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TM 5-3810-293-14&P-1 for

1. CHECK RESERVOIR el CLUTCH MASTER CYLINDER S POWER TAKE OFF SHAFT 2 FITTINGS La BEES CLEAN FLUSH FLUID LEVEL Pume CONTROL ROD TRANSMISSION CONTROL RODS y HOURS HYDRAULIC DIL Link REFILL CRANKCASE A ANNUALLY NOTE STEERING GEAR Sc WHEN FILLING REAR AXLES TRANSMISSION LM FOOT BRAKE FOOT TREADLE LLL l DIP STICK pp amp P T O CASES REMOVE OIL LEVEL PLUG RI ADJUSTING ROD 1 FITTING REPLACE ENTER OIL LEVEL EE IS LEVEL WITH BOTTOM OF 22 STEERING LINK 2 FITTINGS Latus __ DIL LEVEL STICK 211 EVERV 260 HOURS E STEERING KNUCKLE i2 FITTINGS E gi fe STEERING KNUCKCE 2 FUT TINGS malo ENGINE TME 9 TIE ROD CLAMP ASSY 2 FITTINGS 7 WHEEL BEARING NA WHEEL BEARING Kee 275 THE ROD N FITTASI Le CLEAN REPACK ROD FITTING CLUTCH THROWOUT SHAFT Io rer E REPLACE FILTER jie CL TCH THROWOUT BRG STARTING MOTOR Ge BOGIE BEAM 2 TRANSMISSION ROO JOINTS FILTER 7 n GL BEAM CLUTCH SHAFT BEARING 11 FITTING AOD 1 FITTING TRANSMISSION Fic LER uu u mn BA POWER STEERING LINK 13 FITTINGS STEERING KNUCKLE 12 FITTINGSI Tet STEER NG CYLINDER 1 FITTING WHEEL BEARING a STEERING KNUCKLE 2 FITTINGS 2 TTIE ROD 11 FITTING WHEEL CLEAN amp REPACK WH
2. MULTIPURPOSE GREASE PRH AMBIENT MILITARV EQUIVALENT SVMBOL SPEC NO RANGE SPEC NO LUBRICANTS MANUFACTURERS 472A Below 10 F MIL L 7645 Litholine Atlantic Richfield Oil Co NLGI 0 EP 32 C MIL G 10924 Industrial 0 MIL G 23827 EP Sinclair MIL G 2349 MIL G 81827 Conolith EP 0 Continental Oil Company Rolubricant 0 Humble Oil and Refining Company Mobilux EP 0 Mobil Oil Corporation Alvania EPRO Shell Oil Company Prestige EP 0 Sun Oil Co DX Division Multifak EP 0 Texaco Incorporated 472B 20 to 40 F MIL L 7645 Amolith No 1 American Oil Company NLGI 1 EP 29 to 4 C MIL G 10924 EP MIL G 23827 MIL G 2349 pass Atlantic Richfield Company MIL G 81822 EP Sinclair Conolith EP 1 Continental Oil Companv Rolubricant 1 Humble Oil and Refining Company Mobilux EP 1 Mobi Oil Corporation Alvania EP 1 Shell Oil Company Prestige EP 1 Sun Oil Co DX Division Multifak EP 1 Texaco Incorporated 472C 1420 to 125 F MIL L 7645 Amolith No 2 American Oil Company NLGI 2 EP 6 to 52 C MIL G 10924 EP MI 7 us e Sa peal EP Atlantic Richfield Companv MIL G 81827 ee Sinclair Conolith EP 2 Continental Oil Companv Rolubricant 2 Humble and Refining Companv Mobilux EP 2 Mobil Oil Corporation Alvania EP 2 Shell Oil Company All Purpose Sun Oil Company EP 2 Multifak EP 2 Texaco Pumpability tests also required when used in centralized lubrication systems Consult manufac
3. 31 1 2 quarts 29 8 1 Detroit C 48 quarts 45 4 CUMMINS NAP AAO 2 iterata teer ene beate die tes 46 quarts 43 5 1 Engine Lube Oil including filter s Detroit Diesel 6VbSN desees 18 1 2 quarts 17 5 1 Cummins G190 ii sieb a a a nal eine Ia 18 1 2 quarts 17 5 1 Detroit Diesel 671 i A tete 20 quarts 18 9 Gummins NHEF 240 easter oa Att 22 quarts 20 8 1 Main Transmission Oil ele 17 pints 8 0 1 Fuller S GW gg CELERE 24 pints 11 4 Fuler TOOSE see bete iet L het 22 pints 10 4 Auxiliary Transmission Oil lejos cao EE 13 pints 6 2 I Spicer R 6941 Eo taka cte Un ie ee o ee bel ndr n tedio dte 13 pints 6 21 Hr eet 12 pints 5 7 1 Rear Axles Rockwell SSHD Front 32 pints 15 1 l Rear 28 pints 13 2 l Interaxle Differential net te m e EE EIE E Roue 2 pints 0 91 Rear Axles Rockwell SRHD Front 37 pints 17 5 1 Rear 3 6 pints 17 0 Interaxle Differential niger A ue 2 pints 0 9 1 Power Take Off TEE EE 6 quarts 5 7 1 iE 3 1 2 quarts 3 3 1 Hydraulic Oil Beservolt E 200 gallons 757 1 Winch Planetary Housings each 2 quarts 1 9 1 Swing Reducer HOUSING ivi deh loa alin 7 quarts 6 6 1 Ste
4. Section IV REMARKS 1 2 Reference code Remarks Change 3 3 2 26 TM 5 3810 293 14 amp P 1 APPENDIX 2 B CCE MANUFACTURER FIELD CAMPAIGNS AND MODIFICATION PROCEDURES APPROVAL OF FIELD CAMPAIGN OR MODIFICATION PLAN REPORT OF APPLIED MODIFICATION REPORT OF DEFICIENCV TARCOM REPORT OF DEFICIENCV THEATER FIELD CAMPAIGN OR MATERIEL CCE MANUFACTU S MODIFICATION PLAN REPAIR OR REPLACE FLOW REPORTING FIELD CAMPAIGN OR MODIFICATION PLAN 072413 3 2 33 3 2 34 blank TM 5 3810 293 14 amp P 1 APPENDIX 2 C BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED Section INTRODUCTION 1 This appendix lists basic issue items items troop installed or authorized which the CCE Crane and required by the crew operator for operation installation or operator s maintenance 2 General This basic issue items items troop installed or authorized list is divided into the following sections a Basic Issue Items isi SEO TE A list in alphabetical sequence of items which are furnished with and which must be turned in with the end item b Items Troop Installed or Authorized List Section A list in alphabetical sequence of items which at the discretion of the unit commander may accompany the end item but are NOT subject to be turned in with the end item 3 Explanation of Columns The fol
5. gt VIEWED FROM LEFT SIDE OF CARRIER FILLER LEVEL PLUG A112 Figure 4 20 Changing Main Transmission Oil CHANGE AUXILIARY TRANSMISSION OIL To change the oil in the auxiliary transmission proceed as follows see Figure 4 21 1 Drive the machine to warm the oil in the transmission to normal operating temperature 2 Remove the drain plug and drain the oil into a suitable container Clean the drain plug 3 Install the drain plug and remove the filler level plug Add oil through the filler level plug opening until the oil reaches the bottom of the opening Replace the filler level plug CHANGE PUMP DRIVE OIL To change the oil in the pump drive proceed as follows see Figure 4 22 1 4 18 PREVENTIVE MAINTENANCE VIEWED FROM LEFT SIDE OF CARRIER A113 ja Changing Auxiliarv Transmissio n Oil VIEWED FORWARD FROM BELOW CARRIER DRAIN PLUG Figure 4 22 Changing Pump Drive Oil 1 Engage the pump drive and run it until the oil is warmed to normal operating temperature 2 Remove the drain plug and drain the oil into a suitable container Clean the drain plug Replace the drain plug after all the oil has been drained from the pump drive 3 Remove the breather at the top of the pump drive wash it in fuel oil and dry it with compressed air 4 Clean the area around the oil level plug opening and then remove the oil level plug Add oil through the breather opening
6. 35 315 Cubic Meters Cubic 1 308 Milliliters Fluid Ounces 0 034 Liters Lk EE 2 113 Liters 1 057 RE Gall ns i Sen eege Zeen 0 264 f MS ara RI Ounces eve i 0 035 E Pounds d EE ees 2 205 Metric Short 1 102 Pounds Feet 0 738 Pounds per Square Inch 0 145 ometers per Liter Miles per Gallon 2 354 meters per Hour Miles per Hour 0 621 PIN 046755 003 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT pro
7. MM TELESCOPIC CONTROL BOX MECHANICAL ASSEMBLY Case Telescopic Actuating Arm Slide Bar Slide Block Actuating Bar Actuating Block Relay Base Relay Cover 2 1 23 Relay Radius Pointer amp Screws Packing Tubes Radius Plate Housing R H Radius Plate Housing LH Toggle Fastener Cam Follower Grub Screw z b uv 04 5 4 4 Way ius sa UR Lan Vera MI D GE A E a SE EN id ge gt STRUT JIB CONTROL BOX MECHANICAL ASSEMBLV 3 Slide Bar 12 Radius Plate Housing R H 4 Slide Block 13 Radius Plate Housing L H 5 Actuating Bar 14 Toggle Fastener 6 Actuating Block 15 Cam Follower 7 Relay Base 16 Grub Screw 8 Relay Cover 30 Case 9 Relay 31 Actuating Arm 10 Radius Pointer 32 Pivot Pin 11 Packing Tubes amp t Screws IMPORTANT 2 1 24 gt AX TELESCOPIC CONTROL BOX DRIVE ASSEMBLIES 20 Driven Pulley 25 Flexible Drive Cable 21 Anchor Bracket 26 Adjusting Stop 22 Anchor Bracket Bolts 27 Drive Pulley 23 Conduit 28 Bearing Bracket 24 Trunnion 29 Rotary Flexible Drive Shaft IMPORTANT 2 1 25 STRUT JIB CONTROL BOX DRIVE ASSEMBLIES 21 Anchor Bracket 26 22 Anchor Bracket Bolts 27 23 Conduit 28 24 Trunnion 40 25 Flexible Drive Cable 2 1 26 Adjusting Stop Drive Pullev Bearing Bracket Driven Pullev INDICATOR amp LOAD CELL ASSEMBLY REF
8. Describing these adjustments in detail 1 CAM CHANGE The cam is a brown fibre plate which is mounted within the Control Box secured by one wing nut on its boss Access to this cam is obtained by opening the front door of the Control Box All the 2 1 2 information required to identifv the cam is stamped on the face namelv a Crane on outriggers side and rear ratings condition b Length of boom or jib c Number of parts of line Additional duties may also be catered for e g Main boom with jib attached etc etc and it is most important to ensure that the correct cam is fitted to suit the working condition of the crane When fitting a cam locate it over it s mounting spindle and location dowel turning the cam and geared boss so that the cam slot lines up with the follower peg protruding from the top bracket of the cross slide When the cam is correctly located fully tighten the wing nut On the radius indicator the scale is also stamped with identifying information and must be changed when different boom lengths are employed and or jibs To change a radius scale lift it out of it s retaining guides and replace it with the appropriate scale 2 REEVING CHANGE In most cases the only adjustment necessary apart from ensuring that the correct cam is fitted to suit the number of parts is to change the scale of the weighing dial in the Control Box so that the correct number of parts appears in the window on the left hand si
9. NUMBER COMPONENT ASSEMBLY FUNCTION clo r nj np EQUIPMENT REMARKS ENGINE Engine Assembly Inspect Test Service Replace Repair Overhaul Crankcase Block Cylinder Head Engine Block Inspect Replace Repair Overhaul Cylinder Head Inspect Replace Repair Overhaul Crankshaft Inspect Replace Repair Bearings Main Inspect Replace Pulley Inspect Replace Flywheel Assembly Inspect Replace Repair Flywheel Housing Inspect Replace Repair Gear Spur Inspect Replace Pistons Connecting Rods Inspect Replace Repair Bearings and Rings Inspect Replace Repair Valves Camshafts and Timing System Valves Springs and Inspect Guides Replace Rocker Arms Inspect Replace Repair Covers and Gasket Rocker Inspect Arm and Side Covers Replace Repair Camshaft Bearings Timing Inspect Gears Replace Repair Change 3 3 2 13 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS ENGINE CONTINUED Engine Lubrication System Dipstick Inspect Replace Filter Oil Service Replace Repair Housing Oil Cooler Inspect Test Replace Repair Pan Oil Inspect Replace Pump Oil Inspect Replace Repair Element Cil Filter Service Replace Manifolds Inspect Replace Compressor Air Inspect Replace Repair Shafts and Adapter Inspect Replace CLUTCH Clutch Assembly Replace Repair Clu
10. TRUNNION PIN 2 FITTINGS 12 FITTINGS CLEAN amp REPACK WHEEL BRG ha a TEXT AL EE Tew EA EA BRAKE CLEVIS ROD PIN 12 FITTINGS LO CHART B ENGINE LUBRICATI CHART A GENERAL LUBRICATION LUBRICATION 1 5 Motor Od CAPACITY 451C MIL L 21048 SAE 30 s recommended foi TRANSMISSION SPICER 6352 LUBRICANT year round use when cold starting be accomobished 1 491 SEE CHART B Engine Manufacture for further information AUX TRANS SPICER 6 5 6 21 POWER TAKE OFF 35 3 31 A SEE CAR EE Ein Many 2 2 MULTIPURPOSE GREASE 472 SEE LUBE SPEC ee Cen ECKE 325 GT amp REAR AXLES 55 HD __ STEERING GEAR 254241 3 GEAR OIL 497 BELOW 32 to 90 F ABOVE 90 DETROIT DIESEL 6V SSNI enge 30 75 n POWER STEERING IEXTREME PRESSURF 12 C 1 e i AIR TEMP P amp H NO SAE NO 7 HYDRAULIC RESERVOIR 800 7670 Below 10 12 CI 451A 10W 510 32 4 HYDRAULIC OIL 484 SEE LUBE SPEC 5 HEAVY DUTY T sse AGMANOA4 0 4518 2020w usc can SEE 1 ABOVE x 32 F ro 90 F ALLSEASON 7 D 32 Ci 451C N LG I NO 2 1 Abov
11. XDP Indicates the requisition is in support of CONUS the CCE Crane but will be treated as non DSS USARAL parts shipments will be made directly from USARSO Depot Vendor to requisitioners 2 Weapon System Designator Code WSDC 7Y is the WSDC assigned to the crane 3 Distribution Code Code F will be cited in Card Column 54 for all CONUS only requisitions All OCONUS will cite the applicable code as cited in AR 725 50 c MILSTRIP Requisition Card Column Entries 1 NSN Requisitions See Appendix 1 B for Card Column entries 2 Non NSN Requisitions See Appendix i A for Card Column entries d Requisitioning and Flow of Requisitions 1 NSN Requisitions See paragraph 3 4 titled Requisitioning of Repair Parts 2 Non NSN Requisitions See paragraph 314 titled Requisitioning of Repair Parts 1 3 MAINTENANCE FORMS AND RECORDS DA Forms and Procedures used for the equipment maintenance will be those prescribed iii Section 2 12 3 1 2 090 SINGLE LINE ITEM REGUISITION SYSTEM DOCUMENT MECHANICAL 2 3316 APPENDIX 1 VARIAJ ELEMENT DEPT ADI Ge COOL Za MEN 35 DD FORM 1348m 1 MAR 74 EDITION OF APR 71 MAY BE USED wsielcjejnimj niwinli irfiel lr E e Et acon ie a Re ji E di iar ies m ER SE Rr VEO U A33 3 8 at Man
12. 100 Centimeters 1000 Millimeters 39 37 Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Kilometer 1000 Meters 0 621 Miles 1 Sq Kilometer 1 000 000 Sq Meters 0 386 Sq Miles MEIGHTS CUBIC MEASURE Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Cu Centimeter 1000 Cu Millimeters 0 06 Cu Inches 1 Kilogram 1000 Grams 2 2 lb 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons TEMPERATURE OCF 32 C LIQUID MEASURE 212 Fahrenheit is evuivalent to 100 Celsius 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 90 Fahrenheit is equivalent to 32 2 Celsius 1 Liter 1000 Milliliters 33 82 Fluid Ounces 32 Fahrenheit is equivalent to 0 Celsius 9 5C 32 F APPROXIMATE CONVERSION FACTORS TO CHANGE TO MULTIPLY BY Inches 3 a Centimeters 2 540 eet i 4L ee Se e Met T8 e bis pp PAS 0 305 Yards sequ UA da weeks Meters ce uad RET UN 0 914 HUE 1 609 Square Inches Square Centimeters 6 451 Square Feet Square Meters 0 093 Square Yards Square Meters 0 836 Square Square Kilometers 2 590 E Square Hectometers 0 405 Cubic Cubic Meters 0
13. CALIBRATING THE DYNAMOMETER 1 Remove the cam from the Control Box and rotate the cam mounting in a counter clockwise direction so that the RED pointer is moved to the extreme right hand side of the scale 2 Set the BLACK pointer to read zero with the hook block resting on the ground Adjuster at top right hand side of Indicator dial 3 Rig a convenient number of parts of line set the scale of the indicator so that the correct number of parts appear in the window on the dial Adjuster at top left hand side of dial a Hoist the maximum possible known weight within scale for that particular reeving 5 Set the Dynamometer by rotating the long hexagonal nut in the center of the Black dial after slackening the locknut on the opposite side of the Dynamometer just sufficient to allow the long nut to be turned with a wrench Turn this nut and shaft until the correct load reading is obtained on the black pointer in the Control Box Tighten the locknut lower the load so that the block is at rest and recheck the zero reading which may have to be readjusted Hoist the load again and recheck the black pointer reading readjusting the Dynamometer if necessary Repeat this procedure until a consistently accurate reading is obtained It is wise to exercise the system 5 or 6 times to be sure of the readings Using a 1 1 diameter drill drill through the Black dial on the Dynamometer from the opposite side of the center block using the guide hole pr
14. If oil is added to the axles allow sufficient time for any excess oil to run out before installing the filler level plug Under no circumstances should the differential be overfilled VIEWED FROM LEFT SIDE OF CARRIER FILLER LEVEL PLUG A111 Figure 4 5 Differential Oil Level Plug CHECK MAIN TRANSMISSION OIL LEVEL Clean the area around the filler level plug and remove the plug see Figure 4 6 The oil in the main transmission should be just up to the bottom of the opening Be sure the machine is level when checking the oil level If oil is added to the transmission allow sufficient time for any excess oil to run out before installing the filler level plug Do not overfill the transmission Ke VIEWED FROM LEFT SIDE OF CARRIER M FILLER LEVEL PLUG A112 Figure 4 6 Main Transmission Oil Level Plug SECTION IV CHECK AUXILIARV TRANSMISSION OIL LEVEL Clean the area around the filler level plug and remove the plug seel Figure 4 7 The oil in the auxiliary transmission should be just up to the bottom of the plug opening Be sure the machine is level when checking the oil level If oil is added to the auxiliary transmission allow sufficient time for any excess oil to run out before installing the filler level plug Do not overfill the transmission Ho VIEWED FROM LEFT SIDE OF CARRIER Figure 4 7 Auxiliary Transmission Oil Level Plug CHECK TIRES Each week check the tires for cuts bruises
15. TECHNICAL MANUAL l No 5 3810 293 14 amp 1 HEADQUARTERS DEPARTMENT OF THE ARMV WASHINGTON DC 15 September 1980 OPERATOR ORGANIZATIONAL DIRECT SUPPORT GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS FOR CRANE TRUCK MOUNTED HYDRAULIC 25 TON CCE HARNISCHFEGER MODEL 250 NON WINTERIZED NSN 3810 00 018 2021 HARNISCHFEGER MODEL MT 250 WINTERIZED NSN 3810 00 018 2007 REPORTING ERRORS You can help improve this publication If you find any mistakes or if you know of a way to improve the procedures please let us know Mail your letter DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 20282 located in back of this manual direct to US Army Tank Automotive Command ATTN DRSTAMBP Warren MI 48090 A reply will be furnished to you PARTIONE CRANE OPERATOR S MANUAL i i 1 1 1 WEIGHLOAD AUTOMATIC SAFE LOAD INDICATOR eene 2 1 1 SUPPLEMENTAL MAINTENANCE AND REPAIR PARTS INSTRUCTIONS 3 1 1 NOTE Refer ta TM 5 3810 293 148 2 lor Crane Shop Manual Crane Repair Parts Manual Front AxleTransmissions and Winches NOTE Refer to TM 5 3810293 14 amp P 3 for Engine Operator s Manual Engine Service Manual Engine Parts Catalog This technical manual an authentication of the manufacturer s commercial literature and does not conform with the format a
16. 3 Rotary Flexible Drive Certain brackets and pulleys are also required according to the type of crane although the general method of installation is common on all Telescopic Cranes on which the Weighload Model 4T 5T or 6T Indicator is fitted INSTALLING THE SPRING MOTOR RECOIL DRUM The most suitable position for this drum assembly is on the superstructure under the boom hinge mounted so that the wire cord stowed on the drum periphery can be passed up the entire boom without hindrance or severe deflection see Installing the Boom Wire Cord The other factor governing the position of the Drum Assembly is the routing of the Rotary Flexible Drive from the Drum Gear Box to the Control Pox see Installation of Rotary Flexible Drive Care must be taken that the Drum Assembly is clear of all obstructions especially the boom hoist cylinders during operation When the most suitable position has been ascertained the Drum Assembly can be bolted in position with 1 2 dia bolts either directly to the crane structure or to a subplate specially made for the purpose If itis necessary to reverse the rotation of the spring this Is achieved as follows a Remove all screws from the large cover on the spring housing and carefully lift off the cover b Ifthe spring is Not fitted with a retaining band slide a suitable band over the outside diameter to retain it in its present shape winding the drum to tighten the spring to allow this band
17. B P North America Inc International Cities Service Oi Company Continental Oil Company Guif Oil Company Humble Oil Company Exxon and Imperial Esso of Canada Molub Alloy Imperial Oil and Grease Company Hydraulic Oil 4771 DTE 24 Hydraulic Oil Lo Hvdraul 427 Chevron EP Hydraulic Oil 9 Mobil Oil Companv Shell Oil Company Standard Oil of California Standard Oil of Ohio S Ohio Texaco Union Oi Company of California Union 76 The American Lubricants Industron 44 Rando Oil HD A Union Unax AW 160 Alubco Moly Above 65 F Above 18 C Hydraulic Oil Company Medium Amoco AW 21 American Oil Company Citco Extra Du Cities Service Oil Company Circulating Oil 48 Continental Oil Company Gulf Oil Company Humble Oil Company Exxon and imperial Oil Company Esso Imperial Oi and Grease Company Nuto H 48 Molub Alloy Hy draulic Oil 772 DTE 26 Mobil Oi Company Hydraulic 29 Shell Oil Company Chevron EP Hy Standard Oil Company of draulic Oil 11 California Chevron Industron 48 Standard of Company of Ohio Sohio Sun Oil Company Texaco Union Oil Company of California Union 76 Sunvis 821 WR Rando Oil HD B Union Unax AW 215 1 3 7 SECTION III LUBRICATION MANUFACTURERS Shell Oil Company HIGH TEMPERATURE GREASE P amp H AMBIENT 7 MILITARY SYMBOL SPEC NO RANGE SPEC NO
18. CONTROLS AND OPERATION 2 Install the boom stop as shown in View B 3 Remove the cylinder pin end caps 4 Center the cylinder pin in the manual fly section Extend the boom until the second hole in the manual fly action is aligned with the hole in boom section 2 5 Remove the cylinder pin in boom section 2 6 Install the cylinder pin so that it passes through boom section 2 the second hole in the manual fly section and cylinder rod eye Install the cylinder pin end caps 7 Remove the boom stop The boom can now be operated as it would normally be operated WARNING The machine must not be operated with the telescope cylinder pinned only to the manual fly section The telescope cylinder must be retracted and pinned to boom section 2 as shown in Section A A CYLINDER PIN END CAP 1219 mm VIEW A BOOM BASE BOOM SECTION BOCM SECTION 1 SECTION r B MANUAL FLY SECTION VIEW B Figure 2 18 Manual Fly Section 105JB81 1 2 26 Retract the telescope cylinder until the cylinder rod eye is aligned with the hole SECTION II To retract the manual fly section beck to the storage position proceed as follows 1 Install the boom stop as shown in View B 2 Remove the cylinder pin end caps and cylinder pin Extend the telescope cylinder until the cylinder rod eye is aligned with the hole nearest the tip of the manual fly section 3 Install the cylinder pin in the cylinde
19. JIB ASSEMBLY JIB PIVOT MOUNT BRACKET BRACKET 218 MOUNT BOOM ASSEMBLY JIB SUSPENSION JIB ASSEMBLY CARLE ALLOW 1 16 TO 1 8 1 6 3 2 mm CLEARANCE BETWEEN THE JIB AND PIVOT WHEN THE JIB IS IN THE STORED POSITION Figure 2 16 Jib Storage 911J90 E 1 2 24 SECTION II CONTROLS AND OPERATION BOOM POINT ion 3 CABLE 1 15 Ni NOR CAEN c AB t gt 1 2 1 INSTALL ONE CABLE LINK TO OBTAIN OPERATING ANGLE OF 18 2 INSTALL TWO CABLE LINKS TO OBTAIN A OPERATING ANGLE OF 30 Figure 2 17 Jib Suspension 911J91 1 Rotate the upper so that the boom is over either side of the rear of the carrier Do not attempt to fold the jib with the boom over the front of the carrier 2 Remove the hook block from the main or auxiliary winch line and attach the line to becket 11 Take up on the winch line to relieve the tension on the jib suspension cable 3 Remove the suspension cable from the boom point and attach it to the bracket at the base of the jib as shown in Elevate the boom to an angle of approximately 45 degrees and pay out line from the winch slowly until the jib is suspended vertically from the boom point 4 Telescope the boom back leaving approximately one foot of boom extended 5 Remove the winch line from becket 11 and attach it to becket 4 Slowly lower the boom and take up slack in the line wit
20. NN lt x Figure 1 5 Dimensions and Clearance 105J831 B 1 1 7 1 1 8 blank SECTION ll CONTROLS AND OPERATION SECTION II CONTROLS AND OPERATION CARRIER CONTROL IDENTIFICATION The instruments and controls in the cab of the carrier are shown in The numbers on this figure correspond to the numbers on the following list which identifies the controls and describes their function Before attempting to operate this machine the operator should study carefully all of the information in this section and in Catalog 221 The operator should become thoroughly familiar with the location and purpose of each control on the machine 1 IGNITION INDICATOR This lamp is illuminated whenever the ignition switch is in the ON position If the lamp remains lit after the carrier ignition switch is placed in the OFF position the upper ignition switch is in the ON position and must be placed in the OFF position to shut down the ignition system 2 HIGHBEAM INDICATOR This lamp when illuminated indicates that the high headlight beams are on 3 VOLTMETER The voltmeter measures the voltage produced by the alternator and indicates the condition of the battery See Figure 2 2 for an explanation of the voltmeter readings Figure 2 1 Carrier Controls 1 2 1 SECTION II Engine not running or running at slow idle Deod or disconnected battery Disconnected or badly connected meter CONTROLS AND
21. NOTE The gear box is mounted in a clamp bolted to the Drum Bracket and is held bv a pinch bolt in the clamp Slackening this pinch bolt allows the gear box to be rotated so that the output direction is as required IMPORTANT After slackening this pinch bolt ensure that the gear box is pushed hard against its shoulder in the clamp before re tightening the pinch bolt Ensure that the bronze bearings and thrust cans are fully tightened in the gear box housing and also the pinch bolt is fully tightened 2 1 19 INSTALLING THE STAINLESS STEEL WIRE CORD The object of this cord is to rotate the Recoil Drum as the boom is telescoped thus measuring the length of boom extended at all times The most suitable path for this cord is along the outside side of the boom anchored at its free end to the extreme end of the final telescoping section Not to the manual section The anchorage should be of the spring shock absorber tvpe to reduce the snatch on the cable when telescoping commences Another anchorage mav be needed Point section extended and jib cams are cut for angle ratings When these cams are used boom extension wire must be fastened at a point 3 foot back of the normal position This will bring the wire to the base section of boom and reel will not extend with the boom Ratings are then proportioned to angle Suitable cleats should be provided along the boom to provide adequate guiding and protection of the cord At the root secti
22. Preventive Maintenance Checks and Services 0 8 C mm mg SOEN BM E o A eb 4 C2 ee AQ QIM 1 1 km de de Section 111 Appendix 6 3 A REPAIR PARTS SUPPLV General Prescribed Load List PLL Authorized Stockage List ASL Requisitioning Repair Parts Submitting Requisitions DA Equipment Publications Prescribed Load List PLL Authorized Stockage List ASL Page No ee ee Co EN EN EN SECTION I INTRODUCTION 1 1 SCOPE The instructions in Part 3 are for a The use of the personnel to whom the end item is issued b Maintenance personnel responsible for maintaining and or repairing the end item c Supply personnel responsible for requisitioning and stockage of repair parts 1 2 MILSTRIP REQUISITION IDENTIFICATION AND CONTROL a Parts Requisition Identification and Control 1 Since only limited repair parts will be initially provisioned it is necessary to provide a method for supplying parts which were not initially provisioned When necessary to come to the wholesale level for supply all non NSN requisitions CONUS or Overseas will be directed through Defense Automatic Address System DAAG to DCSC for supply Visibility of these
23. When the machine is equipped with a P amp H winch this lever is also used to operate the free fall feature of the winch All P amp H winches have free fall capability Not all Gearmatic winches have free fall capability Gearmatic winches which have the free fall feature will always be equipped with a separate free fall lever attached to the winch lever WARNING Be sure you know whether or not you have a free fall winch the make of winch P amp H or Gearmatic and that you fully understand the operation of the free fall feature which is described below before lifting or lowering a load The auxiliarv winch lever will function as follows when the machine is equipped with a P amp H winch CAUTION Maintain ample tension on the winch line when lowering light loads to prevent the cable on the winch drum from loosening If the layers of cable are loose damage to the cable can occur resulting in possible damage to the machine or injury to personnel Pull back on the winch lever to lift a load with the auxiliary winch Push the lever forward part way t6 power down the load see Figure 28 Push the lever forward to the extreme forward position to free fall the load SECTION II The auxiliary winch lever will function as follows when the machine is equipped with Gearmatic winch seelEigurel 2 8 Pull the lever back to lift a load with the auxiliary CONTROLS AND OPERATION Figure 2 7 Upper Controls Maximum recommende
24. being lifted 16 AUXILIARY WINCH SPEED SELECTOR SWITCH This switch controls the speed of the auxiliary winch Its operation is identical to that of the main winch speed selector switch 17 OUTRIGGER CONTROL SWITCHES These switches control the operation of the outriggers The operation of the outriggers from the upper cab is identical to the operation from the carrier except that all outriggers can be controlled from the upper cab Refer to the topic Outrigger Operation for instructions on extending or retracting the outriggers 1 2 11 CONTROLS AND OPERATIONS 18 SWING BRAKE LOCK Depress this button to lock the swing brake in the applied position Lift this button to unlock the swing brake NOTE This control operates independently of the swing brake pedal and will override the swing brake pedal 19 HAND THROTTLE Use this lever to set the engine high idle speed as required for the machine application For maximum efficiency and safety of operation the high idle speed must be set high enough by means of this control to handle the typical load The Accelerator should be used for momentary increases in engine speed 20 HEATER CONTROL This control regulates the heater temperature and heater fan speed Turn the knob clockwise to start the heater fan Fan speed is controlled by turning the knob clockwise or counterclockwise until the desired fan speed is obtained Heater temperature is increased by pulling the knob o
25. wheels are spinning to lock the interaxle differential This could result in damage to the axles Place the lever in the UNLOCK position after passing adverse conditions This permits the interaxle differential to compensate for differences in the tire size and give you maximum speed and performance NOTE Let up on the accelerator to provide an interruption in torque to the drive train when locking or unlocking the interaxle differential 16 EMERGENCY RELEASE VALVE The emergency release valve provides a means of transferring the isolated emergency air tank to the Maxibrake control valve item 17 when pressure in the service tanks is lost SECTION II Push this knob in and pull out the Maxibrake control knob item 17 if it becomes necessary to use the air in the emergency air tank to release the Maxibrakes CAUTION The carrier will have no brakes except the Maxibrakes which are controlled by the Maxibrake control valve Never move the carrier farther than is absolutely necessary under these conditions and avoid steep grades Make certain that this knob is pulled out at all time during normal operation 17 MAXIBRAKE CONTROL VALVE Pull this knob out to release the Maxibrakes Push this knob in to vent air from the Maxibrake chambers and apply the Maxibrakes This control will return to the applied position automatically if pressure in the air system drops below 28 psi 1 93 bars 18 AIR PRESSURE GAUGE This ga
26. 22 Enter the end item serial number from which the item was removed Date submitted calendar block on sections 2 3 and 4 Enter date item is received for exchange l Block 23 Date of manufacture or last overhaul m Block 24 Name of manufacturer or overhaul activity n Block 25 Place X in the space which best identifies when failure was detected o Block 26 Place X in the space which best identifies first indication of trouble p Block 27 Utilizing the information on DA Form 24n4 describe briefly and clearly the failure e g carburetor will not adjust for idle 2 If immediate exchange is not possible the bottom portion of the tag is detached by the support unit and furnished to the customer as a receipt Upon availability of a serviceable like item the receipt tag is exchanged for the serviceable item NOTE In those cases in which the support agency cannot provide a serviceable item to the supported organization within a time frame compatible with the priority designator PD the support agency will place a requirement on the supply System in accordance with local procedures 3 2 5 3 Block 7 will be completed by the individual making the repair 4 DA Form 2402 used to identify warranty claim exhibits are completed as described above the preprinted control number of the applicable DA Form 2407 is entered in block 27 5 If applicable serial number of the unserviceable DX
27. 34 FUEL GAUGE This gauge shows the amount of fuel remaining in the fuel tank 35 LIGHT SWITCH Pull this switch out halfway to the detent to use the tail lights clearance lights and CONTROLS AND OPERATION dash lights Pull this switch out fully to use the headlights in addition to the other lights Push this switch in completely to turn off all the lights 36 CLUTCH PEDAL Depress this pedal to disengage the engine from the transmission when shifting gears Do not use this pedal for a foot rest as this will lead to rapid clutch wear 37 HEADLIGHT DIMMER SWITCH The headlight dimmer switch allows the driver to raise or lower the headlight beams The highbeam indicator item 2 will be lit when the high beams are on 38 BRAKE PEDAL Depress this pedal to apply the carrier service brakes 39 ACCELERATOR PEDAL Depress this pedal to feed more fuel to the engine thereby increasing carrier sped 40 SEAT CONTROL NOT SHOWN A lever on the left side of the seat locks the seat in position To adjust the seat push the lever back toward the rear of the cab and then slide the seat forward or back as desired Be sure the seat is locked in position before driving the carrier 41 REMOTE CONTROL AIR VALVE This valve is only furnished when the machine is equipped with the optional carrier remote controls Place this lever in the ON position to supply air to the carrier remote controls Place the lever in the OFF position w
28. BRAKE OFF position F Release the Clutch button to engage the clutch G Control the speed of the carrier with the Accelerator and steer the machine in the desired direction by depressing the Steer Left or Steer Right buttons as required H Stop the carrier by first depressing the Clutch button and then place the Brake switch in the BRAKE ON position Maintain the Clutch button in the depressed position while the carrier is stopped or shift the transmission to neutral by depressing the Neutral button The Clutch button can be released when the transmission is in the neutral 5 To transfer control of the carrier back to the carrier cab perform the following steps A Shift the main transmission to neutral depressing the Clutch and Neutral buttons by B Place the Brake switch in the BRAKE ON position C Go to the carrier cab and apply the Maxibrakes by pushing the Maxibrake button in D Return to the upper cab and place the Brake switch in the BRAKE OFF position Place the Ignition key in the OFF position if the machine is to be completely shut down E Place the Remote Control Air Valve in the carrier cab in the OFF position Place the Throttle Selector 1 2 18 CONTROLS AND OPERATION Valve in the LOWER position The operation of the carrier is now controlled from the carrier cab HAND SIGNALS It is frequently necessary during crane operation for the operator to depend on a signalman for instructions W
29. F Direct Support Maintenance H General Support Maintenance D Depot Maintenance TM 5 3810 293 14 amp P 1 e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets not individual tools and special tools TMDE and support equipment required to perform the designated function Column 6 Remarks This column shall when applicable contain a letter code in alphabetical order which shall be keyed to the remarks contained in Section 2 A 4 Explanation of Columns in Tool and Test Equipment Requirements Section Ill a Column 1 Reference Code The tool and test equipment reference code correlates with a code used in the MAC Column 5 b Column 2 Maintenance Category The lowest category of maintenance authorized to use the tool or test equipment c Column 3 Nomenclature Name or identification of the tool or test equipment d Column 4 National Stock Number The National stock number of the tool or test equipment e Column 5 Tool Number manufacturer s part number 2 A 5 Explanation of Columns in Remarks Section IV a Column 1 Heference Code The code recorded in column 6j Section 11 b Column 2 Hemarks This column lists information pertinent to the maintenance function being performed as indicated in the Section Ill Change 3 3 2 12 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND
30. Joints Inspect Service Replace FRONT AXLE Front Axle Assembly Inspect Service Replace REAR AXLE Rear Axle Assembly Inspect Service Replace Differential Inspect Replace Repair Overhaul Shaft Assemblies Replace Repair BRAKES Service Brakes Brake Shoe Assemblies Inspect Adjust Replace Repair Air Brake System Hoses Lines Fittings Inspect Replace Chamber Brakes Inspect Adjust Replace Repair Valves Brake Inspect Replace Repair Reservoir Air Inspect Service Replace Change 3 3 2 19 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS WHEELS AND TRACKS Wheel Assembly Hub and Drum Assemblies Inspect Replace Repair Tires Tubes Tire Chains Tires Inspect Service Replace Repair STEERING Mechanical Steering Gear Assembly Column Steering Replace Repair Tie Rod Assembly Inspect Adjust Replace Steering Wheel Inspect Replace Power Steering Gear Inspect Assembly Service Replace Repair Hydraulic Pump or Fluid Motor Assembly Pump Power Steering Inspect Test Service Replace Repair Filter Fluid Replace Hoses Lines Fittings Inspect Replace Hydraulic or Air Cylinders Oylinder Steering Inspect Test Replace Repair Steering System Valves Steering Valve Inspect Replace Repair TM 5 3810 293 148P 1 Section MAIN
31. NUMBER PART NUMBER FCSM PART DESCRIPTION PLL ASL 1 5 1 5 6 20 21 50 PAOZZA 4330 00 277 3274 28605A 90005 Cartridge Filter Hydraulic Steer EA 1 3 5 PAOZZA 2940 00 836 9668 923070 62983 Cartridge Ftlter Hydraulic Oil EA 2 6 10 PAOZZA 3030 00 088 4643 5133177 72582 Belt Set Alternator SE 1 1 2 PAOZZA 3030 00 982 1208 5134212 72582 Belt Set Fan SE 1 1 2 PAOZZA 2940 00 580 6283 PF132 80659 Element Filter Engine Oil EA 2 6 10 PAOZZA 2910 00 781 1354 6438840 72582 Element Filter Fuel Secondary EA 1 3 5 PAOZZA 2910 01 025 6853 6438837 72582 Element Fuel Strainer Primary EA 1 3 5 PAOZZA 6330 00 792 9026 5147994 72582 Gasket Rocker Arm Cover EA 6 10 PAOZZA 2940 00 842 1878 P32 21585 Element Air Cleaner EA 2 4 PAOZZA 6240 00 752 2424 6013 08108 Lamp Incandescent Flood Light EA 3 5 PAOZZA 6240 00 155 8717 67 08108 Lamp Incandescent Clearance EA 3 5 PAOZZA 6240J00 295 1184 1034 08108 Lamp Incandescent Directional EA 3 5 PAOZZA 6240 00 889 1799 1157 08108 Lamp Incandescent Stop amp Tail EA 3 5 PAOZZA 6220 00 364 1592 56211701 27315 Headlight RH EA 2 4 PAOZZA 6220 00 364 1593 56211702 27315 Headlight RH EA 2 4 PAOZZA 2910 00 315 9911 5229350 71934 Injector Assy C50 EA 3 5 3 3 3 3 3 A blank SETTING BOOM ANGLE Position the boom at the proper angie for the load and working conditions Refer to the rating plate for proper angie Pull the boom hoist lever or peda
32. OPERATION Engine running fost enough to make generator produce Di connected meter Engine could not run with dead or disconnected battery unless circuit was completed oround baHery e Very low battery charge Engine might nat start Low battery charge Constant reading in this area would indicate need for check on generator and vol tage regulator When meter pointer stoys below 13 3 with the engine running fast enough ta operate generator it shows thot generator is not operating or voltage regulator is out of odjustment or that current being drawn from battery by lights heater fan or other lood exceeds generator output o Well charged battery This indicates a good battery and also that generator and voltage regulator ore operating properly The pointer might remain in this position temporarily when the engine hos been stopped ofter consideroble use due to a surface charge in the battery To get a Correct reading turn headlights fora few minutes When engine is storted pointer moy stay in this areo temporarily but should gradually rise above 13 3 as generator reaches normal output Under normal conditions a 12V battery is fully char ged at 12 8V A slightly higher reading may occur under the conditions outlined in No 5 but generally speaking any reading above 12 8 when the engine is stopped 15 not a true reading NOTE The word generator refers to b
33. P 1 Section Il MAINTENANCE ALLOCATION CHART 1 2 3 GROUP MAINTENANCE NUMBER COMPONENT ASSEMBL GAGES WEIGHING AND MEASURING DEVICES CONTINUED Gages Mountings Lines and Fittings Continued Weigh Load Indicator Inspect Repair Replace CRANES SHOVELS AND EARTH MOVING EQUIP MENT COMPONENTS Crane Dragline or Clamshell Attachments Boom Assembly Inspect Service Replace Repair Hook Block Inspect Service Replace Repair Cables and Ropes Inspect Replace Tagline Inspect Service Replace Repair Jib Mount Inspect Replace Repair Pile Drive Attachment Shaft and Plates Service Replace Base Deck Slewing Rim Replace Brackets and Covers Inspect Replace Transmission Assembly Transmission Swing Replace Repair Change 3 3 2 2 1 Tool or test equipment ref code SECTION TOOL AND TEST EQUIPMENT REQUIREMENTS 2 Maintenance category OO 3 Nomenclature Tool Kit Auto Maint Org Maint Common 1 Tool Kit Auto Mech Light Weight Gage Oil Pressure Shop Eqp Auto Maint amp Repair Org Suppl No 1 Less Power Shop Eop Welding Set Tool Set Veh Full Tracked Supp No 2 Multimeter Shop Equip Contact Maint Truck Mounted Shop Equip Gen Purp Repair Semitrir Mtd Shop Equip Org Repair Light Truck Mtd Tool Kit Automotive Fuel and Elec Sys Repair Tool Kit Auto Maint Org Maint Common 2 Tool Kit Master Mech Equip Maint amp
34. Repair Wrench Set Socket 3 4 Drive Hex Type Wrench Torque 3 4 Drive 100 500 Lb Capacity Shop Eqp Fuel amp Elec Sys Engine Shop Set Fuel amp Elec Sys Supp No 2 Test Set Dsl ljn Shop Eqp Machine Shop Trk Mtd Change 3 3 2 25 4 National stock number 4910 00 754 0654 5180 00 177 7033 4910 00 792 8304 4910 00 754 0653 4940 00 357 7268 4940 00 754 0743 6625 00 999 7465 4940 00 294 9518 4940 00 287 4894 4940 00 294 9516 5180 00 754 0655 4910 00 754 0650 5180 00 699 5273 5130 00 351 5135 5120 00 542 5577 4940 00 754 0714 4940 00 390 7775 4910 00 317 8265 3740 00 754 0708 TM 5 3810 293 14 amp P 1 5 Tool number SC4910 95CLA74 19204 SC5180 90 CL N26 50980 3005456 61465 SC4910 95CLA73 19204 SC3470 95CLA08 19204 SC4940 95CLA08 19204 SCDL551651 80063 MILS45855 81349 MILS45538 81349 MILS45537 81349 SC4910 95CLA50 19204 SC4910 95CLA72 19204 SC5180 90 CL N05 50980 A A 399A 58536 6017F 47805 SC4910 95CLAOI 19204 SC4910 95CLA65 19204 5910359 19204 SC3470 95CLA02 19204 TM 5 3810 293 14 amp P 1 SECTION TOOL AND TEST EQUIPMENT REQUIREMENTS 1 2 3 4 5 Tool or test equipment Maintenance National Tool ref code categorv Nomenclature stock number number F Tool Kit Machinist 5280 00 511 1950 SC5280 95CLA02 19204 F Tool Kit Bodv and Fender 5180 00 754 0643 SC5180 9OCLN34 Repair 50980
35. after they have reviewed the initial list distributed by TARCOM Support units and activities in CONUS will establish ASL stocks through normal requisitioning process 3 4 Requisitioning Repair Parts a Using Units Organizations Requisitions DA Form 2765 Series will be prepared according to AR 710 2 and local command directives All requisitions will have the Weapons System Designator Code 74 Interim Change 5 1 AR 710 2 per DA Message DALO SMS 091400Z Jan 78 entered in the 2nd and 3rd positions of block 18 Units in CONUS will use Project Code BGW in block 19 Units OCONUS will enter in block 19 Project Code JZC Appendix H 3 3 1 TM 5 3810 293 14 amp P 1 b Support Units and Activities 1 General All MILSTRIP requisitions DD Form 1348 Series prepared for repair parts support of CCE items will include distribution and Project Codes see Appendixes J and 2 Distribution Code Supply customers CONUS will use code column 54 Customers OCONUS will use the appropriate code from Appendix P paragraph P 3a 1 AR 725 50 Weapons System Designator Code DA Message DALO SMS 091400Z Jun 78 willbbe entered in card columns 55 and 56 of all requisitions 3 Project Codes The applicable Project Code will be entered in card columns 57 59 of requisitions for NSN parts whether CONUS or OCONUS customers Project Code BGW will be used by CONUS customers when requisitioning part numbered parts Supply customers OCONUS w
36. carried out at short regular intervals During the normal crane overhaul the rollers should be removed from the Dvnamometer the bearings washed in solvent and repacked with Shell Alvania No 2 grease Should it be necessary to remove the Load Cell from the Dynamometer it is only necessary to remove the two 5 16 Allen screws from the underside of the platform on which the Load Cell is mounted The Load Cell is located on a shallow pin and must be slightly lifted before being drawn out of the Dynamometer THE HOIST ROPE MUST BE COMPLETELY UNLOADED WITH THE BLOCK RESTING ON THE GROUND while the Load Cell is out of the Dynamometer The U shaped block may be lifted by hand to give added clearance when removing the cell LOAD CELL ASSEMBLY The Load Cell flexible capillary and Load Indicator assembly is a sealed unit and capillary joints must NOT be dismantled under any circumstances The only maintenance necessary is to regularly clean away any clogged grease or dirt from the cell and to ensure that it is correctly located and secured in the Dynamometer Should the black pointer in the Control Box fail to operate when the crane hook is loaded and the Load Cell is suspect the cell may be removed from the Dynamometer see Maintenance Dvnamometer and loaded by squeezing a vice If there is still no reaction from the black pointer the complete assembly must be returned to the Manufacturer for repair See Service Manual Note When making this
37. check CI Clean crankcase breather LI Inspect amp clean blower screen Clean cooling system CI Clean exterior of radiator CI Clean hydraulic tank breather CI Change axle oil CI Change main transmission oil C Change Auxiliary transmission oil CI Service quick start SECTION IV PREVENTIVE MAINTENANCE A Maintenance Checks PERFORM DAILV LUBRICATION Refer to the lubrication charts Section of this manual and lubricate all the dailv lubrication points indicated with the tvpe of lubricant specified FILL FUEL TANK The fuel tank is located under the deck plates on the left side of the carrier behind the operators cab The filler cap is protected bv a cover hinged to the deck plates The fuel tank should be kept as full as possible with a quality grade of No 2 Diesel Fuel to minimize condensation The fuel tank has a capacity of 70 gallons 265 I CHECK ENGINE OIL LEVEL Check the oil level using the dipstick located at the left rear corner of the engine For accurate readings the oil level should not be checked for approximately 15 minutes after shutting down the engine Maintain the oil level as near the F full mark as possible at all times seq Figure 4 1 CAUTION Never operate the engine with the oil level below the L low mark or above full mark If necessary add oil of the type specified in Section III of this
38. cleaned off the drum 4 Bearings should be checked 5 Cracks or breaks in the drum should be reported Whenever any of these conditions are observed the winch should be removed from service and properly cleaned repaired or replaced This recommendation is made not only to improve or maintain good rope life but to eliminate a potential hazard After establishing the satisfactory condition of the winch drum mount the reel of wire rope on suitable jacks at the front of the boom Pass the end of the rope over the idler sheave at the boom point and attach the rope to the winch drum as shown In Figure 2 13 NOTE A tension should be induced into the rope by providing some means of braking the shipping reel while installing the rope on the winch drum A tight winding is imperative SECTION ll Figure 2 13 Securing Rope to Drum Slowly wind the rope onto the winch drum by moving the winch lever to the raise position A lead or brass hammer may be useful in tapping the rope over as it is being wound on the drum Do not use a steel hammer or pinch bar These can readily cause damage to the rope REEVING WITH ODO NO PARTS OF LINE St iit 2PART 3PART 4 PART S MAIN sHEAVE 9 9 HOOK CONTROLS AND OPERATION REEVING Reeving diagrams for the main hoist line are shown in Figure 2 14 The number of parts of line from one to seven used in reeving the main hoist line will depend on the load to be lifted R
39. covered in the PMCS Be alert for anything that might cause a problem 2 E 2 Maintenance Forms and Records Every mission begins and ends with the paperwork There isn t much of it but you have to keep it up The forms and records you fill out have several uses They are a permanent record of the services repairs and modifications made on your equipment They are reports to maintenance people and to your commander They are also a checklist for you when you want to know what is wrong with the equipment after its last use and whether those faults have been fixed For the information you need on forms and records see TM 38 750 2 E 3 Preventive Maintenance Checks and Services a Operator crew shall perform the preventive maintenance checks and services shown in Table 2 E 1 1 Do your B Preventive Maintenance just before you operate the equipment Pay attention to the Cautions and Warnings 2 Do your D Preventive Maintenance during operation During operation means to monitor the crane and its related components while it is actually being operated 3 Do your A Preventive Maintenance right after operating the equipment Pay attention to the Cautions and Warnings 4 Do your W Preventive Maintenance weekly 5 Do your M Preventive Maintenance once a month b Organizational maintenance personnel shall perform the preventive maintenance checks and services shown in Table 2 E 2 1 Do the Q checks and services once every t
40. discharged battery will freeze at a higher temperature than that in a fully charged battery NOTE If it is necessary to add water to the battery do so only immediately before or during operation or with an external charger connected to the battery Charging the battery by any means mixes the water electrolyte and thereby prevents the water from freezing Keep the battery terminal connections clean and free from snow or ice which could short circuit the terminals Clean the cable connectors and battery posts thoroughly using a soda and water solution to remove corrosion In extremely cold weather it is advisable to remove the battery and store it in a heated area if the machine is to be idle overnight or for any extended period 4 Keep the fuel tank as full as possible at all times to minimize condensation lf water is detected in the fuel supply drain the tank and refill it with clean fuel 5 Engage the pump drive and jog the starter for about one minute to move hydraulic oil through the pumps thereby insuring proper lubrication of pump components Then start the engine in accordance with the engine manufacturers recommendations for cold weather starting and run it at approximately 1200 RPM until the engine has warmed up NOTE Cover part of the radiator to aid warmup and to maintain engine running temperature During warmup only the entire radiator may be covered 1 2 20 CONTROLS AND OPERATION 6
41. drops of engine oil on each exposed pin or lever not equipped with grease fittings to prevent rust and to provide the limited lubrication required NOTE The lubrication recommended in this manual is based on operation of the machine for a period not to exceed eight hours per day five days per week If a machine is operated in excess of the above time per day or week lubrication schedules must be adjusted accordingly All attachment fittings whether illustrated on the lubrication chart or not must be lubricated with multipurpose grease every 8 hours CAUTION Initial factory fill of MPG is of the soap base 12 Hydroxy Lithium Stearate type Other soap base greases are not always compatible with initial fill lubricant and Barium base grease is definitely not compatible Various other soap base greases may be used if experience by the purchaser has 1 3 1 shown these greases to be acceptable for the application The grease svstems must be thoroughiv purged and the affected parts removed cleaned before switching from a grease having one type of base to a grease having a different soap base LUBRICANT SPECIFICATIONS The following list will identify suitable lubricants for points shown in the lubrication charts by three methods They are 1 BY P amp H SPECIFICATION NUMBER This lubricant specification identifies the initial fill lubricant as classified by internal Harnischfeger Corporation Standards 2 BY MI
42. in balance Insert the wedge as shown in View B 3 Secure the ears of the socket to a sturdy support and carefully take a strain on the live side of the rope Pull the wedge and rope loop into position tight enough to hold the wedge in place during handling Final wedge positioning takes place under full operating loads 4 After the socket is pinned to the hook block or boom point apply gradually increasing loads until the wedge is seated Avoid applying any sudden shock loads before the wedge is in its final position View C shows the general operating appearance of the rope socket with the wedge pulled into the socket and the end of the wedge showing VIEWB LINE END VIEWC Figure 2 15 Installing a Rope Socket 1 2 23 CONTROLS AND OPERATION JIB ATTACHMENT The optional jib attachment is mounted on the boom point when it is in the operating position and is stored under the boom when not used NOTE Consult the rating plate in the operators cab for lifting capacities when operating with the jib attachment To place the jib into the operating position from the storage position proceed as follows sed Figure 2 16 1 Rotate the upper so that the boom is over either side or the rear of the carrier Do not attempt to unfold the jib with the boom over the front of the carrier 2 Install T pins 1 spacers 2 and cotter pins 3 to attach the jib to the boom point Install the T pin upward from the bottom so
43. in the revolving frame see Figure 4 14 Figure 4 13 Oil Level Plug Gearmatic Winch SECTION IV REVOLVING SECTION A A FRAME BOLT EXTERIOR BOLT CIRCLE CARRIER RING MOUNTING HOLES PREVENTIVE MAINTENANCE SECTION 8 B ACCESS COVER LOCATED HERE 1 ISTART BOLT TIGHTENING PROCEDURE HERE INTERIOR BOLT EXTERIOR BOLT CIRCLE CIRCLE N REVOLVING FRAME Figure 4 14 Slewing Ring Check the mounting bolts in the exterior bolt circle using a suitable torque wrench to be sure they are torqued to 440 foot pounds 60 8 m kg CHECK PUMP DRIVE OIL LEVEL Clean the area around the oil level plug and then remove the oil level plug sed 4 15 The oil in the pump drive should be up to the oil level plug opening Be sure the machine is level when checking the oil level If the oil is not up to the oil level opening remove the breather at the top of the pump drive and add oil of the type specified in Section the oil reaches the bottom of the oil level plug opening Wash the breather in fuel oil and dry it with compressed air before reinstalling it on the pump drive r VIEWED FORWARD m BELOW CARRIER f Figure 4 15 Pump Drive Level Plug 1 4 13 SECTION IV PREVENTIVE MAINTENANCE CHECK CLUTCH OIL LEVEL To check the oil level in the clutch master cvlinder proceed as follows see 1 Remove the panel on the front side of the carrier cab das
44. is driven by a cam in the Control Box operated by a flexible drive from the boom hinge pin The gear train which drives the red pointer also rotates electrical contacts which light a warning light at 9096 S W L and sounds a warning bell should the Safe Working Load be exceeded The Bell and Light Unit is a separate item mounted in the crane cab so that it is clearly audible to the Operator VISUAL INDICATION The safety margin is clearly indicated by the gap between the black pointer indicating the load on the crane hook and the red pointer indicating the Safe Working Load An amber light is illuminated at 9096 S W L A Red Light goes on at 10096 S W L AUDIBLE WARNING The Warning Bell sounds when the lifted load meets or exceeds the Safe Working Load It follows therefore that as soon as the black pointer reaches the red pointer the load should be reduced or the boom derricked in On no account should the crane be operated with the bell continuously ringing In addition to the dial indicating the load on the crane hook the Control Box is fitted with a further scale indicating the actual working radius of the crane This is positioned in the lower half of the Control Box ADJUSTMENTS Certain adjustments are necessary to cater for the various duties of the crane and these have been made as simple as possible In most cases three adjustments only are necessary and are as follows 1 Cam Change 2 Reeving Change 3 Black Pointer Zero
45. item will be entered in block 27 d Disposition 1 When a part or component to which DA Form 2402 has been attached is installed on an item of equipment or disposed of the form will be destroyed 2 Sections of this form used as a receipt will be destroyed after the exchange transactions are completed 3 When used to identify a warranty claim exhibit section 1 of DA Form 2402 will remain attached to the exhibit until there is no further requirement e Preparation of DA Form 2407 1 DA Form 2407 will be used to submit warranty claim action for end items When components parts or assemblies are identified as being defective and are covered by manufacturer s warranty and to obtain reimbursement for maintenance man hours expended in replacing the defective items End items under warranty are identified by a decal plate All warranty actions settled or unsettled will be reported to the national level For warranties settled locally the DA Form 2407 will contain a statement in Block 35 For information only 2 The organizational direct and general support maintenance and depot activities will prepare the DA Form 2407 as follows a Heading Enter a W in the EIR space and control number in the space provided b Block 1a Enter the name of the organization submitting the report c Block 1b Enter the location of the unit initiating the request units overseas enter APO only d Block 1c Enter the unit identification code of th
46. line of this block State in clear terms all factors which contributed to the failure include date the part failed the contract number and date warrantv period began USA registration number of the end item if applicable complete accounting classification for unit to be credited for cost of labor expended the MILSTRIP document number and supplementarv address of the unit which is to receive disposition instructions and notice of favorable claim actions Block 34 Enter nomenclature of defective part or assembiv 3 Support activities Maintenance activities in support of organizational maintenance are the responsible points of contact between the originator of warrantv claim actions and the national maintenance point which serves as the DA representatives with the contractor in warrantv matters NOTE In certain instances the originating organization and the support activitv are one and the same As such support and depot maintenance activities will establish the following procedures for processing and disposing of warrantv claim actions a Non direct exchange DX claim items When the defective component part or assembly is not a DX item the originating organization will prepare and submit a completed DA Form 2402 with exhibit and DA Form 2407 as prescribed herein to the support maintenance activity The support maintenance activity will process DA Form 2407 as follows 3 2 8 1 Copy 1 Destroy 2 Copies 2 and 5 Forward t
47. other fist rotated ver tically in front of body For crawlar cranes only LOAD With arm extended thumb pointing up Rex fingers im and owt as long as load movement is desired ta EXTEND BOOM Teletcoping Booms Both fists in front el body with thumbs pointing outward 1 2 19 CONTROLS AND OPERATION MOVE SLOWLY Use motionless im bet motion signal Hoist ampi USE WHIP LINE Auxiliary Host elbow with ena hand then ma regular WE NW TRAVEL Both Tracks Use both fists front of body mating a circular motion about each other indication irection of travel forward or backward For crawler cranes only WAS LOWER THE BOOM AND RAISE THE LOAD With arm exwaded thumb pointing beer in aad out as long es load movement is desired i RETRACT BOOM Teletcoping Booms Both fists in front of body with thumbs pointing toward each other SECTION ll When assured that the cooling svstem is clean and in good condition refill the system with an ethylene glycol and water solution of the proper strength for the anticipated low temperatures NOTE A high qualitv corrosion inhibitor can be added to the cooling svstem if desired Do not however use a Chromate base inhibitor with an ethylene glycol anti freeze That combination can produce Chromium Hydroxide commonly known as green slime 3 Keep the battery fully charged at all times The electrolyte in a
48. push rods Replace the covers 12 Cover all engine openings including manifold exhaust and intake ports coolant inlets to cylinder head and block oil breather and crankcase with heavy paper and tape 13 Tag the engine to indicate that it has been treated with preservative oil and that the cooling system has been drained This tag should warn against turning the engine over until it is restored to service The tag should also show the date on which preservation was accomplished and that the engine is not to be run without first removing the preservative film 14 If possible store the machine in a building where the air is dry and the temperature will remain uniform 15 Inspect the engine periodically during storage for rust or corrosion and take corrective steps as necessary NOTE If the machine is stored for longer than 24 months repeat the above preservation procedure This will insure continued preservation of the Cummins engine REMOVAL GENERAL The procedures outlined below must be carefully followed to insure that the machine is properly restored to normal service following short term storage Note that separate procedures are given for the Detroit Diesel engine the Cummins engine and the machine proper FROM SHORT TERM STORAGE RESTORING DETROIT DIESEL ENGINES TO SERVICE To restore the Detroit Diesel engine to service following short term storage proceed as follows 1 Remove the seals from the engine ope
49. removal installation disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system j Overhaul That maintenance effort service action prescribed to restore an item to a completely serviceable operational condition required by maintenance standards appropriate technical publication e DMWR Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition Service inspect test service adjust aline calibrate and or replace 3 Fault locating troubleshooting The process of investigating and detecting the cause of equipment malfunctioning the of isolating a fault within a svstem or unit under test UUT Disassembly assembly encompasses the step by step taking apart or breakdown of a spare functional group coded item to the level of its least componency identified as maintenance significant e assigned an SMR code for the category of maintenance under consideration Action welding grinding riveting straightening facing remachining and or resurfacing Change 3 3 2 11 k Rebuild Consists of those services actions necessarv for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturi
50. return to the free position to release the swing brake NOTE This brake is to be used primarily as a holding brake Movement of the upper should be slowed by plugging the swing lever before the swing brake pedal is depressed 8 ACCELERATOR Depress this pedal to increase engine speed Let up on the pedal to decrease engine speed Engine speed will return to low idle speed when no pressure is applied to this pedal unless the engine idle speed has been preset to a higher speed by means of the Hand Throttle 1 2 10 NOTE The Throttle Selector Valve in the carrier cab must be in the UPPER position to allow the accelerator to control the engine 9 GAUGE GROUP The gauge group contains the following A Engine Oil Pressure Gauge This gauge should read between 40 and 60 psi 2 75 4 14 bars during normal operation CAUTION Be sure that engine oil pressure reaches the normal operating range within 15 seconds after starting the engine If it does not stop the engine and correct the cause of the pressure failure before restarting the engine B Fuel Gauge This gauge shows the amount of fuel remaining in the fuel tank C Engine Water Temperature Gauge This gauge shows the temperature of the engine coolant The gauge should read between 160 and 185 71 85 C during normal operation SECTION II D Voltmeter The voltmeter measures the voltage produced by the alternator and indicates the condition of the batter
51. snags punctures and abrasions These minor injuries if neglected will cause tire failures If these injuries are spotted in time they can be repaired and the tires will provide safer and more profitable service life In addition to checking the tires for damage check the condition of PREVENTIVE MAINTENANCE the tire valves and be sure each tire valve is equipped with a valve cap The tire rims should be checked to be sure they are not bent loose cracked or otherwise damaged If any of these conditions exist the rim must be repaired or replaced When tire wear or damage occurs as a result of a mechanical deficiency of the machine such a deficiency should be corrected immediately The tires should be inflated to the pressures shown in unless otherwise specified in the machine for a specific application The tires should be adjusted to these pressures when the tires are cool When the tires are hot from running the pressure gauge reading should be approximately 15 psi 1 bar higher due to heat buildup TIRE SIZE ON HIGHWAY OFF HIGHWAY 11 00 X 20 75 psi 5 bars 85 psi 5 8 bars 12 00 X 20 80 psi 5 5 bars 90 psi 6 2 bars Table 4 1 Tire Pressures The wheel mounting nuts should be checked to be sure they are tightened securely CHECK AIR TANK SAFETY VALVE At least weekly manually pull out the stem of the safety valve on the dry tank to insure that the valve is not sticking If the stem cannot be pulled out the saf
52. test the red pointer must be rotated to the right hand side of the scale by removing the cam and turning the cam boss by hand counter clockwise This ensures that there is no restriction of the black pointer CONTROL BOX The interior of the Control Box especially the three slide bars must be kept clean and free from grit After cleaning the side bars they should be coated within oil It is advantageous to smear a small amount of molybdenumdisulphide grease in the slot of the cams Wipe off all surplus grease after lubricating FLEXIBLE DRIVE CABLES Ensure that the run of these cables is as straight as possible and that there are no kinks in the outer conduits 2 1 6 Grease the conduits through the lubricators provided ensuring that there is sufficient grease to prevent water from entering the conduits Smear grease on the exposed ends to prevent corrosion Remove ice in frostv weather before operating the crane Note On no account should the cables be bar tight There should be approximately 14 of sideways movement mid way between the pulley and the adjuster when tested with finger pressure and no noticeable backlash at the pulley behind the Control Box MAINTENANCE Models 4T amp 5T Telescopic Crane Units Maintenance operations for these Units are exactly as those laid down in the previous pages for Models 4 5 amp 6 with the addition of the following BOOM WIRE This cable attached to the boom head and Recoil
53. the carrier Pull the lever toward the operator to actuate the left directional signal push the lever away from the operator to actuate the right directional signal 10 HAZARD WARNING INDICATOR This lamp when illuminated indicates that all the directional lights are energized for use as hazard warning lights 11 HORN BUTTON Depress this button to sound the carrier horn 12 STEERING WHEEL NOTE If the machine is equipped with a Power Steering Outrigger Selector Valve item 25 be sure it is pushed in and latched when operating the carrier 13 HAZARD WARNING LIGHT SWITCH Push this switch away from the operator to energize all directional lights for use as hazard warning lights 14 WINDSHIELD WIPER SWITCH Turn this switch clockwise to energize the windshield wiper control the speed of the wiper by turning the switch clockwise or counterclockwise as desired 1 2 3 CONTROLS AND OPERATION Figure 2 8 Heater Shut Off Valve 15 DIFFERENTIAL LOCKOUT CONTROL This lever locks and unlocks the interaxle differential Place the lever in the LOCK position when approaching or anticipating icy or poor tractive conditions This will provide maximum axle traction The interaxle differential can be shifted to the locked position at any vehicle speed except if the wheels have already lost traction and are spinning CAUTION Do not wait until you have lost traction and our Do not wait until you have lost traction and your
54. to be fitted 2 1 18 c Allow drum to unwind and lift the banded spring out of its housing d Slacken the screw retaining the stepped arbor lift it off turn it over and refit Tighten the screw ensuring that it locates in the indentation in the shaft e Turn the spring over and refit passing outer eye over the anchor post and locating the inner end of the spring in the arbor recess Check that ratchet now works in required direction f Remove the special band if this was not originally fitted and replace cover and screws If it was found necessary to reverse the spring rotation it will also be necessary to change the rotation of the Gear Box output shaft to which the Rotary Flexible Drive is attached lt is essential that when looking on the end of the slotted output shaft on the Control Box the shaft must rotate counter clockwise when tension is being applied to the spring This direction of rotation should be checked before installation continues The reversing of the output shaft direction is as follows 1 The output shaft is retained in the gear box by the bronze bearing which is screwed into the box Unscrew this bearing to remove it with the shaft 2 Unscrew the bronze hexagon nut which forms a thrust cap for this shaft 3 Screw this hexagon cap into the gear box hole from which the output shaft was removed a Screw the bronze bearing and output shaft assembly into the gear box hole from which the cap was removed
55. 028 Cubic Yards Cubic Meters 0 765 Fluid 29 573 amp cea e 0 473 BIiS o AJ liters ra erg x ed 0 946 lll ege itu csc ea 3 785 A RN 28 349 4 Kilograms 0 454 Short Metric 0 907 Newton Meters 1 356 Pounds Square Inch Kilopascals 6 895 Miles per Gallon Kilometers per Liter 0 425 Miles per Hour SE Kilometers per Hour 1 609 TO CHANGE TO MULTIPLY BY Centimeters Inches de cede e 0 394 Eet Age a home E EE 3 280 Yards 1 094 Kilometers 0 621 Square Centimeters Square Inches 0 155 Square Meters Square Feet 10 764 Square Meters l a Square Yards 1 196 Square Kilometers Square Miles 0 386 Square Hectometers ACTOS irr eur 2 471 Cubic Meters Cubic Feet
56. 51B See Lubrication MIL L Equivalent lubricants and manufacturers are the same as for P amp H Spec 451A Motor Oil as de scribed above The only difference insofar as this description is concerned is that P amp H Specification 451C is an SAE 30 grade oil MIL L 2104B or latest issue in effect See Lubrication Chart See Lubrication MO MIL L Equivalent lubricants and manufacturers are the Chart 2104B or same as for P amp H Spec 451A Motor Oil as de latest issue scribed above The only difference insofar as in effect this description is concerned is that P amp H Specification 451D is an SAE 40 grade oil MO See Lubrication MIL L Equivalent lubricants and manufactureres are the Chart 2104B or latest issue in effect same as for P amp H Spec 451A Motor Oil as de scribed above The only difference insofar as this description is concerned is that P amp H Specification 451E is an SAE 50 grade oil 1 3 6 SECTION III LUBRICATION HVDRAULIC OIL P amp H ND EQUIVALENT SVMBOL SPEC NO AMBIENT RANGE LUBRICANTS GRADE MANUFACTURER II 10 to 465 F Alubco The American Lubricants 23 to 18 C Hydraulic Oil Company Medium Amoco AW 15 B P Energo SHF 60 Citco Extra Duty Circulat ing Oil 42 Conoco Super Hydraulic 15 Gulf Harmony 43 AW Nuto H 44 American Oi Company
57. AL FROM GENERAL The procedures outlined in the following paragraphs must be carefully followed to insure that the machine is properly restored to normal service Separate procedures are provided for the Detroit Diesel engine the Cummins engine and the machine proper LONG TERM STORAGE RESTORING DETROIT DIESEL ENGINES TO SERVICE To restore the Detroit Diesel engine to service following long term storage proceed as follows 1 Drain the preservative oil from the engine if applicable and refill the crankcase with the oil type recommended for normal operation Allow for the oil added in Step 2 below 2 Remove the valve rocker covers from the engine and pour at least one half gallon 1 9 1 of engine oil over the rocker arms and push rods Replace the covers 3 Check the condition of the radiator hoses and clamps Then fill the engine cooling system with dean soft water and a high quality rust inhibitor or a solution of permanent antifreeze depending on expected weather conditions 4 Remove the seals from the engine exhaust outlets and air cleaner 5 Fill the fuel tank 6 Install the battery fully charged in the carrier 7 Using diesel fuel remove the rust preventive from the engine exterior 8 Remove the paper from between the drive belts and pulleys and tighten the belts Refer to the engine manufacturer s manuals 9 Make a final inspection of the carrier and the upper to insure that the engine can be saf
58. ARRIER OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B BEFORE D DURING A AFTER W WEEKLY M MONTHLY ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT NO PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED NOTE Perform weekly as well as before PMCS s if A You are the assigned operator but have not operated carrier since the last weekly B You are operating the carrier for the first time Make the following walk around checks Exterior of vehicle a Check for evidence of leakage oil fuel hydraulic fluid Class Ill leakage is or coolant on or under the carrier evident No fuel leakage allowed b Check tires for damage low pressure Correct pressure is 75 PSI c Check for loose missing or damaged parts Radiator Check coolant level Fill to overflow Class 1 leakage is evident Inspect fan alternator air compressor steering pump and water Belt is missing or broken pump belts for fraved or deteriorated condition Batterjes Check level of electrolyte If low fill with clean water dis tilled if possible to the split ring In freezing weather run engine at least 15 minutes after adding water See TM 3 2 48 TM 5 3810 293 14 amp P 1 Table 2 E 1 Preventive Maintenance Checks and Services CONTINUED CARRIER OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B BEFORE D DURING A AFTER W WEEKLY MO
59. After the hydraulic oil has warmed to a minimum of 70 21 CJ slowly and gradually actuate each cylinder a number of times in turn without allowing the cylinders to travel to the end of their stroke Then slowly swing the upper and operate the winches in both directions The oil in the lines and other components of these systems will thus be warmed CAUTION Cold fluid makes relief valves sluggish in operation It can add 500 to 1000 psi 34 5 68 9 bars to the maximum pressure setting of the relief valves Therefore extreme care must be used when actuating a cold svstem to prevent a hose or tube from rupturing or causing other damage 7 Before shutting down the machine raise the outriggers to the stored position and drive the machine onto wooden planks or mats to prevent the machine from being frozen to the ground OPERATION IN EXTREME HEAT Operation in extreme heat presents special problems due to the difficulty in keeping the engine and hydraulic oil from overheating 1 Refer Section Lubrication for lubricant recommendations for hot weather operation Change the lubricant if necessary 2 Make certain that the engine crankcase oil is at the proper level An inadequate supply of crankcase oil will prevent proper dissipation of heat from the engine 3 Drain and flush the cooling system to insure proper circulation of coolant throughout the radiator core Clean the radiator cooling fins particular
60. CCE HARNISCHFEGER MODEL MT 250 NON WINTERIZED NSN 3810 00 018 2021 HARNISCHFEGER MODEL MT 250 WINTERIZED NSN 3810 00 018 2007 TM 5 3810 293 14 amp P 1 15 September 1980 is changed as follows 1 Remove old pages and insert new pages as indicated below 2 New or changed material is indicated by a vertical bar in the margin of the page 3 Added or revised illustrations are indicated by a vertical bar adjacent to the illustration identification number Remove pages Insert pages i ii blank i and ii 1 2 5 and 1 2 6 1 2 5 and 1 2 6 1 2 21 and 1 2 22 1 2 21 and 1 2 22 1 2 22 1 1 2 22 2 blank 1 2 25 through 1 2 27 1 2 28 blank 1 2 25 through 1 2 27 1 2 28 blank 2 1 3 and 2 1 4 2 1 3 and 2 1 4 File this change in the front of the publication for reference purposes TM 5 3810 293 14 amp P 1 Bv Order of the Secretarv of the Armv E C MEVER General United States Armv Chief of Staff Official ROBERT M JOVCE Major General United States Armv The Adjutant General Distribution To be distributed in accordance with DA Form 1225B Operator Organizational Direct Support General Support and Depot Maintenance Manual for Crane Truck Mounted Hvdraulic 25 Ton CCE Harnischfeger Model MT 250 TM 5 3810 293 14 amp P 1 This Manual contains copvrighted material Published with permission of Dana Corporation Spicer Transmission Division Toledo Ohio and Rockwell International Automotive Operations Trov Michigan
61. Check for proper operation adjust if required b Check master cylinder hydraulic fluid level Engine a Change oil and filters after 160 engine hours b Adjust or replace belts as required c Clean crankcase breather er screen TM 5 3810 293 14 amp P 1 Table 2 2 ORGANIZATIC NAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONTINUED CARRIER Q QUARTERLY S SEMIANNUALLY A ANNUALLY B BIENNIALLY H HOURS M MILES ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT NO PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED T 8 9 10 Batteries Check for corrosion and damage Air System Check for leaks damage and deterioration Power Steering Outrigger Filter Inspect and clean Hydraulic Tank Clean breather 3 2 53 3 2 54 blank TM 5 3810 293 14 amp P 1 Section Ill REPAIR PARTS SUPPLV 3 1 General a The basic policies and procedures in AR 710 2 and AR 725 5n are generally applicable to repair parts management for CCE items b Manufacturer s parts manuals are furnished with CCE items instead of Department of the Armv Repair Parts and Special Tool List RPSTL c National Stock Numbers NSN s are initially assigned only to PLL ASL parts and major assemblies i e engines transmissions etc Additional NSNs are assigned by the supply support activities as demands warrant d Automated Processing AUTODIN of Federal Supply Code for Manufacturers FSCM part number requisit
62. Drum should be regularly inspected for fraying or kinks and should be lightly greased to prevent corrosion Any guide pulleys along it s path should be inspected for free rotation and lubricated as necessary RECOIL DRUM ASSEMBLY No maintenance is necessary apart from general cleaning and lubrication of the driving chain This drum must apply sufficient tension to the wire to keep it taut especially when the telescopic boom is fully retracted If this does not operate correctly refer to the Service Manual ROTARY FLEXIBLE DRIVE Ensure that the run of this drive is as straight as possible with no severe bends Inspect the knurled screwed couplings at each end of the drive for tightness No further maintenance is necessary IMPORTANT The Serial Number of the Equipment CO should be quoted in all communications and requests for service 2 1 7 WEIGHLOAD AUTOMATIC SAFE LOAD INDICATOR MK 1 MODELS 4 5 and 6 INSTALLATION INSTRUCTIONS The following instructions and recommendations are given as a general guide Mounting positions for the various components may vary on cranes of different type or manufacture but the general principle is the same in all cases 1 For cranes with a single hoist rope used for main boom duties only or re reeved through the jib three main components are necessary i e a Dynamometer b Control Box including Load Cell and Capillary c Alarm Unit 2 For cranes with two hoist ropes fo
63. EEL BEARING fe ROD CLAMP ASSY 1 FITTING e WHEEL TIE ROD 11 FITTING Sm PROPELLER SHAFT 3 FITTINGS o TRANSMISSION MOUNTING 7 FITTING RODIN RGB pin LLL FLOAT 1 FITTINGI E FLOAT FITTING i2 FITTINGS 2 FITTINGS TRUNNION PIN 2 FITTINGS TRUNNION PIN 2 FITTINGS 7 AUXILIARY TRANSMISSION FILLER Be REAR AXLE PLUG FRONT REAR AXLE FILLER FRONT REAR AXLE FILLER PLUG BRAKE CLEVIS XXII PROPELLER SHAFT 3 FITTINGS BRAKE CLEVIS REMOVE PLUG SLACK ADJUSTER SLACK ADJUSTER REMOVESLUG TO LUBRICATE BRAKE CAMSHAFT BEARING 2 FITTINGS so SS MSHAFT BEARING 2 FITTINGS TO LUBRICATE CLEAN amp REPACK WHEEL BEARING WHEEL WHEEL BEARING BOGIE BEAM 1 FITTING BOGIE BEAM j GREASE ANCHOR PIN BEARING WHEN GRAKES ARE RELINED TO LUBRICATE 7 91 915259 GREASE ANCHOR FIN BEARING BOGIE BEAM 1 ELT TING WHEEL BEARING WHEN BRAKES ARE RELINED REMOVE PLUG TO LUBRICATE WHEEL BEARING BRAKE CAMSHAFT BEARING 11 FITTINGI SLACK ADJUSTER ES BRAKE CAMSHAFT BEARING 1 FITTING FLOAT 1 FITTING TRUNNION PIN 2 FITTINGS 7 SLACK ADJUSTER BRAKE CAMSHAFT BEARING 1 FITTINGI 1 BRAKE CAMSHAFT BEARING 1 FITTING 2 dd BRAKE CLEVIS d ae REAR REAR AXLE FILLER e V REAR REAR AXLE FILLER CAP ji FLOAT 1 FITTING ROD PIN
64. ENNIALLY H HOURS M MILES ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT NO PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF Q S A JB H FILLED OR ADJUSTED AS NEEDED NOTE Perform operator crew PMCS prior to or in conjunction with organizational PMCS 200 Torque mounting bolts on slewing ring to 550 pounds foot after each 200 hours of operation Hoses and Tubing Check fo 5 da and deterioration ITEM NO TM 5 3810 293 14 amp P 1 Table Z E 2 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES Q QUARTERLY INTERVAL Q S A JB H 160 spect and clea CRANE S SEMIANNUALLY A ANNUALLY B BIENNIALLY H HOURS M MILES ITEM TO BE INSPECTED EQUIPMENT IS NOT PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED NOTE Perform operator crew PMCS prior to or in conjuction with organizational PMCS Cooling System a Inspect hoses and lines for damage leaks restrictions and deterioration b Use hydrometer to measure coolant system freezing point Add antifreeze as required to protect coolant system to lowest expected ambient temperature c Inspect radiator for leaks and cleanliness Fuel System a Check for leaks b Change filters after 160 engine hours c Drain sediment and water from fuel tank Air Cleaner Disassemble clean replace filter and reassemble Brakes Check for proper operation and adjust or replace linings as required Engine Clutch a
65. ERENCE 35 2 1 27 RS 1429 1 RADIUS FEET ALLEN GROVE 1564 O O O O 28 70 BOOM i EW REF 37 CAM ASSEMBLV REFERENCE 36 SPECIFV DUTV RADIUS SCALE REFERENCE 37 SPECIFV BOOM LENGTH 2 1 28 I bi di 5 1 NAT Wax Jom ern hh ro e SCT PB REFERENCE 38 REFERENCE 39 DOOR ASSEMBLY REFERENCE 38 TOP COVER ASSEMBLY REFERENCE 39 2 1 29 GEAR PLATE ASSEMBLV REFERENCE 44 2 1 30 REMOTE RADIUS INDICATOR 12V or 24V REFERENCE 57 IMPORTANT 2 1 31 SPECIAL REFINEMENTS A REMOTE RADIUS INDICATOR UNIT B SLEW AND DERRICK LIMIT INTERLOCKS 50 Radius Transmitter 12v or 24v 54 Derrick Limit Switch 51 Drive Coupling 55 Special Segment Assembly 52 Spiral Drive Strip c w Derrick Limit 53 Nut Bracket Interlock Switch REFERENCE 56 INSERT Special Segment Assembly c w Derrick and Slew Limit Interlock Switches 2 1 32 BELL AND LIGHT WARNING BOX REFERENCE 58 6V 12V OR 24V 59 Bell Unit Complete including 60 Lamp Glass amp Bezel Lamp Base 61 Festoon Bulb BELL WARNING BOX REFERENCE 62 6V 12V OR 24V IMPORTANT 2 1 33 DVNAMOMETER Sideplate L H Drum End Spindle Roller Spindle Eccentric Spindle Drum End Roller Drum End Roller Bearings Drum End Roller Thrust Washers Centre Roller Centre Roller Bearings Centre Roller Thrust Washers Loading Roller Loading Roller Bearings Loading Roller Thrust Washers Sheave End Roller Loadi
66. Form 2408 10 Equipment Component Register 6 DA Form 2408 14 Uncorrected Fault Record 2 16 WARRANTY a The contractor warrants the supplies furnished under this contract as described on the warranty decal and cited on the warranties in the equipment manual b Procedures 1 Selection of exhibits When it has been determined that a component part or assembly of an end item under warranty is defective because of design deficiency or poor workmanship in production the defective component part of assembly will be identified as a warranty claim exhibit Claim actions are initiated at organizational direct and general support and depot levels 2 Use of DA Form 2402 In warranty claim cases organizational direct support general support and depot maintenance activities will tag all warranty claim exhibits with a DA Form 2402 The DA Form 2402 will be used as an exchange tag to identify items being held for warranty claim exhibits In each case the tag will be marked Warranty Exhibit The exchange tag consists of four sections a Section remains with the item to assure identification until the item is repaired and used It identifies the tagged item as Serviceable after repair b Sections 2 3 and 4 serve as receipts Usually section 4 is a receipt for the unit section 3 the battalion level and section 2 for support activities All sections are not always required When used as a receipt the date and signature of th
67. Gallons STEERING GEAR HYDRAULIC OIL 2 1 2 Qts 9150 00 265 9425 MIL L 2104 OE HDO 10 1 Qt 9150 00 242 7603 MIL L 10295 OES 5 Gallons 9150 00 186 6682 MIL L 46152 LUBE OIL 1 Qt 9150 00 985 7231 MIL L 46152 2075 TH 1 Qt 9150 00 966 8830 MIL H 46001B Type 1 HYD FLUID 5 Gallons 3 2 40 MAINTENANCE AND OPERATING SUPPLIES TM 5 3810 293 148P 1 1 COMPONENT APPLICATION HVDRAULIC SYSTEM 2 NATIONAL STOCK NUMBER HYDRAULIC OIL 9150 00 265 9429 9150 00 242 7603 9150 00 985 7233 9150 00 966 8831 3 DESCRIPTION 200 Gallons MIL L 2104 OE HDO 10 55 Gallons MIL L 10295 OES 5 Gallons MIL L 17672B 2075 TH 55 Gallons MIL H 46001B Type 1 HYD FLUID 55 Gallons 3 2 41 3 2 42 blank 4 QUANTITV REQUIRED F INITIAL OPERATION 5 QUANTITV REQUIRED F 8 HRS OPERATION 6 REMARKS TM 5 3810 293 14 amp P 1 APPENDIX 2 E PREVENTIVE MAINTENANCE CHECKS AND SERVICES CRANE 2 E 1 General Preventive maintenance is detecting correcting problems before thev happen or fixing little problems before thev become big problems Table 2 E 1 contains a list of preventive maintenance checks and services to be performed bv operator crew Table 2 E 2 contains preventive maintenance checks and services to be performed by organizational maintenance personnel Attention to these checks and services will increase the useful life of the equipment but every possible problem cannot be
68. HLOAD AUTOMATIC SAFE LOAD INDICATOR MK 1 MODELS4 5 amp 6 OPERATOR S INSTRUCTIONS GENERAL DESCRIPTION The basic equipment consists of three main a Control Box b Dynamometer c Bell Unit Occasionally the following is supplied in addition d Summator Unit for use when a second Dynamometer is installed e g on a separate Whip Hoist Rope e Remote Radius Indicator The Dynamometer is mounted in such a position that the hoist rope passes through it According to the type of crane it may be rigidly mounted on the base section of the boom or on a swinging arm frame which allows it to follow the true path of the rope As the load on the hoist rope increases the rope within the Dynamometer tends to straighten out exerting an increasing force on the center sheave which in turn applies an increasing force on the Hydrostatic Load Cell mounted beneath it The force on the Load Cell is converted to fluid pressure and transmitted through an armoured flexible capillary tube to the Control Box which is mounted at a convenient position within the vision of the crane operator The Control Box contains a dial with an adjustable range The pressure from the Load Cell causes a black pointer to rotate around this dial indicating at all times the actual load being lifted or suspended 2 1 1 A second pointer colored red indicates the Safe Working Load for the actual radius at which the crane is working This red pointer
69. HTG 476 working Not available temperature range OF to 450 21 to 232 Note The above lubricant is the only one currently approved as meeting P amp H Specification No 476 It is Shell Oil Code Number 71522 This is a special grease which shows high thermal stability and resistance to shock loading and adverse chemical environmental conditions It is used as a replacement for P amp H 472 MPG when reversing service long life or high temperature operation demands this premium lubricant EQUIVALENT LUBRICANTS Shell Darina No 2 E P 1 3 8 PREVENTIVE MAINTENANCE SECTION IV PREVENTIVE MAINTENANCE SECTION IV GENERAL Preventive maintenance is the easiest and least expensive type of maintenance It permits the Maintenance Department to do the work at a convenient time The actual operating environment of the machine governs the maintenance schedule The suggested check sheet on the following page indicates the areas of the machine to be checked and the intervals at which they should be checked NOTE The following suggested check sheet is based on average operating conditions The tvpe of work being done size of loads and ground and weather conditions are all factors which must be considered when establishing a maintenance schedule for vour machine The suggested schedule basis is given for hours of operation and calendar intervals Anv change in the established maintenance schedule sho
70. INE STORAGE GENERAL ff this machine is to be removed from service for an extended period of time the following procedure should be used when removing the machine from service and placing the machine back into service to ensure proper operation of the machine at all times PREPARATION FOR SHORT TERM STORAGE GENERAL Short term storage for the machine proper and for Detroit Diesel engine is 30 davs or less For the Cummins engines short term storage is for periods of up to six months To prepare for longer storage periods refer to the topic Preparation for Long Term Storage Separate procedures are outlined below for the machine proper and for both engine types MACHINE PREPARATION Perform the following to prepare the machine proper for short term storage 30 days or less 1 Clean the entire machine 2 Touch up painted surfaces as necessary after proper preparation and priming 3 Lubricate the machine in accordance with the instruction on the lubrication charts NOTE Step 4 is unnecessary if the machine is stored in a building and the air will be dry for the duration of storage 4 With the boom retracted and lowered to the boom rest coat the exposed portions of the hoist cylinder piston rods with multipurpose grease DETROIT DIESEL ENGINE PREPARATION Prepare the Detroit Diesel engine for short term storage 30 days or less by performing the following steps 1 With the engine warmed to normal operating t
71. LITARY SPECIFICATION NUMBER If the lubricant classified by P amp H Specification Number has a known military specification equivalent number this equivalent number is also listed in the individual lubricant description NOTE The absence of an entry in the Military Specification Column in a lubricant description does not mean that the lubricant recommended does not meet any equivalent military specification It may mean for instance that the lubricant has not been tested and qualified by the military because it is relatively new For that reason it is not certified as meeting the standards of a particular military specification even though it may be perfectly capable of so doing 3 BY EQUIVALENT LUBRICANT Equivalent lubricants presently confirmed as meeting the requirements of the P amp H specification are listed by trade names The absence of a lubricant from this list does not mean that it is unsuitable It means only that as of the date of this writing the lubricant has not been tested by P amp H The order in which the lubricants appear on any list is of no significance No superiority of any brand listed should be read into the order of appearance on a list The listing is purely random and all products on the list are equally acceptable SECTION III LUBRICATION
72. M Muffler and Pipes Exhaust Pipes and Inspect Muffler Replace Repair COOLING SYSTEM Radiator Evaporative Cooler or Heat Exchanger Radiator Assembly Inspect Test Service Replace Repair Cowling Deflectors Air Ducts Shrouds Etc Shrouds Radiator Inspect Replace Water Manifold Headers Thermostats and Housing Gasket Thermostat Housing and Inspect Housing Gasket Replace Hoses Radiator Inspect Replace Water Pump Inspect Replace Repair Fan Assembly Bearings Shaft and Pulley Service Replace Blade Fan Inspect Replace Belt Fan Water Pump Inspect Drive Replace ELECTRICAL SYSTEM Alternator Test Replace Repair Alternator Drive Belts Inspect Adjust Replace Regulator Voltage Test Adjust Replace Repair Change 3 3 2 16 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS ELECTRICAL SYSTEM CONTINUED Starting Motor Test Replace Repair Brushes Replace Solenoid Test Replace Engine Safety Controls Switches and Solenoid Test Engine Shut Off Replace Instrument or Engine Control Panel Switches and Gages and Inspect Meters Replace Lights and Lamps Inspect Test Replace Panel and Wiring Inspect Replace Repair Control Box Outrigger Replace Repair Fuses Test Replace Lights Inspect Test Replace Sending Units and
73. NTHLY ITEM TO BE INSPECTED EQUIPMENT IS NOT PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED Instruments Engine Water Temperature Pressure temperature gages Engine Oil Pressure not within proper range Voltmeter Air Pressure Tachometer Lights Check for proper operation Brakes Check for proper operation Stopping ability impaired Windshield Wiper a Inspect blade and arm for damage and deterioration b Check for proper operation Outriggers a Check for damage Inoperative or class Ill b Check for proper operation leakage Air Reservoir a Check safety valve for proper operation Safety valve inoperative b Drain water and sediment Engine Check oil level add oil to full mark on dipstick 3 2 49 TM 5 3810 293 14 amp P 1 Table 2 E 1 Operator Crew Preventive Maintenance Checks and Services CONTINUED CARRIER OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B BEFORE D DURING A AFTER W WEEKLY MONTHLY ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT NO PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED 12 Controls Check each control for proper operation Improper operation 13 Air Cleaner Check for cleanliness replace element if excessively dirty TM 5 3810 293 14 amp P 1 Table Z E 2 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES CRANE Q QUARTERLY S SEMIANNUALLY A ANNUALLY B BI
74. OVE GRADE SWING CLEARANCE AAOIUS OF REAR END FROM AXIS OF ROTATION D DISTANCE OF BOOM FOOT PIN TO AXIS OF ROTATION 50 HEIGHT OF BOOM FOOT PIN ABOVE GRADE 88x MAX HEIGHT OF ATTACHMENT TRAVEL POSITION G DISTANCE UNDER COUNTERWEIGHT TO GRADE 45 H WHEEL GROUND CLEARANCE OUTRIGGER CYL S oak EXTENDED bi A OF ROTATION TO 4 OF FRONT OUTRIGGER BOX rar d FRONT TO 4 OF REAR OUTRIGGER BOX 18 p BOOM LENGTH 80 800M FULLY RETRACTED 32 8 BOOM LENGTH 100 BOOM FULLY RETRACTED 334 ERTU TURNING CIRC CIRCLE 87 0 26 52 METER GROUND CLEARANCE REAR AXLE HOUSING 97105 OF REAR BOGIE 4 OF ROTATION xa VEHICLE CLEARANCE CIRCLE 94 8 28 85 METERS tel OISTANCE BETWEEN CENTERS OF AXLES OF TANDEM ar AXLE BOGIE REAR DISTANCE BETWEEN CENTERS OF AXLES OF TANDEM AXLE BOGIE IFRONTI WHEEL BASE OF REAR BOGIE TO REAR END OF CARRIER e OVERALL LENGTH OF CARRIER 331 OVERALL WIDTH TRACK TAEAO WIDTH REAR 55 11 TRACK OR TAEAD WIOTH FRONTI 6 5 EFFECTIVE LENGTH OF EXTENOED OUTRIGGERS 16 0 OVERALL WIDTH OVER FLOATS OUTRIGGERS EXTENDEO 17 10 BACK OF CARRIER CAB TO 4 OF REAR BOGIE 110 OVERALL LENGTH 80 BOOM RETRACTED OVER FRONT 381 OVERALL LENGTH 100 BOOM RETRACTED OVER FRONT 389 DISREGARD OVERHANG OF FRONT END ATTACHMENT SINCE 1 MAY BE SWUNG TO CLEAR lt lt
75. PM m min 155 47 24 170 51 82 195 59 44 200 60 86 220 67 06 230 70 10 5 200 2 359 4 700 2 132 4 300 1 950 4 000 1 814 3 700 1 678 3 400 1 542 Pressure Flow Drum Torque Up Low SPD Drum Torque Up High SPD Drum RPM Up Low SPD Drum RPM Up High SPD Full Load Line SPD m min 320 97 54 350 1106 68 380 115 82 415 126 49 450 137 16 480 146 30 No Load Line SPD Up FPM m min 365 111 25 400 121 92 435 132 59 475 144 78 515 156 97 550 167 64 TM 5 3810 293 14 amp P 1 INTRODUCTION 3000 5 1 206 Bars 55 G P M 208 l min 65 000 in Ibs 749 m kg 29 000 in Ibs 334 m kg 46 109 Accum Drum Capacity Ft m 67 67 20 42 20 42 143 43 59 226 68 88 316 96 32 413 125 88 517 157 98 Drum Capacity Ft Layer m Layer 3000 P S i 206 Bars 55 G P M 208 l min 65 000 in tbs 749 m kg 29 000 in Ibs 334 m kg 46 109 Accum Drum Capacity Ft m 67 20 42 143 43 59 226 68 88 316 96 32 413 125 88 517 157 98 Drum Capacity Ft Layer m Layer TM 5 3810 293 14 amp P 1 SECTIONI INTRODUCTION LIQUID CAPACITIES U S UNITS EE 70 gallons 265 1 Engine Cooling Svstem DetroitiDisseliOVOSN EE 40 quarts 37 8 1 Cummins C190 5 m eene deed cete a dep Re Lire
76. RATION GENERAL The following operating suggestions are offered as a reminder rather than as an attempt to instruct since the Harnischfeger Corporation is well aware of the fact that a machine of this size is not entrusted to anyone except a fully qualified operator 1 Always consult the rating plate in the upper cab for the maximum load which may be lifted with the various combinations of boom length boom angle and other variable factors which may be involved with lifting the load 2 Always perform all machine operations with the engine running at governed speed Machine performance and safety of machine operations require that the engine be run at governed speed 3 When the load is being swung it should be kept as near the machine and as close to the ground as possible 4 Always pay out cable from the main and or auxiliary winch when the boom is being extended or when the boom is being lowered to prevent two blocking the hook block 5 Always set the outriggers before operating the machine PREOPERATION INSPECTION Before actually operating the machine each day perform the A Maintenance Check outlined ir Section IV STARTING THE ENGINE To start the engine from the upper cab proceed as follows 1 Perform the following functions before leaving the carrier cab A Shift the main transmission to neutral B Place the Throttle Selector Valve in the UPPER position C Engage the pump drive D Apply the Maxibrakes by pus
77. RS further than required to perform the operation Be sure to pay out line from the main and or auxiliary winch as required to prevent the hook from coming in contact with the boom point AUXILIARY WINCH LEVER MAIN WINCH LEVER SECTION II SWINGING Push the swing lever forward to swing the upper to the left Pul the swina lever back to swing to the right Depress the swing brake pedal to stop and hold the upper CONTROLS AND OPERATIONS SPOTTING THE LOAD Spotting the load requires accurate control of the boom hoist and swing movements It takes practice to locate the load at the exact spot without hunting or overshooting Raise or lower the boom with the boom hoist 21 BOOM HOIST PEDAL lever as necessary to accurately locate the ioad Never extend the boom out so far that rated load is exceeded See the rating plate LOWERING THE LOAD The load can be lowered by two methads Push the main or auxiliary winch lever forward to power down the load Light loads can be free falled by slowly squeezing the free fall lever toward the main winch lever Figure 2 10 Crane Operating Cycle Gearmatic Winch 1 2 15 1 2 16 blank AUXILIARY WINCH LEVER DH MES MAIN WINCH LEVER Release the free fall control lever slowly to avoid shock loading of the main winch and main winch line SECTION III UPPER LUBRICATION CHART COLLECTOR RING BASE 1 FITTING DO NO
78. T OVERGREASE BEARINGS PEDAL LINKAGE 8 FITTINGS 9 FITTINGS MI ANNUALLY OR EVERY 1000 HOURS D el MONTHLY OR EVERY 200 HOURS im W v6 VERY HOUR DAILV OR EVERV 8 HOURS ox U 7 040 SLEWING RING OF OIL TO ALL PINS 8 LEVERS NOT EQUIPPED WITH GREASE FITTINGS EVERY 40 HOURS PLANETARY GEARING 5 2 PLACES i NE SPRAG CLUTCH 2 PLACES SHEAVES 1 FITTING EACH SHEAVE BOOM PIVOT 2 FITTINGS 2 FITTINGS 2 FITTINGS LUBRICATION RECOMMENDATIONS 2 LEGEND No 7 2 ISVMBOL No 40 F 4 C BELOW 40 F 4 C CHECK FREQUENCY MULTIPURPOSE GREASE f wea 2c 428 O SERVICE FREQUENCY 2 LuBaicant ALL SEASONS 3 GEAR co ce 4 POWER TRANSMISSION amp GEAR OIL ATF 44 AtLsEAsONS Figure 3 1 Upper lubrication Chart 10J827 1 3 9 1 3 10 blank USE OIL CAN TO APPLY SEVERAL DROPS CYLINDER CYLINDER SLIDER PADS BOOM POINT SHEAVES 1 FITTING EACH SHEAVE LUBRICATION INTERNAL SLIDER PADS CABLE ROLLER 2 FITTINGS IDLER SHEAVE 1 FITTING EACH SHEAVE SECTION III CARRIER LUBRICATION CHART 6000 MILES OR SEMI ANNUAELY 1000 MILES OR MONTHLY 500 HOURS ENGINE TIME DAILY
79. TENANCE ALLOCATION CHART S GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS FRAME TOWING ATTACH MENT AND DRAWBAR Superstructure Crane Replace Counterweight Replace Pintles and Towing Inspect Attachments Replace Repair Spare Wheel Carrier and Inspect Tire Lock Replace Repair SPRINGS AND SHOCK ABSORBERS Springs Inspect Service Replace Torque Radius and Stabilizer Rods Torque Arms Inspect Service Replace BODY CAB HOOD AND HULL Body Cab and Hood Assemblies Cab Assembly Inspect Replace Repair Door Assembly Cab Inspect Replace Repair Control Panel Inspect Replace Repair Outriggers Fenders Running Inspect Boards Glass Service Replace Repair Float Outrigger Inspect Service Replace Repair Change 3 3 2 2 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS BODY CAB HOOD AND HULL CONTINUED Upholstery Seats and Carpets Seat Assemblies Inspect Replace Repair HOIST WINCH CAPSTAN WINDLASS POWER CONTROL UNIT AND POWER TAKE OFF Hoist Capstan Windlass Crane or Winch Assembly Winch Assembly Replace Repair Pump Winch Auxiliary Replace Repair Motor Hydraulic Winch Replace Repair Valve Main and Auxiliary Replace Winch Control R
80. TM 5 3810 293 14 amp P 1 TECHNICAL MANUAL OPERATOR S ORGANIZATIONAL DIRECT SUPPORT GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS FOR CRANE TRUCK MOUNTED HYDRAULIC 25 TON CCE HARNISCHFEGER MODEL MT 250 NON WINTERIZED NSN 3810 00 018 2021 HARNISCHFEGER MODEL MT 250 WINTERIZED NSN 3810 00 018 2007 This copy is a reprint which includes current pages from Changes 1 through 3 HEADQUARTERS DEPARTMENT OF THE ARMY 15 SEPTEMBER 1980 TM 5 3810 293 14 amp P 1 WARNING A hvdraulic crane is NOT like a lattice boom friction crane in one verv important wav In most cases the safe lifting capacitv of a lattice boom crane is based ON THE WEIGHT NEEDED TO TIP THE MACHINE Therefore operators of friction machines sometimes depend on signs that the machine might tip to warn them of impending danger This is a very dangerous thing to do with a hydraulic crane Hydraulic crane ratings are based ON THE STRENGTH OF THE MATERIAL OF THE BOOM and other components Therefore the hydraulic crane operator who waits for signs of tipping to warn him of an overloaded condition WILL OFTEN BEND THE BOOM OR CAUSE SEVERE DAMAGE TO HIS MACHINE BEFORE ANY SIGNS OF TIPPING OCCUR OPERATORS OF ALL HYDRAULIC CRANES MUST BE GUIDED SOLELY BY THE RATING PLATE RECOMMENDATIONS CONCERNING LOAD BOOM LENGTH BOOM RADIUS and other factors listed on the rating plate such
81. Unusual Conditions ener nnne 1 2 18 Installing Rope on 1 2 21 aliu TH Jib Attachmemt ELTE m 2 23 Manual Fly SECON mE erem Em Installation and Operation of Self Powered Pile Driver Hammer NSN 3895 00 014 0583 UE 1 2 27 SECTION III LUBRICATION General xiii M 1 3 1 Lubricant Specifications nennen ennt intent en resins interest eniin nn nnne 1 3 1 SECTION IVIPREVENTIVE MAINTENANCE General EE 1 4 1 Using the Suggested Check Gheet 00 esee 1 4 1 ISECTION VIMACHINE STORAGE General 1 5 1 General pa SIN 1 5 1 Preparation for Short Term Storage sse 9 1 5 Preparation for Long Term Gtorage renis 1 5 2 Removal from Short Term Storage AEN 1 5 4 Removal from Long Term Storage AEN 1 5 5 Change 1 i ii blank SECTION I INTRODUCTION SECTION I INTRODUCTION SCOPE This manual provides operating instructions and excavators and cranes at no cost Submit such requests information concerning routine lubrication and service as required for the most efficient use of this machine Overhaul and repair information is provided in a separate sho
82. Warning Switches Transmitters and Switches Inspect Replace Back Up Warning and Replace Indicator Box Repair Assemblies Horn Siren Horn and Horn Button Inspect Test Replace Batteries Storage Inspect Test Service Replace Cables Battery Inspect Service Replace TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS ELECTRICAL SYSTEM CONTINUED Batteries Storage Continued Box Battery Inspect Service Replace Chassis Wiring Harness Replace Repair TRANSMISSION Transmission Assembly Main Transmission Inspect Service Replace Repair Overhaul Auxiliary Transmission Inspect Service Replace Repair Overhaul Transmission Shafts Synchronizers Shafts Inspect and Gears Replace Transmissions Top Cover Assembly Forks Shifter Cover and Inspect Rods Adjust Replace Tower Rod and Bracket Inspect Adjust Replace Repair Cover Assembly Clutch Inspect Service Adjust Gear Shift Vacuum Booster Inspect and Controls Replace Repair TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION EQUIPMENT REMARKS PROPELLER PROPELLER SHAFTS UNIVERSAL JOINTS COUPLER AND CLAMP ASSEMBLY Propeller Shafts Inspect Replace Universal
83. air valves and cylinders should be checked periodically for leaks To do so actuate the valve or cylinder and coat the device with a soap solution Leakage which causes a bubble one inch or larger to form in one second is considered excessive and the device should be scheduled for repair or replacement CLEAN STEERING OUTRIGGER FILTER The power steering outrigger filter is located on the left side of the engine compartment ahead of the radiator Access to the filter is gained by reaching up from below the front of the machine 1 4 15 To clean the steering outrigger filter proceed as follows sea Figure 4 17 1 Block the machine to prevent possible machine movement 2 Remove the filter bowl using a suitable box wrench 3 Remove the wire filter element from the bowl and inspect the material trapped in the filter The type of material trapped in the filter can indicate that a component in the system is deteriorating or is about to fail 4 Clean the filter element in a suitable solvent and dry it with clean compressed air Assemble the filter element on the filter head and then replace the filter bowl Tighten the filter bowl using a suitable box wrench VIEWED FROM BELOW FRONT OF CARRIER A121 Figure 4 17 Steering Outrigger Filter CHECK CLUTCH ADJUSTMENT The amount of clutch pedal free travel should be checked to determine the need for clutch adjustment Free travel is the distance the pedal can be depressed
84. an airtight seal 11 Drain the engine cooling system Tighten the drain cocks and radiator cap securely 12 The preservative oil may be drained from the engine if desired and saved for reuse or it can be left in or the duration of the storage If the oil is drained install and tighten the drain plug 13 Cover the exhaust outlet with moisture resistant tape or other suitable material 14 Loosen the drive belts on the engine and insert heavy paper strips between the pulleys and belts This will prevent sticking Leave the belts loose 15 Clean the exterior painted surfaces of the engine and dry thoroughly Spray the surfaces with a suitable liquid automotive wax a synthetic resin varnish or a rust preventive compound 1 5 3 MACHINE STORAGE 16 Cover the engine with a weather resistant tarpaulin or other cover if the machine is stored outdoors Cover with a heavy plastic sheet if the machine is stored indoors CUMMINS ENGINE PREPARATION To prepare a Cummins engine for long term storage periods in excess of six months proceed as follows 1 Perform step 1 of the temporary storage procedure for Cummins engines 2 Drain the oil from the engine crankcase and refill to the proper level with an SAE 30 preservative oil Shell Brand Code 66202 Texaco Preservative Oil 30 or equal 3 Perform steps 2 through 6 of the temporary storage procedure for Cummins engines 4 Drain the carrier fuel tank replace the dra
85. and the injector drain line at the carrier fuel tank Mark these lines for positive identification SECTION V 3 Fill one portable container with regular diesel fuel and a second container with preservative oil Daubert Chemical Co Nox Rust No 518 or equal Daubert Chemical Co 2000 Spring Rd Oakville IL 4 Insert both the fuel supply line and the injector drain line into the container of diesel fuel and start the engine 5 When the engine is running smoothly at idle switch the fuel supply line over to the container of preservative oil Operate the engine for five to ten minutes on the preservative oil 6 Stop the engine and reconnect the fuel lines to the fuel tank 7 Drain the engine crankcase fuel filters and the carrier fuel tank Reinstall the drain plugs 8 New oil may be added to the crankcase or the crankcase may remain empty for the duration of storage If it is left empty appropriate tags should be placed on the engine and in the carrier cab 9 Remove the air line connecting the engine air cleaner to the intake manifolds 10 Turn the fuel pump manual shut off valve to off so the engine will not start 11 While cranking the engine slowly and intermittently spray approximately one half cup of SAE 10 motor oil into the engine intake manifold and the air compressor Either a hand or power sprayer may be used 12 Cover all intake manifold openings with tape to prevent the entrance of dirt and moisture Co
86. ar axle differentials the interaxle differential lockout housing and the steering gear housing Clean the magnetic plugs and breathers replace the drain plugs and refill each housing and case with the oil type specified on the lubrication charts 6 Spray or brush a liberal coat of open gear lubricant on the slewing ring gear 7 Remove the battery clean it thoroughly and store it in a cool dry location where the temperature will not fall below 320F 0 C Check the battery charge periodically during storage and recharge as necessary 8 Clean the battery compartment using a soda and water solution if necessary to remove corrosion Wrap the cable terminals with waterproof tape after cleaning 9 Run the engine until the hydraulic oil is warm Then drain the hydraulic system completely 10 Replace the hydraulic filter cartridges and gaskets 11 Refill the reservoir to the prescribed level with the proper oil type 12 Operate all hydraulic functions to distribute the new oil throughout the systems 13 Apply a suitable preservative grease to exposed portions of hydraulic cylinder piston rods control valve spools and other exposed unpainted surfaces 14 When the machine is parked in the spot it is to be stored in fill the hydraulic reservoir to the top with hydraulic oil DETROIT DIESEL ENGINE PREPARATION To prepare the Detroit Diesel engines for long term storage SECTION V periods in excess of 30 davs proceed as f
87. as outrigger position and level terrain TM 5 3810 293 14 amp P 1 C3 CHANGE HEADQUARTERS 1 DEPARTMENT OF THE ARMV NO 3 Washington D C 10 October 1986 TECHNICAL MANUAL OPERATOR S ORGANIZATIONAL DIRECT SUPPORT GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS FOR CRANE TRUCK MOUNTED HYDRAULIC 25 TON CCE HARNISCHFEGER MODEL MT 250 NON WINTERIZED NSN 3810 00 018 2021 HARNISCHFEGER MODEL MT 250 WINTERIZED NSN 3810 00 018 2007 TM 5 3810 293 14 amp P 1 15 September 1980 is changed as follows 1 Part Three Crane Repair Parts Manual has been replaced by TM 5381029320P Organizational Maintenance Repair Parts and Special Tools Lists anc TM 5381029334P Direct Support and General Support Maintenance Repair Parts and Special Tools Lists 2 Remove old pages and insert new pages as indicated below Remove Pages Insert Pages Pages 3 2 11 through 3 2 31 3 2 32 blank Pages 3 2 11 through 3 Z 26JAPPENDIX 2 A APPENDIX 2 A 3 File this change sheet in front of the publication for reference purposes TM 5 3810 293 14 amp P 1 Bv Order of the Secretarv of the Armv JOHN A WICKHAM JR General United States Armv Chief of Staff Official R L DILWORTH Brigadier General United States Armv The Adjutant General Distribution To be distributed in accordance with DA Form 1225AR Blocks 571 572 573 Operators Organizational Direct Su
88. assemblies 3 2 9 3 2 10 blank TM 5 3810 293 14 amp P 1 APPENDIX 2 A MAINTENANCE ALLOCATION CHART Section I 2 A 1 General a This section provides a general explanation of all maintenance and repair functions authorized at various maintenance categories b The Maintenance Allocation Chart MAC in section IT designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance categories c Section Ill jlists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from section II d Section IV contains supplemental instructions and explanatory notes for a particular maintenance function 2 A 2 Maintenance Functions Maintenance functions will be limited to and defined as follows a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel b Test To verify serviceability by measuring the mechanical pneumatic hydraulic electrical characteristics of an item and comparing those characteristics with prescribed standards c Service Operations required periodical
89. aster switch is in the OFF position 26 PUMP DISCONNECT LEVER Pull this lever toward rear of cab to engage the pump drive Push this lever forward toward dash panel to disengage the pump drive The engine must be stopped before engaging or disengaging the pumps 27 SHIFT CHART This chart shows the shifting pattern of the main and auxiliary transmissions 28 IGNITION SWITCH Turn this key switch clockwise to the START position to start the engine Allow the key to return to the ON position as soon as the engine has started CAUTION If the engine does not start within 30 seconds release the key and allow the starter motor to come to a stop and rest for two minutes before attempting to start the engine again 29 ENGINE WATER TEMPERATURE GAUGE This gauge shows the temperature of the engine coolant The gauge should read between 160 and 1850 F 7185 C during normal operation 30 SPEEDOMETER ODOMETER The speedometer shows carrier speed in miles per hour while the odometer indicates the total numbers of miles the carrier has traveled 31 ENGINE OIL PRESSURE GAUGE This gauge should read between 40 and 60 psi 2 754 14 bars during normal operation 32 R H DIRECTIONAL SIGNAL INDICATOR 33 ENGINE WARNING LIGHT This light is furnished when the machine is equipped with the optional engine warning system This light when illuminated indicates that the engine is overheated or the engine oil pressure is below normal
90. at everv part is in equal tension REMOVE THE 3 16 ROD LOCKING THE ACTUATING ARM otherwise damage will occur during booming INSTALLING THE ALARM UNIT AND ELECTRICAL WIRING The alarm unit consists of a bell a red light and an amber light These must be mounted in such a position that it is plainly audible and visible to the crane operator Bolt the bell in position in the crane cab using the two holes provided Mount the lights either on the bell or at any place where they are readily visible Remove the plastic cover from the connection box at the Control Box revealing the terminal strip Connect one wire from the BLACK terminal to the Bell and Red light The other terminal of the bell and red light should be connected to ground Connect from the purple terminal to the amber warning light Other side of light to ground again Connect one more wire from the RED terminal at the Control Box to the live side of the crane s electrical supply by way of a 2 amp fuse Depress the test button to check functioning of the circuit The Bell should ring and the Red light should light REFER WIRING DIAGRAM FIG 2 1 14 e ALTER WATE cem p gt Boom Foer Bow SHEAVE gt TES tow or b e 55 SPOING ae PPLE x 36s ree SMEANVES ARE NOT LIVE SKETCH 2 2 1 15 CALIBRATION AND SETTING INSTRUCTIONS MODELS 4 5 amp 6
91. before resistance is felt and is best checked by hand SECTION IV PREVENTIVE MAINTENANCE The proper amount of clutch pedal free travel is 3 4 to 1 2 Check clutch pedal free travel If the free travel is inch 1 9 2 54 cm within 3 4 to 1 inch 1 9 2 54 cm hold the adjusting screw and tighten the jam nut A gradual reduction in the amount of free travel is a normal condition caused by wearing of the clutch friction 3 If the free travel is not within 3 4 to 1 inch 1 9 2 54 material If free travel is less than 3 4 inch 1 9 mm cm increase or decrease the clearance between the adjust the clutch as follows seg Figure 4 18 release levers until proper free travel is obtained Then hold the adjusting screw and tighten the jam nut 1 Loosen the jam nut Back the adjusting screw out until the clearance between the release levers is approximately 1 16 inch 0 16 mm TT KA EN 4 streng fi CHECK CLEARANCE HERE Figure 4 18 Clutch Adjustment 1 4 16 SECTION IV E Maintenance Checks PREVENTIVE MAINTENANCE Perform A B C amp D Maintenance Checks each time the following check is performed CLEAN CRANKCASE BREATHER Remove the crankcase breather from the engine every 1000 hours and wash the steel mesh pad in fuel oil and dry it with compressed air This cleaning period may be reduced or lengthened according to the severity of service CLEAN AND INSPECT BLOWER SCREEN Inspect the blower screen an
92. by the end item manufacturer after TARCOM approves the field campaign or modification plan Se Appendix 2 B 2 9 Equipment Improvement Recommendations EIR Equipment Improvement Recommendations will be submitted in accordance with TM 38 750 2 10 Shipment and Storage Refer to the Operating Instructions and Service Manual and TB 740 97 2 2 11 Destruction to Prevent Enemy Use Refer to TM 750 244 3 for instructions governing destruction of equipment to prevent enemy use 2 12 Basic Issue Item List BIIL Sed Appendix 2 C 2 13 Special Tools and Equipment ee Section af Appendix 2 A 2 14 Maintenance and Operating Supplies ee Appendix 2D for a list of maintenance and operating supplies required for Initial operation 2 15 Maintenance Forms and Records a Operational Records Operational records DA Form 2400 and 2401 are optional any may be utilized at the discretion of the using organization b Maintenance Records 1 DA Form 2402 Exchange Tag 1 2 DA Form 314 Preventive Maintenance Schedule and Record 3 DA Form 2404 Equipment Inspection and Maintenance Worksheet 4 DA Form 2405 Maintenance Request Register 5 DA Form 2407 Maintenance Request c Historical Records 1 DA Form 2408 Equipment Logbook Assembly 2 DA Form 2408 1 Equipment Daily and Monthly Log 3 DA Form 2408 5 Equipment Modification Record 3 2 3 4 DA Form 2408 9 Equipment Control Record b DA
93. cedure for the other outrigger WARNING Do not set the outriggers near holes or on rocky or extremely soft ground This may cause the machine to tip resulting in injury to personnel 5 Lower the outrigger to raise the machine off the ground by placing the desired VERTICAL switch in the DOWN position Repeat the procedure for the other outrigger 6 Repeat Steps 4 and 5 for the outriggers on the opposite side of the carrier After all four outriggers have been extended and lowered make the necessary leveling adjustments by raising or lowering each outrigger as required until the machine is level Check the level of the machine using the levels on each side of the carrier or in the upper cab 7 the machine is equipped with safety locks engage the safety locks by placing the SAFETY LOCKS switch in the ON position This step is not required if the machine is not equipped with safety locks 8 Return the MASTER switch to the OFF position NOTE The operation of the outriggers from the upper cab is identical to the procedure described above except that all four outriggers are controlled from one position in the upper cab TM 5 3810 293 14 amp P 1 CONTROLS AND OPERATION DO R R VERTICAL R F VERTICAL IN Our HORIZONTAL HORIZONTAL iN DUT HYDRAULIC OUTRIGGER CONTROL CARRIER PANEL Figure 2 6 Outrigger Control Panels RETRACTING THE OUTRIGGERS To retract the outriggers proceed as follow
94. ces should the circuit breakers be prevented from tripping by any means Overloaded electrical circuits can cause extensive damage to the machine and or could cause injury to personnel 22 THROTTLE SELECTOR VALVE This valve transfers control of the throttle from the lower to the upper Place the lever in the LOWER position when driving the carrier Place the lever in the UPPER position when operating the upper 23 MAIN TRANSMISSION SHIFT LEVER This lever is used to select the gears in the main transmission 24 AUXILIARY TRANSMISSION SHIFT LEVER This lever is used to select the gears in the auxiliary transmission The auxiliary transmission should be kept in the lowest gear range that will allow the machine to reach the desired maximum speed Maintaining the auxiliary transmission in a higher than required range could cause gear tooth failure due to excessive torque from the main transmission 25 OUTRIGGER STEERING SELECTOR VALVE This valve transfers hydraulic fluid from the engine driven pump to either the power steering system or the outrigger system Push the knob in and engage the latch to direct fluid to the power steering system Pull the knob out to direct fluid to the outrigger system SECTION II NOTE The outrigger steering selector valve is not furnished when the machine is equipped with the optional carrier remote control system The transfer from outrigger to steering is done automatically when the outrigger m
95. ch identifies the controls and describes their function CAUTION Holding a control lever in either engaged position after a cylinder has reached its maximum stroke in the corresponding direction will force hydraulic fluid through the relief valve at maximum speed and pressure and will cause overheating of the hydraulic fluid 1 SIGNAL HORN BUTTON Depress the button on the top of the swing lever to sound the upper signal horn 2 SWING LEVER Push this lever forward to swing the upper to the left toward the boom Pull this lever back to swing the upper to the right 3 BOOM TELESCOPE LEVERS Two levers are used to extend and retract the boom sections Each lever controls one telescoping section of the boom and each is identified below Lever A controls boom section No 2 Lever B controls boom section No 1 1 2 8 TM 5 3810 293 14 amp P 1 CONTROLS AND OPERATION CAUTION Be sure to pay out line from the main and or auxiliary winch as required to prevent the hook block s from coming in contact with the boom point Push both levers forward to extend all the telescoping sections of the boom Pull both levers back to retract all the telescoping sections of the boom CAUTION Extend all boom sections equally If all the sections are not extended equally operate the control levers individually as required to equalize the boom sections 4 AUXILIARY WINCH LEVER This lever controls the operation of the optional auxiliary winch
96. clean system the maximum pump inlet restriction must not exceed 6 inches 152 4 mm of mercury At normal operating speeds 1800 2800 rpm the fuel pressure is 45 to 70 psi 3 1 4 8 bars Change the fuel filters whenever the inlet restriction suction at the fuel pump reaches 12 inches 304 8 mm of mercury at normal operating speed and whenever the fuel pressure at the inlet manifold drops to 45 psi 3 1 bars To replace the fuel filters proceed as follows seelFigurel 4 9 1 Unscrew the fuel filters and discard them 2 Fill the new filters with clean fuel 3 Install the fuel filter Tighten them by hand until the seal touches the filter head Then tighten each filter an additional one half to three fourths turn d D 4 9 Engine Fuel Filters CHANGE HVDRAULIC OIL FILTERS The hvdraulic svstem oil is filtered on the return side bv two full flow tvpe filters located at the right rear corner of the engine compartment To change the hvdraulic oil filter proceed as follows see Figure 4 10 1 Remove the cover above the filters The cover is held in place by Zeus fasteners 2 Remove the center bolt and washer from the bottom of the filter 3 Remove the shell and gasket from the filter head 1 4 10 PREVENTIVE MAINTENANCE 4 Before discarding the filter elements inspect the foreign material trapped in them The type of material trapped in the filter elements could give an indicatio
97. d gasket assembly between the blower and air inlet housing every 1 000 hours and if necessary clean the screen in fuel oil Dry the screen with compressed air Reinstall the screen and gasket assembly with the screen side of the assembly toward the blower CLEAN COOLING SYSTEM Clean the cooling system using a good radiator cleaning compound in accordance with the instruction on the container After the cleaning operation rinse the cooling system thoroughly with fresh water then fill the system with soft water adding a good grade of rust inhibitor or high boiling point type antifreeze as specified in the Engine Manufacturer s Manual With the use of a proper antifreeze or rust inhibitor this interval may be lengthened until normally this cleaning is done only in the spring or fall The length of this interval will however depend upon an inspection for rust or other deposits on the internal walls of the cooling system When a thorough cleaning of the cooling system is required it should be reverse flushed CLEAN EXTERIOR OF RADIATOR Inspect the exterior of the radiator core and if necessary clean it with a quality degreasing solvent and dry it with compressed air It may be necessary to clean the radiator more frequently if the machine is being operated in extremely dusty or dirty areas 1 4 17 CLEAN HYDRAULIC TANK BREATHER Remove the hydraulic tank breather and wash it in fuel oil Dry the breather with compressed air Thi
98. d load to be lowered using free fall must not exceed 5090 of the rating plate or hoist reeving chart Caution must be exercised when using free fall Always allow the winch lever to return to the power down position slowly to avoid shock loading of the winch and winch line 1 2 9 winch Push the lever forward to power down a load on the auxiliary winch see Figure 2 8 The Gearmatic winch free fall feature allows a load to be free fall lowered whenever the free fall lever is squeezed regardless of winch lever position In other words it is possible to free fall a load when the winch lever is in the raise neutral or lower positions just by squeezing the free fall lever Squeeze the free fall lever toward the winch lever to free fall lower a load Release the squeeze lever slowly to return the winch to normal operation This squeeze lever is only furnished when the Gearmatic winch has a free fall feature SECTION II P amp H WINCHES FRONT OF UPPER CONTROLS AND OPERATION d GEARMATIC WINCHES Figure 2 8 Winch Lever Positions 5 MAIN WINCH LEVER This lever controls the operation of the main winch The operation of the main winch is identical to that of the auxiliary winch 6 BOOM HOIST LEVER AND PEDAL Push this lever or pedal forward to lower the boom Pull this lever or pedal to raise the boom 7 SWING BRAKE PEDAL Depress this pedal to apply the swing brake Allow the pedal to
99. datory Entry Card Column Description of Data for CCE 1 3 Document Identifier Code A CONUS Overseas 4 6 Routing Identifier Code 7 Media Status Code 8 22 FSCM and Part Number 23 24 Unit of Issue 25 29 Quantity 30 43 Document Number 44 Demand Code 45 50 Supplementary Address 51 Signal Code 52 53 Fund Code 54 56 Distribution Code CC 54 F for CONUS see AR 725 50 for OCONUS CC 55 56 Weapons System Code 57 59 Project Code 60 61 Priority Code 62 64 Required Delivery Date Will not be assigned 65 66 Advice Code 67 69 Blank 70 Identification code applicable to entry in cc 71 80 A Technical order or Technical Manual End Item Identification C Noun Description D Drawing or Specification No 71 80 Reference Identification Identification of reference specified in cc 70 Sample Format MILSTRIP requisition for CCE Non NSN TAO72414 3 1 3 APPENDIX 1 B 0 d Wo o Ka foster ra fae ZS Gel Steeg QUANTITY Mrs come m E UNIT Lesen IER CODE QUANTITY DOO SINGLE LINE ITEM REQUIS TION SYSTEM DOCUMENT MECHANICAL NE P 23316 00 FORM 1348 1 MAR 74 EDITION OF 1 APR 71 MAY BE USED Tuv ee eem 7 URI DREES ED nog sqm VLC 3n WW Mandatory Entry Card Column Description of Data for CCE 1 3 Document Identifier Code QA CONUS O 1 Overseas 4 6 Routing Identifier Code 7 Media Stat
100. de of the dial This is achieved by rotating the knurled knob at the top left hand side of the Control Box 3 BLACK POINTER ZERO This adjustment is made at the Control Box and may be necessary at certain times The adjuster is on the top right hand side of the control box and is a recessed screwdriver slot DO NOT ATTEMPT TO TURN THIS ADJUSTMENT PAST IT S INTERIOR STOPS WHEN RESISTANCE IS FELT Counter clockwise rotation of the adjuster will cause the black pointer to rise and vice versa Once the pointer is correctly set slightly rotate the adjuster in the opposite direction to relieve the strain on it The Indicator should be lightly tapped during this adjustment As the block is normallv part of the lifted load the black pointer reading should equal the weight of the block when the block is hanging free and unloaded and NOT zero The electrical circuit can be tested bv depressing the switch on the top of the Control Box causing the relav to operate and sounding the warning bell THIS SHOULD BE TESTED AT LEAST ONCE EVERY WORKING DAY If a separate isolation Switch is fitted ensure that it is switched on The foregoing information can be condensed into the following main points to be observed when operating the crane AT ALL TIMES ENSURE THAT 1 Correct cam is fitted to suit boom length and number of parts 2 Correct radius scale is fitted 3 Index window on dial of Control Box shows correct number of parts and no further adju
101. der pressure is delivered through a swivel to the control valves in the upper When the operator engages the controls in the operators cab the control valves direct the fluid to the boom cvlinders swing motor and winch motors Ee a EEETHINAT i SECTION f A 9 L 4 d x NR CARRIER CAB GTUPED POSITION ET CT DL WITH L FOOT A Figure 1 2 Crane Terminology TABULATED DATA DIMENSIONS AND TRANSPORTATION DATA Overall length with boom in travel position Overall length without boom uis tenta e Overall height Gro nd cleararice 2 2 acce iiic doc EES Mee Gross vehicle weight with main and auxiliary winches jib bottom block 4 500 Ib 2 041 kg counterweight amp 1 2 tank of fuel Weight Distribution Rear axle eR ee e MEE 80 Boom 37 800 Ibs EE 38 1 3 8 11 62 m huoc MM 33 1 1 2 10 10 m A eL 8 2 44 m 0 10 1 2 0 27 m S 80 Boom 24 38 m 64 400 Ibs 29 211 kg 100 Boom 30 48 m 65 300 Ibs 29 620 kg 80 Boom 26 600 16 12 066 kg 17 146 kg 100 Boom 27 200 Ibs 12 338 kg 100 Boom 38 100 Ibs 17 282 kg SECTION I Rope Size Drum Dia Drum Pitch Dia Drum Width Flang
102. der machines have control panels on each side of the carrier that allow all four outriggers to be operated from one control panel Even though all four outriggers can be operated from one side of the carrier as a safety precaution it is suggested that only the outriggers in view while standing by the control panel be operated EXTENDING THE OUTRIGGERS To extend the outriggers from the carrier control panels proceed as follows 1 Pull the Outrigger Steering Selector Valve knob out to the OUTRIGGER position This step is not required when the machine is equipped with the optional carrier remote control system The transfer from steering to outriggers is accomplished automatically when the MASTER switch on the outrigger control panel is placed in the ON position NOTE The power steering system is inoperative when the selector valve is in the OUTRIGGER position 2 Remove the retainer pin and move the lock pin to the unlocked position on each outrigger Install the retainer pin to keep the lock pin in the unlocked position see Figure 25 CAUTION Make certain that the swing brake is locked in the applied position with the Swing Brake Lock before extending the outriggers 3 Place the MASTER switch in the ON position me Figure 2 6 SECTION II UNLOCKED POSITION RETAINER PIN Figure 2 5 Outrigger Locks 4 Extend the outrigger by placing the desired HORIZONTAL switch in the OUT position Repeat the pro
103. e 90 32 Po 50 Figure 3 2 Carrier Lubrication Chart 105J828 C 1 3 11 1 3 12 blank TM 5 3810 293 148P 1 Bv Order of the Secretarv of the Armv E C MEVER General United States Armv Official Chief of Staff J C PENNINGTON Major General United States Army The Adjutant General Distribution To be distributed in accordance with DA Form 12 25B operator maintenance requirements for cranes truck mounted U S GOVERNMENT PRINTING OFFICE 1996 406 421 43255 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE BE EXACT PIN POINT WHERE IT 15 IN THIS SPACE TELL WHAT 16 WRONG i l D A FORM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR Y JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS e goen s mm vm Gee emm mmm comm sms TEAR ALONG PERFORATED LINE omama amam emp mmm CERO green degen quem ate THE METRIC SYSTEM AND EQUIVALENTS NEAR MEASURE SQUARE MEASURE Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Meter
104. e O D P D to rope dia ratio 11 1 4 285 7 12 3 8 314 3 13 1 2 342 9 14 5 8 371 5 15 3 4 400 0 16 7 8 428 6 Rope Size Drum Dia Drum Pitch Dia Drum Width Flange O D P D to rope dia ratio 11 1 4 285 7 12 3 8 314 3 13 1 2 342 9 14 5 8 371 5 15 3 4 400 0 16 7 8 428 6 MAIN WINCH DATA P amp H PART NO 923P5 FiG 1 MODEL P amp H 10 1 9 16 Dia 14 3mm 10 11 16 271 5mm 11 1 4 285 6mm 14 355 6mm 19 482 6mm 20 1 LOW SPEED Full Load Line SPD Up FPM m min No Load Line SPD Up FPM m min 155 47 24 170 51 82 195 59 44 200 60 86 220 67 06 230 70 10 5 200 2 359 4 700 2 132 4 300 1 950 4 000 1 814 3 700 1 678 3 400 1 542 Pressure Flow Drum Torque Low SPD Drum Torque High SPD Drum RPM Up Low SPD Drum RPM High SPD Full Load Line SPD Up FPM m min 320 97 54 350 106 68 380 115 82 415 126 49 450 137 16 480 146 30 No Load Line SPD Up FPM m min 365 111 25 400 121 92 435 132 59 475 144 78 515 156 97 550 167 64 AUXILIARY WINCH DATA P amp H PART NO 923P5 FIG 1 MODEL P amp H 10 1 9 16 Dia 14 3mm 10 11 16 271 5mm 11 1 4 285 6mm 14 355 6mm 19 482 6mm 20 1 LOW SPEED Full Load Line SPD Up FPM m min No Load Line SPD Up F
105. e individual accepting the item will be entered on the reverse side of the section used c When an unserviceable item is immediately exchanged for a tagged serviceable item the receipt portion of the card is not used c Preparation 1 The unserviceable part or assembly will be identified by making entries in DA Form 2402 blocks as follows a Block 1 Enter the support agency where the item is to be exchanged b Block 2 Enter calendar date the item was prepared for exchange c Blocks 3 11 and 15 Enter unit or organization originating the exchange 3 2 4 d Block A Enter national stock number or manufacturer s part number when an NSN has not been assigned to the defective part or assembly with the priority designator PD assigned by unit or organization listed in block Unit commander or acting unit commander will place his signature in the upper right margin of the form when PD 01 through n8 is used e Blocks 12 16 and 20 Enter national stock number of the defective part or assembly f Blocks 5 19 and Item Noun nomenclature sections 1 2 3 and 4 e g carburetor generator starter etc g Block6 Enter a W in the EIR Exhibit space h Blocks 8 13 17 and 21 Enter the nomenclature and manufacturer if applicable of the end item from which the item was removed i Block 9 Model of the equipment from which the item was removed e g M151A1 UHID AN GRC 46 if applicable j Blocks 10 14 18 and
106. e unit identified in block la Block 2 Enter serial number of the end item f Block3 Enter the noun nomenclature of equipment for which the form was initiated 7 3 2 6 g Block 4 Leave blank h Block 5 Enter the model designation of equipment for which the form was initiated If the item has no model designation leave blank i Block 6 Enter the National Stock Number of equipment listed in block 3 When completing this form for bulk items having multiple NSN s leave blank Block 7 Enter the symbol of the maintenance activity performing the maintenance entry shall be made in the yes or no blocks K Block8 Enter the appropriate utilization code Block 9 Place a V or an X in the yes block if the item is a DA directed sampling item For all other equipment place a or an X in the no block m Block 10 Enter the hour reading rounded to the nearest hour from the hour meter If not applicable leave blank n Block 11 Enter the mileage reading rounded to the nearest mile from the odometer If not applicable leave blank o Block 12 Leave blank p Block 13 Leave blank q Block 14 Enter a V or an X in the space provided to indicate when the failure was detected Exception Leave blank if no failure is involved or DA directed sampling items organizational maintenance 2 Block 15 Place a or an X in the space provided that most accurately desc
107. e variations in dust and weather conditions even in the same location changing as required is usually more economical Until sufficient experience is gained however to determine the as required change interval the air cleaner should be checked weekly NOTE Loss of engine power or excessive smoke in exhaust gases indications that the filter cartridge is clogged and requires changing Figure 4 3 Swing Reducer Filler Plug To replace the filter cartridge proceed as follows see Figure 4 4 1 Remove the four clamps which hold the moisture eliminator in place and remove the moisture eliminator HOUSING FILTER CARTRIDGE MOISTURE ELIMINATOR Figure 4 4 Engine Air Cleaner SECTION IV 2 Remove the dirtv filter cartridge bv inserting fingers in the cartridge openings Loosen all four corners of the cartridge one at a time by pulling straight out 3 Clean the moisture eliminator openings of all soot oil film and any other objects that may have become lodged in the openings Inspect the inside of the air cleaner housing for foreign material 4 Inspect the dirty cartridge for soot or oil If there is soot inside the tubes check for leaks in the engine exhaust system If the cartridge appears oily check for fumes escaping from the crankcase breather Excessive oil mist shortens the life of the cartridge Troubleshooting at this point can appreciabiv lengthen new cartridge life NOTE It is not
108. eed 1200 feet per Richcote Lu Atlantic Richfield minute 365 8 bricant Jet Company m min Lubricants Sinclair and Atlantic Lubricants 36 thru 40 Coglube Continental Oil Ccmpany Surett Humble Oil amp Refining Company Mobitac Mobil Oil Corporation Cardium EP Shell Oil Company Com ds amp Fluids DX Coating Sun Oil Co DX Division Compounds Crater X Texaco Inc Open Gear Whitmore Mfg Co Dipper Stick and Cam Lube Consult lubricant manufacturer for proper viscosity grade which will depend on application and climate 1 3 5 SECTION III LUBRICATION HEAVY DUTY MOTOR OIL P amp H MILITARY EQUIVALENT SYMBOL SPEC NO AMBIENT RANGE SPEC LUBRICANTS MANUFACTURER See Lubrication MIL L Conoco Tracon Continental Oil Company Chart 2104B or 7 a latest issue Encolube Humble Oil amp Refining Co ineffect Delvac 1200 Mobil Oil Corporation Series Rotella T Oils Shell Oil Company TBD Mil 8 Sun Oil Co DX Division Motor Dil Ursa Oils Texaco Inc Extra Duty Super Tenol Sinclair Refining Company Amoco 200 American Oil Company Motor Oils MO Equivalent lubricants and manufacturers are the same as for P amp H Spec 451A Motor Oil as de scribed above The only difference insofar as this description is concerned is that P amp H Specification 451B is an SAE 20 20W grade oil Chart 2104B or latest issue in effect 4
109. eepage of fluid indicated by wetness or discoloration not great enough to form drops Class Leakage of fluid great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class Leakage of fluid great enough to form drops that fall from the item being checked inspected 3 2 44 TM 5 3810 293 14 amp P 1 CAUTION Equipment operation is allowable with minor leakage class lI Of course consideration must be given to the fluid capacitv in the item svstem being checked inspected When in doubt notifv vour supervisor Class Ill leaks should be corrected before releasing equipment for operation f If the crane doesn t work properly you can t see what is wrong refer to troubleshooting instructions 3 2 45 B BEFORE ITEM INTERVAL i ei als Table 2 E 1 Operator Crew Preventive Maintenance Checks and Services CRANE OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES D DURING A AFTER ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND HAVE REPAIRED FILLED OR ADJUSTED AS NEEDED NOTE Perform weekly as well as before PMCS if A You are the assigned operator but have not operated the crane since the last weekly B You are operating the crane for the first time 1 Make the following walk around checks Exterior of vehicle a Check for evidence of leakage oil hvdraulic fluid on or under the crane b Visually check for loose missing or damaged parts In
110. efer to the rating chart in the upper cab to determine reeving requirements for various loads Hoisting and lowering speeds decrease as the number of parts of line increases When practical use the minimum number of parts required for the loads to be lifted Boom reeving diagram for clamshell operation is shown in Figure 2 14 NOTE Jib reeving is limited to a single part of line The main or auxiliary winch line can be used to reeve the jib The auxiliary winch line cannot however be used for reeving the main hoist line REEVING WITH EVEN NO PARTS OF LINE NOTE THE 80 24 38 BOOM HAS 4 MAIN 5 BOOM POINT SHEAVES THE 100 30 48 m BOOM HAS 5 MAIN BOOM POINT SHEAVES BLOC P 6 PART EAVE 7 PART Figure 2 14 Reeving Diagram 105N416 Change 1 1 2 22 SECTION II CONTROLS AND OPERATIONS CLOSING LINE HOLDING LINE TA217513 Figure 2 14 1 Boom Reeving For Clamshell Operation Change 1 1 2 22 1 1 2 22 2 blank SECTION II The dead end of the rope is attached to the hook block or boom point with a wedge type rope socket The rope socket should be installed on the rope as follows sed Figure 2 15 1 Place the socket in an upright position as shown in View A and bring the rope around in a large easy to handle loop 2 The dead end of the rope should extend from the Socket for a distance of at least one rope lay permitting the strands to adjust around the wedge and to keep the rope
111. efore operating the machine RUNNING THE CARRIER To run the carrier proceed as follows 1 Engage the auxiliary transmission in a range suitable for the road conditions The gear range selected should be the lowest range that will allow the machine to travel at the desired speed 2 Depress and hold the clutch pedal transmission into a range suitable conditions 3 Depress the brake pedal Then pull the Maxibrake control knob out from the dash panel The carrier is now ready to be moved Shift the main for the road STOPPING THE ENGINE To stop the engine proceed as follows 1 Place the main transmission lever in the neutral position 2 Push the Maxibrake control knob in to apply the parking brakes 3 If possible allow the engine to idle for 3 to 5 minutes before shutting down the engine This will allow the engine to cool down and will prevent overheating due to localized residual heat 4 Depress the Engine Stop button on the dash panel to stop the engine 5 After the engine has stopped turn the ignition key to the OFF position 1 2 6 TM 5 3810 293 14 amp P 1 CONTROLS AND OPERATION OUTRIGGER OPERATION GENERAL The outriggers on this machine are controlled electrically from each side of the carrier and the upper cab The control panels on each side of the carrier control only the outriggers on that side of the carrier while the control panel in the upper cab controls all four outriggers NOTE Ol
112. ely started 1 5 5 MACHINE STORAGE 10 Start the engine in the normal manner and allow it to warm up fully The preservative fuel will produce a harmless smoky exhaust until it is consumed 11 Observe for unusual noise or other symptoms of malfunction when the engine is started Shut the engine down immediately if there is any evidence of malfunction RESTORING CUMMINS ENGINES TO SERVICE To restore the Cummins engine to service following long term storage proceed as follows 1 Clean all accumulated dirt from the engine exterior 2 Remove all paper covers tape and wrappings 3 Using a suitable solvent cleaner or degreaser remove rust preventive compound from the unpainted surfaces of the engine 4 Flush the entire fuel system with clean fuel oil until all preservative oil is removed from the system 5 Remove the plug from the oil header and force hot light mineral oil through the oil passages to flush away all preservative oil and gummed oil that may have accumulated Bar the engine over several times during this flushing operation 6 Remove all filter screens and strainers and clean them thoroughly Refer to the engine manufacturer s manual for locations and procedures 7 Fill the engine crankcase with new oil of the type and amount specified in the carrier lubrication chart Install a new oil filter cartridge 8 Flush the cooling system thoroughly and refill with clean soft water and a high quality corrosio
113. emperature drain the crankcase 1 5 1 2 Replace the drain plug change the oil filter element and fill the crankcase to the proper level with the recommended oil type 3 Fill the fuel tank and operate the engine for two minutes at 1200 RPM and no load NOTE Do not drain the crankcase or fuel tank after this run 4 Service the engine air cleaner if inspection reveals the need 5 Check the condition of the water or antifreeze solution in the engine cooling system If the coolant appears unfit for further use drain the cooling system flush with clean soft water and refill with clean water or a permanent antifreeze solution according to expected weather conditions Add a high quality rust inhibitor if only water is used in the system and run the engine until the rust inhibitor is thoroughly mixed 6 Clean the exterior of the engine except the electrical components and wiring with diesel fuel and dry with air 7 Seal the engine exhaust outlet and air cleaner face using a suitable water resistant material The material used must be waterproof vapor proof and be strong enough to resist puncture and damage from the expansion of entrapped air CUMMINS ENGINE PREPARATION The following steps will prepare a Cummins engine for storage for up to six months 1 Start the engine and gradually increase speed up to 1200 RPM Run the engine at 1200 RPM until it is thoroughly warmed 2 Disconnect both the fuel supply line
114. epair BODY CHASSIS AND HULL ACCESSORY ITEMS Accessory Items Mirror Assemblies Inspect Replace Repair Air Horn and Reflectors Inspect Replace Windshield Wiper Inspect Assembly Replace Repair Wiper Motor Inspect Replace Heater Personnel Inspect Replace Repair Defroster Inspect Replace Data Plates and Instruction Holders Data Plates Labels and Inspect Decals Replace TM 5 3810 293 14 amp P 1 Section Il MAINTENANCE ALLOCATION CHART GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBL FUNCTION EQUIPMENT REMARKS HYDRAULIC AND FLUID SYSTEMS Pump and Motor Pump Drive Assembly Inspect i Test 2 Replace Repair i Manifold and or Control Valves Hydraulic Control Valves Inspect Replace Repair Hydraulic Controls and or Manual Controls Lever Assemblies Inspect d Control Hvdraulic Service Replace Repair Strainers Filters Lines and Fittings Etc Hydraulic Lines and Inspect Fittings Replace Filter Oil Hvdraulic Inspect Replace d Repair Hvdraulic Cvlinders Inspect 1 Service Replace Repair Liquid Tanks or Reservoirs Reservoir Inspect Service d Replace Repair GAGES WEIGHING AND MEASURING DEVICES Instruments Speedometer and Cable Test Replace Gages Mountings Lines and Fittings Indicators and Gages Inspect Replace Change 3 3 2 28 TM 5 3810 293 14 amp
115. ering inca ava ele es Foy Rae eek ee eee a ee A a ey cg dee aude 2 1 2 quarts 2 4 l LIGHT BULBS LOCATION NUMBER Headlights High Beam Low Beam Stop Tail Lights Clearance Lights Directional Signal Front Rear Indicator Hazard Warning Indicator FILTER ELEMENTS Low Air Pressure Light Upper Ignition Indicator Light LOCATION VENDOR NUMBER Engine Oil AC PF 132 Fuel Strainer 6V53N AC T 815 Instrument Lights Fuel Filter AC TP816 Engine Warning Indicator High Beam Indicator Ignition Indicator Drum Turn Indicators Dome Light License Plate Light Identification Lights Outrigger Indicators Master Switch Safety Lock Air Cleaner Farr P 32 Hydraulic Oil Filters Vickers 923070 1 1 4 INTRODUCTION SECTION I Ce ROTATION 5 FEET x HOOK DISTANCE FROM 4 OF ROTATION 58 9 25 3AOBV 1333 NI LH913H Figure 1 3 Range Diagram 80 Boom 105X75 A 1 1 INTRODUCTION SECTION I 3 8 bB R 3A08V LHDISH 20 25 30 35 40 45 50 55 60 65 70 10 15 5 RADIUS FROM CENTER LINE OF ROTATION Figure 1 4 Range Diagram 100 Boom 105J683 1 1 6 SECTION I INTRODUCTION i NOMENCLATURE FT JN METERS A WIDTH OF REVOLVING SUPERSTRUCTURE MAX HEIGHT AB
116. ety valve should be repaired or replaced 1 4 7 1 4 8 blank SECTION IV C Maintenance Checks At each C Maintenance Check perform all A amp B Checks in addition to the following PERFORM MONTHLY LUBRICATION Refer to the lubrication charts in Section TII of this manual and lubricate all the monthly lubrication points indicated with the type of lubricant specified CHANGE ENGINE OIL amp OIL FILTER The engine oil and filter change interval should be started with a monthly interval The change interval may then be gradually increased or decreased following the recommendations of an independent oil analysis laboratory or the oil supplier based on the oil sample analysis until the most practical oil change period for the particular service has been established To change the engine oil and filter proceed as follows sed Figure 4 8 1 Bring the engine up to operating temperature Shut down the engine remove the drain plug from the bottom of the oil pan and drain the oil into a suitable container a VIEWED FROM LEFT at SIDE OF CARRIER gt TA CENTER BOLT Figure 4 8 Engine Oil Filter 1 4 9 PREVENTIVE MAINTENANCE 2 Replace the oil pan drain plug and tighten the plug securely 3 Remove the drain plug from the filter shell and allow it to drain Replace the drain plug 4 Loosen the center bolt and remove the filter shell and filter element Before discard
117. h the winch to fold the jib under the boom 6 Telescope the boom back fully and take up slack with the winch until the jib mount bracket is aligned with the jib mounts Install spacers 8 retainers 7 lockwashers 6 and capscrews 5 7 Install pin 10 and lock it in place with cotter pin 9 8 Unhook the winch line from becket 4 and attach the line to the hook block 9 Remove T pins from boom jib pivot point and install in stowed position Change 1 1 2 25 SECTION ll MANUAL FLV SECTION This machine can be equipped with an optional manuallv operated fly section which will increase the maximum boom length to 100 feet 30 48 m The manual fly section is stored within the telescoping boom and is extended by means of boom section 2 telescoping cylinder as described below To extend the manual fly section proceed as follows sel Figure 2 18 CAUTION The crane boom must be in a horizontal position while the manual fly section is being extended or retracted If this is not observed it is possible that the fly section could move when the cylinder pin is removed and cause damage to other parts of the boom 1 Extend the boom sections until boom section 2 is out approximately 48 inches 1219 mm and the cylinder pin is visible as shown in View A CYLINDER ROD EYE CY LINDER PIN MANUAL FLY SECTION BOOM SECTION 2 SECTION A A CYLINDER CYLINDER PIN PIN ND CAP 4 CYLINDER PIN END CAP
118. hboard 2 Clean the area around the master cylinder filler cap and then remove the filler cap The oil should be up to the bottom of the filler neck If necessary add oil of the type specified Section TII to bring the oil to the proper level Replace the filler cap NOTE If the oil in the master cylinder is extremely low check the master cylinder slave cylinder and connecting lines and fittings for leaks Repair or replace anv faultv Figure 4 16 Clutch Master Cylinder components immediately 7 VIEWED FROM FRONT 7 OF CARRIER CAB WITH gt i PANEL REMOVED 1 4 14 SECTION IV D Maintenance Checks PREVENTIVE MAINTENANCE Repeat the A B amp C Maintenance Checks each time the following checks are performed PERFORM QUARTERLY LUBRICATION Refer to the lubrication charts in Section and lubricate the quarterly lubrication points with the type of lubricant specified DRAIN SEDIMENT amp WATER FROM FUEL TANK Keep the fuel tank filled to reduce condensation to a minimum Since some condensation and sediment will accumulate in the fuel tank the drain at the bottom of the fuel tank should be opened every 500 hours to drain off any accumulated water and sediment CHECK CONDITION OF COOLING SYSTEM HOSES Inspect all of the engine cooling system hoses at least once every 500 hours for signs of deterioration Replace the hoses if necessary CHECK AIR VALVES amp CYLINDERS FOR LEAKS All
119. he abrasive action of dust which shortens the life of parts Make every effort to keep dust and sand out of the moving parts of the crane machinery and engine 1 All lubricants and lubricating equipment must be kept clean Service breathers and air cleaner frequently to remove accumulated sand and dust Lubricate more frequently to keep a supply of clean lubricant in the moving parts Clean all lubrication fittings thoroughly before attaching the grease gun 2 Keep the fuel tank filler cap tight to prevent sand or dust from entering the fuel tank Service fuel filters frequently to keep them free from sand and dust 3 Keep the hydraulic oil reservoir filler cap tight to prevent sand and dust from entering the hydraulic system Service the hydraulic oil filter frequently to keep the system free from send and dust 4 Use wood blocking or mats under the outrigger jack floats when operating in send See that the carrier does not shift during operation OPERATION IN HUMIDITY OR SALT WATER AREAS Moisture and salt will cause deterioration of paint cables wiring and all exposed metallic parts Keep parts dry and well lubricated in high humidity or salt water conditions 1 Completely remove rust and corrosion at the first appearance on any part of the truck crane Wash off sit water and dry all parts thoroughly paint the exposed surfaces immediately Place a film of lubricant or grease on all polished or machined metal surfaces and othe
120. hen moving the machine into a position where there is very limited clearance or when handling loads that are out of sight of the operator the use of a signalman is essential The hand signals illustrated Figure 2 12 are those generally accepted throughout the industry Both the operator and the signalman should be thoroughly familiar with the standard hand signals illustrated to ensure cooperation and teamwork OPERATION UNDER UNUSUAL CONDITIONS GENERAL Unusual conditions refer to environment specifically extreme cold extreme heat dusty or sandy conditions areas with high humidity or salt air and high altitudes Separate paragraphs are devoted to each of these conditions OPERATION IN EXTREME COLD Operation in extreme cold presents special problems due to the increased brittleness of metallic and rubber parts the danger of freezing and the increased difficulty of keeping parts lubricated adequately WARNING Personnel should use care to keep from spilling fuel coolant or other liquids upon themselves Exposed parts of the body should not come into contact with metal during cold weather as serious and painful injury may result 1 Refer to Section lll Lubrication for lubricant recommendations for cold weather operation Change the lubricant if necessary 2 Drain and flush the cooling system to insure proper circulation of coolant throughout the radiator core Clean the radiator cooling fins particularly
121. hen the carrier remote controls are not being used CARRIER OPERATION GENERAL The following paragraphs are not intended to describe the method of operating the carrier but to describe the sequence for starting the engine releasing the parking brakes running the carrier and shutting down the engine PREOPERATION INSPECTION Before actually operating the machine each day perform the A Maintenance Check outlined ir Section IV STARTING THE ENGINE To start the engine proceed as follows 1 Place the main transmission shift lever in the neutral position 2 Depress the accelerator pedal slightly and turn the ignition key to the START position As soon as the Change 1 1 2 5 SECTION II engine starts release the key Do not hold the starting motor on for more than 30 seconds at one time If the engine does not start in this period of time release the ignition key and wait for two minutes before trying to start the engine again NOTE The use of a cold weather starting aid furnished as an option may be required in extremely cold weather 3 Check all gauges immediately after the engine starts to be sure they are reading properly If the readings are improper stop the engine immediately and determine the cause of the improper gauge reading before continuing operation 4 Allow the engine to run at 800 to 1000 RPM for 4 to 5 minutes or preferably until the water temperature reaches normal operating temperature b
122. hing the Maxibrake button in 2 Turn the upper ignition key clockwise past the detent to start the engine Do not hold the starter on 1 2 12 CONTROLS AND OPERATION for more than 30 seconds at one time If the engine does not start in this period of time release the ignition key and wait two minutes before attempting to start the engine again 3 Check all gauges immediately after the engine starts to be sure they are reading properly If the readings are improper stop the engine immediately and determine the cause of the improper gauge reading before continuing operation 4 Allow the engine to run at 800 to 1000 rpm for 4 to 5 minutes or preferably until the water temperature reaches normal operating temperature before working the machine CRANE OPERATING CYCLE The crane operating cycle consists of six steps setting the boom angle boom hoist operation setting the boom length boom telescope operation lifting the load hoisting operation swinging the load spotting the load and lowering the load sed Figures 2 9 and 2 10 CAUTION Figure 2 9 illustrates the operation of the machine when it is equipped with P amp H winches while illustrates the operation of machines equipped with Gearmatic winches The operation of these machines is different Therefore be sure you understand the operation of your machine before you begin to operate it The operation of both types of winches is described in the top
123. hree months 2 Do S checks and services twice each year or once every six months 3 2 43 TM 5 3810 293 14 amp P 1 Dothe Dothe Dothe Dothe A checks and services once each vear B checks and services once every two years H checks and services at the hour interval listed MI checks and services when the mileage of the vehicle reaches the amount listed WARNING Drvcleaning solvent SD 2 used to clean parts is potentially dangerous to personnel and property Do not use near open flame or excessive heat Flash point of solvent is 1380 c Make cleanup a part of your preventive maintenance Dirt grease oil and debris may cover up a serious problem Wipe off excess grease and spilled oil Use drycleaning solvent SD 2 to clean metal surfaces Use soap and water when you clean rubber or plastic material d Watch for and correct anything that might cause a problem with the equipment Some things you should watch for are 1 Bolts nuts and screws that are loose missing bent or broken 2 Welds that are bad or broken 3 Electric wires and connectors that are bare broken or loose 4 Hoses and fluid lines that leak or show signs of damage or wear e You should know how fluid leaks affect the status of your equipment Learn and be familiar with the following definitions of the types classes of leakage Remember when in doubt notify your supervisor Leakage Definitions for PMCS are Class S
124. ic Upper Control Identification STOPPING THE ENGINE To stop the engine proceed as follows 1 Make certain that all controls are in the neutral position and the swing brake is locked in the applied position Lower the boom onto the boom rest or to a horizontal position 2 f possible allow the engine to run at half speed or less for several minutes before stopping the engine This will allow the engine to cool down 3 Depress the Engine Stop Button to stop the engine After the engine has stopped place the ignition key in the OFF position SECTION II CARRIER REMOTE CONTROLS GENERAL The purpose of the carrier remote controls is to provide a means of moving the carrier without having to leave the upper cab CONTROL IDENTIFICATION The controls provided on the carrier remote control panel are shown in Figure 2 11 The function of the controls are as follows REMOTE CONTROL CARRIER A Pe ALWAYS PUSH IN BRAKE SWITCH WHEN LEAVING CAB BRAKE ON LIGHT ON INDICATES LOW AIR PRESSURE DO NOT OPERATE IN if STEER BRAKE OFF 7 ee FORWARD NEUTRAL REVERSE Figure 2 11 Carrier Remote Control Panel 1 LOW AIR PRESSURE LIGHT This lamp when illuminated indicates that the air pressure is below the pressure required to operate the carrier by remote control Do not operate the carrier by remote control when this lamp is illuminated 2 L H STEER Depre
125. ical system and is equipped with a charging alternator with a rating of 35 amperes The crane is the manufacturer s latest standard model which has been produced and marketed for a minimum period of one year and meets the requirements set forth in the item description The category of maintenance for the crane will be in accordance with the Maintenance Allocation Chart MAC Seb Appendix 2 A Refer tb paragraph 3 4 for requisitioning of repair parts and support The intended uses are as follows a Intended Use The crane is intended for use in a wide variety of construction and rehabilitation missions 1 Roads 2 Airfields 3 Pipeline Systems 4 Structures and Utilities 5 Heliports 6 Railroads 7 Bridges 8 Port Beach and Marine POL Facilities 3 2 1 b Construction Tasks 1 Lifting 2 Pile Driving 3 Clamshell 2 3 Procurement Status The procurement contract number is DSA700 73 C 9003 is a multi year contract for a total of 330 Cranes in FY72 and FY73 2 4 MOS Requirements a Operator Crane operator MOS62F30 b Organizational Engineer equipment repairman MOS62B20 c Direct General Support Engineer equipment repairman MOS62B30 Special Electrical Electronic Repairman MOS35E20 2 5 Logistics Assistance AR 700 4 US Army Tank Automotive Materiel Readiness Commande field maintenance technicians stationed at CONUS and OCONUS installations are available to furnish on site training and or tech
126. igure 4 12 Oil Levels P amp H Winch 2 Remove the level plug from the planetary housing The oil should be just up to the level plug opening If the oil is not up to the opening remove the breather and add oil of the type specified if Section for the winch gearing through the breather opening to bring the oil to the proper level Replace the breather and oil level plug To check the oil level in a Gearmatic Winch proceed as follows see Figure 4 13 1 Non free fall Gearmatic Winches are equipped with a combination oil level filler plug on the final drive end of the winch Remove this plug to check the oil level The oil should be just up to the opening Add oil of the type specified ih Section for the winch gearing through the oil level filler opening to bring the oil to the proper level 2 Free fall type Gearmatic Winches are continuously lubricated by the hydraulic oil used to operate the winch and therefore do not require periodic inspection CHECK SLEWING RING BOLT TORQUE The slewing ring mounting bolts should be retorqued after the first 200 hours of operation and every 200 hours thereafter 1 4 12 Check the mounting bolts in the interior bolt circle using a suitable torque wrench to be sure that they are torqued to 550 foot pounds 76 m kg The bolts can be reached by removing the cover from the revolving frame Slowly swing the upper as required to position the interior mounting bolts under the opening
127. ill use Project Code JZC for part numbered parts 3 5 Submitting Requisitions a Using Units and Organizations will submit DA Form 2765 Series requisitions to designated support units or activities in accordance with local procedures b Support units and activities will forward MILSTRIP requisitions for NSN part through the Defense Automated Addressing System DAAG to the Managing Supply Support Activity Requisitions for part numbered parts will be forwarded through DAAS to the Defense Construction Supply Center DCSC NOTE When the manufacturer s part number and Federal Supply Code for Manufacturer FSCM exceed the space in card columns 8 through 22 of A02 AOB requisitions prepare an requisition DD Form 1348 6 and mail it to Commander Defense Construction Supply Center ATTN DCSC OSR Columbus OH 43215 3 6 DA Equipment Publications a Utilization of Construction Equipment TM5 331B MAY 68 b Safe Use of Cranes Crane Shovel and Draglines TM 385 101 JAN 71 c Procedures for Licensing Operators of Construction Equipment TB600 2 SEP 78 3 3 2 APPENDIX 3 A PRESCRIBED LOAD LIST PLL AUTHORIZED STOCKAGE LIST ASL TM 5 3810 293 14 amp P 1 END ITEM Crane 25 Ton Hydraulic MAKE P amp H MODEL MT250 MFR PART NO N A NSN 3810 00 018 2021 SERIAL NUMBER RANGE E36080 TO E36199 DATE 28 MAR 78 QTY OF PARTS REQ D FOR NO OF END ITEMS SMR CODE NATIONAL STOCK
128. in plug and cover the filler cap vent with waterproof tape 5 Drain the engine crankcase air compressor oil sump and fuel filters Replace the drain plugs and tighten securely CAUTION In step 6 below inject approximately one quarter cup of preservative oil into each port A larger amount may cause hydraulic lock upon startup unless the excess oil is purged from the combustion chambers 6 Remove the intake and exhaust manifolds and spray all intake and exhaust ports including the air compressor intake port with preservative oil of the type added to the crankcase 7 Replace the intake and exhaust manifolds 8 Drain the engine cooling system and refill with clean soft water and a high quality rust preventive compound Flush the cooling system thoroughly and drain while it is hot NOTE Water soluble oils are available for flushing the cooling system in step 8 If these are used the entire cooling system must be flushed before restoring the engine to service 9 Loosen the tension on all drive belts 10 Brush or spray a film of rust preventive compound on all exposed unpainted surfaces of the engine Use 1 5 3 SECTION V Daubert Chemical Co Nox Rust 207 E F Houghton Co Cosmoline 1046 Pennsvivania Refining Co Petrotect 3 or equal 11 Remove the cylinder head covers and spray preservative oil of the type added to the crankcase over the rocker arms valve stems springs guides crossheads and
129. ing the filter element inspect it as follows A Inspect for metal particles B Inspect the outside wrapper of the element for wrinkles and the pleats for waviness or bunching Presence of these conditions indicates that the oil contains moisture C If the element is relatively clean it may be possible to lengthen the change interval If the element is dogged the change interval should be shortened 5 Remove the gasket from the filter head and discard it 6 Clean the filter shell thoroughly with a suitable Solvent 7 Check that the element end seal is in place in the filter shell and install a new element over the spring support assembly 8 Install a new gasket in the filter head Position the filter shell and element on the filter head and tighten the center bolt 9 Fill the engine to F mark on the dipstick with the type of lubricating oil specified in Section TIT Run the engine and check for leakage 10 Shut down the engine Allow 15 minutes for oil to drain back into the oil pan and recheck the oil level Add oil as required to bring the oil level to the F mark on the dipstick CHANGE FUEL FILTERS New fuel filter should be installed each month or when they become plugged SECTION IV A method of determining when the elements are plugged to the extent that thev should be changed is based on the fuel pressure at the cvlinder head fuel inlet manifold and the inlet restriction at the fuel pump In a
130. ions without edit for matching NSNs and exception data is authorized e Proper use of Direct Support Systems DSS project codes and weapon systems designator codes on parts requisitions is essential f Repair parts are available from commercial sources for CONUS units and may be purchased locally in accordance with AR 710 2 and AR 735 110 g Initial Prescribed Load List PLL and Authorized Stock List ASL will be distributed by Tank Automotive Materiel Readiness Command TARCOM DRSTA MVB 3 2 Prescribed Load List PLL The PLL distributed by TARCOM is an estimated 15 days supply recommended for initial stockage at organizational maintenance Management of PLL items will be governed by the provisions of AR 710 2 and local command procedures An initial stock of PLL parts will be shipped to OCONUS units before shipment of the end item Selection of PLL parts for shipment to OCONUS units is based upon the receiving command s recommendations after their review of the TARCOM prepared list Organizations and activities in CONUS will establish PLL stocks through normal requisitioning process 3 3 Authorized Stockage List ASL The ASL distributed by TARCOM is an estimated 45 days supply of repair parts for support units and activities An initial stock of ASL parts will be shipped to designated support units OCONUS before shipment of the end items The parts shipped will be selected according to the recommendations of the receiving commands
131. iption is concerned is that P amp H Specification 497C is an SAE 140 grade lubricant 1 3 3 SECTION III LUBRICATION HYDRAULIC BRAKE FLUID P amp H AMBIENT MILITARY SYMBOL SPEC NO RANGE SPEC NO EQUIVALENT FLUIDS MANUFACTURER Not applicable VV B 680 218 Brake Fluid Wagner Electric Corporation latest Formula H 68 issue UCON Brake Fluid 4823 Union Carbide Corporation POWER TRANSMISSION FLUID AND GEAR OIL P amp H MILITARY EQUIVALENT SYMBOL SPEC NO SPEC NO LUBRICANTS MANUFACTURER None Dexron B Continental Oil Company Assigned Enco ATF Humble Oil and Refining NOTE This specification covers a petroleum power transmission fluid and lubricating oil properly described as Dexron fluid Mobil ATF 220 Mobil Oil Corporation Shell Donax T 6 Shell Oil Company DX ATF Dexron amp Sun Oil Company DX Division Texamatic Fluid 6673 Texaco Incorporated ATF Dexron amp Sinclair Refining Company American American Oil Company Dexron e ATF 1 3 4 SECTION III LUBRICATION OPEN GEAR AND WIRE ROPE LUBRICANT P amp H AMBIENT RANGE MILITARY EQUIVALENT SAE SYMBOL SPEC NO or application SPEC NO LUBRICANTS GRADE MANUFACTURER Open gears and VV L 751C Amovis Lubri American Oil Company racks under vary cant and Amoco ing weather con Gear ditions Peripheral Comp d speeds not to ex c
132. is parallel to but some distance away from the boom In this case the turnbuckle must be replaced by an arm of adjustable length set to the same dimension as the distance between the center of the boom foot pin and the center of the pulley The dimension between the boom foot pin and the mounting position of this new arm on the boom must be identical with the operating length of the existing lever arm In this way a parallelogram is formed ensuring that the movement of the lever arm is identical to that of the boom On some machines where the boom foot pin is securely fastened to the boom and hence rotates with the boom the pulley may be attached directly to the boom foot pin INSTALLING THE FLEXIBLE DRIVE CABLES Position the boom so that it is truly horizontal Rotate the pulley at the rear of the Control Box until the actuating arm within the box is also truly horizontal A setting hole is provided in the actuating arm which lines up with a hole in the back face of the Control Box A 3 16 diameter rod of suitable length may now be used to lock this arm in position while the drive cable is fitted 2 1 13 Now refer to Sketch 2 Determine the routing for the boom foot cable and install deflecting pullevs where required Run the cable and install the solderless nipples at both Sheaves Tighten the solderless nipple at the boom foot sheave Tension the spring about 2 Tighten the solder less nipple at the control box after ascertaining th
133. l back to raise the boom Push the boom hoist lever or pedal SETTING BOOM LENGTH Push the boom telescope levers forward to extend the boom sections Pull the boom telescope levers back to retract the boom sections Be sure the boom sections are extended equally and do not extend the boom AUXILIARY WINCH LEVER LIFTING THE LOAD HOISTING Push the main or auxiliary winch lever forward to lower the hook block Attach the load to the hook biock then puli the main or auxiliary winch lever back to raise the load forward to lower the boom Be sure to pay out line from the main and or auxiliary winch as required to prevent the hook block s from coming in contact with the boom point further than required to perform the operation Be sure to pay out line from the main and or auxiliary winch as required to prevent the hook block s from coming in contact with the boom point MAIN WINCH LEVER SECTION II SWINGING Push the swing lever forward to swing the upper to the left Pull the swing lever back to swing to the right Depress the swing brake pedal to stop and hold the upper CONTROLS AND OPERATIONS Z BOOM a i LEVER En 9 SPOTTING THE LOAD Spotting the load requires accurate control of the boom oist and swing movements it takes i practice to locate the load at the exact spot without hunting or overshooting Raise or lower the boom with the boom hoist lever as necessar
134. lowing provides an explanation of columns in the tabular list of Basic Issue Items List Section and Items Troop Installed or Authorized Section IIT a Source Maintenance and Recoverability Code s SMR 1 Source Code indicates the source for the listed item Source codes are Code Explanation P Repair parts special tools and test equipment supplied from GSA DSA or Army Supply System and authorized for use at indicated maintenance levels P2 Repair parts special tools and test equipment which are procured and stocked for insurance purposes because the combat or military essentiality of the end item dictates that a minimum quantity be available in the supply system 3 2 35 2 Maintenance code indicates the lowest level of maintenance authorized to install the listed item The maintenance level code is Code Explanation Crew Operator b National Stock Number This column indicates the National stock number assigned to the item and will be used for requisitioning purposes c Description This column indicates the National item name and any additional description of the item required d Unit of Measure U M A 2 character alphabetic abbreviation indicating the amount or quantity of the item upon which the allowances are based e g ft ea pr etc e Quantity Furnished With Equipment BIIL only This column indicates the quantity of an item furnished with the equipment f Quantity Authorized Items Troop Installed
135. ly This bracket may be welded to suitable spacers so that the center of the pulley is over the center of the boom foot pin Keep welding clear of the area surrounding the terminating holes and slots 2 1 12 Care must be taken to ensure this assembiv does not foul anv part of the boom or boom foot when the boom is raised or lowered At the extreme end of the lever arm which is bolted to the pullev is a turnbuckle which terminates in a small angle bracket This bracket is welded or clamped to the boom the turnbuckle being at right angles to the lever arm Spacers mav be needed when mounting this bracket to ensure that there is no strain on the arm during its operation The turnbuckle is desired for adjustment purposes at a later stage The pullev contains alternative tapped holes allowing the lever arm to be mounted at the required angle Additionallv the cast bracket when removed from the shaft can be replaced the reverse way Thus the assembly may be used at either the left or right hand boom foot with the cable exit either to the rear or downwards It is most essential to ensure that during the total boom movement the cable remains on the opposite side of the pulley away from the bracket As a guide the cable should be directly opposite the bracket when the boom is at 45 to the horizontal Should it not be suitable to mount this assembly directly on the center line of the boom foot pin it is possible to position it so that the level arm
136. ly the air passages through the core of insects leaves dirt and other foreign material that will restrict air flow 4 Inspect the cooling system for leaks Replace worn or damaged hoses Tighten the hose clamps 5 Keep the water pump fan belt adjusted properly 6 If the engine becomes overheated from lack of coolant let the engine run at a fast idle and add coolant slowly 7 f the engine overheats after refilling the cooling system shut down the engine and allow it to cool Drain the cooling system by opening the drain cocks on the radiator and the engine block and flush out the system Refill the cooling system with clean water do not use salt or mineral water solutions in the cooling system SECTION ll 8 Keep as much air as possible circulating around the battery Check the electrolyte level frequently add distilled water as necessary to keep the electrolyte level 3 8 inch 9 2 mm above the plates 9 Keep the air intake and exhaust openings clear Keep the engine dean and allow air to circulate freely around the engine 10 Avoid racing the engine and avoid operation at full throttle when part throttle will handle the load 11 Avoid lugging the engine keep the engine speed high enough to maintain fan speed 12 Avoid idling the engine unnecessarily shut the engine down during a lull in the operation OPERATION IN DUSTY AND SANDY AREAS Operation in dusty or sandy areas present special problems due to t
137. ly to keep an item in proper operating condition i e to clean including decontaminate when required to preserve to drain to paint or to replenish fuel lubricants chemical fluids or gases d Adjust To maintain or regulate within prescribed limits by bringing into proper or exact position or by setting the operating characteristics to specified parameters INTRODUCTION e Aline To adjust specified variable elements of an item to bring about optimum or desired performance Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision measurement Consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared g To remove and install the same item when required to perform service or other maintenance functions Install may be the act of emplacing seating or fixing into position a space repair part or module component or assembly in a manner to allow the proper functioning of an equipment or system h Replace To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and is shown as the third position of the SMR code i Repair The application of maintenance service including fault location troubleshooting
138. manual to bring the oil to the proper level CHECK COOLANT LEVEL Check the engine radiator coolant level and add water or antifreeze as required Use the type and amount of anti freeze recommended by the engine manufacturer for the prevailing temperature 1 4 3 Figure 4 1 Checking Engine Oil Level VIEWED THROUGH BATTERY COMPARTMENT Tie WS aw A108 CHECK HYDRAULIC OIL TANK LEVEL Check the oil level in the hydraulic tank as follows see Figure 4 2 1 Retract all telescoping boom sections lower the boom onto the boom rest and raise the outriggers to the stored position Be sure the machine is on level ground 2 Remove the dipstick from the hydraulic tank and note the level of the oil The oil level should be up to the mark on the dipstick If necessary add hydraulic oil of the type specified ih Section UL to bring the oil to the proper level through the filler opening CAUTION Never add hydraulic oil to the tank through the dipstick opening SECTION IV PREVENTIVE MAINTENANCE FILLER CAP Le Figure 4 2 Hyaraulic Oil Level DRAIN AIR TANKS Open the drain cock on the bottom of each air tank daily or as frequently as is found necessary to blow out moisture and accumulated sediment INSPECT WIRE ROPE FOR DAMAGE Inspect the wire rope wire rope sockets and any other wire rope fitting for damage A wire rope inspection form has been provided at the end of this maintenance check to a
139. n inhibitor or a permanent antifreeze solution as applicable 9 Install the carrier battery fully charged and connect it 10 Clean the fuel pump strainer and install a new fuel filter cartridge Then fill the carrier fuel tank with the proper grade of diesel fuel 11 Prime the engine lubrication system as instructed in 7 through 9 of Removal From Short Term Storage 12 Make a thorough visual inspection of the carrier to insure that the engine can be started safely and the carrier driven Correct any malfunction found SECTION V 13 The engine can now be started in the normal manner RESTORING MACHINE PROPER TO SERVICE To restore the machine proper to service following long term storage proceed as follows 1 Clean the entire machine thoroughly then Inspect the machine thoroughiv paving particular attention to hvdraulic hoses tubes and fittings 2 Lubricate all points equipped with grease fittings per the lubrication charts 1 5 6 MACHINE STORAGE 3 Check the oil levels in the upper gear housings and in the carrier drive train components Add oil as required of the tvpes specified in the lubrication charts 4 Drain the hvdraulic reservoir down to the proper level 5 Remove the preservative grease from the cvlinder rod pistons and other machined surfaces if applicable 6 Check all tire pressures and the general condition of the tires PART TWO WEIGHLOAD AUTOMATIC SAFE LOAD INDICATOR WEIG
140. n of deterioration of some hydraulic system component 5 Clean the shell thoroughly in a suitable solvent 6 Install a new gasket in the filter head Install the new filter element in the shell position the shell under the filter head and tighten the center bolt to 30 35 FT LBS 4 15 4 8 m kg Run the engine with the pump drive engaged several minutes and check for leakage Sc A116 Figure 4 10 Hydraulic Oil Filters CHECK ENGINE BELTS New drive belts will stretch after the first few hours of operation Retighten the fan drive water pump drive and alternator drive belts after the first 8 hours or 240 miles of operation Thereafter check the tension of the drive belts monthly and adjust if necessary Too tight a belt is destructive to the bearings of the driven part a loose belt will slip Replace all belts in a set when one is worn Single belts of similar size should not be used as a substitute for a matched set premature belt wear can result because of belt length variation All belts in a matched set are within 032 8 1 mm of their specified center distances Adjust the belt tension so that a firm push with the thumb at a point midway between two pulleys will depress the belt 1 2 to 3 4 12 7 19 0 mm CHECK BRAKE ADJUSTMENT The wheel brakes should be checked at a monthly interval to determine the need for adjustment The rear brakes should be adjusted when the stroke needed to apply the brakes reache
141. nd content specified In AR 310 3 Military Publications This technical manual does however contain available information that is essential to the operation and maintenance of the equipment Change 1 PART ONE CRANE OPERATOR S MANUAL TM 5 3810 293 14 amp P 1 TABLE OF CONTENTS SECTION IJINTRODUCTION SCOP xi R 1 1 1 General INOM AOM NODI 1 1 1 O 1 1 Serial NEEN dE aan kalb 1 1 1 1 1 1 RE le E 1 1 2 Tabulated Data 1 1 2 Dimensions and Transportation 1 1 2 Gapa itiesi p 1 1 4 Light 1 1 4 Filter ENG E CN 1 1 4 SECTION Il CONTROLS AND OPERATION Carrier Control Identification nennen tnnr intente 1 2 1 Carrier Operation TE 1 2 5 1 2 6 Upper Control Identification AA 1 2 8 Grane Operation E 9 1 2 12 Carrier Remote Controls ines 1 2 17 Control 1 2 17 1 2 17 E TREE m 1 2 18 Operation Under
142. ng Fork Assembly Reeving Dial Flexible Strip Loading Plate Locator Sideplate R H Spacer Centre Roller Spacer Standard Lockpin RECOIL DRUM ASSEMBLV REFERENCE 90 91 Gear Box 93 Chain 92 Gear Box Clamp 94 Periphery IMPORTANT 2 1 35 2 1 36 blank PART THREE SUPPLEMENTAL MAINTENANCE AND REPAIR PARTS INSTRUCTIONS Section Appendix 1 Section Appendix w de H gt l dk NIN NID ck QOJJOO nofno A IO ee 2 A w M m es m TABLE OF CONTENTS INTRODUCTION Scope MILSTRIP Requisition Identification and Control Maintenance Forms and Records Non NSN MILSTRIP Requisition for CCE Sample Format NSN MILSTRIP Requisition for CCE Sample Format MAINTENANCE SUPPORT PLANNING DATA Purpose Description Procurement Status MOS Requirements Logistics Assistance AR 700 4 Maintenance Concept Maintenance Allocation Chart Modifications Equipment Improvement Recommendations EIRs Shipment and Storage Destruction to Prevent Enemy Use Basic Issue ltem List Special Tools and Equipment Maintenance and Operating Supplies Maintenance Forms and Records Warranty Maintenance Allocation Chart CCE Manufacturer s Field Campaign and Modification Procedures Basic Issue Item List and Items Troop Installed or Authorized List Maintenance and Operating Supply List CCE
143. ng standards Rebuild is the highest degree of materiel maintenance applied to Armv equipment The rebuild operation includes the act of returning to zero those age measurements hours miles etc considered in classifving Armv equipment components 2 A 3 Explanation of Columns in the Section lil a Column 1 Group Number Column 1 lists functional group code numbers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the next higher assembly End item group number shall be 00 b Column 2 Component Assembly Column 2 contains the names of components assemblies subassemblies and modules for which maintenance is authorized c Column 3 Maintenance Function Column 3 lists the function to be performed on the item listed in Column 2 For detailed explanation of these functions see paragraph 2 A 2 d Column 4 Maintenance Category This column specifies the average total man hours required to do the job For example if it takes two people five hours to complete the job the figure would be ten This figure represents the time required to perform the job at the lowest indicated category of maintenance and restore the item to a serviceable condition It includes disassembly troubleshooting quality assurance and assembly The symbol designations for the various maintenance categories are as follows C Operator or Crew O Organizational Maintenance
144. nical assistance When training or technical assistance is required contact the appropriate Logistics Assistance Office LAO listed in Appendix B AR 700 4 2 6 Maintenance Concept a Operator Crew Maintenance Operator and crew maintenance is limited to daily preventive maintenance services b Organizational Maintenance Organizational maintenance consists of scheduled preventive maintenance services minor repairs and adjustments c Direct Support Maintenance Direct support maintenance consists of all the repairs required to restore an unserviceable end item of assembly to a serviceable condition d General Support Maintenance General Support Maintenance exceeds the capability of Direct Support Maintenance e Depot Maintenance 1 Depot Maintenance will overhaul items of equipment assemblies and components for return to supply stocks and in accordance with normal Army maintenance procedures 2 The Government may enter into an overhaul and or repairs contract with crane manufacturer when determined to be more economical or feasible 3 2 2 3 The Maintenance Expenditure Limit is depicted in TB 43 0002 28 4 Mission essentiality None b Maintenance Allocation Chart MAC 2 7 Maintenance Allocation Chart MAC See Appendix 2 A Units may exceed their authorized scope and function in the MAC when approved by the Support Maintenance Commander 2 8 Modifications Modifications will be accomplished
145. nings 2 Check the oil level in the engine crankcase Add oil as necessary per the lubrication charts 3 Check the coolant level in the radiator Add clean water or antifreeze as applicable if the level is low 1 5 4 MACHINE STORAGE 4 Make a thorough visual inspection of the machine to insure that the engine can be safely started and then start the engine in the normal manner Observe for any unusual noise or other symptoms of malfunction Shut the engine down immediately if there is any evidence of malfunction RESTORING CUMMINS ENGINES TO SERVICE To restore the Cummins engine to service following short term storage proceed as follows 1 Clean all accumulated dirt from the engine exterior 2 Remove all paper covers tape and wrappings 3 Using a suitable solvent cleaner or degreaser remove rust preventive compound from the unpainted surfaces of the engine 4 Refill the engine crankcase with new oil of the type specified in the carrier lubrication chart 5 Flush the cooling system and refill with either clean water and a corrosion inhibitor or an antifreeze solution as applicable 6 Have the fuel injectors valves and drive belts adjusted Also check head capscrews oil filter connections air cleaner screens and traps 7 Remove the plug from the gear case cover to prime the lubricating system Then connect a hand or motordriven priming pump from a source of clean lubricating oil to the plug boss in the gea
146. nism Never use a wrench on engaging the adjusting screw when making at jestments the sleeve portion PREVENTIVE MAINTENANCE CAUTION Be sure the machine is level and the boom is in the boom rest before checking the oil in the winch CHECK HOSES AND TUBING Carefully inspect all hoses and tubing on the machine for leaks and or damage Leaks that cannot be stopped by tightening the fitting should be removed and repaired or replaced CHECK WINCH OIL LEVELS Two makes of hydraulic winches have been used on this machine Earlier machines were equipped with free fall and non free fall type Gearmatic Winches while later machines are equipped with P amp H Winches To check the winch oil levels in a P amp H Winch proceed as follows seelFigure 4 12 1 Remove the cover over the winch brake Then remove the oil level plug and relief valve Pour oil of the type specified Section for the Sprag clutch into the relief valve opening until the oil just runs out of the oil level opening Replace the oil level plug and relief valve ADIVETING SCREW BLEEVE IM LOCKED POSITION This diagram shows the locking sleeve in its en gaged position is im portant that this sleeve is retumed to this locked position engaging the hexagon head of the ad justing screw following adjustments Figure 4 11 Adjusting Positive Slack Adjusters 1 4 11 SECTION IV PREVENTIVE MAINTENANCE CLUTCH HOUSING LEVEL PLUG F
147. non NSN items will be maintained NSN s obtained and the items stocked when warranted by sufficient demands 2 Identification and control of CCE crane requisitions will be by a combination of project and weapon system codes Where applicable in accordance with existing procedures CCE crane requisitions will follow the Direct Support System DSS Both a CCE DSS project code and a unique weapon system code have been assigned to the CCE crane The purpose and intended use of the CCE DSS project code is to enable DSA to identify the end item contract and manufacturer for supply action of non NSN parts that DSA will take in support of the CCE crane National stock numbered parts will be requisitioned using the standard supply system and applicable assigned DSS codes or in the case of a non DSS unit the normal supply channels The appropriate weapon system code will be used on every parts requisition NSN or non NSN Entry of the weapon system code will provide supply management information to the Logistic Intelligence File LIF for the CCE crane 1 CCE DSS CODE DEFINITION XDY Indicates the requisition is in support of USAREUR the CCE Crane and designates parts shipments to the East Coast Consolidation Containerization Point CCP New Cumberland Army Depot XDM Indicates the requisition is in support of USARPAC the CCE Crane and designates parts shipments to the West Coast Consolidation Containerization Point Sharpe Army Depot
148. o appropriate NMP for disposition instructions 3 Copy 3 Retain at support maintenance level for a period of 180 days including exhibit and DA Form 2402 unless disposition instructions are not received follow up will be made with the responsible NMP 4 Copy 4 Receipted copy 4 is authorization for immediate replacement action by the claim originator through supply channels The copy 4 will be retained for a period not to exceed 180 days or until notice has been received that the claim has been honored b Direct Exchange DX claim items When the defective component part or assembly is a DX item the organization initiating the claim action will follow the procedures prescribed for non DX items except as follows 1 The activity operating the DX facility will initiate replacement action for supported organizations using copy 4 as described above to obtain replacement action 2 Normal DX replacement actions will be made by the DX facility for like serviceable items in stock pending completion of claim action c Final processing of approved claims Support or depot maintenance activities are responsible to assure expeditious handling of all warranty claim actions This includes processing of approved claims back to the originator whose supplementary address and MILSTRIP document number appear in block 35 DA Form 2407 and the processing of funds reimbursed for costs of labor required to replace defective components parts or
149. oil level L Check machine for leaks amp damage C Check auxiliary transmission oil level CI Check tires CI Check air tank safety valve The information on this check sheet is intended to supp ement the original equipment manufacturer s recommendations Refer to the equipment manufacturer s manual for additional recommendations If a conflict exists between this check sheet and the equipment manufacturer s manual the equipment manufacturer s manual takes precedence CI Check main trans C Change engine oil amp oil filter C Change fuel filter elements PREVENTIVE MAINTENANCE A Check B Check C Check D Check Dailv Weekiv 40 hours Monthiv 160 hours Quarteriv 500 hours Semi Annualiv 1000 hrs Repeat A 8 check Perform quarterly lubrication Drain sediment amp water from fuel tank CI Check condition of cooling system hoses CI Change hydraulic oil filter CI Check engine belts CI Check brake adjustment for leaks amp damage CI Check winch levels CI Check slewing ring bolt torque 0 Check pump drive oil level 1 4 2 CI Check hoses amp tubing CI Check clutch oil level CI Check air valves amp cylinders for leaks C Clean steering outrigger filter CI Check clutch adjustment E Check Repeat A amp D
150. ollows 1 Drain the cooling svstem and flush thoroughiv with clean soft water 2 Refill the cooling svstem with clean soft water and a high qualitv corrosion inhibitor 3 Circulate the coolant by running the engine until normal operating temperature is reached Shut off the engine 4 Drain the engine oil while the engine is still hot 5 Install and tighten the engine oil drain plug replace the engine oil filter and filter gasket and refill the engine crankcase to the normal level with a 30 weight preservative oil 6 Remove and inspect the fuel injectors Have them reconditioned if necessary 7 Drain the fuel tank completely and pour a small quantity of rust preventing fuel oil American Oil Co No LF4089 Mobil No 4Y17 or equal into the tank Enough rust preventive fuel to run the engines for about 10 minutes is all that is needed 8 Remove and discard the fuel filter elements from the engine Wash the shells in clean diesel fuel and insert new elements Fill the cavity between the elements and shells about two thirds full of the same rust preventive fuel that was added to the tank Reinstall the fuel filters and tighten the retaining bolts securely 9 Start the engine and let it run for about five minutes to circulate the rust preventive through the fuel system 10 Service the air cleaner install a new cartridge if inspection reveals the need Cover the face of the air cleaner with heavy plastic taped to form
151. on adjacent to the boom hinge one or two deflector pullevs mav be required to direct the cord to the Recoil Drum These pulleys should be as free running as possible preferably on needle roller bearings Careful positioning of the deflector pulley or pulleys will reduce the error caused during booming to negligible limits although it will be found that the optimum position for the pulley is as near as possible directly on the center of the boom hinge pin It is also important to ensure that the cord does not come out of the groove of the pulley when the boom is fully derricked in Moving the Recoil Drum forward will improve this condition but if necessary the cord may be passed once round the pulley to keep it in engagement The deflector pulley should be far enough away from the Recoil Drum to allow the cord to coil correctly on the drum without bunching Introducing shins under the Drum mounting to tilt the assembly will assist the coiling should difficulty be met TO SET THE DRUM TENSION AND BOOM CORD 1 Before assembling the Boom Cord to the Recoil Drum rotate the drum periphery until it is fully wound up spring solid Apply a suitable sprag 2 Fully extend the boom The manual extension may be in or out Outriggers should be out 3 Attach the Boom Cord to the periphery of the Recoil Drum passing the end through the hole in the periphery and securing it with a solderless nipple within the periphery Two holes are provided to sui
152. or Authorized Only This column indicates the quantity of the item authorized to be used with the equipment g Illustration BIIL only This column is divided as follows 1 Figure Number Indicates the figure number of the illustration in which the item is shown 2 ltem Number Indicates the callout number used to reference the item in the illustration NOTE Paragraphs 4 and 5 to be used if applicable 4 Special Information Identification of the usable on codes included in column 3 of this publication are Code Used On None None 3 2 36 TM 5 3810 293 14 amp P 1 2 3 NATIONAL STOCK DESCRIPTION NUMBER ILLUSTRATION NONE FOR THE CRANE TM 5 3810 293 14 amp P 1 1 CODE 2 NATIONAL STOCK NUMBER 3 DESCRIPTION REF NO amp MFG CODE USABLE ON CODE 4 UNIT MEAS 5 QUANTITV AUTHOR PC PC PC PC PC PC PC PC PC 7520 00 559 9618 7510 00 889 3494 4210 00 889 2221 5120 00 251 1102 NOTE The following are overpacked with the crane Adapter grease gun extension 217682 27315 Case Cotton Duck MIL B 11743 81349 Gun Grease 2172 27315 Handle sheel nut wrench 217111 27315 Hose assembly grease gun 442186 27315 Log Book Binder MIL B 43064 Wrench Wheel Nut 21233 27315 NOTE The following items are authorized but not issued with the crane Requisition if required Extinguisher Fire Dry Chemical Handle wheel w
153. oth generator and alternator since both require the same instrumentation This is the area in which the pointer should be when generotor voltage regulator and bottery are all in good condition ond working properly When the pointer goes obove 15 2 the voltoge regul ator set too high or is jammed ond continued oper ation of the engine will burn out the bottery Figure 2 2 Voltmeter Operation SECTION II 4 TACHOMETER HOURMETER This gauge indicates the engine speed in revolutions per minute RPM and the total number of hours the engine has been run 5 L H DIRECTIONAL SIGNAL INDICATOR 6 HEATER CONTROLS This switch controls the heater fan Turn the switch clockwise to energize the heater fan control the speed of the fan by turning the switch clockwise or counterclockwise as desired Figure 2 3 illustrates the heater shut off valve Turn the valve clockwise to stop the flow of water through the heater when heat is not required Turn the valve counterclockwise when heat is desired 7 ENGINE STOP BUTTON G M ENGINES ONLY Depress this button to stop the engine After the engine has stopped place the ignition key in the OFF position 8 DEFOGGER FAN SWITCH Turn the switch clockwise to energize the defogger fan control the speed of the fan by turning the switch clockwise or counterclockwise as desired 9 DIRECTIONAL SIGNAL LEVER This lever actuates the directional signal lamps at the front and rear of
154. ovided Place the locking pin attached to the chain through this hole SETTING THE RED POINTER READING AT THE CONTROL BOX a Rigthe crane with a convenient length of boom preferably short and reeve the hoist rope to suit the length of boom chosen b Turn the adjuster on the dial of the Control Box so that the correct number of parts shows in the window on the dial c Fit the correct cam to the Control Box i e marked with the boom length number of parts of line and outrigger condition see Operators Instructions Adjustments ensuring that the cam is correctly located on its boss and with the follower pin in the cam slot 2 1 16 d Hoist a known load equal to the S W L at approximately half the maximum radius available for that boom length e Boom OUT until this radius is obtained using a steel tape to measure the distance NOT the crane radius indicator or Control Box radius scale if fitted f Check the RED pointer reading at the Control Box This should indicate the Safe Working Load for that particular radius If this reading is incorrect the angle of the Actuating Arm in the Control Box must be adjusted by means of the turn buckle or adjustable arm see Installing the Boom Foot Fitting until the RED pointer reading is correct If the Boom Foot pulley is of the type with no adjustment then this correction must be made by means of the nipple on the drive When a correct reading is obtained boom IN until well within
155. ox and Re coil Drum should be supported so that the weight of the drive is not hanging on the end couplings Do not tightly clip the drive at the Control Box end as the conduit must be allowed to rotate through approx 900 To install and set proceed as follows a Fully extend the boom The manual section may be in or out Outriggers should be out b Connect the Rotary Flexible Drive to the Gear Box out put shaft on the Recoil Drum by locating the tongue on the Flexible Drive in the slot in the output shaft Fully tighten the screwed retaining sleeve b By hand rotate the squared shaft protruding from the center of the pulley shaft at the rear of the Control Box until the bronze nut in the actuating arm within the Control Box is registered against the maximum boom length i e when the cursor mark on the nut lines up the maximum length on the actuating arm scale 2 1 21 d Connect the driven end of the Rotary Flexible Drive to the squared shaft at the back of the Control Pox and fullv tighten the screwed retaining sleeve Check the operation of this drive especially that the direction of the nut in the actuating arm is correct i e the nut should move toward the center hub of the arm when the boom is retracted All settings are now complete and reference must be made to Data Sheets Installation Instructions for general calibration and testing 2 1 22 IMPORTANT a f
156. p manual Overhaul information on the engine and certain other purchased components is not included in the shop manual since the original manufacturer s manuals are both authoritative and complete GENERAL INFORMATION The information specifications and illustrations in this publication are based on the information in effect at the time of approval for printing This publication is revised and reprinted periodically It is recommended that the user contact the Harnischfeger Technical Publications Department for information on the latest revisions The Harnischfeger Corporation reserves the right to make changes to this manual at any time without prior notice or obligation Any part numbers which appear in this manual are for reference only refer to the P amp H Replacement Parts Manual when ordering parts SAFETY A separate publication Catalog 221 Safe Operating Practices is furnished with each machine It is most important that operators and maintenance personnel read and be familiar with the information in Catalog 221 and this manual before operating or servicing this machine both for personal protection and for the safety of other workmen and bystanders Additional copies of Catalog 221 are available in reasonable quantities to Owners of P amp H hydraulic 1 1 1 to the Harnischfeger Technical Publications Department Figure 1 1 Machine Serial Number SERIAL NUMBER LOCATION Figure 1 1 illustrates the machine se
157. pport General Support and Depot Maintenance requirements for Cranes Truck Mounted Hydraulic 25 T Model MT 250 TM 5 3810 293 14 amp P 1 C2 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY No 2 WASHINGTON D C 12 October 1983 Operator Organizational Direct Support General Support and Depot Maintenance Manual Including Repair Parts Information and Supplemental Maintenance Instructions For CRANE TRUCK MOUNTED HYDRAULIC 25 TON CCE HARNISCHFEGER MODEL MT 250 NON WINTERIZED NSN 3810 00 018 2021 HARNISCHFEGER MODEL MT 250 WINTERIZED NSN 3810 00 018 2007 TM 5 3810 293 14 amp P 1 15 September 1980 is changed as follows 1 Change Sheet for Change 1 following Washington DC insert date 30 June 1983 2 File this change sheet in front of publication for reference purposes By Order of the Secretary of the Army JOHN A WICKHAM JR General United States Army Official Chief of Staff ROBERT M JOYCE Major General United States Army The Adjutant General DISTRIBUTION To be distributed in accordance with DA Form 12 25B Operators Maintenance requirements for Cranes Truck Mounted TM 5 3810 293 14 amp P 1 C1 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY NO 1 WASHINGTON DC 30 June 1983 OPERATOR ORGANIZATIONAL DIRECT SUPPORT GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS FOR CRANE TRUCK MOUNTED HYDRAULIC 25 TON
158. r surfaces which cannot be painted 1 2 21 CONTROLS AND OPERATION 2 Keep parts lubricated thoroughly to repel water from polished metal surfaces and to prevent the entry of water into bearings Keep lifting cables lubricated OPERATION AT HIGH ALTITUDES Operation at high altitudes present special problems due to lower atmospheric pressure and wide temperature ranges At altitudes above 5000 feet 1524 m it may be necessary to change the engine fuel injectors Make certain that the air cleaner is clean and free from obstructions Check the engine frequently for overheating INSTALLING ROPE ON DRUMS The manner in which a new or replacement wire rope if installed on the winch drum will to a large measure determine the service life of that rope Improperlv wound ropes will cause undue crushing of the rope doglegs kinks excessive abrasion and cutting of the individual wires Bad spooling also causes uneven application of force and motion This results in fast fatiguing of the rope from the hook block to the drum The following five precautionary steps should be taken particularly with a replacement wire rope before starting the actual installation of the rope 1 A check should be made of the drum to determine the condition size and shape of the drum grooves 2 Drum flanges should be checked to determine the extent if any of undercutting at the base of the flange 3 Dirt grit or any other type of debris should be
159. r case cover 8 Operate the priming pump until a minimum pressure of 30 psi 2 bars is obtained Crank the engine at least 15 seconds with the fuel shut off valve closed or disconnected to prevent starting while maintaining the external oil pressure at a minimum of 15 psi 1 bar 9 Remove the priming pump line and replace the plug in the gear case cover Torque the plug to 15 to 20 ft Ibs 2 2 7 m kg Fill the crankcase to the H high mark on the dipstick 10 Run the engine for a short time Then clean the fuel pump strainer and replace the fuel filter and oil filter cartridges RESTORING MACHINE PROPER TO SERVICE To restore the machine proper to service following short term storage proceed as follows 1 Lubricate all points equipped with grease fittings per the lubrication charts 2 Remove preservative grease if applicable from the cylinder piston rods and other surfaces where applied SECTION V 3 Check the oil levels in each gear housing in the upper and the lower and the levels in the main and auxiliarv transmissions Add oil as necessarv as specified in the lubrication charts 4 Check the oil level in the hvdraulic reservoir Add oil of the proper tvpes as required 5 Install the batterv fullv charged and connect it 6 Make a thorough visual inspection of the entire machine before operating it for the first time following storage Check especiallv for damaged or deteriorated hvdraulic hoses REMOV
160. r main boom duties the other for jib duties two further components are supplied d 2nd Dynamometer for Auxiliary Hoist Rope e Summator Unit 3 Various fittings are also supplied a Boom Foot fittings including Pulley b Flexible Drive Cables Conduits and Fittings c Mounting Plate for Control Box NOTE The Model Number as shown on the Serial Plate on both Control Box and Dynamometer refers to the physical size and capacity of the equipment Installation Instructions are the same for each of these models INSTALLING THE DYNAMOMETER According to the type of crane on which it is to be fitted the Dynamometer may be rigidly mounted on the base section of the boom on on a swinging arm frame which allows it to follow the true path of the hoist rope as the rope travels across the hoist drum and or changes angle with the boom during derricking 2 1 8 a If rigidly mounted as on most telescopic machines the Dynamometer should be positioned so that the hoist rope is deflected as little as possible When viewed in plar i e looking down on top of the Dvnamometer it must be mounted directly on the natural line of the rope when the rope is on the center of the hoist drum It is recommended that a string be stretched between the boom head sheave and the center groove of the drum to ascertain the correct mounting position The largest sheave on the Dynamometer must be toward the hoist drum Long mounting bolts are provided for
161. r rod eye as shown in Section 8 8 Retract the telescope cylinder until the cylinder pin is aligned with the hole in boom section 2 4 Push the cylinder pin toward the left side of the machine so that it engage boom section 2 Then install the cylinder pin end caps see Section A A 5 Remove the boom stop COUNTERWEIGHT The counterweight on this machine is attached to the rear of the revolving frame and can be removed when necessary as described below 1 Rotate the upper so that the boom is over either side of the carrier 2 Reeve the auxiliary winch line a shown in Figure 2 19 and dead end the cable by means of the cable socket to the bottom of the winch platform 3 Loosen the counterweight hold down screws 4 Take up on the auxiliary winch line slightly to relieve the weight on the counterweight pins Remove the cotter pins in the counterweight pins and remove the counterweight pins 5 Pay out the auxiliary winch line to lower the counterweight to the ground 6 The counterweight can now be lifted onto a truck using the main winch line CONTROLS AND OPERATION AUX WINCH MAIN WINCH 2 COUNTERWEIGHT HOLD DOWN SCREWS 1 J COUNTERWEICHT PINS lt COUNTERWELGHT 2 za Figure 2 19 Counterweight Removal 100N2382 CAUTION Be sure that the boom sections are retracted fully before lifting the counterweight Installation and operation of self po
162. recommended to clean and reuse the filter cartridge When returned to service the life expectancy of a paper cartridge will be only a fraction of the original service life 5 Inspect the air cleaner mounting bolts to be sure they are tight Inspect the clamps and flexible hose to be sure they are air tight and in good condition 6 Install a new cartridge hold the cartridge in the same manner as when removing it from the housing Insert the clean cartridge into the housing avoid hitting the cartridge tubes against the sealing flange of the housing CAUTION Since the air cleaner requires no separate gaskets or seals care must be taken when inserting a new cartridge to insure a proper seat within the housing Firmly press all edges and corners of the cartridge by hand to effect a positive air seal against the sealing flange in the housing Under no circumstances should the cartridge be pounded or pressed in the center with a fist to effect a seal 7 Replace the moisture eliminator panel and tighten the clamps bv hand Then turn the nuts an additional 1 1 2 to 2 turns with a small adjustable wrench Do not overtighten CHECK AXLE OIL LEVEL Remove the combined filler level plug from the side of the differential carrier to check the oil level of these units The oil should be just up to the bottom of the level opening Be sure the machine is level when checking the oil level see Figure 4 5 1 4 6 PREVENTIVE MAINTENANCE
163. rench 3 4 in dia 20 in long 3 2 38 EA EA EA EA EA EA EA EA EA TM 5 3810 293 14 amp P 1 APPENDIX 2 D MAINTENANCE AND OPERATING SUPPLIES 1 2 3 4 5 6 QUANTITY QUANTITY COMPONENT NATIONAL STOCK DESCRIPTION REQUIRED REQUIRED REMARKS APPLICATION NUMBER F INITIAL F 8 HRS OPERATION OPERATION ENGINE No 2 D Diesel Fuel 55 Gallons COOLANT 50 Ethylene Glycol 50 Water 40 Qts ENGINE ENGINE OIL 18 1 2 Qts 9150 00 188 9858 MIL L 2104C OE HDO 30 5 Gallons 9150 00 242 7603 MIL L 10295 OES 5 Gallons TRANSMISSION GEAR OIL 17 Pints MAIN 9150 00 754 2635 MIL L 2105 GO 90 1 Qt 9150 00 905 9100 MIL L 2105 GO 80 1 Qt 9150 00 261 7904 MIL L 10324 GOS 1 Qt TRANSMISSION GEAR OIL 12 Pints AUXILIARY 9150 00 754 2635 MIL L 2105 GO 90 1 Qt MIL L 2105 GO 80 1 Qt MIL L 10324 GOS 1 Qt 3 2 39 TM 5 3810 293 14 amp P 1 MAINTENANCE AND OPERATING SUPPLIES 1 2 3 4 5 6 QUANTITV QUANTITV COMPONENT NATIONAL STOCK DESCRIPTION REQUIRED REQUIRED REMARKS APPLICATION NUMBER F INITIAL F 8 HRS OPERATION OPERATION FRONT REAR GEAR OIL 32 Pints AXLE 9150 00 754 2635 MIL L 2105 GO 90 1 Gt 9150 00 905 9500 MIL L 2105 GO 80 1 Gt 9150 00 242 7603 MIL L 10295 OES 5 Gallons REAR REAR AXLE GEAR OIL 28 Pints 9150 00 754 2635 MIL L 2105 GO 90 1 Gt 9150 00 905 9500 MIL L 10295 GO 80 1 Qt 9150 00 242 7603 MIL L 10295 OES 5
164. rial number which is located on the lower front side of the operator s cab Always indicate the machine serial number in all correspondence to properly identify the machine and to ensure that the correct parts are obtained when ordered WARRANTY The terms under which this machine is guaranteed are clearly defined under the warranty which accompanies every P amp H product This warranty while generous will be voided if the machine is operated with loads in excess of the rating plate maximums under unsafe operating conditions or with accessories or attachments not designed furnished or approved by the Harnischfeger Corporation Modifications made upon the machine which will affect its operation or capacity will void the warranty SECTION I DESCRIPTION This truck crane is a fully hydraulic machine All work functions are performed by fluid power Hydraulic cylinders are used to raise or lower and extend or retract the boom hydraulic winches raise or lower the load on the main hoist and jib lines a hydraulic motor swings rotates the upper of the machine on the carrier LUFFER BHH Weiber HES CAR TFLIMOEN UTA OER HMDA ALL PETAACTED TM 5 3810 293 14 amp P 1 INTRODUCTION The carrier engine serves as the power supplv for both the upper and lower A pump drive mounted at the front of the engine drives the hvdraulic pumps which provide the hvdraulic power for the upper Hvdraulic fluid un
165. ribes the condition at time of first indication of trouble Exception Leave blank if block 14 was left blank or DA directed sampling items organizational maintenance s Block 16 Enter Warranty Claim Actions t Block 20 column d Enter noun identifying the part or assembly u Block 20 column e Enter serial number of the part or assembly v Block 20 column g Enter the number of man hours required for the task of replacing the defective part Use the appropriate TB time schedule guide if available otherwise record actual man hours used w Block 20 column h Enter NSN of defective part or manufacturer s part number when NSN has not been assigned 3 2 7 x Block 20 columns i j and k Self explanatorv Block 201 Self explanatory z Block20m Multiply the value of block 201 by 6 00 and enter the product in block 20m aa Block 20n Self explanatory bb cc Block 30 Place check in space provided for ROUTINE dd Block 31 Enter a or an X in space for other and state under remarks in block 35 Replace Defective Part a Block23 Enter signature of the individual authorized to submit DA Form 2407 a ee Block 32 Enter organization submitting the report ff Block 33 Enter National Stock Number of defective part or assembly 99 hh Block 35 Enter the complete telephone number autovon commercial with area code of the originator on the first
166. rive which connects with the Control Box Within the Control Box a lead screw is built in to the actuating arm miniature boom and is driven by the Rotary Flexible Drive accurately positioning the slide block in proportion to the boom length The actuating arm is marked with a scale indicating the length of boom extended ADJUSTMENTS There are no further adjustments to make on Units on Telescopic Cranes In this case all the instructions given in the previous pages apply especially those with reference to the use of the correct cam to suit the working condition of the crane In most cases when working with the main boom it is only necessary to change the cam if the number of parts are changed Use of the manual section and jib also requires the cam to be changed The Radius Scale showing the working radius of the crane is standard on all Units supplied for Telescopic Cranes and must be changed when working with Manual Extension and or Jibs NOTE When using the jib or manual extension the ratings are proportional to angle Consequently the wire from the recoil drum must be fastened to the place provided on the base section MAINTENANCE Models 4 5 amp 6 Dynamometer Clean out any clogged grease and dirt especially adjacent to the center roller U shaped block and Load cell 2 1 5 Check the mounting bolts and nuts for tightness and also all other bolts and nuts on the Dvnamometer and supporting framework This check should be
167. rm the following function before leaving the carrier cab A Shift the main transmission to neutral B Shift the auxiliary transmission to low gear C Place the Remote Control Air Valve in the ON position D Place the Throttle Selector Valve in the UPPER position 2 Go to the upper cab and place the Ignition switch in the ON position Then place the Brake switch in the BRAKE ON position WARNING Be sure the Low Air Pressure Light on the carrier dash panel is not lit before releasing the Maxibrakes the light is lit it is possible that the carrier could move because the air pressure is not sufficient to apply the service brakes via the remote control system SECTION ll 3 Return to the carrier cab and release the Maxibrakes bv pulling out the Maxibrake button 4 The carrier can now be operated from the upper bv remote control as follows A Start the engine by turning the Ignition key to the START position B Raise the outriggers to the stored position if they are extended as described in the topic Outrigger Operation Be sure the MASTER switch on the outrigger control panel is returned to the OFF position C Depress the Clutch and either the Forward or Reverse buttons on the carrier remote control panel to engage either the first or reverse gear of the main transmission D Release the Forward or Reverse button while maintaining the Clutch button in the depressed position E Place the Brake switch in the
168. s 1 Place the MASTER switch in the ON position 2 Disengage the safety locks if the machine is so equipped by placing the SAFETY LOCKS switch in the OFF position NOTE If the weight of the machine is resting on the safety locks it will be necessary to raise the machine slightly by placing the required VERTICAL switch in the DOWN position to disengage the safety locks SECTION ll 3 Raise the outrigger bv placing the desired VERTICAL switch in the UP position Repeat the procedure for the other three outrigger before thev are retracted 4 Retract each outrigger by placing the appropriate HORIZONTAL switch in the IN position Be sure the lug on each outrigger float engages the outrigger beam see Figure 25 5 Remove the retainer pin and move the lock pin to the locked position Install the retainer pin to maintain the lock pin in the locked position 6 Place the MASTER switch in the OFF position 7 Push the Outrigger Steering Selector Valve in and engage the latch to divert hydraulic fluid to the steering System This step is not required on machines equipped with the optional carrier remote control system The transfer from outrigger to steering is accomplished automatically when the MASTER switch is placed in the OFF position UPPER CONTROL IDENTIFICATION The instruments and controls in the upper cab are shown in Figure 27 The numbers on this illustration correspond to the numbers in the following list whi
169. s 2 1 4 57 mm SECTION IV If the brakes require adjustment proceed as follows see Figure 4 11 1 Raise the wheels off the ground using the outriggers 2 Push in the locking sleeve on the slack adjuster and turn the adjusting screw until the stroke required to apply the brakes is reduced to one inch 3 Check the adjustment by making several brake applications The air chamber push rod should move a total of one inch from the released to the applied position 4 Release the brakes and spin the wheel by hand to be sure the brake shoes are not dragging The lining to drum clearance of the front brakes should be checked using a feeler gauge the clearance is more than 0 060 1 5 mm adjust the brakes manually as described below and schedule the vehicle for brake service 1 Jack or hoist the front wheels off the ground 2 Remove the dust cover from the adjusting slots above and below the brake chambers 3 The adjusting bolts have right hand treads Using an adjusting spoon turn the star wheel until a heavy drag is developed then back off the star wheel to a very light drag on the drum Reinstall the dust covers in the adjusting slots ADJUSTING SCREW BLEEVE IN UNLOCKED POSITION oN This diagram shows the locking sleeve in its dis engaged position Be sure this is held in dis in making ad justment Make certain locking sleeve is held in thereby dis engaging the locking mecha
170. s are not damaged in the process The side thrust washers and sheaves can now be lifted out b Remove the bolts or studs retaining the three spacers directly above each of the three center sheaves and remove the spacers 2 1 9 c Lav the hoist rope over these three center sheaves replace the spacers and bolts d Ensure that there is sufficient slack in the rope and replace the two outer sheaves on too of the rope ensuring that the side thrust washers are in position e Carefully the shafts ensuring that the cotter pin holes in the shafts line up with the holes in the side plate bosses Refit the cotter pins NOTE When supplied from the Manufacturer the cotter pins through these shafts are unopened enabling them to be reused INSTALLING THE CONTROL BOX The Control Box should be positioned as far as possible well within the vision of the operator but allowing as straight a run as possible for the drive cable from the pullev at the rear of the box to the boom foot Free access must be made to the door at the front of the Control Box and also to the zero adjuster and parts of line changing knob at the top of the indicator dial The mounting plate for the Control Box mav be welded or bolted to the floor of the cab It mav be more suitable to raise the level of the Control Box for better visibility in which case convenient spacers may be used beneath the pedestal If spacers are used suitable bracing may be required to make
171. s cleaning period may be reduced or lengthened according to the severity of service CHANGE AXLE OIL The oil in the rear axles should be changed twice yearly spring and fall Each time the oil is changed the magnetic drain plug must be cleaned to remove any accumulated material before it is replaced NOTE The axle manufacturer recommends a drain plug with a magnetic element capable of picking up approximately 2 pounds of low carbon steel To change the axle oil proceed as follows see Figure 4 19 1 Drive the machine to warm the oil in the axles to normal operating temperature 2 Remove the drain plug and drain the oil into a suitable container Clean the drain plug 3 Install the drain plug and add oil of the type specified in Section TIT Juntil the oil reaches the bottom of the oil level plug opening Replace the filler level plug VIEWED FROM LEFT SIDE OF CARRIER A111 Figure 4 19 Changing Rear Axle Oil SECTION IV CHANGE MAIN TRANSMISSION OIL To change the oil in the main transmission proceed as follows sea Figure 4 20 1 Drive the machine to warm the oil in the transmission to normal operating temperature 2 Remove the drain plug and drain the oil into a suitable container Clean the drain plug 3 Install the drain plug and remove the filler level plug Add oil through the filler level plug opening until the oil reaches the bottom of the opening Replace the filler level plug we
172. securing the Dynamometer to the members welded or clamped to the boom These long bolts together with the taper washers provided allow the Dynamometer to be jacked up so that the rope line is as straight as possible through the unit when viewed from the side It is essential that the mounting bolts are fully tightened and that all members are firm and rigid b Ifthe angle of the hoist rope and it s distance from the boom prohibit the use of rigid mountings as described in section a the Dynamometer may be mounted on a swinging arm frame specially constructed for the purpose Typical mounting arrangements are shown on Sketch 1 Polyurethane bumpers are usually fitted on the boom or superstructure to support the Dynamometer when the rope is slackened or during transit The mounting position of this frame varies for each type of crane and again the largest sheave on the Dynamometer must be toward the hoist drum REEVING THE HOIST RAPE THROUGH THE DYNAMOMETER The rope is passed under the two outer rollers and over the three center rollers This applies a slight deflection to the rope causing a load to be imparted to the Load Cell under the middle roller If it is not possible to pass the rope through the Dynamometer proceed as follows a Remove the cotter pins which lock the shafts of the two outer sheaves in the side plates With a punch or drift pin tap out the shafts making sure that the needle roller bearing in the bores of the sheave
173. ss and hold this button to turn the front wheels to the left The number of degrees that the wheels are turned vary with the length of time the button is held depressed Release the button to stop turning the wheels 3 R H STEER This button operates in the same manner as the L H Steer button except that this button causes the wheels to turn to the right 4 CLUTCH This button controls the operation of the clutch Depress and hold this button to disengage the clutch Release the button to engage the clutch 1 2 17 CONTROLS AND OPERATION 5 BRAKE This toggle switch controls the operation of the carrier service brakes Place the switch handle in the up position to apply the brakes Place the switch handle in the down position to release the brakes 6 FORWARD This button when used in conjunction with the Clutch button shifts the main transmission into first gear 7 NEUTRAL This button when used in conjunction with the Clutch button shifts the main transmission into neutral 8 REVERSE This button when used in conjunction with the Clutch button shifts the main transmission into reverse OPERATION To operate the carrier by remote control proceed as follows CAUTION The following instructions describe the steps necessary to transfer control of the carrier from the carrier cab to the upper cab These instructions must followed carefully to ensure safe proper transfer of carrier control 1 Perfo
174. ssist the inspector 1 4 4 If damaged components are found they should be replaced or repaired before the machine is placed in service CHECK MACHINE FOR LEAKS AND DAMAGE Make a complete visual inspection of the entire machine looking for leaks loose connection or any other unsafe condition Repair or replace any faults which are found before placing the machine in service SECTION IV B Maintenance Checks PREVENTIVE MAINTENANCE At each B Maintenance Check perform all A Checks in addition to the following PERFORM WEEKLY LUBRICATION Refer to the lubrication charts ir Section of this manual and lubricate all the weekly lubrication points indicated with the type of lubricant specified CHECK BATTERY ELECTROLYTE LEVEL The battery is located in the compartment just behind the carrier cab Check the battery water level and add distilled water as necessary to maintain the water level 3 8 inch 9 2 mm above the plates Clean any corrosion and or dirt from the battery and terminals CHECK SWING REDUCER OIL LEVEL Remove the filler plug from the swing reducer to check the level of the oil in the reducer The oil should be just up to the bottom of the filler opening If the oil is not at the proper level add oil of the type specified in Section ill as required to bring the oil to tie proper level see Figure 4 3 CHECK AIR CLEANER Air cleaner filter cartridge changes can be scheduled but due to wid
175. stment is necessary at the Dynamometer Load Cell is correctly positioned in Dynamometer Dynamometer is free of accumulated rope grease Bowden cables from the boom hinge pin are lubricated and free of ice Alarm operates when test button is pressed NOTE RED POINTER INDICATES SAFE WORKING LOAD BLACK POINTER INDICATES LOAD BEING WHEN BOTH POINTERS COINCIDE OVERLOAD IS IMMINENT WHEN BELL RINGS STEADILY IMMEDIATELY LOWER LOAD OR REDUCE RADIUS IMPORTANT During constant clamshell or Piling operations REMOVE DYNAMOMETER Should any query arise with this equipment the Serial Number of the Unit should be quoted in all communications The Serial Number has the prefix and appears on the nameplates of the Control Box and the Dynamometer Maintenance Instructions appear at the end of these instructions and should be carried out at regular intervals Change 1 2 1 4 MODELS 4T 8 5T The following additional equipment is supplied for use on TELESCOPIC Cranes f Spring operated Recoil Drum assembly g Rotary Flexible Drive The Recoil Drum assembly is used to transmit the telescoping movement of the boom to the Control Box A wire cable attached at one end to the boom head is passed down the boom through suitable guides and is wrapped round the drum which is spring loaded to keep the cable taut Rotation of the drum during telescoping is geared through a chain drive and gear box to the Rotary Flexible D
176. struments Check for normal operating readings for the instruments as follows a Engine Oil Pressure b Engine Water Temperature c Voltmeter d Hydraulic Oil Temperature Control Levels and Pedals Check for proper operation 40 60 PSI 160 185 F Hoisting Cables Inspect for stretch wear and damage WEEKLY MONTHLY TM 5 3810 293 14 amp P 1 EQUIPMENT IS NOT READY AVAILABLE IF Class III leakage is evident Pressure temperature gages not within ranges specified Improper operation Six broken wires in one rope lay or three wires in one strand of one rope lay or four percent of total number of wires in rope in length of one rope lays TB 43 0142 TM 5 3810 293 14 amp P 1 Table 2 E 1 Operator Crew Preventive Maintenance Checks and Services CONTINUED CRANE OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B BEFORE D DURING A AFTER W WEEKLY MONTHLY ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT NO PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED Boom Assembly E Inspect for cracks bends and damage Check boom point for cracks Bent or broken boom and damaged sheaves Hook Block i Inspect for cracks and damaged sheaves Cracked or deformed sheaves Hydraulic Fluid Reservoir Addjfluid to full mark on dipstick TM 5 3810 293 14 amp P 1 Table 2 E 1 Operator Crew Preventive Maintenance Checks and Services CONTINUED C
177. t the direction of the rotation of the drum 2 1 20 4 Rotate the drum one revolution to relieve the spring from its solid state and then wind two coils of cord around the periphery coiling them close to the side of the drum Sprag the drum against accidental rotation 5 Pass the boom wire over the deflector pulley s and through the cleats on the boom to an anchorage provided at the last powered section 6 Fully retract the boom checking the operation of the drum during the whole operation The spring tension on the drum must hold the boom cord taut at all boom extensions If the boom cord is wrapped one turn around a deflector pulley it must be examined during the operation If scuffing occurs this can be improved by reversing the coil i e right over left instead of left over right 7 Check the direction of rotation of the output shaft in the gear box of the Recoil Drum When looking on the end of the slotted shaft the shaft MUST rotate counter clockwise as the boom is telescoped OUT See Installing the Spring Motor Recoil Drum INSTALLING THE ROTARY FLEXIBLE DRIVE AND SETTING These drives are supplied in various lengths to suit the individual types of crane The length chosen should ensure that the path of the drive is as natural as possible and with out sharp bends When installed it should be clipped in place to support it and provide protection against other moving parts on the superstructure Both ends at the Control B
178. tch Release Mechanism Pedal Linkage Inspect Adjust Replace Yoke and Bearing Inspect Replace Hydraulic Clutch System Cvlinders Hydraulic Replace Master Repair FUEL SYSTEM Carburetor Fuel Injector Nozzle Assembly Fuel Test Injector Adjust Replace Repair Change 3 3 2 14 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS FUEL SYSTEM CONTINUED Fuel Pumps Gearshaft and Gear Test Assembly Replace Repair Air Cleaner Filter Air Service Replace Housing Air Cleaner Service Replace Repair Supercharger Blower Inspect Turbocharger Replace Repair Housing Assembly Air Replace Inlet Tanks Lines Fittings Headers Tank Fuel Inspect Service Replace Repair Lines and Fittings Inspect Replace Engine Speed Governor and Controls Housing Governor Replace Repair Engine Speed Governor Inspect Adjust Replace Repair Fuel Filters Filter Element Fluid Service Replace Engine Starting Aids Hardware Starting Aid Inspect Replace Accelerator Throttle or Choke Controls Pedal and Valve Inspect Replace Repair Change 3 3 2 15 TM 5 3810 293 148P 1 Section MAINTENANCE ALLOCATION CHART ji GROUP MAINTENANCE MAINTENANCE LEVEL TOOLS AND NUMBER COMPONENT ASSEMBLY FUNCTION F EQUIPMENT REMARKS EXHAUST SYSTE
179. tected 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 A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
180. that the cotter pin will be on the bottom side of the jib when it is erected 3 Remove the hook block from the main or auxiliary winch line and attach the line to becket 4 with a rope Socket Take up the slack in the line with the winch so that the jib point is supported by the line 4 Remove capscrews 5 lockwashers 6 retainers 7 and spacers 8 Remove cotter pin 9 and pin 10 5 Elevate the boom to an angle of approximately 45 degrees and extend the boom while paying out on the winch line until the jib is suspended vertically from the boom point 6 Disconnect the winch line from becket 4 and attach itto becket 11 Take up slack in the winch line to raise the jib to the operating position 7 Attach the jib suspension cable as shown in Figure 2 17 to fix the jib at the required operating angle The angle at which the jib operates can be varied by increasing or decreasing the length of the suspension cable by means of cable links The cable links are installed between the main suspension cable and the boom point Figure 2 17 illustrates the positions at which the jib can operate and the number of cable links required to obtain the operating angles shown 8 Remove the winch line from becket 11 and attach the hook block to the line To place the jib into the storage position from the operating position proceed as follows sed Figure 2 16 SECTION II CONTROLS AND OPERATION T OE STOP PIN
181. the air passages through the core Check the condition of the radiator hoses clamps thermostat and radiator core SECTION II ALWAYS STAND IN CLEAR VIEW OF CRANE OPERATOR BE SURE TO STAY A SAFE OISTANCE FROM HDOK BLDCK OR BOOM EMERGENCY STOP Arm extended palm down move hand rapidly right ond RAISE BOOM Arm extended fingers thumb pointing upward SWING Arm extended point with finger in direction of swing of boom HOIST With forearm vertical foretinger pointing up move hand in small hori circle RETRACT BOOM Telescoping Boom One Hand Signal One fist in front of chest thumb pointing outward sad af fist tapping chest STOP Arm extended palm down hold position rigidiv LOWER BOOM Arm extended fingers clesed thumb pointing dewnwerd d TRAVEL Arm extended forward hand open and raised make pushing motion in direction of travel LOWER With acm extended downward forefinger pointing down move hand small horizontal circles EXTEND BOOM Telescoping Hand Signal One fist in front of chest with thumb tapping chest Figure 2 12 Hand Signals for Crane Operation 006 EVERYTHING Clasp hands in beet of body USE MAIN HOIST Tap fist on head then use regular signals TRAVEL One Track Lock the track on side indicated by caised fist Travel oppo site track in direction indicated by cir cular motion of
182. the mounting rigid If more convenient the Control Box may be bolted direct to the cab structure by means of additional holes which may be drilled through the Control Box casting It is essential though that the bolt heads do not foul any fixed or moving parts within the Control Box and all burrs must be removed after drilling NO ATTEMPT MUST BE MADE TO WELD THE CONTROL BOX DIRECTLY TO THE CAB STRUCTURE A hole must be provided to allow the Load Cell to be threaded through from the Control Box to the Dynamometer THE CAPILLARY TUBE JOINING THESE TWO COMPONENTS IS A SEALED ASSEMBLY AND MUST NOT BE DISCONNECTED AT ANY TIME The hole therefore must be large enough to allow the complete Load Cell to be passed through not just the capillary A further hole must be provided to allow the boom foot drive cable to be passed through from the Control Box to the boom foot The holes should be on the natural run of the cable to avoid chafing kinking and sharp bends 2 1 10 EE C LU ie LD NOTE As the electrical supply required to operate this is a single wire ground return circuit it is essential that the Control Box be bonded to the frame to ensure a good ground Should the Control Box be mounted directly onto a fibreglass cab then a separate ground wire MUST be fitted DO NOT RELY ON GROUNDING THROUGH THE CAPILLARY TUBE AND DRIVE CABLES ALONE INSTALLING THE LOAD CELL IN THE DYNAMOMETER Pass the Load Cell carefully from the Control Bo
183. the working radius and then boom OUT against the tape to that radius and check the RED pointer again Repeat this until a correct reading is obtained adjusting the turnbuckle or flexible drive if necessary h This procedure should be repeated at both minimum and maximum radii hoisting the S W L for each of these radii when it should be found that only a very slight adjustment of the turnbuckle or flexible drive may be required at the minimum radius setting All settings are now complete and the Indicator should be accurately set for all boom lengths If radius scales are fitted these are automatically corrected by the preceding adjustments made to correct the RED pointer on the Load Indicator Scale It will now be found that the Amber light will light at 9096 S W L and the Red light will light and the Alarm will ring at 10096 S W L 2 1 17 MODELS AT 5T and 6T ADDITIONAL INSTALLATION INSTRUCTIONS FOR TELESCOPIC CRANE UNITS These instructions are additional to those given for Models 4 5 and 6 in Data Sheets The complete instructions given for those models apply also to units for use on Telescopic Boom Cranes The telescopic action of the boom must be transmitted to the Control Box to give a true indication of the working radius as well as the Safe Working Load for that radius as the boom ex tends or retracts The additional parts supplied are as follows 1 Spring Recoil Drum 2 Stainless Steel Wire Cord 0 080 dia
184. turer of system tests also required when used in centralized lubrication systems Consult manufacturer of system 1 3 2 SECTION III LUBRICATION PETROLEUM GEAR OIL P amp H MILITARY EQUIVALENT SAE SYMBOL SPEC NO AMBIENT RANGE SPEC NO LUBRICANTS GRADE 497A Varies depending MIL L Multipurpose 80 MANUFACTURER T American Oil Company on use See the Gear Lube Ultragear Atlantic Richfield rt and Company Extra Duty Gear Lube Sinclair Conoco Uni Continental Oil Company versal Gear Lubricant Humble Oil amp Refining Company Mobil Oil Corporation Enco Gear Oils GX Mobilube HD Spirax Heavy Duty DX Geartran HD Multigear Lubricant Shell Oil Company Sun Oil Company DX Division Texaco Incorporated Varies depending See above on use See the Lubrication Chart NOTE Equivalent lubricants and manufacturers are the same as for P amp H Spec 497A Petroleum Gear Oil as described above The only difference insofar as this description is concerned is that P amp H Specification 497B is an SAE 90 grade lubricant Varies depending See above onuse See the Lubrication Chart Equivalent lubricants and manufacturers are the same as for P amp H Spec 497A Petroleum Gear Oil as described above The only difference insofar as this descr
185. uge shows the pressure of the air in the air system of the machine In normal operation the pressure reading on this gauge should range between 105 and 120 psi 7 28 2 bars 19 LOW AIR PRESSURE LIGHT When illuminated this lamp indicates that the pressure in the air system is below the normal safe operating level Do not operate the machine when this light is lit 20 EMERGENCY ENGINE SHUTOFF CONTROL G M ENGINES ONLY Pull this handle out if the engine continues to run after the Engine Stop button item 7 is depressed or if an abnormal condition should arise NOTE If the engine is shut down using the Emergency Engine Shutoff Control the butterfly valve in the intake manifold must be manually reset see Figure 24 21 CIRCUIT BREAKERS The function of the circuit breakers is to protect the various electrical circuits of the machine The circuit which is protected by each circuit breaker is marked on the decal above the circuit breakers An electrical overload will cause the circuit breaker button to move outward indicating that the circuit breaker has tripped Reset the circuit breaker by depressing the button If the same circuit breaker should trip shortly after it is reset check the circuit protected by the circuit breaker for the cause of the overload 1 2 4 CONTROLS AND OPERATION EMERGENCY SHUTDOWN SHOWN IN NORMAL POSITION Figure 2 4 Emergency Engine Shut Off WARNING Under no circumstan
186. uld be preceded bv a complete re analvsis of the 1 4 1 machine operation Carefully study previous maintenance check sheets and records before making any changes in or extending the check intervals USING THE SUGGESTED SCHEDULE CHECK SHEET The maintenance schedule check sheet is designed as a preventive maintenance guide until adequate experience is obtained to establish a schedule to meet a specific operating environment Following the check sheet are detailed procedures grouped in check intervals describing the procedure that should be used to perform the check sheet operations The check sheet shown can be reproduced by any printer to obtain additional copies of the check sheet The maintenance man making each check can then indicate on the sheet that the required check has been completed When a check has been completed the machine will be ready for additional service until the next check is due SECTION IV Perform daily lubrication 0 Repeat A check CI Fill fuel tank TT Perform weekly lubrication C Repeat A amp B check CJ Perform monthly lubrication Check engine oil level Check battery electrolyte level Check coolant level TT Check swing reducer oil level TT Check hydraulic oil tank level C Check air cleaner Drain air tanks TT Check axle levels C Inspect wire rope for damage mission
187. until the oil reaches the bottom of the oil level opening Replace the breather and oil level plug SERVICE QUICK START Periodically service the quick start system if the machine is so equipped to assure good performance se Figure 4 23 SECTION IV 1 Remove the fluid cylinder and lubricate the valve around the push rod under the gasket with a few drops of oil 2 Lubricate the actuator cable 3 Actuate the valve with the cable to distribute the oil on the cable and allow the oil to run down through the valve 4 Remove any dirt from the orifice by removing the air inlet housing fitting the orifice block and the screen Then blow air through the orifice end only These items are located beneath the fluid cylinder 5 Assemble and tighten the air inlet housing fitting to the actuator valve and tube ACTUATOR PREVENTIVE MAINTENANCE 6 Check for leakage of fluid fogging on the outside of the engine air inlet housing by actuating the starting aid while the engine is stopped If fogging occurs disassemble and retighten the air inlet housing fitting to the housing CAUTION Do not actuate the starting aid more than once with the engine stopped Over loading the engine air box with this volatile fluid could result in a minor explosion 7 Replace the fluid cylinder Hand tighten the cylinder y A123 Figure 4 23 Quick Start 1 4 19 1 4 20 blank SECTION V MACHINE STORAGE SECTION V MACH
188. us Code 8 22 NSN 23 24 Unit of Issue 25 29 Quantity 30 43 Document Number 44 Demand Code 45 50 Supplementary Address 51 Signal Code 52 53 Fund Code 54 56 Distribution Code CC 54 F for CONUS see AR 725 50 for OCONUS CC 55 56 Weapons System Code 57 59 Project Code 60 61 Priority Code 62 64 Required Delivery Date Will not be assigned 65 66 Advice Code Sample Format MILSTRIP requisition for CCE NSN TAO72415 3 1 4 SECTION ll MAINTENANCE SUPPORT PLANNING DATA 2 1 PURPOSE The crane is a truck mounted hvdraulic operating crane of 25 ton capacitv used for the construction tasks of lifting pile driving and clamshell operation 2 2 DESCRIPTION Part 3 covers a commercial diesel engine driven 8 x 4 truck mounted full revolving hvdraulic operating crane of 25 ton capacitv The crane is an off the shelf item of the latest model of the standard product used in the civilian construction industrv The crane consists essentiallv of eight wheels four rear wheel drive four front wheel steer pneumatic tired diesel engine powered carrier The carrier is equipped with a full continuous 3600 revolving superstructure with cab and a full power hydraulic telescoping boom The boom is capable of extending to a radius of 72 feet when in a horizontal position The crane carrier is equipped with a main and auxiliary transmission clutch and selective gears that provide 20 forward and 4 reverse speeds The crane engine has a 12 volt electr
189. utward and is decreased by pushing the knob inward 21 DEFOGGER FAN The defogger fan is controlled by the switch on the fan housing Place the switch in the center position to operate the fan at low speed Place the switch in the extreme right position to operate the fan at high speed 22 WINCH TURN INDICATORS These lights indicate the rate at which the winch drums are turning The upper light indicates main winch rotation while the lower light indicates auxiliary winch rotation The lights will flicker whenever the winch drums are turning The light will flicker at different rates depending upon how fast the winch drum is turning NOTE The lights will have a slight glow when the winches are not turning and will increase in intensity when the winches are turning This slight glow provides a means of checking the lamps in the turn indicators The lamp should be replaced if it does not glow as it is burned out 23 BOOM ANGLE INDICATOR This gauge indicates the number of degrees the boom is raised above the horizontal 24 FLOODLIGHT SWITCH This switch switches turn the optional floodlights on and off 25 ENGINE WARNING LIGHT This light when illuminated indicates that the engine is overheated or the engine oil pressure is below normal or SECTION II 26 CARRIER REMOTE CONTROLS These switches are used to operate the carrier from the upper cab Refer to the topic Remote Control Carrier Operation CRANE OPE
190. ver all other engine openings including coolant inlets cylinder block oil breather and crankcase in a similar manner 13 Drain the engine cooling system unless it is filled with a permanent antifreeze solution with a rust inhibitor added 14 If possible store the machine in a building where the air is dry and the temperature uniform 15 Every three to four weeks of storage crank the engine over two or three turns PREPARATION FOR LONG TERM STORAGE GENERAL Long term storage for the machine proper and for the Detroit Diesel engines is for periods longer than 30 days Long term storage for a Cummins engine is for periods longer than six months Separate procedures are outlined below for preparation of the machine 1 5 2 MACHINE STORAGE proper the Detroit Diesel engine and the Cummins engine MACHINE PREPARATION To prepare the machine proper for long term storage periods in excess of 30 davs proceed as follows 1 Clean the entire machine thoroughiv 2 Inspect for loose or missing attaching hardware throughout the machine Tighten or replace as necessary 3 Inspect all painted surfaces for rust bare metal chipping or other defects Prepare prime and repaint as necessary 4 Liberally lubricate all points equipped with grease fittings 5 Drain the swing reducer gear case the pump drive housing and the winch planetary housing in the upper On the carrier drain the main and auxiliary transmissions the re
191. wered pile driver hammer NSN 3895 00 014 0583 Refer to TM 5 3895265 14 TOWING Should it become necessary to tow this machine to a repair facility the propeller shaft between the auxiliary transmission and the front rear axle must be disconnected If the propeller shaft is not removed the transmission could be damaged due to inadequate lubrication of the internal gear train while the machine is being towed Towing cables or chains of adequate length should be attached to the two towing eye located behind the front bumper Change 1 1 2 27 1 2 28 blank SECTION III LUBRICATION SECTION III LUBRICATION GENERAL To insure proper operation of this machine all points requiring lubrication must be serviced with the correct lubricant at the proper time interval All normal wear points which require lubrication are shown in the lubrication charts at the rear of this portion of the manual with the possible exception of that lubrication information concerning purchased components For information concerning the lubrication of purchased major components not manufactured by Harnischfeger Corporation see the manufacturer s manual Note that the original manufacturers recommendations take precedence over lubrication recommendations contained in this manual if any conflict exists Points not considered to be normal wear points levers linkages pins and so forth should be lubricated with an oil can once a week Use a few
192. x to the Dynamometer ensuring that there are no sharp bends or kinks in the capillary tube and that it will not be damaged by any adjacent moving part Lift the center pulley and U shaped block in the Dynamometer and slide the Load Cell into position so that it locates on its dowel in the Dynamometer IMPORTANT It is essential that the platform on which the Load Cell rests and also the mounting face and loading platen on the Load Cell are completely clean and free of grit when installing the Cell Secure the Load Cell to the Dynamometer with the two Allen head screws provided which must be fully tightened NOTE Ensure that the Load Cell is correctiv located before tightening these screws and that there is no davlight under the Cell Clip the Capillarv to the structure at regular intervals along its length especially adjacent to the Dynamometer so that the Load Cell does not have to support the weight of the hanging capillary If the Dynamometer is on a swinging arm frame ensure that there is enough slack on the capillary to accommodate the movement of the Dynamometer looping the capillary if necessary Also be sure there is sufficient slack in the capillary so that it will not be stretched tight around the boom foot when booming INSTALLING THE BOOM FOOT FITTING This assembly must be mounted in such a manner that the pulley center lays on the exact center of the boom foot pin A steel angle bracket is bolted to this assemb
193. y See Figure 2 2 for an explanation of the voltmeter readings 10 IGNITION INDICATOR This lamp is illuminated whenever the ignition switch is in the ON position If the lamp remains lit after the upper ignition switch is placed in the OFF position the carrier ignition switch is still in the ON position and must be placed in the OFF position to shut down the ignition system 11 ENGINE STOP BUTTON Depress this button to shut down the engine After the engine has stopped place the ignition switch in the OFF position 12 IGNITION KEY The ignition key has three positions Starting from the vertical position they are OFF ON and START 13 TEMPERATURE GAUGE This gauge measures hydraulic oil temperature The oil should be warmed to 70 F 210 C before operating the machine and should not be allowed to exceed 2000 F 930 C during operation 14 WINDSHIELD WIPER SWITCH Turn this switch clockwise to the detent to operate the upper windshield wiper at slow speed Turn the switch past the detent to operate the wiper at high speed 15 MAIN WINCH SPEED SELECTOR SWITCH Place this switch in the HI position to operate the main winch at high speed Place the switch in the LO position to operate the winch at low speed CAUTION The winch is only capable of producing approximately 5090 of the maximum line pull when the speed selector switch is in the HI position Be sure the switch is in the appropriate position for the load
194. y to accurately locate the load Never extend the boom out so far that rated load is exceeded See the rating AUXILIARY WINCH LEVER LOWERING THE LOAD The load can be lowered by two methods Push the main or auxiliary winch lever forward part way to power down the load Light loads can be free falled by pushing the lever to the extreme forward position Figure 2 9 Crane Operating Cycle P amp H Winch 1 2 13 1 2 14 blank Return the control lever to the power lowering position slowly to avoid shock loading the winch and winch line SETTING BOOM ANGLE Position the boom at the proper angle for the load and working conditions Refer to the rating plate for proper angle Pult the boom hoist lever pedal back to raise the boom Push the boom hoist lever or pedal SETTING BOOM LENGTH Push the boom telescope levers forward to extend the boom sections Pull the boom telescope levers back to retract the boom sections Be sure the boom sections are extended equally and do not extend the boom LIFTING THE LOAD HOISTING Push the main or auxiliary winch lever forward to lower the hook block Attach the load to the hook block then pull the main or auxiliary winch lever back to raise the load BOOM HOIST PEDAL forward to lower the boom Be sure to pay out line from the main and or auxiliary winch as required to prevent the hook block s from coming in contact with the boom point BOOM TELESCOPE LEVE

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