front of machine to broadside of container NOTE Tophandler aligning arm mounting bolts will break under pressure to prevent damage to container or tophan dler If bolts break notify Organizational Maintenance c Approach container cautiously d Position container locks over container corners using tophandler corner guides READY e Push lift control lever to lower container locks into container fittings Ensure that BOTH yellow READY TO LOCK lights come on One light means only one container locks is in position Red LOAD LOCKS UNLOCKED light will also f Pull container locks control lever to lock tophan UNIONES dler to container Ensure that green LOAD LOCKS LOCKED light comes on Two yellow READY TO LOCK lights will also stay on but CONTAINER LOCK 422 0042 red LOAD LOCKS
44. lubricate more frequently i Check hydraulic cylinders frequently DO NOT allow dust dirt or sand to collect in these areas especially on cyl inder rods OPERATION IN SALTWATER AREAS l Keep machine as clean as possible Wash down with fresh water after use Inspect wiring connections closely for corrosion Keep lubrication points clean and well lubricated 2 3 4 Carefully check for rust all areas that could seriously affect operation of 5 Check all hydraulic cylinders for rusting and pitting If you see rusting or pitting notify Organizational Maintenance 6 Have Organizational Maintenance check for water in any of the oils OPERATION AT HIGH ALTITUDES NOTE Engine operates at less than peak performance at high altitudes 1 Coolant level and engine indicators must watched closely 2 Add coolant if necessary OPERATE IN SNOW AND ICE 1 General a Fuel tank should be kept full Keep snow and away from fuel filler b Clean snow away from outside indicators 0006 00 5 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN SNOW AND ICE CONTINUED 2 Driving Drive at slower speeds b Give signals sooner c Apply brakes sooner to give early warning of intention to stop This will also help to avoid skidding d Maintain double the normal distance from machine ahead e Keep windshields mirrors and lights clean and free of snow and ice f I
45. manual Become familiar with these warnings before operating or performing operator troubleshooting or maintenance on the machine Al Table of Contents located in the front of the manual lists all chapters and work packages in the publication The Table of Contents also provides Reporting Errors Recommending Improvements information and DA Form 2028 addresses for the submittal of corrections to this manual If you cannot find what you are looking for in the Table of Contents refer to the alphabetical Index at the back of the manual General Information Equipment Description and Data and Theory of Operation provides general information on the manual and the equipment 4 Operation Instructions explains and illustrates all operator controls and indicators and contains a Decal and Data Plate Guide It also describes how to perform all operating procedures for the RTCH Operation Under Usual Conditions and Operation Under Unusual Conditions overs all Operator Troubleshooting WP 0009 00 contains a Troubleshooting Symptom Index If the RTCH malfunctions this index should always be consulted to locate the appropriate troubleshooting procedure Chapter 4 covers Operator Maintenance Instructions Major areas covered are Preventive Maintenance Checks Services PMCS Introduction and Preventive Maintenance Checks and Services PMCS Chapter 5 lincludes Supporting Information References Componen
46. or missing filler tery filler caps caps are noted d Check for missing broken split or d Damage is noted frayed battery cables e Check for damaged battery posts e Damage is noted f Check for rust corrosion and f Rust or corrosion is noted cleanness 0012 00 24 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 62 Cont 63 64 Right Side g Check battery cable grommets for Battery dry rot and loose or missing condi Compart tion ment h Check electrolyte level Electrolyte h Electrolyte level is low must be to bottom of filler openings 1 Notify Organizational Maintenance of any problems noted a Check ROPS for loose damaged or a Loose damaged or missing missing mounting hardware Notify mounting hardware is Organizational Maintenance noted retorque replace mounting hard ware b Check ROPS for any signs of crack b Any signs of damage or ing in base metal or welded areas cracked welds are noted Wheels and a Check for loose or missing lug nuts a Two or more lug nuts are Tires or valve stem caps Notify Organi missing or valve stem is zational Maintenance if lug nuts are damaged loose WARNING Operating machine with underinflated or defective tire may lead to tire failure and loss of traction or control Damage to
47. the needed is not the same for different models of equipment Usable on Code 15 not applicable to the RTCH Column 4 Unit of Measure U M Indicates how the item is issued for the National Stock Number NSN shown in Column 1 Column 5 Oty Indicates the quantity recommended 0015 00 1 10 3930 641 10 ADDITIONAL AUTHORIZATION LIST AAL CONTINUED 0015 00 Table 1 Additional Authorization List 1 2 3 National Description Cagec Usable Stock Number and Part Number on Code 3990 01 107 5717 TOPHANDLER 35 FT 65508 E9138 3990 01 107 5718 TOPHANDLER 40 FT 65508 E9139 END OF WORK PACKAGE 0015 00 2 10 3930 641 10 EXPENDABLE AND DURABLE ITEMS LIST 0016 00 SCOPE This work package lists expendable and durable items you will need to operate and maintain the RTCH This listing 15 for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items EXPLANATION OF COLUMNS 1 Column 1 Item Number This number is referenced in the appropriate work package Initial Setup list and in the nar rative instructions to identify the item e g Use antifreeze Item WP 0016 00 Ze Column 2 Level This column identifies the lowest level of maintenance that req
48. to idle Shift trans mission to neutral and shut down engine d Shut down engine and park machine on level ground 0005 00 Ensure parking brake 1s applied transmission is in N Neutral con tainer handler forks are lowered to the ground and wheels are blocked 0012 00 11 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED LOCATION ITEM TO ITEM INTERVAL HOURS SERVICE PROCEDURE LEFT SIDE 0012 00 NOT FULLY MISSION CAPABLE IF AND REAR 37 After Overall View NOTE Ensure machine is clean in order to facilitate performance of PMCS inspections a Check under machine for evidence a Class III oil coolant or of fluid leakages such as oil cool hydraulic oil leaks are evi ant fuel or hydraulic oil dent Any fuel leak is evi dent b Check machine for obvious dam b Damage that would impair age to fenders mirrors handrails operation is evident ladders engine covers and guards c Check for loose wiring or damaged c Parts are damaged or miss lines or hoses ing d Check for loose or damaged parts 4 Parts are damaged or miss ing 38 After Front of a Check for missing parts or damage a Parts are missing or dam Machine to tophandler hydraulic cylinder aged container locks container lock cyl inders forks carriage lift chains and mast cylinders b Check condition of windshield cab windows windshield wipe
49. windshield wipers ONE CLICK LOW SPEED TWO CLICKS HIGH SPEED Push knob in to turn on front windshield washer pump 48 Fuses Protect machine electrical circuitry 49 Floodlight Switch Push up to turn on front and rear floodlights 0004 00 11 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED LEFT HAND INSTRUMENT PANEL CONTINUED 94 t MP ND 2 Q Lo PRESS AA STER BRAKE ON fa CLO 5 HEAD FLOOD O 90 2 TA LEFT HAND INSTRUMENT PANEL 0004 00 422 0041 CONTROL OR INDICATOR FUNCTION 50 Headlight Switch Push up to turn on headlights 51 Tail and Panel Light Switch Push up to turn on instrument panel lights gage lights and taillights 32 Panel Light Provides light for switches and fuses in left hand instrument panel 53 Supplemental Steering Indicator Red indicator lamp should be ON when testing panel lamps engine 15 running ON when engine 15 not running steering mode 54 Low Brake Pressure Indicator Red indicator lamp Should be ON when testing panel lamps normal 0004 00 12 ON when vehicle 15 operating with supplemental steering only and OFF when engine 15 running and machine 15 operating in normal Will flash ON and OFF when accumulator oil pressure is low Should be OFF when engine is running and brake pressure 1s 10 3930 641 10 DESCRIPTION AND USE OF OPE
50. working in area of hitch Ensure area around machine is clear of personnel or obstructions before articulating machine Failure to follow this warning may cause injury or death to personnel or damage to equipment Use caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used 15 in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may cause injury or death to personnel 10 3930 641 10 LIST EFFECTIVE PAGES WORK PACKAGES Date of issue for original manual 15 Original 15 May 2006 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 34 AND TOTAL NUMBER OF WORK PACKAGES IS 16 CONSISTING OF THE FOLLOWING Page WP Cover Back Blank a to i j Blank A B Blank to iv WP 0001 00 to WP 0016 00 Index 1 to Index 4 Authentication Page DA Form 2028 Sample DA Form 2028 three Back Cover PIN Number O O O Zero in this column indicates an original page or work package 10 3930 641 10 TECHNICAL MANUAL HEADQUARTERS TM 10 3930 641 10 DEPARTMENT OF THE ARMY Washington D C 15 May 2006 OPERATOR S MANUAL FOR TRUCK CONTAINER HANDLER ROUGH TERRAIN 50 000 LB CAPACITY DIESEL ENGINE DRIVEN DED PNEUMATIC TIRES PT MODEL DV43 NSN 3930 01 082 3758 WITH TOPHANDLER S REPORTING ERRORS AND R
51. 0 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE MACHINE CONTINUED 2 Driving WARNING DO NOT move machine if LOW PRESS BRAKE light is flashing on and off Shut down engine and report problem a Press and hold right brake pedal NOTE If transmission 15 placed in gear with parking brake on park brake on indicator light will come on and warning buzzer will sound b Push parking brake control knob in to release parking brake c Move transmission range selector to desired direction of travel 4 Rotate transmission range selector to desired speed 1 Low ranges for extra power 2 High ranges for faster speed e Release right brake pedal NOTE e During operation watch gauges and indicators often All gauges must indicate in normal range and all indicators must operate properly e Operate under a light load for the first five minutes f Press accelerator pedal to move machine faster Release accelerator pedal and machine will resume governed speed g Upshift one position at a time as engine and ground speeds increase h Downshift one position at a time while at the same time reducing machine speed with service brake applications 3 Steering RTCH WARNING Drive carefully alertly and at an appropriate speed for road conditions Remember that machine has articu lated frame steering and will require special handling a Operator controls machine direction using steering wheel b
52. 0 seconds at a time After 30 seconds allow starter motor to cool for at least 2 minutes before attempting to start engine again Excessive heating of starter motor may result in damage or premature starter failure Turn power switch to START position CAUTION Use ether starting aid sparingly and for cold starting purposes ONLY Excessive ether without cranking can cause piston and ring damage NOTE Inject ether only while cranking engine or after initial start up until engine 15 running smoothly Push ether starting aid switch down for 2 3 seconds then release for 2 3 seconds Operate switch at 2 3 second intervals as engine is cranked Continue to use switch at 2 3 second intervals until engine starts and is running smoothly Release power switch when engine starts If engine does not start after 30 seconds let starter cool for two minutes then try to start again If engine oil pressure indicator does not stop flashing within 10 seconds after engine starts stop engine by turning off power switch Perform troubleshooting After engine has started verify that the following indicator lights are OFF 1 NO COOLANT FLOW indicator If indicator does not turn OFF perform troubleshooting 2 SUPP STER indicator If indicator does not turn OFF perform troubleshooting 3 LOW PRESS indicator If indicator does not stop flashing perform troubleshooting 4 ALTERNATOR INDICATOR If indicator does not turn OFF perform tro
53. 0002 00 Equipment Description and 0002 00 1 WP 0003 00 Theory of Operation 0003 00 1 WP 0003 00 of Op 10 3930 641 10 Table of Contents Continued Page Number CHAPTER 2 OPERATION INSTRUCTIONS WP 0004 001 Description and Use of Operator Controls and Indicators 0004 00 1 WP 0005 00 Operation Under Usual 0005 00 1 WP 0006 00 Operation Under Unusual 5 0006 00 1 WP 0007 00 Decal and Data Plate 0007 00 1 CHAPTER 3 JOPERATOR TROUBLESHOOTING WP 0008 00 Troubleshooting Introduction 0008 00 1 WP 0009 00 Troubleshooting Symptom Index 0009 00 1 WP 0010 00 Troubleshooting Procedures 0010 00 1 CHAPTER 4 OPERATOR MAINTENANCE INSTRUCTIONS WP 0011 00 Preventive Maintenance Checks and Services PMCS Introduction 0011 00 1 WP 0012 00 Preventive Maintenance Checks and Services PMCS 0012 00 1 CHAPTER 5 SUPPORTING INFORMATION IRGICTENCES 2 4 od sm qoe sere a aub aub due d ded isis Components of End Item and Basic Issue Items Lists Additional Authorization List Expendable and
54. 002 etc are art control numbers and are used for tracking purposes only 6 Dashed leader lines used in the lubrication illustrations WP 0011 00 and in the PMCS table WP 0012 00 indicate that called out lubrication points are located on both sides of the machine 7 Technical instructions include metric units as well as standard units For your reference Metric Conversion Chart 15 located on the inside back cover of the manual 10 3930 641 10 1 GENERAL INFORMATION EQUIPMENT DESCRIPTION AND DATA AND THEORY OF OPERATION 10 3930 641 10 GENERAL INFORMATION 0001 00 SCOPE 1 Type of Manual This manual 15 for your use in operating and performing operator maintenance the Rough Terrain Container Handler RTCH 2 Equipment Name and Model Number a Truck Container Handler Rough Terrain 50 000 Lb Capacity Diesel Engine Driven DED Pneumatic Tires PT NSN 3930 01 082 3758 Model DV43 with Tophandler s b 20 ft tophandler NSN 3990 01 107 5716 is available as part of the end item c The following tophandlers are also available for use as Additional Authorization List AAL items WP 0015 00 1 35 ft tophandler NSN 3990 01 107 5717 2 40 ft tophandler NSN 3990 01 107 5718 3 Purpose of Equipment The RTCH is used for loading unloading handling and stacking ISO containers weighing 50 000 lb 22 700 kg or less MAINTENANCE FORMS RECORDS AND REPORTS Department of the
55. 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 WARNING gt PRESSURIZED COOLING SYSTEM DO NOT service cooling system unless engine has been allowed to cool down This 15 pressurized cooling system and escaping steam or hot coolant will cause serious burns DO NOT remove cooling system radiator cap when engine is hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause serious burns Wear effective eye glove and skin protection when handling coolants Failure to follow this warning may cause injury to personnel 10 3930 641 10 WARNING SLAVE STARTING e When slave starting use NATO slave cable that does NOT have loose or missing insulation e DO NOT proceed if suitable cable is not available e DONOT use civilian type jumper cables e DO NOT allow disabled and booster machines to come in contact with each other at any time during slave starting Failure to follow these warnings may cause injury or death to personnel WARNING Solvent cleaning compound 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ventilated areas Keep away from open flames and other sources of ignition Failure to follow this warning may cause injury or death to per
56. 14 5 1 1 8 4 3 6 5 7 2 Diesel 2 3 200 lb 1 451 kg Caterpillar Inc Power shift planetary 5 6049 4 9043 3 1429 2 7500 1 7751 1 5532 1 0000 0 8750 1 756 lb 796 kg 1 0256 1 1795 1 080 Ib 490 kg 5 0526 3 7500 Fixed 13 degrees All wheel disc Full hydraulic o1l bath disc 2 300 sq in x 4 14 839 Gear 28 gpm at 1 000 psi 1 8 L sec at 7 000 kPa 2 200 psi 15 168 kPa 70 lb 32 kg non adjustable 10 3930 641 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED Tires A EEEE EE E EE E E EE Radial E AE re EAE 35 65 R33 Front Inflation a A A 70 psi 482 kPa Rear Int 2310 eat In ee RE EEE EEE 40 ps 276 kPa Weiche Tireand ID ouo 52 Rear 3 000 Ib 1 361 kg Steering ae ee essen Ee EE Full hydraulic center point frame articulation steering Angle Each Direction 2 25 0644 25 203 A ee 27 degrees Pump Type eens den a re en Gear OD tra 101 gpm at 1 000 psi 6 4 L sec at 7 000 kPa Rene Vale Selline 2 ami uota ducet uen a 2 500 psi 17 236 kPa Operating Pressure ii dcs 2 500 psi 17 236 kPa Ne Nei io IN 70 lb 32 kg Capacities Eel TiN o
57. 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF Monthly 0 3 Hours Carriage Rollers WARNING DO NOT proceed unless carriage 1s securely supported Fail ure to suitably support carriage could cause injury or death to personnel if carriage should fall b Raise carriage 4 ft 122 cm and block securely to prevent lowering Apply GAA grease Item 6 wel to two lower fittings through holes carriage In A Tr 27 O LOWER UPPER Lap mm p 422 0005 0012 00 28 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF Monthly 0 2 Hours Mast Mount With carriage still raised 4 ft 122 cm ing Hinges and supported apply GAA grease Item 6 WP 0016 00 to two fittings through holes in carriage GAA 2 PLACES 422 0004 71 Monthly 0 2 Hours Mast Chains Lubricate full length of chains with lubricating oil Item 8 WP 0016 00 72 Monthly 0 1 Hours Carriage Apply grease Item 64 WP 0016 Pivot Pin to pivot pin fitting 73 Monthly 0 2 Hours Side Tilt Cyl Apply GAA grease Item 6 WP 0016 inder to two fittings 74 Monthly 0 2 Hours Side Shift Apply grease Item 64 WP 0016 Cylinder to two fittin
58. 81349 M 10924 A 1 1 4 Ounce Tube 81349 M 10924 B 14 Ounce Cartridge 81349 M 10924 C 1 3 4 Pound Can 81349 M 10924 E 35 Pound Can 0016 00 2 0016 00 5 U M CN CN DR CN CN DR BT CN GL CN DR TU CA CN CN EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 1 ITEM NUMBER END OF WORK PACKAGE TM 10 3930 641 10 3 NATIONAL STOCK NUMBER 9150 00 402 4478 9150 00 402 2372 9150 00 491 7197 9150 00 189 6727 9150 00 186 6668 9150 00 191 2772 9150 00 247 0481 9150 01 152 4117 9150 01 152 4118 9150 01 152 4119 9150 00 186 6681 9150 00 188 9858 7920 00 205 1711 0016 00 4 DESCRIPTION CAGEC AND PART NUMBER OIL Lubricating Arctic OEA 81349 MIL L 46167 1 Quart Can 81349 MIL PRF 46167 5 Gallon Can 81349 MIL PRF 46167 55 Gallon Drum OIL Lubricating OE HDO 10 81349 2104 1 Quart 5 Gallon Can 55 Gallon Drum OIL Lubricating OE HDO 10W 30 81349 MIL L 2104 OIL Lubricating OE HDO 15W 40 81349 MIL PRF 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum OIE Lubricating OE HDO 30 81349 MIL PRF 2104 1 Quart 5 Gallon Can RAG Wiping 64067 7920 00 205 1711 50 Pound Bale 0016 00 3 10 3930 641 10 INDEX Subject Work Package Page A Abbreviations Acronyms List 0001 00 3 Additional Authorization List AAL
59. Brakes Do Not Operate Concculy lt ep teens 0010 00 1 2 Parking Emergency Brake Will Not Engage or Disengage 0010 00 1 3 Transmission Does Not Disengage When Left Brake Pedal Inching Pedal Is Pushed 0010 00 1 ELECTRICAL INDICATORS 1 Low Brake Pressure Indicator Light Comes 0010 00 1 2 Back up Warning Buzzer Does Not Sound When in Reverse 0010 00 1 2 Alternator Indicator Light Comes Rub ws e t 0010 00 1 4 Low Engine Oil Level Indicator Light Comes 0010 00 1 implement Plugged Filter Light Comes On zu 080 uet pedore er t OR Ee rx ac ee 0010 00 2 6 Transmission Plugged Oil Filter Light Comes On During 0010 00 2 ELECTRICAL SYSTEM 1 Floodlights Auxiliary Floodlights 0010 00 2 2 Horn Will Not Sound When Button Is 0010 00 2 3 Headlight s Do Not Operate 2 0010 00 3 4 Stoplights Do Not Operate When Brake Pedal Is Pressed 0010 00 3 5 Taillights Do Not Come On
60. CEDURE CAPABLE IF 36 After Brake Sys WARNING Be ALERT for personnel in the area while operating machine Always check to ensure area 15 clear of personnel Failure to follow this warning may cause injury or death to personnel a With engine running apply service a Machine moves with ser brakes release parking brake and vice brakes applied at full shift transmission to 2nd gear for throttle in gear ward Slowly increase engine speed to full throttle for not more than five seconds Machine must not move Reduce engine speed shift trans mission NEUTRAL and apply parking brake NOTE Indicator light will come on and horn will sound if brake is on and transmission is engaged e It will be necessary to hold transmission range selector in REVERSE or spring load will cause lever to move to NEU TRAL b With engine running apply parking b Parking brake on indicator brake and shift transmission to 2nd light or buzzer don t acti gear reverse Parking brake on indi vate or backup alarm does cator light and buzzer should acti not sound vate and backup alarm should sound CAUTION Extended load on drivetrain such as load produced when the following test 15 NOT completed quickly could result in damage to machine Only hold throttle wide open momentarily Gradually increase engine speed to Machine moves more than full throttle and then immediately 5 ft 1 5 m during test decrease engine
61. CKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 85 Monthly All Systems NOTE SURE mn If temperature 15 below 32 F 0 C operate controls before Exercise moving machine d When machine has warmed up begin to operate ALL controls slowly 1 Transmission in all ranges including reverse 2 Parking and service brakes applied and released 3 Steering from full left to full right 4 Allhydraulic controls Operate controls for another five minutes f Move machine and operate all con trols through full motion to bring all systems to operating temperature Move machine and continue to operate all controls through full motion for 30 minutes AFTER machine systems have reached operating temperature h Stop machine and allow to idle for five minutes 1 Shut down engine j Perform After operation PMCS END OF WORK PACKAGE 0012 00 36 10 3930 641 10 5 SUPPORTING INFORMATION 10 3930 641 10 REFERENCES 0013 00 SCOPE This work package lists all publication indexes forms field manuals technical bulletins technical manuals and other publications referenced in this manual and which apply to operation and operator maintenance of the RTCH PUBLICATION INDEXES The following indexes should be consulted frequently for latest changes or revisions and for new publicatio
62. Durable Items List 10 3930 641 10 HOW USE THIS MANUAL NOTE If at any time you are unsure how to use this manual or you cannot locate the information you need notify your supervisor INTRODUCTION 1 This revised manual 15 designed to help you operate the RTCH and to perform operator troubleshooting and maintenance on the equipment 2 This manual 15 written in work package format Chapters divide the manual into major categories of information e g General Information Equipment Description and Theory of Operation Operator Instructions Operator Troubleshooting Operator Maintenance Instructions and Supporting Information b Each Chapter is divided into work packages which are identified by a 6 digit number e g 0001 00 0002 00 etc located on the upper right hand corner of each page The work package page number e g 0001 00 11 0001 00 2 etc 1s located centered at the bottom of each page c Ifa Change Package is issued to this manual added work packages will use the 5th ang 6 digits of their number to indicate new material For instance work packages inserted between WP 0001 00 and WP 0002 00 will be numbered WP 0001 01 WP 0001 02 etc 3 Read through this manual to become familiar with its organization and contents before attempting to operate or maintain the equipment CONTENTS OF THIS MANUAL P N Al Warning Summary 8 located at the beginning of this
63. E Tactical Ama Oil ICE Ama OE HDO 30 GEHDOdO ERE 0011 00 6 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED LUBRICANT INTERVAL INTERVAL LUBRICANT Tilt Cylinders GAA M Lubricate Fittings 4 Places M GAA Drive Shaft Spline Lubricate Fitting D OE Hydraulic Tank HDO Check Level Add See Detail A Fan Drive and Steering Cylin Belt Tensioner der Bearings Pulley Lubricate Lubricate Fitting Fittings 2 Places GAA M 4 Places Pintle Hook M GAA Rear Lubricate Fittings Trunnion 3 Places GAA M Bearings Lubricate Fittings CONTAINER HANDLER 2 Places OVERHEAD VIEW 422 0002 0011 00 7 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED LUBRICANT INTERVAL INTERVAL LUBRICANT Mast Slider Blocks GAA M GAA Mast Rollers Lubricate Fittings 4 Places Mast Chains HDO Oil Chains GAA Carriage Pivot Pin Mast Mtg Hinges Lubricate Fitting Lubricate Fittings GAA M 2 Places Side Shift Cylinder Lubricate Fittings 2 Places Carriage Rollers Lubricate Fittings 4 Places GAA qam L7 M GAA Side Tilt Cylinder Lubricate Fittings i 2 Places CONTAINER HANDLER 422 0001 FRONT VIEW 0011 00 8 10 3930 641 10
64. ECOMMENDING IMPROVEMENTS You can help improve this publication If you find any mistakes or 1f you know of a way to improve the proce dures please let us know Submit your DA Form 2028 Recommended Changes to Equipment Technical Publica tions through the Internet on the Army Electronic Product Support AEPS website The Internet address 15 https aeps ria army mil The DA Form 2028 is located under the Public Applications section in the AEPS Pub lic Home Page Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program You may also mail fax or e mail your letter or DA Form 2028 direct to AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 The e mail address is TACOM TECH PUBS ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 SUPERSEDURE NOTICE This manual supersedes TM 10 3930 641 10 dated 15 May 1981 including all changes DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited Table of Contents Page Number Wammeo Sama leonesas ee eee di How Use This 111 CHAPTER 1 GENERAL INFORMATION EQUIPMENT DESCRIPTION AND DATA AND THEORY OF OPERATION WP 0001 00 General Information 0001 00 1 WP
65. Es 7 x 19 25 in 17 8 x 49 cm Side Shift Bore EYED e 6 x 24 in 15 2 x 61 cm Side Tit Bore Stroke heilen be ess 6 x 6 5 in 15 2 x 16 5 cm END OF WORK PACKAGE 0002 00 7 10 3930 641 10 THEORY OF OPERATION 0003 00 INTRODUCTION 1 This work package describes the following functional systems fuel system air inlet and exhaust system steering sys tem brake system electrical system and mast hydraulic system Ze This work package explains how the systems and components of the machine work together A functional description 1s provided for each major system and component 3 The RTCH is an all purpose medium sized wheeled machine used for handling ISO containers It is powered by a Cat erpillar V 8 direct injected intercooled diesel engine Hydraulically operated implements allow for up down side shift and tilt positioning of the tophandler for ease of use during container handling operations Articulated frame steering provides maximum maneuverability FUEL SYSTEM 1 General Diesel fuel 15 drawn from the tank by a fuel pump filtered by primary fuel filter routed to the fuel injection pump and secondary filter and then injected through the fuel injection nozzles into the engine cylinders Air 15 drawn in through dry type replaceable filter elements A dust ejector removes incoming dust from the air and routes 1t out through the exhaust system Primin
66. Failure to do so may cause injury to personnel a Remove filler cap slowly b Check coolant level Coolant should be within 1 2 in 1 3 cm of bottom of fill opening c If level 15 low add a 50 50 mixture of antifreeze Item 1 WP 0016 00 and water to bring level up to cor rect level TB 750 651 0012 00 16 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 48 After Radiator d Inspect filler gasket Ensure it is 4 Filler cap gasket 15 missing Cont present and in good condition or damaged e Reinstall filler cap securely RADIATOR FILLER CAP 422 0059 f Check radiator grille for damage or debris Remove debris If debris cannot be removed or 1f grille 15 damaged notify Organizational Maintenance g Visually check radiator for signs of g Class III leaks or damage leakage or damage that would impair operation are evident 49 After Rear of Check backup alarm and pintle hook Damage that would impair Machine for damage operation 15 evident 0012 00 17 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF RIGHT SIDE AND FRONT 50 After Overall View a Check under machine for evi
67. GURE ITEM OF MAJOR NO NO NO NO NO NO ITEMS RECOMMENDED ACTION SUPPORTED NATIONAL STOCK NUMBER PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets be used if more space needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 DATE Use Part reverse for Repair Parts and Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s Manual for Truck Container Handler Rough TM 10 3930 641 10 15 May 2006 Terrain 50 000 Lb Capacity Diesel Engine Driven DED Pneumatic Tires PT Model DV43 TABLE RECOMMENDED CHANGES AND REASON ITEM PAGE PARA FIGURE NO TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to address
68. MAN IN THIS AREA WHEN TURNING VEHICLE WHEN MACHINE 15 TO BE LIFTED TRANSPORTED ON ANOTHER VEHICLE OR SERVICE WORK I BEING PERFORMED NEAR CENTER OF MACHINE insit E A FRAMES MAL RP Reip Bec WARNING A A BEFORE OPERATION AND WHEN OPERATING REOR SAU LATE A OS TO S RATES 422 0024 END OF WORK PACKAGE 0007 00 3 10 3930 641 10 3 OPERATOR TROUBLESHOOTING 10 3930 641 10 TROUBLESHOOTING INTRODUCTION 0008 00 INTRODUCTION 1 Troubleshooting procedures are grouped by system containing information you need to locate malfunctions trouble shooting symptom index 11 WP 0009 0015 provided to aid in locating a malfunction or symptom and direct you to the appropriate troubleshooting table im WP 0010 00 The troubleshooting table contains a listing of malfunctions test or inspection procedures and corrective actions The corrective action column further directs you to the required corrective maintenance procedure within this manual by work package number However if the required maintenance procedure is beyond Operator level capabilities the direc tion 15 to notify Organizational Maintenance PRELIMINARY TROUBLESHOOTING PROCEDURES NOTE Fluid leaks are classified as either Class I Class II or Class III Class I Seepage of fluid as indicated by wetness or discoloration not great enough to form drops Class Leaka
69. MS LISTS CONTINUED 0014 00 3 6 422 0065 Table 2 Basic Issue Items List 3 4 5 6 NATIONAL STOCK DESCRIPTION CAGEC USABLE NUMBER AND PART NUMBER ON CODE ROD 7520 00 559 9618 Case Maintenance and Operational Manuals 83421 7520 00 559 9618 Hand Manual TM 10 3930 641 10HR 2540 01 444 7987 Link Shipping Towbar 11083 147943 Operator Manual for Rough Terrain Container Handler TM 10 3930 641 10 5315 00 011 9198 Pin Cotter 11083 3B4647 5315 01 98 3295 Pin Straight Headed 11083 9K5639 END OF WORK PACKAGE 0014 00 3 10 3930 641 10 ADDITIONAL AUTHORIZATION LIST AAL 0015 00 SCOPE This work package lists additional items that you are authorized for the support of the RTCH GENERAL This list identifies items that do not have to accompany the machine and that do not have to be turned with it These items are authorized to you by CTA MTOE TDA or JTA EXPLANATION OF COLUMNS 1 Column 1 National Stock Number Indicates the National Stock Number NSN assigned to the item and will be used for requisitioning purposes Column 2 Description CAGEC and Part Number Indicates the Federal item name followed by a minimum description when needed The entry for each 1tem ends with the Commercial and Government Entity Code CAGEC in parentheses followed by the part number Column 3 Usable on Code Indicates a code if
70. N CORRECTIVE ACTION 1 Service Brakes Do Not Operate Correctly Parking Emergency Brake Will Not Engage or Disengage Transmission Does Not Disengage When Left Brake Pedal Inching Pedal Is Pushed TM 10 3930 641 10 BRAKES 1 Inspect hydraulic oil level WP 0012 00 2 Check for mud or dirt under brake pedal 3 Inspect brake linkage for binding damage or defective parts 4 Inspect for leaking brake lines or fittings Shut down engine Shut down engine ELECTRICAL INDICATORS Low Brake Pressure Indicator Light Comes On Back up Warning Buzzer Does Not Sound When in Reverse Alternator Indicator Light Comes On Low Engine Oil Level Indicator Light Comes On 1 Inspect hydraulic oil level WP 0012 00 2 Inspect for leaking brake lines or fittings Inspect direction control linkage at access opening behind operator s cab for defective parts l Inspect for missing or loose drive belt 2 Check for loose battery connections l Check engine oil level WP 0012 00 0010 00 1 0010 00 Add hydraulic oil if needed WP 0011 00 arid WP 0012 00 If problem still exists go to test step 2 Clean mud or dirt from under brake pedal If problem still exists go to test step 3 If damage or binding is found notify Organizational Maintenance If problem still exists go to test step 4 If damage is found notify Organizational Maintenance Notify Organizational
71. NTERVALS Tophandler Force D Daily Limiter Guide Rods W Weekly Tophandler Operat M Monthly ing Shaft Bearings ANTIFREEZE Ethylene Glycol Inhib ited Heavy Duty 1 106 L All T t Engine Radiator 28 Ga 06 emperatures System Capacity For artic operation refer to FM 9 207 0011 00 5 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED Table 1 CHART A ENGINE CRANKCASE EXPECTED TEMPERATURES AA AA Table 2 CHART B TRANSMISSION OE HDO Lubricating Oil ICE Tactical Oil ICE OE HDO 10W 30 OE HDO 15W 40 OFA EXPECTED TEMPERATURES e t d ue OE HDO Lubricating Oil ICE Tactical me Oil ICE me OE HDO 30 OE HDO 10 If lubricant is required to meet the low expected temperature range lubricant is to be used lieu of OE HDO 10 lubricant for all expected temperatures where OE HDO 10 15 specified Table 3 CHART C HYDRAULIC SYSTEM EXPECTED TEMPERATURES AAA _ AA SA ASS E AE ee As A A AE If lubricant is required to meet the low expected temperature range lubricant is to be used in lieu of OE HDO 10 lubricant for all expected temperatures where OE HDO 10 is specified OE HDO Lubricating Oil IC
72. RATOR CONTROLS AND INDICATORS CONTINUED 0004 00 CONTAINER LOCK INDICATOR PANEL NOTE To test for burned out lamps on container lock indicator panel press lenses inward while main disconnect switch 15 in ON position 55 READY TO LOCK 56 97 LOAD LOCKS LOCKED UNLOCKED 422 0042 CONTROL OR INDICATOR FUNCTION 55 Ready to Lock Indicators NOTE Both yellow lights must be ON before attempting to lock tophandler container locks to container Both yellow indicator lights should be ON When testing light ON When tophandler container locks are engaged in top of container and ready to lock Left light ON Left side engaged Right light ON Right side engaged ON During lifting and while moving container OFF When tophandler container locks are disengaged 56 Load Locks Unlocked Indicator Red indicator light will be ON any time tophandler container locks are in unlocked position 57 Load Locks Locked Indicator NOTE Green indicator light will not come on unless both READY TO LOCK indicators are on Green indicator light must be ON before lifting container to ensure that all four comers of tophandler are locked to container Remains ON after locking and while lifting and moving container 0004 00 13 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 MAIN DISCONNECT SWITCH 22 58 422 0043 CONTROL OR INDICATOR FUNCTION 58 Ma
73. RS SERVICE PROCEDURE CAPABLE IF Monthly 0 2 Hours Steering Cyl A GAA grease Item 6 WP 0016 inders 00 to four fittings RIGHT REAR STEERING CYLINDER GAA 2 PLACES GAA 1 PLACE 422 0010 0012 00 32 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF y WARNING Ensure area around machine is clear of personnel or obstructions before articulating machine Failure to follow this warning may cause injury or death to personnel or damage to equipment Hitch and steering movement can reduce clearances suddenly and cause injury Always stop engine BEFORE working in area of hitch CAUTION Articulate machine full right or left before lubricating center drive shaft spline to prevent damage to seal 81 Monthly 0 1 Hours Center Drive With shipping link in stowed position Shaft Spline start engine and steer machine to full right or full left Shut down engine Apply GAA grease Item 6 WP 0016 to spline fitting a 422 0011 0012 00 33 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 82 Monthly 0 2 Hours Tophandler Apply GAA grease Item 6 Container 00 to four fittings
74. TECTION REQUIRED SHELF BEHIND SEAT TO RIGHT OF RIGHT HAND SIDE OF DASH MASTER SERIAL NO PLATE SIDE OF TORQUE CONVERTER ENGINE PATENT AT REAR OF ENGINE ON AIR CLEANER CATERPILLAR Jeees aai PART NO SERIAL ON PLATFORM NEAR FUEL FILLER CAP DIESEL FUEL 0007 00 2 422 0023 10 3930 641 10 DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DECALS AND DATA PLATES CONTINUED AVOID POSSIELE WEAKENING OF THIS ROPS CONSULT A CATERPILLAR DEALER BEFORE ALTERING WARNING mors i ANY war THE PROTECTION OFFERED BY THIS ROPS WILL BE IMPAIRED IF IT HAS BEEN SUBJECTED STRUCTURAL DAMAGE OR HAS BEEN INVOLVED IN AN OVERTURN INCIDENT PROTECTIVE STRUCTURE ROPS CERTIFICATION THIS ROPS WHEN PROPERLY INSTALLED ON A MACHINE WHICH IS NOT ALTERED ROPS CERTIFICATION TEST WEIGHT EAGEED THE ROPS CERTIFICATION TEST WEIGHT MEETS AT THE TIME OF WN STALLATION CRITERIA ESTABLISHED BY POUNDS KILOGRAMS 9886 113 000 51255 OSHA REGULATIONS 29 CRF 1926 1001 5 APRI 72 1 5 ARMY CORPS OF ENGINEERS 385 1 1 1 JUNE 77 CATERPILLAR TRACTOR CO SAEJ231 SAEJE94 SAEJI040b 1803471 1803149 GENERAL OFFICES WARNING REAR CENTER OF CENTERED ABOVE DOOR ON LEFT HAND SIDE OF ROPS CANOPY MAST CROSS BAR ON EACH SIDE TOP FORK ASSEMBLY BELOW PLATFORM caremr Lan car H AT FRAME ARTICULATION EACH ea SIDE OF MACHINE WARN NO CLEARANCE FOR
75. TM 10 3930 641 10 TECHNICAL MANUAL OPERATOR S MANUAL FOR TRUCK CONTAINER HANDLER ROUGH TERRAIN 50 000 LB CAPACITY DIESEL ENGINE DRIVEN DED PNEUMATIC TIRES PT MODEL DV43 NSN 3930 01 082 3758 WITH TOPHANDLER S SUPERSEDURE NOTICE This manual supersedes TM 10 3930 641 10 dated 15 May 1981 including all changes DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY MAY 2006 10 3930 641 10 WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment Failure to observe these precautions could result in serious injury or death to personnel Also included are explanations of safety and hazardous materials icons used within the technical manual BIOLOGICAL abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health CHEMICAL drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue EAR PROTECTION headphones over ears show that noise level will harm ears ELECTRICAL electrical wire to arm with electricity symbol running through human body shows that shock hazard is present EYE PROTECTION person with goggles shows that the material will injure the eyes FIRE flame shows that a material may ignite a
76. a CPC problem The form should be submitted to the address specified in DA PAM 750 8 THREAT OF NUCLEAR BIOLOGICAL AND CHEMICAL NBC CONTAMINATION 1 The incorporates CARC painted exterior Materials used in the machine are metal rubber plastic fabric and glass 2 In the event of NBC contamination decontaminants for these surfaces and materials are listed 3 5 NBC Decon tamination For decontamination procedures refer to FM 3 7 NBC Field Handbook ELECTROMAGNETIC PULSE EMP EXPOSURE Components listed and designated as EMP susceptible may be damaged by EMP exposure If the machine is exposed to an EMP incident verify proper operation and repair as necessary 0001 00 1 10 3930 641 10 GENERAL INFORMATION CONTINUED 0001 00 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use refer to TM 750 244 3 WARRANTY INFORMATION The RTCH is warranted by Caterpillar Inc for 15 months or 1 500 hours of operation whichever comes first Warranty starts on the date found on DA Form 2408 9 in the logbook Report all defects in material or workmanship to your supervisor who will take appropriate action through your Field Maintenance shop 0001 00 2 10 3930 641 10 GENERAL INFORMATION CONTINUED 0001 00 LIST OF ABBREVIATIONS ACRONYMS NOTE Refer to ASME Y 14 38 1999 for standard abbreviations ABBREVIATION ACRONYM DEFINITION
77. akes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may result in injury or death to personnel e DO NOT use compressed air to clean batteries Use a clean dry rag Eyes Flush with cold water for no less than 15 minutes and seek medical attention immediately Skin Flush with large amounts of cold water until all ac d is removed Seek medical attention as required Internal If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magne sia beaten egg or vegetable oil Seek medical attention immediately Clothing Equipment Wash area with large amounts of cold water Neutralize acid with baking soda or household ammonia WARNIN SI gt BE ETHER STARTING AID SYSTEM e Ether fuel is extremely flammable and toxic DO NOT smoke and make sure you are in a well venti lated area away from heat open flames or sparks Wear eye protection Avoid contact with skin and eyes and avoid breathing ether fumes If fluid enters or fumes irritate the eyes wash immediately with large quantities of clean water for 15 minutes Seek medical attention immediately if ether is inhaled or causes eye irritation Failure to follow this warning may cause injury or death to personnel e NEVER use starting fluid or spray to aid in starting the engine other than the on board ether cold start sys tem Failure to follow this warning may
78. ase contact The Army Environmental Hotline at 1 800 872 3845 Failure to follow this warning may result in injury to personnel b Hazardous Waste Disposal Ensure all spills are cleaned up and disposed of in accordance with local policy and ordinances c Rust and Corrosion Check metal parts for rust and corrosion If any bare metal or corrosion exists report it to your supervisor d Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness and missing bent or broken condi tion You can t try them all with a tool but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose tighten it or report it to your supervisor e Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to your supervisor f Electric Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connec tors Tighten loose connectors and ensure that the wires are in good condition g Hoses and Fluid Lines Look for wear damage and signs of leaks Ensure that clamps and fittings are tight Wet spots indicate leaks but a stain around a fitting or connector can also mean a leak If a leak comes from a loose fit ting or connector tighten it If something is broken or worn out report it to your supervisor h Fluid Leakage It is necessary for you to know how fluid leakage affects the status of your machine The
79. cause injury or death to personnel or damage to equipment WARNING FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in tempo rary breathing difficulty during and immediately after the discharge event Discharge fire extinguisher from outside the cab Ventilate cab thoroughly prior to reentry 10 3930 641 10 WARNING E FUEL HANDLING pii e NOT smoke or permit any open flame in area of machine while you are servicing fuel system Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity Failure to follow this warning may cause injury to personnel or equipment damage e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury or death to personnel or damage to machine e Operating personnel must wear fuel resistant gloves when handling fuels If exposed to fuel promptly wash exposed skin and change fuel soaked clothing gt WARNING HAZARDOUS WASTE DISPOSAL When servicing this machine performing maintenance or disposing of materials such as engine coolant hydraulic oil lubricants battery acids or batteries and CARC paint consult your unit local hazardous waste disposal center or safety office for local regulatory guidance If further information 15 needed please contact The Army Environmental Hotline at 1 800 872 3845 Fa
80. ce Brakes Steering Hydraulic Tank Hydraulic Control Levers PROCEDURE a Verify that backup alarm functions when transmission 15 placed in Reverse b Check operation of horn Check operation of lights Move all control levers though each position and observe mast movement Ensure movement 15 smooth without binding Release parking brake and drive machine slowly forward Apply ser vices brakes to ensure correct func tioning Watch for evidence of fluid leakage Operate windshield wipers and washer to verify correct operation Check accelerator pedal and left and right brake pedals for binding and obstructions Check service brakes for pulling grabbing or reduced braking capacity Notify Organizational Maintenance of any malfunction Check for smooth controlled steering without pulling or drifting Notify Organizational Maintenance of any malfunction With warm and engine running ensure oil level in sight gage is above ADD COLD mark in sight gage Add oil Item 7 8 or 11 WP 0016 00 if level 1s low Check all control levers for proper operation Ensure mast movement 15 smooth without binding 0012 00 7 0012 00 NOT FULLY MISSION CAPABLE IF a Backup alarm does not function b Horn does not function Any lights do not function 1f required for mission Mast does not respond to con trol lever movements Service brakes do not stop machine Class
81. ctrical system power when key is turned counter clockwise left to OFF position START starts engine when key is turned all the way clockwise right to START position and held Returns to ON position when released 31 Panel Test Switch With main disconnect switch and power switch in ON position push upward and hold to turn on all indicator lamps in right hand and left hand instrument panels to check for burned out lamps 32 Protect machine electrical circuitry 0004 00 8 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 LEFT HAND INSTRUMENT PANEL TAIL HEAD FLOOD AUX LIGHTS 422 0041 LEFT HAND INSTRUMENT PANEL CONTROL OR INDICATOR FUNCTION 33 Low Fuel Level Indicator Amber indicator lamp should be ON when testing panel lamps ON if fuel level is less than 10 of tank capacity whether engine is running or not 34 High Fuel Level Indicator Green indicator lamp should be ON when testing panel lamps ON only if enough fuel in tank for 10 hour day Engine is not running OFF during normal operation with engine running 35 Cleaner Indicator Amber indicator lamp should be ON when testing panel lamps OFF during normal operation or when engine 15 not running ON when filter becomes plugged while engine is running 36 Low Engine Oil Level Indicator Amber indicator lamp should be ON when testing panel lamps ON when oil lev
82. dence a Class III oil coolant or of fluid leakages such as oil cool hydraulic oil leaks are evi ant fuel or hydraulic oil dent Any fuel leak is evi dent Check machine for obvious dam b Damage that would impair age to fenders mirrors handrails operation is evident ladders engine covers and guards Check for loose wiring damaged Parts are damaged or miss lines or hoses ing d Check for loose or damaged parts 4 Parts are damaged or miss ing 51 After Right Rear a Visually check right rear tire for a Tire has cuts abrasions or Wheels and cuts abrasions or bulges in tread or bulges in tread or sidewall Tires sidewall area Check for uneven area Other damage that wear or underinflation Look would impair operation 15 foreign material embedded in tread evident or sidewall area Remove foreign material 1f found b Check for loose or missing lug nuts b Two or more lug nuts are or valve stem caps missing or valve stem is damaged 0012 00 18 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE 52 After NATO a Release retainer and open right side Receptacle engine compartment access doors b Inspect NATO slave receptacle and cover for damage Ensure cover 1s installed c Turn main disconnect switch
83. e each month 3 Man Hours Column This column indicates man hours required to complete prescribed lubrication service 4 Location Item to Check Service Column This column provides the location and item to be checked or serviced NOTE The WARNINGs and CAUTIONS appearing in your PMCS table must always be observed WARNINGs and CAUTIONS appear before applicable procedures You must observe these WARNINGS to prevent seri ous injury to yourself and others and CAUTIONS to prevent your equipment from being damaged 3 Procedure Column This column gives procedure you must perform to know if the equipment is ready or available for 1ts intended mission or for operation You must perform the procedure at the time stated in the interval column 6 Not Fully Mission Capable If Column Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission If you perform check service procedures that show faults listed in this column the equipment is not mission capable Follow standard operating procedures for maintaining the equipment or reporting equipment failure GENERAL PMCS PROCEDURES 1 Always perform PMCS in the same order With experience you should be able to identify problems easily If the machine does not perform as required refer to the Troubleshooting Symptom Index 0009 00 If anything looks wrong and you can t fix it write it on your DA Form 2404 or DA Form 5988
84. e fas and fasten seat belt tened Date on belt is more than three years old Unlock and adjust steering column Steering column does not WP 0004 00 unlock or hold adjustment 18 Before Panel Test Turn power switch to ON and push Any indicator light does not panel test switch upward and hold function Check that all indicator lights in right hand and left hand instrument panels come on 19 Engine Star Start engine and allow to warm up tup WP 0005 00 20 Instrument With engine running ensure the fol a Indicator light s remain on Panel lowing indicator lights are off while engine 15 running 1 LOW ENG OIL indicator 2 LOW HYD OIL indicator 3 NO COOLANT FLOW indica tor 4 IMPLEMENT filter indicator TRANS filter indicator AIR filter indicator PILOT filter indicator HI TEMP HYD OIL indicator LOW PRESS BRAKE indica tor 10 SUPP STER indicator b With machine at normal operating b Gages indicate an abnormal temperature monitor readings on reading gages WP 0004 00 0012 00 6 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED ITEM NO INTERVAL HOURS Before Before Before Before 0 1 Hours LOCATION ITEM TO CHECK SERVICE Backup Alarm and Horn Lights Hydraulic Control Levers Service Brakes Overall Leakage Wipers and Windshield Washers Accelerator and Brake Pedals Servi
85. e to follow this warning may cause injury or death to personnel Before operation ensure shipping link located near center of machine is disconnected and pinned to retainer Before operation ensure Rollover Protective Structure ROPS is not damaged or altered A structurally damaged ROPS will not protect you in a rollover accident DO NOT move machine if LOW PRESS BRAKE light is flashing on and off Shut down engine and report problem Failure to follow warning may cause injury or death to personnel DO NOT allow riders on machine Failure to follow this warning may cause injury or death to person nel NEVER leave operator compartment without applying parking brake Failure to follow this warning may cause injury or death to personnel in the event machine moves inadvertently when parked DO NOT use parking emergency brake to stop a moving machine under usual conditions Only if service brakes fail apply parking emergency brake Failure to follow this warning may result in injury or death to personnel or damage to equipment Machine will stop suddenly during emergency brake engagement Use caution to guide machine to a stop as quickly and safely as possible Failure to follow this warning may result in injury to personnel Drive carefully alertly and at an appropriate speed for road conditions Remember that machine has articulated frame steering and will require special handling NEVER operate RTCH or move load near a power line o
86. ee listed in publication FROM Activity and location Include ZIP Code DATE PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE TOTAL NO PAGE COLM LINE REFERENCE FIGURE ITEM OF MAJOR NO NO NO NO NO NO ITEMS RECOMMENDED ACTION SUPPORTED NATIONAL STOCK NUMBER PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets be used if more space needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 THE METRIC SYSTEM AND EQUIVALENTS Linear Measure 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches 1 Kilometer 1000 Meters 0 621 Miles Weights 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Kilogram 1000 Grams 2 2 Pounds 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons Liquid Measure 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1000 Milliliters 33 82 Fluid Ounces Square Measure 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Sq Kilometer 1 000 000 Sq Meters 0 0386 Sq Miles Cubic Measure 1 Cu Centimeter 1 000 Cu Millimeters 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet Tempe
87. el in engine oil pan is low and engine is not running OFF during normal operation with engine running 37 No Coolant Flow Indicator Amber indicator lamp should be ON when testing panel lamps ON when engine is not running OFF during normal engine operation ON and HORN WILL SOUND when coolant flow stops while engine 15 running 0004 00 9 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED LEFT HAND INSTRUMENT PANEL CONTINUED 0004 00 42 41 CONTROL OR INDICATOR Low Hydraulic Oil Level Indicator Hydraulic Oil High Temperature Indicator Brake Oil Filter Indicator PILOT Transmission Oil Filter Indicator Hydraulic Tank Internal Oil Filter Indicator IMPLEMENT TAIL HEAD FLOOD Aux AUX eses O LIGHTS LOw PRESS PARK BRAKE O Q C 422 0041 FUNCTION Amber indicator lamp should be ON when testing panel lamps ON when hydraulic oil level in hydraulic tank is low and engine 15 not running OFF during normal operation with engine running Amber indicator lamp should be ON when testing panel lamps OFF during normal operation or when engine is not running ON when temperature of oil in hydraulic tank 15 high while engine is running Amber indicator lamp should be ON when testing panel lamps OFF during normal operation or when engine is not running ON when brake oil filter bec
88. ermarks 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 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
89. est step 2 Notify Organizational Maintenance Add transmission oil as needed WP 0011 WP 0012 00 If problem still exists notify Organizational Maintenance Turn switches to ON position If problem still exists go to test step 2 If fuse 15 blown request replacement fuse of same rating from Organizational Maintenance If fuse 1s OK go to test step 3 Reconnect connector ifrequired If connector s is OK notify Organizational Maintenance If fuse is blown request a replacement fuse of same rating from Organizational Maintenance If fuse is OK and problem still exists go to test step 2 Reconnect connectors if required If connectors are OK notify Organizational Maintenance 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM CONTINUED 3 Headlight s Do Not Operate 1 Ensure headlight switch main Turn switches to ON position If disconnect switch and power problem still exists go to test step switch are ON position 2 2 Check lights for disconnected Reconnect connectors if connectors or damage required If any damage to lights is found notify Organizational Maintenance If connectors and lights are OK notify Organizational Maintenance 4 Stoplights Do Not Operate When Brake 1 Check for blown fuse 1 at If fuse 15 blown request a Pedal Is Pressed left hand instrument pane
90. f RTCH is operated DO NOT operate engine in enclosed areas without adequate ventilation DO NOT idle engine without adequate ventilation DO NOT drive machine with inspection plates or cover plates removed BE ALERT for exhaust poisoning symptoms They are e Headache e Dizziness e Sleepiness e Loss of muscular control If you see another person with exhaust poisoning symptoms e Remove person from area e Expose to fresh air e Keep person warm e DO NOT permit physical exercise e Administer cardiopulmonary resuscitation CPR if necessary e Notify a medic BE AWARE The field protective mask for nuclear biological chemical NBC protection will not protect you from car bon monoxide poisoning The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation p TM 10 3930 641 10 WARNING a gt BATTERIES e To avoid injury eye protection and acid resistant gloves must be worn when working around batteries DO NOT smoke use open flame make sparks or create other ignition sources around batteries If a bat tery is giving off gases it can explode and cause injury to personnel Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery terminal a direct short will result in instant heating or electric shock damage to equipment and injury to personnel 2 e Sulfuric acid contained in batteries can cause serious burns If battery corrosion or electrolyte m
91. fapproaching a difficult stretch of road stop and inspect road carefully before driving on it g Select transmission gear range that best suits driving condition 3 Stopping a Ease up on accelerator leaving machine in gear b Apply service brakes lightly and evenly DO NOT pump service brake pedal c Always avoid sudden braking 4 Parking If parking on 1cy slushy wet or muddy surfaces place boards brush or other materials that will provide trac tion underneath tires This will guard against tires freezing to the ground or becoming pocketed in ice and will provide some traction when machine is started and moving again FORDING The RTCH can be forded in water depths up to 60 in 1 50 m Observe the following precautions when fording any body of water 1 Before Fording a Check depth of water at its deepest point Do not ford even the narrowest stream more than 60 in 1 50 m deep b Ensure bottom is level enough for fording c Ensure engine is operating at full efficiency d Set transmission speed in low ranges e Check tire pressure before entering water and adjust as needed 1 Front tire inflation should be 70 psi 480 kPa 2 Rear tire inflation should be 40 psi 275 kPa 25 During Fording a Enter water slowly to minimize waves and backwash b Do not exceed speed of 3 4 mph 5 6 kph c Ifstalling occurs notify Organizational Maintenance de After Fording a Within 10 minutes of fording check the followi
92. follow ing are definitions of the types classes of leakage you need to know to be able to determine the status of your machine Learn and be familiar with them and remember when in doubt notify your supervisor 0011 00 2 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL PMCS PROCEDURES CONTINUED CAUTION Operation is allowable with Class I and Class II leakage WHEN IN DOUBT NOTIFY YOUR SUPERVI SOR When operating with Class or Class leaks check fluid levels more frequently Class leaks must be reported immediately to your supervisor Failure to do this will result in damage to machine and or com ponents NOTE Notify Organizational Maintenance of any leaks the operator cannot fix Leakage Definitions for PMCS Class 1 Leakage indicated by wetness or discoloration but not great enough to form drops Class Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class Leakage great enough to form drops that fall from the item being checked inspected GENERAL LUBRICATION PROCEDURES NOTE e Lubrication instructions contained in this PMCS are mandatory e Overall views of lubrication points are located at the end of this work package e Refer to FM 9 207 for lubrication in arctic operation Included in this PMCS are lubrication services to be performed by the operator 2 Lubrication inter
93. forms Additional blank sheets be used if more space needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 DATE Use Part reverse for Repair Parts and Special Tool Lists RPSTL and Supply Catalogs Supply Manuals SC SM RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s Manual for Truck Container Handler Rough TM 10 3930 641 10 15 May 2006 Terrain 50 000 Lb Capacity Diesel Engine Driven DED Pneumatic Tires PT Model DV43 TABLE RECOMMENDED CHANGES AND REASON ITEM PAGE PARA FIGURE NO TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to addressee listed in publication FROM Activity and location Include ZIP Code DATE PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE TOTAL NO PAGE COLM LINE REFERENCE FI
94. g Pump The priming pump is used to prime the fuel system on initial startup or after changing fuel filters It also removes air from the fuel system Ether Starting Aid The ether starting aid delivers a measured amount of ether into the turbocharger outlet for ease in cold weather starting The ether 1s stored under pressure in a cylinder and the amount to be sprayed into the outlet pipe 15 controlled by an electrically activated valve FUEL FLUID LEVEL PRESSURE INDICATORS GAGE M FUEL FUEL A N mum ETHER STARTING AID FUEL INJECTOR PUMP INJECTION NOZZLE AND PRIMARY ADAPTER 422 0029 0003 00 1 10 3930 641 10 THEORY OF OPERATION CONTINUED 0003 00 AIR INLET AND EXHAUST SYSTEM 1 Air Cleaner The air cleaner 15 a dual element dry type filter Outside air is drawn through the filter elements by vac uum created in the turbocharger When one or both of the elements get clogged a high vacuum switch in the air cleaner housing turns on the PLUGGED AIR FILTER indicator on the instrument panel 2 Muffler and Exhaust Pipe These components reduce engine noise and carry exhaust gases away from the engine com partment AIR GLEANER EXHAUST PIPE AND MUFFLER mS 422 0030 STEERING SYSTEM 1 Steering Wheel and Column The steering wheel and column are adjustable to eight different positions Seven of the positions are for operator comfort while the eighth and most forward position is fo
95. ge of fluid great enough to form drops but not enough to cause drops to drip from item being checked inspected Class Leakage of fluid great enough to form drops that fall from item being checked inspected Before starting any specific troubleshooting procedures perform the following Visually check all hoses and tubes for leaks Check for mechanical jamming or binding caused by rocks or other foreign matter Check fluid levels subject area and fill as required WP 0011 00 and WP 0012 00 ELECTRICAL TROUBLESHOOTING Analyze the symptoms and conditions to determine the most likely cause for problem then troubleshoot that circuit first The more information you have concerning the problem the easier it will be to troubleshoot Isolate to the subsystem level in cases where more than one subsystem is involved next isolate the problem to a single circuit within the subsystem then isolate the problem to the faulty component using the Troubleshooting Symptom Index WP 0009 00 Frayed broken loose or corroded wiring 15 a common source of problems in any electrical circuit Always make a visual inspection before starting detailed troubleshooting Inspect contacts to ground carefully because components with case grounds are especially troublesome END OF WORK PACKAGE 0008 00 1 10 3930 641 10 TROUBLESHOOTING SYMPTOM INDEX 0009 00 Malfunction Symptom Troubleshooting Procedure Page BRAKES I Service
96. gine components e following shutdown procedures allow engine to cool This will prevent excessive temperatures in turbocharger center housing Failure to shut down engine properly may cause premature engine failure e Avoid prolonged idling as this may cause sludge buildup in engine NOTE Refer td WP 0004 00 the location and operation of controls and indicators 1 Operate engine at half speed for five minutes EN Operate engine at low idle for 30 seconds Turn power switch off and remove key 0005 00 8 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 ENGINE SHUTDOWN CONTINUED 4 Turn steering column lock key clockwise right to unlock column release knob 5 Hold steering wheel and pull column release knob out 6 Move steering column all the way forward to stowed position Release column release knob STEERING COLUMN RELEASE KNOB STEERING COLUMN LOCK 422 0035 7 Dismount machine 8 Turn main disconnect switch counterclockwise left to OFF position Chock wheels 0005 00 9 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 AFTER OPERATION 1 Perform After operation PMCS WP 0011 00 and WP 0012 00 2 Remove key from main disconnect switch 3 Close and lock doors and windows LOADING AND UNLOADING CONTAINER e WARNING e NEVER operate RTCH or move load near a power line or overhead wires Failure to follow this warn
97. gs 0012 00 29 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 75 Monthly 0 2 Hours Tilt Cylin Apply GAA grease Item 6 WP 0016 ders 00 to Apply GAA grease Item 6 0016 00 to four fittings GAA 2 PLACES GAA 2 PLACES 422 0006 76 Monthly Drive Belts a Check for missing frayed or a Drive belt is missing or cracked drive belts damaged b Check for loose or damaged drive b Pulley is loose or damaged pulleys 0012 00 30 10 3930 641 10 PREVENTIVE MAINTENANCE 5 AND SERVICES PMCS CONTINUED 0012 00 LOCATION ITEM ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF Monthly 0 2 Hours Fan Drive grease 6 WP 0016 and Belt 00 to two fittings Tightener Pulley GAA 422 0008 78 Monthly 0 2 Hours Pintle Hook Apply GAA grease Item 6 WP 0016 to three fittings 79 Monthly 0 2 Hours Rear Axle Apply grease 6 0016 Trunnion to two fittings A LEFT REAR STEERING CYLINDER REAR AXLE TRUNNION GAA 1 PLACE GAA 2 PLACES 422 0009 0012 00 31 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOU
98. ick 0012 00 8 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF After 0 1 Hours Engine Oil d If IEEE is low add oil Item 7 9 or en Level Hot 101 WP 0016 00 00 through filler tube Check opening until level on dipstick reads between LOW and FULL marks DIPSTICK ENGINE OIL FILLER TUBE 422 0058 0012 00 9 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE 35 After 0 1 Hours Transmis a With engine running at low idle and sion Oil warm access transmission under Level Hot floor panel behind cab Check b Wipe area around dipstick and fill cap with a clean rag Item 12 WP 0016 00 c Remove dipstick and read oil level on dipstick Level must be between LOW and FULL marks on dipstick d If level 15 low add oil Item 7 8 or 11 WP 0016 00 through filler tube opening until level on dipstick reads between LOW and FULL marks DIPSTICK TRANSMISSION 011 FILLER TUBE 422 0062 0012 00 10 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PRO
99. ign matter 6 Maintain a record of lubrication performed and report any problems noted during lubrication Refer to DA PAM 750 8 for forms and procedures to record and report any findings 0011 00 3 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED NOTE Only lubricants authorized for use by the operator are listed in this KEY KEY EXPECTED TEMPERATURES 25 F to 32 F LUBRICANT REFILL COMPONENT CAPACITY 6 F to 122 F 4 F to 50 F 14 C to 50 C 20 C to 10 C 4 C to 0 C INTERVALS OE HDO D Daily Lubricating Oil ICE W Weekly Tactical M Monthly Lubricating Oil ICE Arctic 11 Gal See Chart A Transmission 24 Gal See Chart B 90 8 L 12 As Required Temperatures Grease Automotive and Artillery Side Tilt Cylinder Mast Mount ing Hinges Fan Drive and Belt Tightener Pulley Steering Cylinder Bearings Driveshaft Spline 1 Rear Axle Trunnion Bearings Tophandler Container Lock Housing 0011 00 4 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED EXPECTED TEMPERATURES LUBRICANT REFILL 6 F to 122 F 4 F to 50 F 25 F to 32 F COMPONENT CAPACITY 14 C to 50 C 20 C to 10 C 4 C to 0 C I
100. ilure to follow this warning may result in injury to personnel WARNING HEARING PROTECTION Hearing protection 1s required when operating machine with cab windows open Anyone within 50 ft 15 m of an operating machine must also wear hearing protection Failure to wear hearing protection may cause hearing loss WARNING HOT COMPONENTS With engine running drivetrain components are hot to the touch Use caution to safeguard against burns Failure to follow this warning may result in injury to personnel WARNING HYDRAULIC SYSTEM PRESSURE DO NOT discomnect or remove any hydraulic system line or fitting unless engine 1s shut down and hydraulic system pressure has been relieved Tighten all connections before applying pressure Escaping hydraulic fluid under pressure can penetrate the skin causing injury or death to personnel 10 3930 641 10 WARNING MACHINE OPERATION Use caution and maintain three point contact at all times when mounting or dismounting machine DO NOT use steering wheel as a handhold Failure to follow this warning may cause injury to personnel BE ALERT for personnel in the area while operating machine Always check to ensure area 1s clear of personnel and obstructions before moving machine raising or lowering container handler forks Fail ure to follow this warning may cause injury or death to personnel or damage to equipment DO NOT operate machine unless seat belt has been fastened Failur
101. in Disconnect Switch CAUTION DO NOT turn switch to OFF when engine is run ning or damage to electrical components will result Turn switch counterclockwise left to OFF to remove ground from machine electrical circuits when performing maintenance in engine compartment or on any electrical circuits or anytime machine is left unattended Rotate switch clockwise right to ON to connect ground to machine electrical systems END OF WORK PACKAGE 0004 00 14 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS 0005 00 GENERAL This machine has been designed to operate safely and efficiently within the limits specified in this TM Operation beyond these limits is prohibited in accordance with AR 70 1 without written approval from Commander U S Army Tank automotive and Armaments Command ATTN AMSTA DSA CS Warren MI 48397 5000 WARNING Hearing protection 1s required when operating machine with cab windows open Anyone within 50 ft 15 m of an operating machine must also wear hearing protection Failure to wear hearing protection may cause hearing loss 1 This work package contains instructions for safely operating this machine under usual conditions 2 Read and become familiar with information in this work package BEFORE operating machine D Operation under unusual conditions 15 described MOUNTING AND DISMOUNTING MACHINE WARNING Use caution and maintain three point contact all times when mounting and dismoun
102. ing injury or death to personnel d Shut down engine Move hydraulic control levers through all positions to relieve hydraulic system pressure Install and secure two safety chains Connect electrical connector g Connect two hydraulic connections END OF WORK PACKAGE 0005 00 14 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS 0006 00 GENERAL WARNING This machine has been designed to operate safely and efficiently within the limits specified this TM Operation beyond these limits is prohibited in accordance with AR 70 1 without written approval from Commander U S Army Tank automotive and Armaments Command ATTN AMSTA DSA CS Warren MI 48397 5000 This section contains instructions for safely operating the RTCH under unusual conditions In addition to normal pre ventive maintenance special care must be taken to keep the machine operational in extreme temperatures and other environ mental conditions SLAVE STARTING WARNING e When slave starting use NATO slave cable that does NOT have loose or missing insulation e DO NOT proceed if suitable cable is not available e DO NOT use civilian type jumper cables e DO NOT allow disabled and booster machines to come in contact with each other at any time during slave starting Failure to follow these warnings may cause injury or death to personnel NOTE Ensure that both disabled machine and booster machine are equipped with serviceable NATO slave receptacles
103. ion of columns found in the tabular listings l Column 1 Illustration Number Illus Number This column indicates the number of the illustration that shows the item Za Column 2 National Stock Number Indicates the National Stock Number NSN assigned to the item and used for requisitioning purposes 3 Column 3 Description and Part Number Indicates the Federal item name in all capital letters and if required a minimum description in parentheses to identify and locate the item The entry for each item ends with the Commercial and Government Entity Code parentheses followed by the part number 4 Column 4 Usable on Code USABLE ON codes are used to help identify which component items are used on dif ferent models This column is not used in this manual 5 Column 5 Unit of Measure Indicates how the item is issued for the NSN shown in Column 2 6 Column 6 Quantity Required Qty Indicates the quantity of the item required 0014 00 1 10 3930 641 10 COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS CONTINUED 0014 00 422 0027 Table 1 Components of End Item List 1 2 3 4 ILLUS NATIONAL STOCK DESCRIPTION CAGEC USABLE NUMBER NUMBER AND PART NUMBER ON CODE 1 3990 01 107 5716 20 Ft EA 1 65508 30622 0014 00 2 10 3930 641 10 COMPONENTS OF END ITEM AND BASIC ISSUE ITE
104. ir cleaner media Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures NBC contaminated filters must be handled using adequate pre cautions and must be disposed of by trained personnel For more information refer to FM 3 3 Chemical and Biologi cal Contamination Avoidance FM 3 5 NBC Decontamination FM 3 7 NBC Field Handbook and FM 3 3 1 Nuclear Contam ination Avoidance 0012 00 15 10 3930 641 10 PREVENTIVE MAINTENANCE 5 AND SERVICES PMCS CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 47 After Engine Air Clean engine air precleaner if debris 15 Cont Precleaner visible in precleaner Remove raincap and clean screen and precleaner hous ing with a clean rag Item 12 WP 0012 00 RAINCAP E PRECLEANER A E Ef ti 422 0064 48 After Radiator WARNING DO NOT service cooling system unless engine has been allowed to cool down This 15 a pressurized cooling system and escaping steam or hot coolant will cause serious burns DO NOT remove cooling system radiator cap when engine 15 hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause serious burns Wear effective eye glove and skin protection when handling coolants
105. l replacement fuse of same rating from Organizational Maintenance Install new fuse If fuse is OK and problem still exists go to test step 2 2 Check lights for disconnected Reconnect connectors if connectors or damage required If any damage to lights is found notify Organizational Maintenance 5 Taillights Do Not Come On 1 Ensure main disconnect Turn switches to ON position If switch power switch and problem still exists go to test step headlight switch are in ON 2 position 2 Check operation of the left If left hand panel lamp 15 also hand panel lamp inoperative request a replacement fuse of same rating from Organizational Maintenance Install new fuse If fuse s OK and problem still exists go to test step 3 3 Check lights for disconnected Reconnect connectors if connectors or damage required If problem still exists notify Organizational Maintenance 0010 00 3 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE 1 Engine Cranks but Fails to Start Operating Temperature Above 32 F 0 C WARNING DO NOT perform fuel system checks inspections or mainte nance while smoking or near fire flames or sparks Fuel may ignite causing damage to machine and injury or death to per sonnel Operating personnel must wear fuel resistant gloves when handling fuels If exposed to fuel promptly wash exposed skin
106. ler forks lowered to the ground engine shut down and wheels blocked If leakage is detected during performance of PMCS further investigation is required to determine location and cause of leak LEFT SIDE AND REAR Before Overall View Visually check for leakage on or under Class oil coolant or machine oil fuel coolant and hydraulic oil leaks evi Before Before Before Before hydraulic oil Lights Check left front headlight and flood lights for missing or damaged compo nents Tires and Visually check left side tires for obvi Wheels ously low tire pressure Fuel Tank Ensure fuel tank filler cap is present and secure Left Engine a Release retainer and open left side Compart engine compartment access doors ment b Check left engine compartment for evidence of fluid leakage such as oil coolant and fuel 0012 00 1 dent Any fuel leak is evident Missing or damaged compo nents are evident if necessary for mission Low or flat tire is evident Fuel tank filler cap is missing b Class oil or coolant leaks are evident Any fuel leak is evident 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 6 Before 0 1 Hours Engine Oil a Wipe area around dipstick and filler Level Cold tube with a
107. machine lower mast all the way and run engine at high idle Check hydraulic oil level 0012 00 STEERING 1 Ensure that shipping link 15 not installed 2 Check hydraulic oil level 0012 00 Allow hydraulic oil to warm up to normal operating temperatures 0010 00 7 precleaner WP 0012 00 and retest If problem still exists go to test step 2 Remove restrictions If problem still exists go to test step 3 If oil level is above FULL notify Organizational Maintenance If leaks are found notify Organizational Maintenance If problem still exists go to test step 2 Lubricate as needed WP 0011 00 and WP 0012 00 If leaks are found notify Organizational Maintenance Add oil as necessary WP 0011 o0 and WP 0012 00 If problem still exists go to test step 2 If problem still exists notify Organizational Maintenance Add oil as necessary WP 0011 00 WP 0012 00 Notify Organizational Maintenance If problem still exists go to test step 2 Add oil as necessary WP 0011 00 WP 0012 00 If steering wheel is still hard to turn notify Organizational Maintenance 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEERING CONTINUED 3 Steering Wheel Can Still Be Turned When Shut down engine Notify Organizational Vehicle Is at Full Turn Maintenance TRANSMISSION 1 Transmission Will Not Shift f
108. nd cause burns FLYING PARTICLES arrows bouncing off face with face shield shows that particles flying through the air will harm face 10 3930 641 10 HEAVY PARTS heavy object on human figure shows that heavy parts present danger to life or limb HOT AREA hand over object radiating heat shows that part 15 hot and can burn HYDRAULIC FLUID PRESSURE hydraulic fluid spraying human figure shows that fluid escaping under great pressure can cause injury or death to personnel RADIOACTIVE identifies a material that emits radioactive energy and can injure human tissue or organs VAPOR human figure in a cloud shows that material vapors present a danger to life or health X do de 6 TM 10 3930 641 10 FOR INFORMATION ON FIRST AID REFER TO FM 4 25 11 WARNING CARBON MONOXIDE EXHAUST GASES CAN KILL e Carbon monoxide is a colorless odorless deadly poison which when breathed deprives the body of oxygen and causes suffocation Exposure to air containing carbon monoxide produces symptoms of headache dizziness loss of muscular control apparent drowsiness and coma Permanent brain damage or death to personnel can result from severe exposure e Carbon monoxide occurs in exhaust fumes of internal combustion engines Carbon monoxide become dangerously concentrated under conditions of inadequate ventilation The following precau tions must be observed to ensure safety of personnel when engine o
109. ner Retracts to unlock tophandler from container 0002 00 4 10 3930 641 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA Length Overland 35 25 ft 10 74 m Between Steering Pivot and Rear 6 25 ft 1 91 m 20 Ft Eoi PRI O J C J vrrr 19 8 ft 6 04 m Bt Tophandlek suc o eso paid dua au teh a fe ae 34 9 ft 10 64 m AQ aci ee Et oe daa t b diets 39 7 ft 12 10 m 20 Ft Tophandler from Container Lock to Container Lock 19 2 ft 5 85 m 35 Ft Tophandler from Container Lock to Container Lock 34 25 ft 10 44 m 40 Ft Tophandler from Container Lock to Container 39 3 ft 11 98 m Width Overall st E 11 66 ft 3 51 m MaseWidin oe bee oo ee eee eee eae 9 ft 2 74 m ZU BE TLopRaudlet a drew on cs eisai ee awe o Iaceo Cd awe ie ass 8 3 ft 2 53 m oie arte tired trials ad datis tmi arta 8 3 ft 2 53 m Tophandler 32er 732 3422 5128 aw Dar carded vetet ers 8 3 ft 2 53 m Aie ec seio dee ee Bee t eur ae 12 5 ft 3 81 m Height A 13 25 ft 4 04 m Top ot Mast Lowered lesiona ae 13 9 ft 4 24 m Top of Mast Fully Extended 19 1 ft 5 82 m Weight
110. ng fluid levels 1 Engine oil 2 Transmission oil 3 Fuel 4 Hydraulic oil b Have Organizational Maintenance check 1 Each differential 2 Each wheel c Thoroughly wash machine after saltwater fording 0006 00 6 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 TOWING 10 WARNING e DO NOT tow faster than 5 mph 8 kph e DO NOT allow personnel on machine that is being towed e Always block wheels before preparing machine for towing e DO NOT use a tow line Use a medium duty tow bar with bumper blocks e Failure to follow these warnings may result in injury or death to personnel NOTE e Assistance from Organizational Maintenance is required to tow RTCH e Because engine is not running during towing service brakes and parking brake will not function prop erly Transmission lubrication will be insufficient Chock wheels Have Organizational Maintenance install shipping link WP 0014 00 on front and rear frames Have Organizational Maintenance inspect powertrain for damage If damaged have Organizational Maintenance remove axle shafts Have Organizational Maintenance manually release parking brake Have Organizational Maintenance reverse steering cylinder hoses on one cylinder so cylinders move freely CAUTION Ensure shipping link 15 disconnected before towing or damage to machine may result Have Organizational Maintenance remove shipping link TOW BAR Attach tow bar
111. nge selector range selector lever lever in N Neutral If problem still exists go to test step 3 3 Check for dirty loose or Clean dirty cables WP 0012 00 damaged battery cables Tighten loose connections If cable 15 damaged notify Organizational Maintenance 12 Alternator Is Noisy Inspect drive belt for damage or Notify Organizational wear WP 0012 00 Maintenance 0010 00 6 10 3930 641 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 13 Excessive Exhaust Smoke at Normal 1 Check air filter indicator Ifindicator is illuminated service Operating Temperature 2 Check for restrictions in exhaust system 3 Check engine oil level 0012 00 HYDRAULIC SYSTEM Hydraulic System Will Not Lift Load or Will Not Lower Load Correctly Lift or Tilt Cylinders Do Not Hold Position with Hydraulic Control Levers in Neutral Position Oil Temperature Is Too High Hydraulic Oil High Temperature Indicator Light Comes On Noisy Hydraulic Pump Machine Doesn t Turn When Steering Wheel Is Turned Steering Wheel Is Hard To Turn 1 Inspect lines and fittings for leaks 2 Inspect mast sliding blocks rollers and chains for correct lubrication 1 Inspect lines and fittings for leaks 1 Check hydraulic oil level 0012 00 2 Lengthen unloaded return trip to give hydraulic cooling system time to cool oil Park
112. ns relating to material covered in this technical manual Consolidated Army Publications and Forms Index DA PAM 25 30 Functional Users Manual for the Army Maintenance Management System TAMMS DA PAM 750 8 FORMS NOTE Refer to DA PAM 750 8 Functional Users Manual for the Army Maintenance Management System TAMMS for instructions on the use of maintenance forms Equipment Inspection and Maintenance DA Form 2404 DA Form 5988 E Product Quality Deticicicy 5 da au dee S e Seals de dnd oe eed eta SF Form 368 Recommended Changes to Publications and Blank Forms DA Form 2028 FIELD MANUALS Basic Cold Weather 14 Ee AS Du atio Dar 31 70 Chemical and Biological Contamination Avoidance FM 3 3 Des ED O o ooo 90 3 E A RA FM 4 25 11 Manual tor ihe Wheeled Vehicle Diver 224 0 scr Bee DAS ur d aet PINE 21 305 INBC D6econtanmittiallOB s de 3 5 NBC EIeldiHandb9Oole utis ado en centes hang we Ohta dcs E oca Ehe Sad at FM 3 7 heiss Scri a ee
113. ny speed then adjust speed accordingly Match speed with job conditions Do not coast Failure to follow this warning may cause injury or death to personnel or damage to equipment NOTE Without a load drive forward not reverse when traveling long distance With a load travel in reverse Know traffic pattern of job Obey flag men road signs and signals Carry load close to ground Refer to WP 0004 00 for the location and operation of controls and indicators l Transmission Ranges N Neutral is normal transmission position when machine is not in use Use N to start engine when idling engine and for parking Always lock transmission in Neutral by applying parking brake when machine is left unattended parked or stopped To select a specific reverse gear range pull transmission range selector back and rotate to desired gear normally second or third Backup alarm will sound when in a reverse gear To select a specific forward gear range push transmission range selector forward and rotate to desired gear nor mally second or third WARNING Ensure all personnel are clear of machine and work area Ensure your seat belt is fastened DO NOT coast down hills Keep transmission engaged Downshift one position at a time when reducing engine and ground speeds Downshift when going downhill to same gear used to climb grade or when operating on side slopes where high speed may compromise safety 0005 00 6 10 3930 641 1
114. o maintain sufficient engine RPM to help cooling b Inspect engine oil transmission oil hydraulic oil and engine coolant often and keep at proper levels c Be alert for evidence of overheating Closely monitor all coolant and oil temperature gauges and indicators Reduce operation to 3 4 workload d If indicators stay on after more than 10 minutes of reduced workload stop machine and notify Organizational Maintenance e Inspect the following items often and notify Organizational Maintenance if you see any signs of wear or damage 1 Alternator belt 2 Fan belts 3 Hydraulic system hoses and cylinder rods 4 Transmission and drive axle housings 5 Cooling system coolant level and rubber hoses 6 Tires and tire pressure 7 Protective tubing in electrical system f Bealert for leaks Report any leaks found 0006 00 3 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME HEAT CONTINUED 2 Cooling System WARNING e DO NOT service cooling system unless engine has been allowed to cool down This 15 a pressurized cooling system and escaping steam or hot coolant will cause serious burns e remove cooling system radiator cap when engine is hot Allow engine to cool down Failure to follow this warning may cause serious burns e Wear effective eye glove and skin protection when handling coolants Failure to follow this warning may cause injury to pe
115. omes plugged while engine is running Amber indicator lamp should be ON when testing panel lamps OFF during normal operation or when engine is not running ON when transmission filter becomes plugged while engine is running Amber indicator lamp should be ON when testing panel lamps OFF during normal operation or when engine is not running ON when filter in hydraulic tank becomes plugged while engine is running 0004 00 10 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 LEFT HAND INSTRUMENT PANEL CONTINUED 44 45 46 41 D 2 49 95 NAT NA 49 48 48 LEFT HAND INSTRUMENT PANEL 422 0041 43 Parking Brake On Indicator NOTE A warning buzzer behind cab will sound when parking brake is engaged and transmission 1s in forward or reverse Red indicator lamp should be ON when testing panel lamps ON when parking brake is engaged and engine is not running OFF during normal operation with engine running 44 Service Meter Indicates hours machine has been in service with engine running Used by maintenance personnel to schedule maintenance Meter indicates up to 9 999 hours 45 Auxiliary Floodlight Switch Push up to turn on auxiliary floodlights on top of cab 46 Auxiliary Switch Push up to connect 24 VDC power to auxiliary connector at back of cab 47 Windshield Wiper and Washer Turn knob clockwise right one or two clicks to turn on front and rear Switch
116. ore attempting to start engine again Excessive heating of starter motor may result in damage or premature starter failure Turn power switch to START position Release power switch when engine starts If engine does not start after 30 seconds let starter cool for two minutes then try to start again If engine oil pressure indicator does not stop flashing within 10 seconds after engine starts stop engine by turning off power switch Perform troubleshooting After engine has started verify that the following indicator lights are OFF 1 NO COOLANT FLOW indicator If indicator does not turn OFF perform troubleshooting 2 SUPP STER indicator If indicator does not turn OFF perform troubleshooting 3 LOW PRESS BRAKE indicator If indicator does not stop flashing perform troubleshooting 4 ALTERNATOR INDICATOR If indicator does not turn OFF perform troubleshooting Proceed to Machine Warmup 0005 00 4 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 START ENGINE CONTINUED 2 Starting Engine Below 32 F 0 C Using Ether Starting Aid a Ensure transmission is inN Neutral Ensure parking brake s applied by pulling parking brake control knob out Ensure all hydraulic control levers are in a neutral position Ensure all accessories are off Ensure all personnel are clear of machine Press and hold accelerator pedal 1 4 way down CAUTION DO NOT crank starter motor for more than 3
117. otify Organizational Maintenance 4 In an emergency machine can be moved in first speed range with emergency parking brake engaged This may damage the emergency parking brake have emergency parking brake serviced before machine 15 returned to operation 5 After an emergency stop or trouble with brakes do not operate machine until brake systems have been inspected and repaired END OF WORK PACKAGE 0006 00 9 10 3930 641 10 DECAL AND DATA PLATE GUIDE 0007 00 SCOPE This work package includes illustrations showing the location of all decals and data plates on the machine DECALS AND DATA PLATES COLUMN RELEASE ON FACE OF STEERING CONTAINER LOCK LIGHT MASTER SERIAL NO PLATE ON COLUMN RELEASE LOCK INDICATOR PANEL RIGHT SIDE SHELF BEHIND SEAT ON VERTICAL SURFACE ON RH SIDE OF ENGINE TO LEFT OF DASH BLOCK BEHIND ALTERNATOR O GIVE ALL NUMBERS IN O All COMMUNICATIONS MODIFICATION NUMBER TRANSMISSION CONTROL e STEERING COLUMN MUST BE ite OPERATING POSITION 10 PERMIT CONTROL MOTION SELECT DIRECTION BY MOVING LEVER e SELECT SPEED BY ROTATING ON TURBOCHARGER HANDLE hank t o a T wA wd SET VIF XT run CATERPILLAR TURBOCHAPGER 422 0022 0007 00 1 10 3930 641 10 DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DECALS AND DATA PLATES CONTINUED im 9 4 RIGHT HAND SIDE OF FRAME O CAUTION HEARING PRO
118. ould impair operation is foreign material embedded in tread evident or sidewall area Remove foreign material 1f found b Check for loose or missing lug nuts b Two or more lug nuts are or valve stem caps missing or valve stem is damaged 0012 00 21 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 60 Weekly Left Side Battery Compart u ment 22 WARNING To avoid injury eye protection and acid resistant gloves must be worn when working around batteries DO NOT smoke use open flame make sparks or create other ignition sources around bat teries If a battery is giving off gases 1t can explode and cause injury Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery terminal a direct short will result in instant heating damage to equipment and injury to personnel e Sulfuric acid contained in batteries can cause serious burns If battery corrosion or electrolyte makes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may cause death or serious injury to personnel DO use compressed air to clean batteries Use a clean dry rag CAUTION To reduce battery damage check battery box for corrosion greenish whi
119. over radiator if necessary to bring engine up to operating temperature 0006 00 2 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME COLD CONTINUED Machine Operation a Test brakes and machine controls carefully b Move all hydraulic controls slowly to warm hydraulic oil Cycle each control several times Normal warm up period in extreme cold 1s 30 minutes Operate under a light load for the first five minutes of operation d Start driving very slowly for about 300 ft 91 4 m If a problem is noted notify Organizational Maintenance as required 8 Parking Machine a If machine will be parked for a short period park in a sheltered area out of the wind If shelter is not available park machine so that radiator does not face into the wind b If machine will be parked for a long shutdown period try to park on high ground and use planks or brush to make a raised and relatively dry surface Keep tires out of snow water ice and mud if possible c Clean snow ice and mud from machine as soon as possible after shutdown d Ifmachine will be parked for a long period of time have Organizational Maintenance prepare machine for storage e Ensure tires are properly inflated OPERATE IN EXTREME HEAT I General During very hot weather it may be necessary to alter operating procedures to prevent machine from overheat ing a Avoid continuous high engine RPM However it is important t
120. pply brakes 8 Left Brake Pedal Press to neutralize transmission and apply brakes 0004 00 2 10 3930 641 10 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 MAST CONTROLS P DE SIDE conr 7 LOCKS b TUT a 422 0037 CONTROL OR INDICATOR FUNCTION 9 Side Tilt Control Lever Tilts tophandler to the side Pull back to clockwise right Push forward to tilt counterclockwise left 10 Container Locks Control Lever Locks tophandler to container Pull back to lock Push forward to unlock 11 Tilt Control Lever Tilts mast assembly forward or back Pull back to tilt up Push forward to tilt down 12 Lift Control Lever Raises and lowers container Pull back to raise Push forward to lower 13 Side Shift Control Lever Side shifts container Pull back to shift right Push forward to shift left 0004 00 3 10 3930 641 10 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 HEATER AND DOME LIGHT CONTROLS 14 422 0038 CONTROL OR INDICATOR FUNCTION 14 Heater Temperature Control Adjust switch between OFF and WARM to control amount of heat 15 Dome Light Switch Toggle switch between OFF and ON to control dome light 16 Floor Heater Located below container lock light panel Adjust switch between OFF and ON to control amount of heat 17 Fan Speed Control Rotate clockwise right through OFF low L medium
121. publication or form Include ZIP Code FROM Activity and location Include ZIP Code AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s Manual for Truck Container Handler Rough Terrain 50 000 Lb Capacity Diesel Engine Driven DED TM 10 3930 641 10 15 May 2006 Pneumatic Tires PT Model DV43 ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO 0017 00 2 Part number supplied for item 2 is incorrect TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to addressee listed in publication FROM Activity and location Include Code DATE PART tl REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE TOTAL NO PAGE COLM LINE REFERENCE FIGURE ITEM OF MAJOR NO NO NO NO NO NO ITEMS PERO E OET ACION SUPPORTED NATIONAL STOCK NUMBER a PART 11 REMARK 4 el nde Er y S Or SUI fi ment of publications and be TYPED GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 DATE Use Part reverse for Repair Parts and Special
122. r and blades WARNING Improperly inflated tires can cause excessive heat buildup resulting in blowouts Failure to follow this warning may cause injury to personnel or damage to equipment 39 After Left Front a Visually check left front tire for Tire has cuts abrasions or Wheel and cuts abrasions or bulges in tread or bulges in tread or sidewall Tire sidewall area Check for uneven area Other damage that wear or underinflation Look for foreign material embedded in tread or sidewall area Remove foreign material if found b Check for loose or missing lug nuts b or valve stem caps 0012 00 12 would impair operation is evident Two or more lug nuts are missing or valve stem is damaged 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED ITEM NO 40 41 42 43 44 MAN INTERVAL HOURS LOCATION ITEM TO CHECK SERVICE Steering Hydraulic Cylinders Cab Door Left Mirror and Ladders Below Oper ator Com partment PROCEDURE Check steering linkage for cracks distortion or damage b Check left front steering cylinder and hoses for damage or leaks Check all hydraulic cylinders and hoses for damage or leaks Check door for damage or missing components Check left side mirror and front and rear ladders for damage or missing components Check hoses cables and connections below left side of operator compart
123. r Usual Conditions Operator s Seat Controls 7 4 Preventive Maintenance Checks and Services PMCS I ttOQUCL OE A bane oa ele bas ee eee ee Procedu S il a RO AS Oe Oe bee ar References Reporting Equipment Improvement Recommendations EIRs Risht Hand Instrument Panel ecosport wee ewe ohn Hee ee che ehe Seat Controls Operator Scc Lea dpa wad ee dw eee eke dow Rel es Slave Starting Start Engine Steering Column Mounted Controls Steering System Theory of Operation estira Theory O o aad x ai raue Air Inletand Exhaust System occ Sw eke eek Sheek ee eee eee eet Brake 224 eto E dame A SEM leew Mie falus ee Se Fuel System Theory of Operation seiu ds an toe ee Gaede a Hydraulic Syste Desv Ende oe oud be bus ethan eee ees Mast Hydraulic System ud oua Serie aude SIM nones A eM did ta Index 3 Work Package Page 0006 00 5 0006 00 2 0006 00 3 0006 00 4 0006 00 5 0006 00 5 0006 00 5 0005 00 6 0006 00 1 0005 00 1 0006 00 1 0005 00 1 0004 00 5 0011 00 1 0012 00 1 0013 00 1 0001 00 1 0004 00 6 0004 00 5
124. r completely fills sight gage SIGHT GAGE 422 0061 14 Before Tires and Visually check right side tires for Low or flat tire is evident Wheels obviously low tire pressure 15 Before Lights Check right front headlight and flood Missing or damaged compo lights for missing or damaged compo nents are evident if required nents for mission 16 Before Fire Extin a Visually check for missing or dam a Fire extinguisher is miss guisher aged fire extinguisher Ensure it is ing or damaged securely stowed in mounting bracket b Check gage for reading in green b Pressure gage needle is in area on gage red area c Check for damaged or missing seal c Seal is broken or missing d Inspect fire extinguisher inspection d Inspection date is not cur tag rent and or tag is missing 0012 00 5 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF CAB INTERIOR 17 Before Operator a Enter cab and occupy seat Station b Adjust seat WP 0004 00 Ensure b Seat will not adjust lock in seat adjustments can be made and place seat locks in place Check and adjust rearview mirror With assistance check and adjust side view mirrors d Check seat belt for damage and d Seat belt is missing dam proper operation Adjust as needed aged or can not b
125. r overhead wires Failure to follow this warn ing may result in injury or death to personnel or damage to equipment To avoid tipping over be careful when crossing or working on hills banks or slopes Look behind machine before backing up Wear your seat belt Know stopping distance of your machine at any speed then adjust speed accordingly Match speed with job conditions Do not coast Failure to follow this warning may cause injury or death to personnel or damage to equipment Do NOT lift container unless green LOAD LOCKS LOCKED light is on Failure to follow this warning may result in injury or death to personnel or damage to equipment 10 3930 641 10 S WARNING 52 NBC EXPOSURE If NBC exposure is suspected personnel wearing protective equipment must handle all air cleaner media Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel For more information refer to FM 3 3 Chemical and Biological Contamination Avoidance EM 3 5 NBC Decontamination FM 3 7 NBC Field Handbook and FM 3 3 1 Nuclear Contamination Avoid ance IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PER SONNEL WEARING FULL NBC PROTEC TIVE EQUIPMENT SEE OPERATOR MAINTENANCE MANUAL 7690 01 114 3702 To order this NBC decal use National Stock Number NSN 7690 01
126. r storing and locking the wheel when not in use Pushing the wheel into the stored position also moves the transmission control lever to NEUTRAL Ze Supplemental Steering The supplemental steering system has two purposes It provides an oil supply for the steering system if the primary system fails or if the engine stops when the machine is moving It also adds oil to the primary oil flow when the engine RPM is less than 1 170 and the machine 1s moving 3 Flow Switch This switch warns the operator of a primary pump or line failure STEERING WHEEL AND COLUMN FLOW SWITCH le 2 91 OF 0003 00 2 422 0031 10 3930 641 10 THEORY OF OPERATION CONTINUED 0003 00 BRAKE SYSTEM 1 Transmission Neutralizer Control Valve The control valve causes the transmission to shift into neutral when the left brake pedal 15 pushed This provides full engine power to the hydraulic system 2 Service Brakes Service brakes are o1l activated disc type Pushing either brake pedal causes pressurized oil from the brake control valve to push against discs and plates in the brake housing causing friction This friction causes the wheel to turn slower or stop If the accumulator charging circuit malfunctions causing pressure to drop below 700 psi 4 826 kPa the brakes will automatically be activated 3 Emergency and Parking Brake Control Valve This valve controls oil flow from the accumulator to the emergency and pa
127. rature 5 9 F 32 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9 5 32 F APPROXIMATE CONVERSION FACTORS To Change Multiply By Kilopascals Kilometers per Liter 0 425 Kilometers per Hour 1 609 Inches 2 540 Feet 0 305 Yards 0 914 Miles 1 609 Sq Inches 6 451 Sq Feet 0 093 Sq Yards 0 836 Sq Miles 2 590 5 0 405 Cubic Feet 0 028 Cubic Yards 0 765 Fluid Ounces 29 573 Pints 0 473 Quarts 0 946 Gallons 3 785 Ounces 28 349 Pounds 0 454 Short Tons 0 907 Pound Feet 1 356 Pounds per Sq 6 895 Inch Miles per Gallon Miles per Hour To Change Multiply By Pounds Pounds per Sq Inch Miles per Gallon Centimeters 0 394 Meters 3 280 Meters 1 094 Kilometers 0 621 Sq Centimeters 0 155 Sq Meters 10 764 Sq Meters 1 196 Sq Kilometers 0 386 Sq Hectometers 2 471 Cubic Meters 35 315 Cubic Meters 1 308 Milliliters 0 034 Liters 2 113 Liters 1 057 Liters 0 264 Grams 0 035 2 205 Kilograms Metric Tons 1 102 Newton Meters 0 738 Kilopascals 0 145 Kilometers per Liter 2 354 Kilometers per Hour Miles per Hour 0 621 PIN 048583 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 wat
128. rking brake It s manually activated by the operator Pulling out on the parking brake control knob on the right side of steering column causes the brake to be applied Pushing in on knob causes the brake to release TRANSMISSION NEUTRALIZER EMERGENCY AND PARKING CONTROL VALVE BRAKE CONTROL VALVE ns Lu 422 0032 SERVICE BRAKES 0003 00 3 10 3930 641 10 THEORY OF OPERATION CONTINUED 0003 00 ELECTRICAL SYSTEM 1 The electrical system consists of four 12 volt batteries connected in series parallel with negative grounding providing 24 volts to operate the electrical system and components The electrical system contains all the necessary switches circuit breakers fuses relays harnesses and connectors to operate the machine including a NATO slave receptacle The electrical system includes the following lights a b C d e Auxiliary Floodlights One on each side on top of ROPS Headlights One on each side of lamp group mounted on outside Front Floodlights One on each side of lamp group mounted on inside Stop and Taillights Combination light mounted on each side of radiator guard below floodlights Rear Floodlights One on each side of radiator guard above stop and taillights FRONT AUXILIARY FLOODLIGHTS HEADLIGHTS STOP AND TAILLIGHTS gt REAR FLOODLIGHTS FRONT FLOODLIGHTS AUXILIARY 422 0033 HEADLIGHTS FLOODLIGHTS 0003 00 4 10 3930 641 10
129. rom One Inspect speed control linkage at Notify Organizational Speed or Direction to Another or Shifts access opening behind operator s Maintenance Rough cab for defective parts 2 Transmission Shifts Slowly Check transmission oil level WP If transmission oil is low fill to 0012 00 correct level and WP 0012 00 If problem still exists notify Organizational Maintenance 3 Transmission Doesn t Work When Speed Check transmission oil level WP If transmission oil is low fill to Selection Lever Is Placed in Any Speed 0012 00 correct level WP 0011 00 and WP 0012 00 If problem still exists notify Organizational Maintenance 4 Transmission Overheats Torque Converter 1 Check transmission oil level If transmission oil is low fill to Temperature Gage Needle is in the Red WP 0012 00 the correct level WP 001100 WP 0012 00 If oil level 15 OK go to test step 2 2 Inspecttransmission magnetic If necessary clean magnetic strainer WP 0012 00 strainer WP 0012 00 If magnetic strainer is OK or if problem still exists notify Organizational Maintenance TRANSFER CASES 1 System Loses Oil Check all lines fittings drain Notify Organizational and plug for leaks Maintenance 2 Noisy Transfer Gears Check transmission oil level WP If transmission oil is low fill to 0012 00 correct level WP 0011 00 and WP 0012 00 If problem still exists notify Organizational Maintenance
130. rsonnel a Check coolant level at frequent intervals and keep radiator cap tight b Ensure radiator is free of bugs dust and other foreign debris c Check fan belt tension frequently Report any damaged or loose belts to Organizational Maintenance Lubrication Lubricate according WP 0011 00 Preventive Maintenance Checks and Services PMCS Introduction with the tem perature range that applies to the highest expected temperature Air Cleaner a Check air cleaner indicator frequently Air cleaner filters may need to be serviced at more frequent intervals than normal b Notify Organizational Maintenance to service air cleaner filters 1f red air cleaner indicator light comes on Parking Machine a Park machine under cover if possible Cover windshield to protect against sand blasting b Ensure all tires are inflated to proper pressure c Check frequently for rust Clean and lubricate machine to help prevent deterioration OPERATE IN MUD OR SOFT SURFACES 1 Before entering mud or other soft surfaces select low transmission gear ranges Enter soft area at a medium speed for gear range selected Maintain steady pressure on accelerator pedal to keep machine rolling until solid ground 15 reached DO NOT accelerate to point where wheels spin 1f possible If machine gets stuck try to pull out slowly or rock 1t back and forth always in low range in a low gear Boards brush or similar materials may be placed under
131. sonnel SOLVENT CLEANING COMPOUND WARNING TIRES e Operating machine with underinflated or defective tire may lead to tire failure and loss of traction or con trol Failure to follow this warning may cause injury to personnel or damage to equipment e If tire pressure is 0 psi 0 kPa DO NOT inflate Notify Organizational Maintenance Failure to follow this warning may cause injury or death to personnel e Use a self inflating chuck and stand at a distance behind tire when inflating tire Failure to follow this warning may cause injury or death to personnel WARNING TOWING RTCH e Always block wheels before preparing machine for towing e DO NOT use a tow line Use a medium duty tow bar with bumper blocks e DO NOT allow personnel on machine that is being towed e DO NOT tow faster than 5 mph 8 kph e Failure to follow these warnings may result in injury or death to personnel h 10 3930 641 10 A WARNING WORK SAFETY Lifting cables chains hooks and slings used for lifting machine must be in good condition and of suit able capacity Failure to follow this warning may cause injury or death to personnel and damage to equipment Improper use of lifting equipment and improper attachment of cables to machine may cause injury to personnel and damage to equipment Observe all standard rules of safety Hitch and steering movement can reduce clearances suddenly and cause injury Always stop engine BEFORE
132. te powder and DO NOT jerk or pull on battery cables during visual inspection a Open battery compartment cover Holddown 15 loose or dam Check battery holddowns for loose aged ness or damage b Inspect each battery for a cracked b Battery case 15 cracked case and evidence of leaking leaks are evident c Check for damaged or missing bat c Damaged or missing filler tery filler caps caps are noted 0012 00 22 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 LOCATION ITEM TO ITEM MAN CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 60 Weekly Left Side d Check for missing broken split or d Damage is noted Cont Battery frayed battery cables Compart ment FILLER CAPS BATTERY CABLES 422 0063 e Check for damaged battery posts e Damage 15 noted f Check for rust corrosion and Rust or corrosion is noted cleanness g Check battery cable grommets for dry rot and loose or missing condi tion h Check electrolyte level Electrolyte h Electrolyte level 15 low must be to bottom of filler openings 1 Notify Organizational Maintenance of any problems noted 0012 00 23 10 3930 641 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 CONTINUED 0012 00 LOCATION ITEM TO ITEM CHECK NOT FULLY MISSION NO INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF 61 Weekly Exhaust Check exhaust sys
133. tem pipes clamps Damage or leaks are noted System and muffler for looseness leakage and damage 62 Weekly Right Side Battery Compart ment 22 i WARNING To avoid injury eye protection and acid resistant gloves must be worn when working around batteries DO NOT smoke use open flame make sparks or create other ignition sources around bat teries If a battery is giving off gases it can explode and cause injury Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery terminal a direct short will result in instant heating damage to equipment and injury to personnel e Sulfuric acid contained in batteries can cause serious burns If battery corrosion or electrolyte makes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may cause death or serious injury to personnel DO NOT use compressed air to clean batteries Use a clean dry rag CAUTION To reduce battery damage check battery compartment for corrosion greenish white powder and DO NOT jerk or pull on battery cables during visual inspection a Open battery compartment cover a Holddown is loose or dam Check battery holddowns for loose aged ness or damage b Inspect each battery for a cracked b Battery case is cracked case and evidence of leaking leaks are evident c Check for damaged or missing bat c Damaged
134. tem pressure has been relieved Tighten all connections before applying pressure Escaping hydraulic fluid under pressure can penetrate the skin causing injury or death to personnel b Shut down engine Move hydraulic control levers through all positions to relieve hydraulic system pressure 0005 00 13 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 TOPHANDLER REMOVAL AND INSTALLATION CONTINUED 1 Removal Continued NOTE For access to hydraulic and electrical connections it will be necessary to climb up fender and stand on tire left side c Disconnect two hydraulic connections at tophandler Cap or plug openings d Disconnect electrical connector e Remove two safety chains f Start engine g Back RTCH slowly and directly away from tophandler until forks are clear ELECTRICAL HYDRAULIC CONNECTION SAFETY CONNECTIONS CHAIN SAFETY CHAIN SCA um pa a 2 422 0055 422 0056 2 Installation a Slowly approach tophandler which is resting on an elevated support such as a container b Insert forks into openings on tophandler c Inch RTCH forward until forks are fully inserted into tophandler WARNING DO NOT disconnect or remove any hydraulic system line or fitting unless engine 15 shut down and hydraulic system pressure has been relieved Tighten all connections before applying pressure Escaping hydraulic fluid under pressure can penetrate the skin caus
135. ting machine DO NOT use steering wheel as a handhold Failure to follow this warning may cause injury to personnel l Mount and dismount machine only at locations with steps and or grab handles 2 Ensure steps and or grab handles are clean and secure before using them 3 Face machine when mounting and dismounting 4 Maintain minimum three point contact at all times 1 e two feet and one hand or two hands and one foot 5 Never mount or dismount a moving machine 6 Never jump from machine 7 DO NOT mount or dismount machine while carrying tools or supplies INITIAL ADJUSTMENTS AND DAILY CHECKS NOTE Refer to WP 0004 00 for the location and operation of controls and indicators l Ensure main disconnect switch 15 in clockwise right ON position Ze Perform Before operation Preventive Maintenance Checks and Services PMCS BEFORE starting engind WP 0011 00 and WP 0012 00 0005 00 1 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 INITIAL ADJUSTMENTS AND DAILY CHECKS CONTINUED 3 Occupy seat Adjust seat to allow full brake pedal travel with operator s back against seat back This will permit appli cation of maximum force on brake pedal 4 Adjust rearview and exterior side view mirrors as required WARNING DO NOT operate machine unless seat belt has been fastened Failure to follow this warning may cause injury or death to personnel Fasten seat belt Turn steering col
136. tires to provide traction Notify Organizational Maintenance to clean and inspect for proper lubrication 0006 00 4 10 3930 641 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN SANDY OR DUSTY CONDITIONS l Maintain steady even movement with transmission in lower gears Try to keep machine rolling without straining engine and powertrain If machine gets stuck notify Organizational Maintenance 2 When operating machine on soft sand at slow speeds tire inflation pressure may decreased for improved traction Refer to FM 21 305 3 Whenever operating in sandy or dusty areas you should a Have engine air cleaner serviced more frequently Notify Organizational Maintenance b Ensure each tire has a valve cap c Clean engine oil filler tube and transmission fluid filler tube before dipsticks are removed to check fluid levels Clean accumulations of sand and dirt from around fluid filler locations before checking or adding fluids d Clean spouts of fuel containers and areas around filler caps on fuel tanks before adding fuel Under extremely sandy or dusty conditions filter fuel when filling tanks e Inspect mast slider blocks and mast chains daily f Check hydraulic cylinder rods for leakage Dirt may enter system where leak starts Notify Organizational Mainte nance if leaks are found g Cover windshield to protect against sand blasting Notify Organizational Maintenance to clean inspect and
137. ts of End COEI and Basic Issue Items BII Lists Additional Authorization List and Expendable and Durable Items List 10 3930 641 10 FEATURES OF THIS MANUAL 1 WARNINGs CAUTIONS NOTES subject headings and other important information are highlighted in BOLD print as a visual aid WARNING A WARNING indicates a hazard that may result in injury or death to personnel CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment NOTE A NOTE is a statement containing information that will make the procedures easier to perform 2 Statements and words of particular interest may be printed CAPITAL LETTERS to create emphasis Within a procedural step reference may be made to another work package in this manual or to another manual These references indicate where you should look for more complete information a If you told Service precleaner WP 0012 00 go WP 0012 00 in this manual for instructions on this Service b If you are told For complete information on servicing batteries refer to 9 6140 200 14 go to the References work package WP 0013 00 for complete information on the referenced manual 4 Illustrations are placed after or as close to the procedural steps to which they apply Callouts placed on the art are text or numbers 5 Numbers located at lower right corner of art e g 422 001 422
138. tures 0002 00 1 Dades uq 0002 00 5 Descrptionand Data re ie Rec ae 0002 00 1 Equipment Improvement Recommendations EIRs Reporting 0001 00 1 Exhaust System Theory of Operation 0003 00 2 Expendable and Durable List er UE 0016 00 1 Index 1 10 3930 641 10 INDEX Continued Subject Work Package Page F Foot Operated Controls aaa as eee ee SW eee iau eM Ld run ead e ae 0004 00 2 ia O 0006 00 6 H Heater and Dome Light eEontfrob as wee SP ER v EU RR 0004 00 4 Hydraulic System Theory of Operation 0003 00 5 Indicator Panel Container Lock whe he eee 955866 ERE EET 0004 00 13 Initial Adjustments and Daily Checks 0005 00 1 Instrument Panel NN 0004 00 9 Riehr Hand a o aa 0004 00 6 L Left Hand Instrument Panel oia ann eu Banane a 0004 00 9 List Basic Issue tems BD SA AAA ea 0014 00 1 Components of End Item COED 2 berrea a 0014 00 1 List of Abbreviations Acronyms 0001 00 3 Location and Description of Major Components 0002 00 2 Lubrication Procedures General
139. ubleshooting Proceed to Machine Warmup 0005 00 5 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 MACHINE WARMUP 1 Operate engine at low idle for five minutes to warm up engine During warmup monitor instrument panel indicators for any signs of abnormal temperatures or pressures Shut down engine at the first sign of a problem 2 Continue to warm up machine as follows a Iftemperature is greater than 32 F 0 C warm up machine for total of approximately 15 minutes b If temperature is less than 32 F 0 C warm up machine for a total of approximately 30 minutes c lIftemperature is less than 0 F 18 C or if hydraulic functions are sluggish additional time may be needed 3 Cycle steering and machine controls to assist in hydraulic system warmup Ensure that all are functioning properly OPERATE MACHINE WARNING Be ALERT for personnel in the area while operating machine Always check to ensure area is clear of personnel and obstructions before moving machine or raising or lowering container handler forks Fail ure to follow this warning may cause injury or death to personnel or damage to equipment DO NOT allow riders on machine Failure to follow this warning may cause injury or death to person nel To avoid tipping over be careful when crossing or working on hills banks or slopes Look behind machine before backing up Wear your seat belt Know stopping distance of your machine at a
140. uires the listed 1tem C Operator Crew 3 Column 3 National Stock Number This 1s the National Stock Number assigned to the item which you can use to requisition it 4 Column 4 Description CAGEC and Part Number This provides the other information you need to identify the item Column 5 Unit of Measure U M This column shows physical measurement count of an item such as gal lon dozen gross etc 0016 00 1 10 3930 641 10 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 1 ITEM NUMBER 3 NATIONAL STOCK NUMBER 6850 01 464 9125 6850 00 181 7933 6850 01 441 3223 6850 01 474 2318 6850 01 474 2320 6850 01 474 2321 6850 00 926 2275 7930 00 282 9699 9140 00 286 5294 9140 00 286 5295 9140 00 286 5296 9150 01 197 7688 9150 01 197 7693 9150 01 197 7690 9150 01 197 7692 4 DESCRIPTION CAGEC AND PART NUMBER ANTIFREEZE Permanent Ethylene Glycol Inhibited Heavy Duty 58536 A A 52624 1 Gallon Can 81349 MILA46153 5 Gallon Container 58536 A A 52624 55 Gallon Drum CLEANING COMPOUND Solvent 81349 MIL PRF 680 1 Gallon Can 5 Gallon Can 55 Gallon Drum CLEANING COMPOUND Windshield OFTT5 0854 000 16 Ounce Bottle DETERGENT General Purpose Liquid 83421 7930 00 282 9699 1 Gallon Can DIESEL FUEL DF 2 Grade 81346 ASTM D 975 Bulk 5 Gallon Can 55 Gallon Drum GREASE Automotive and Artillery GAA
141. umn lock key clockwise right to unlock column release knob Hold steering wheel and pull column release knob out dm A Adjust column and release knob when column is in desired position STEERING COLUMN RELEASE KNOB STEERING COLUMN LOCK 422 0035 0005 00 2 10 3930 641 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 INITIAL ADJUSTMENTS AND DAILY CHECKS CONTINUED NOTE DO NOT start engine at this time 9 Turn power switch on right hand instrument panel to ON and perform panel test a Press PANEL TEST switch All indicator lights must illuminate PANEL TEST SWITCH 422 0040 b Ifall lights do not illuminate refer tb WP 0009 00 perform troubleshooting 10 Release panel test switch and observe indicators They should indicate as follows a HIGH FUEL indicator ON If indicator does not come on add fuel WP 0012 00 b NO COOLANT FLOW indicator ON LOW OIL indicator OFF If light is on add engine oil WP 0011 00 and WP 0012 00 LOW HYD oil indicator OFF If light is on add oil to hydraulic tank WP 0011 00 and WP 0012 00 PLUGGED FILTER indicators all OFF If indicator on notify Organizational Maintenance HI TEMP HYD OIL indicator OFF If indicator on notify Organizational Maintenance SUPP STER indicator ON LOW PRESS indicator flashing ON and OFF PARK BRAKE ON indicator ON if parking brake 15 engaged ALTERNATOR INDICATOR ON
142. ure RED LOW GREEN NORMAL Provides light for switches and fuses in right hand instrument panel A metered amount of starting fluid ether is released each time starting aid switch is operated in temperatures below 32 F O C 0004 00 6 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 RIGHT HAND INSTRUMENT PANEL CONTINUED CONTROL OR INDICATOR FUNCTION Engine Oil Pressure Gauge Indicates engine lubricating oil pressure RED LOW WHITE NORMAL Low Idle GREEN NORMAL High Idle Voltmeter Indicates electrical charging system output voltage RED 21 volts or lower Bad battery charge when engine RPM is at low idle BLACK AND WHITE 21 to 24 volts below normal battery charge when engine RPM is at low idle BLACK AND GREEN 24 to 26 volts normal battery charge when engine RPM is at low idle GREEN 26 to 30 volts normal battery charge when engine RPM is at high idle RED 30 volts or higher above normal battery charge when engine RPM is at high idle 0004 00 7 10 3930 641 10 DESCRIPTION AND USE OPERATOR CONTROLS AND INDICATORS CONTINUED 0004 00 RIGHT HAND INSTRUMENT PANEL CONTINUED ph 30 ALTERNATOR 31 422 0040 CONTROL OR INDICATOR FUNCTION 30 Power Switch Three position keyed switch ON turns on electrical system power when key is turned clockwise right to ON position OFF turns off ele
143. vals are based on normal operation Lubricate more during constant use and less during inactive peri ods Use correct grade of lubricant for seasonal temperature expected Refer to KEY on pages 0011 00 4 and 0011 00 5 3 For equipment under manufacturer s warranty hardtime intervals shall be followed Shorten intervals if lubricants are known to be contaminated or if operation is under adverse conditions e g longer than usual operating hours extended idling periods extreme dust etc 4 Keep all lubricants in an environmental storage container and store in a clean dry place away from extreme heat Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep lubrication equipment clean and ready for use Clean top of container before opening mb En WARNING m Solvent cleaning compound MIL PRF 680 Type 15 an environmentally compliant and low toxic material However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ventilated areas Keep away from open flames and other sources of ignition Failure to do so may cause injury or death to personnel 3 Clean area around lubrication points with solvent cleaning compound Item 2 WP 0016 00 or equivalent before lubri cating equipment Keep all external parts of equipment not requiring lubrication free of lubricants After lubrication off excess lubricant to prevent accumulation of fore
144. vel in radiator d Notify Organizational Maintenance if system needs service Fuel Tank a Do not allow fuel tank to remain partially empty for long period of time in extremely cold weather b Fill fuel tank after each work period to help avoid water condensation in tank c Remove all ice and snow from around fuel filler opening before refueling Electrical System a Inspect battery cables wiring harnesses and wiring b Check for breaks or cracks caused by cold weather Report any problems found to Organizational Maintenance c Conserve batteries Use lights and other electrical equipment as little as possible Lubrication Lubricate according to Preventive Maintenance Checks and Services PMCS Introduction WP 001 00 with temper ature range that applies to lowest expected temperature Engine Operation NOTE If oil drips from engine dipstick it is thin enough for engine to be started Before starting ensure fuel and oil in engine and transmission are thin enough to flow b Use Starting Engine Below 32 F 0 C Using Ether Starting Aid procedure in WP 0005 00 and allow engine time to reach operating temperature Be alert that tires may be frozen to ground c Run engine at reduced speed only long enough to circulate oil through engine Then increase engine speed and warm up engine Low idling speeds during extremely cold temperatures can result in incomplete combustion and form heavy deposits on valves d C
145. y trailers rail aircraft or marine vessels The following 15 a list of RTCH capabilities and features 1 2 3 4 5 6 7 Operates over rough terrain including beaches snow mud and cross country Fords up to 60 in 152 cm in fresh or salt water Comes with a 20 ft tophandler may also use a 35 ft or 40 ft tophandler Raises lowers tilts forward or backward side shifts or side tilts a container load Lifts a container from 12 in 30 below ground level to 118 in 300 above ground level measured to bottom of container Articulates bends in center for easy load handling Equipped with a NATO slave receptacle 0002 00 1 10 3930 641 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Radiator Upper Engine Access Panels Hood Operator Cab Tilt Cylinder Mast Forks Wheels Axles and Final Drives Steering Cylinder Hitch Hydraulic Tank Fuel Tank Lower Engine Access Panels Battery Box Counterweights Towing Pintle q T 8 422 0018 DESCRIPTION Transfers heat from coolant passing through radiator to the outside air Grille faces rear Two on each side of machine Allow access to engine for maintenance Hinged for easy access Two piece can be removed for engine maintenance Equipped with Rollover Protective Structure ROPS to protect operator One on

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