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Crane, Wheel Mounted, Hydraulic

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1. Figure 1 10 Safety Decals TM5 3810 305 10 Minimum Safety Requirements for Work Platforms Sus pended From Load Line or Rigidly Mounted on Boom When use of a work platform is least hazardous to personnel and is the only practical means of accomplishing a task make certain all personnel follow these minimum safety procedures Read and understand all safety precautions listed in this section before attempting an operation using a work platform All safety procedures and criteria es tablished in this section are the MINIMUM requirements for use of a work platform on the LRT 110 Crane Applicable govern ment and industry standards must also be adhered to Failure to follow this procedure could cause DEATH or serious injury General There are two methods for mounting a work platform on the LRT 110 Crane The first is to suspend the work platform from the load line The second is to rigidly mount the work platform to the boom Before attempting any operation using a work platform all of the conditions listed here must be met including crane equipment and work plat form requirements and procedures for inspection rigging testing and operation 1 42 LRT 110 Crane Equipment Requirements For Use of a Work Platform 1 The LRT 110 Crane must be in compliance with PCSA Std No 4 and ANSI B30 5 1982 2 In addition the following equipment and or controls must be included and functioning on the LRT 110 Crane
2. Metric 0 907 Newton Meters 1 356 Pounds Square Inch Kilopascals 6 895 Miles per Gallon Kilometers per Liter 0 425 Miles per Hour Kilometers Hour 1 609 TO CHANGE TO MULTIPLY BY Inches de cede of 0 394 coole dv alee ees i oiv DOS Rees 3 280 Yards s 1 094 Kilometers ote neice 0 621 Square Centimeters Square Inches 0 155 Square Square Feet 10 764 Square Meters Square Yards 1 196 Square Kilometers Square Miles 0 386 Square Hectometers 2 471 Cubic Cubic Feet 35 315 Cubic Meters Cubic 1 308 Milliliters Fluid Ounces 0 034 Liters use cc ir ert 2 113 Liters ios eere Rr emis 1 057 T p s Gall ns i 2a ere prete 0 264 Ounces ee ews 0 035 5 Pounds sag aper ees 2 205
3. TM5 3810 305 10 Section XI Warranty Information Refer to Warranty Technical Bulletin TB 5 3810 305 15 Section XIl Safety Precautions Introduction The LRT 110 Crane is designed to conform to all applicable SAE ANSI and OSHA safety requirements As a crane operator your responsibility for safety is not lessened by the operational aids and warning devices provided Guard against a false sense of security Failure to follow even a single safety precaution can cause DEATH or SERIOUS INJURY You are responsible for your own safety as well as others working around you Warning decals are placed conspicuously on the vehicle warning of hazards including the danger of electrocution if the boom or load is swung into power lines In addition to the following list WARNINGS CAUTIONS and NOTES appear throughout the manual directly above the procedure to which they apply A WARNING indicates a hazard which can result in DEATH or serious injury CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment NOTE is a statement containing information that will make the procedure easier to perform Exercise good judgment when operating the LRT 110 Crane Read and understand all safety precautions before operating the crane Failure to follow these precautions could cause DEATH or serious injury GeneralWarnings Do not attempt to operate the
4. 2 The interval column of your PMCS Table tells your when to do a certain check of service a While you operate perform your Before B PMCS Always keep in mind the WARNINGS and CAUTIONS b While you operate perform your During D PMCS Always keep in mind the WARNINGS and CAUTIONS c Right after you operate perform your After A PMCS 3 The procedure column of your PMCS Table tells you how to do the required checks and services Carefully follow these instructions If you do not have the tools or if the procedure tells you to have unit maintenance do the work 4 If your equipment does not perform as required refer to the troubleshooting section in this manual for possible problems Report any malfunctions or failures on the proper DA Form 2404 or refer to DA Pamphlet 738 750 NOTE The terms ready available and mission capable refer to the same status Equipment is on hand and is able to perform listed combat missions see DA Pamphlet 738 750 5 Equipment is not ready available if column This column tells you when and why your equipment cannot be used 6 Always do your PMCS in the same order so it gets to be a habit Once you ve had some practice you will spot anything wrong in a hurry 7 When you do your PMCS take along a rag or two 8 While performing PMCS observe WARNINGS and CAUTIONS preceding those operations which
5. Metric Short 1 102 E Newton Meters 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 068527 001 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 protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
6. PINTLE HOOK TIRE FOOT PRINT mae 216 mm 10 5 267 mm 92 50 In 2 35 37 50 in 953 mm 34 50 in 876 mm 82 25 in 2 09 m TRACK 96 00 mca Figure 5 44 Preparation for Travel 5 47 TM5 3810 305 10 6 Release the parking brake in the operator s cab by pulling up lever to release it If the vehicle s electrical power is available turn on emergency four way flashers The vehicle may now be towed at speeds up to 20 mph 32 km h depending on existing conditions for whatever distance is neces sary When making turns make them as wide as possible no sharp turns at no more than 5 mph 8 km h Air Tranport The overall height of the LRT 110 Crane allows for transport without disassembly by C 5 C 141 and C 130 aircraft Prepare the LRT 110 Crane as follows 1 Retract the boom and lower it over the rear of carrier Figure 5 45 SLIN SLING POINT MEST OVERALL LENGTH 342 in 869 OVERALL HEIGHT 93 in 2 36 CAUTION Apply only enough tension to the cable to take up the slack Fail ure to follow this procedure could cause damage to equip ment Use the link in the tool box to connect the hook block on the rear outrigger With the winch take up the slack in cable Refer to TM55 3810 01 165 14 Transpor tability Guidance for the Crane 7 5 Ton Rough Terrain Koehring Type 1 NSN 3810 01 165 0646 Type 2 NSN 3810 01 165 0467
7. All lubrication and check time intervals are based on hours of operation under average working conditions Daily or 8 hours whichever comes first Weekly or 40 hours whichever comes first Two weeks or 80 to 100 hours whichever comes first Three months or 250 hours whichever comes first Four months or 500 hours whichever comes first Six months or 1 000 hours whichever comes first Yearly or 1 500 to 2 000 hours whichever comes first Time Intervals Unusual Conditions The LRT 110 Crane will require extra service and care when operated under unusual condi tions High or low temperatures long periods of hard use and continued use in sand water mud or snow will break down the lubricants Add or change lubricants more often under these condi tions However during long periods when the crane is not in use the service intervals can be lengthened Turntable Gear and Pinion Gear Teeth Never apply grease to turntable gear while the upperstructure is in motion Failure to follow this procedure could cause DEATH or serious injury Gear teeth must be lubricated with a saturated brush or swab Grease a segment stand clear swing the upperstructure 10 degrees and grease another segment Repeat until entire ring gear is coated B 1 TM5 3810 305 10 No personnel are permitted on the deck while rotating upper structure Failure to follow this procedure could cause DEATH or serious injur
8. 1 Align the upperstructure and swing bearing by manually starting four mounting capscrews and eight washers into the outside comer holes 6 8 9 and 11 Figure 5 38 Lower upperstructure to swing bearing Align torque arm on rotary manifold and anchor ear on inside of upperstructure frame by swinging the upperstructure With alignment correct install four mounting capscrews and eight washers in remaining outside mounting holes Tighten eight mounting capscrews The final torquing will be done after remaining mounting capscrews are installed on inside of upperstructure TM5 3810 305 10 Removing and Stowing Parts Used for Assembly 1 Remove hoist cable from lift arm 16 as fol lows a Remove tether rope from boom head and stow in tool box b Lower hook block to ground and pay out cable 12 in 305 mm while maintaining tension on cable Insert wedge block in winch drum c Remove sheave 14 and cable from lift arm 16 by removing pin 13 from the clevis that retains sheave 14 Figure 5 39 Temporarily lay pin 13 and sheave 14 aside Figure 5 39 Lifting the Upperstructure 5 35 TM5 3810 305 10 d Swing lift arm and mast out of the way e Shut engine off 2 Disconnect winch extension hoses as follows a Relieve pressure in winch circuits by turning ignition switch ON holding on anti two block BY PASS switch and oper ating winch lever in both directions sev eral times until pre
9. CHAPTER 4 OPERATING INSTRUCTIONS AND FUNCTIONS The purpose of this chapter is to familiarize the operator with controls and instruments necessary for the operation of the LRT 110 Crane Included also are the Preventive Maintenance Checks and Services PMCS and vehicle operating procedures Section I II IV Do not attempt to operate the LRT 110 Crane until all operating instruc tions have been read and understood Knowledge of controls alone is inadequate preparation to operate this vehicle Failure to follow this procedure could cause DEATH or serious injury Title Page Use of Operator s Controls and Indicators Controls and Instruments 4 3 Initial Adjustments and Control Settings Checks and Inspections Operator Observations Cable Inspection Preventive Maintenance Checks and Services PMCS Operator Troubleshooting start up Starting the Engine Operation Under Normal Conditions Operating the Engine Before Moving the LRT 110 Crane Pre Move Checklist Moving the Vehicle to a Job Site Upshifting and Downshifting Recommendations Stopping the Engine Lift Procedure on Outriggers Lift Procedure On Tires Hand Signals for LRT 110 Crane Operation Wire Rope Instructions Wire Rope Identification and Construction Wire Rope Installation Unreeling and Uncoiling Seizing Wire Rope Cutting Wire Rope End Fittings and or Attachments Socketing Wire Rope Clips U Bolt Clips Fist Grip Clips TM5 3810 305
10. T O2 FE O2 i oo CA A CA T A a T A oo Ti BR 1 EN rl A oo T A a E P a T BR z DEX 7 TM5 3810 305 10 Peening Wire Rope Slings 4 44 Protruding Core Work Lights Switch 4 5 Reduction in Rope Work Platforms Suspended Diameter from Load Line or Rigidly Scrubbing 4 48 Mounted on Boom Minimum Stretched Rope Safety Requirements for 1 42 Wire Rope Installation 4 30 Work Sites Sandy or Dusty Wire Rope Instructions Working Area Diagram 1 23 Breaking in a New Wire Working Positions 1 23 Rope Cable Lubrication Classifications Clips Cutting Wire Rope 4 35 Diagnostic Guide to Common Wire Rope Abuses 4 50 Drums Plain Smooth End Fittings and or Attachments Equipment Inspection 4 55 Flexibility of Wire Rope 4 42 Guidelines to Inspections and Reports for Equipment Wire Rope and Wire Rope Slings Identification and Construction Illustrated Examples of Possible Wire Rope Damage Inspection 4 45 Inspection Summary Installation 4 30 Operations Inspection Oversized Limits of Wire Rope Diameters Seizing Wire Rope 4 34 Socketing Terminal Efficiencies Approximate Unreeling and Uncoiling Wedge Sockets When to Replace Wire Rope 4 43 INDEX 8 By Order of the Secretary of the Army GORDON R SULLIVAN General United States Army Chief of Staff official PATRICIA P HICKERSON Brigadier General United States Army The Adjutant General Distributi
11. excessively worn wear pads cracked welds ard heat damage Check instruments for the below listed readings TACHOMETER RPM needle moves when thee accelerator pedal is depressed b REAR AXLE CENTERING LIGHT Light on wheels off center Light off wheels centered c ENGINE TEMPERATURE GAUGE Approximately 190 degrees 88 C d ENGINE OIL PRESSURE GAUGE Idle 10 PSI full load 30 PSI cold oll may be 55 e FUEL GAUGE Needle indicates fuel level with the ignition on f TRANSMISSION TEMPERATURE GAUGE Range is 160 degrees to 190 degrges F to BB C Cool down required above 250 F 121 C M MONTHLY EQUIPMENT 15 NOT NEADY AVAILABLE IF Class III leak Clase 111 leak Cracks or inoperable Controls not operating properly Class III leak Class III leak Hook block cantacts bom Controls fail to disconnect Warning light horn fails Boom angle indicator is inoperative missing or binding Stickina Bent bm cracked welc or heat damaac Tachoreter needle doesn t move Gauge inoperative Gauge inoperative Gauge inoperative FJ M5 3810 305 10 APPENDIX F OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES 0 BEFORE D DURING AFTER W WEEKLY M MONTHLY INTERVAL ITEM 10 BE INSPECTED EQUIPMENT 15 NOT PROCEDURE CHECK FOR AND HAVE REPAIRED READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED 9 VOLTMETER Indicates 27 5V charg
12. 12 APPENDIX F TM5 3810 305 10 OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES BEFORE A e e D DURING A AFTER W WEEKLY M MONTHLY ITEM TO BE INSPECTED PMENT 1 PROCEDURE CHECK FOR AND HAVE REPAIRED ees e S READY AVAILABLE IF FILLED OR ADJUSTED AS NEEDED NOTE Outriggers and boom must be fully retracted before checking the hydraulic level HYDRAULIC RESERVOIR Check hydraulic fluid level Maintain the level at the Full mark on the dipstick FUEL WATER SEPARATOR Drain separator into a container check for water in the fuel Milky looking fuel indicates water in the fuel WARNING DO remove the radiator cap when the radiator is hot warm DO NOT touch the radiator Place your hand approximately 2 3 inches fram the radiator top tank if the tank feels hot warm DO NOT remove the radiator cap Hot coolant in the radiator may cause severe injury to personnel RADIATOR a Check coolant level The level should be no lower than one 1 inch from the bottam of the filler neck b Check hoses lines and fittings radiator oore tanks for leaks Any Class III leak cracks damage or loose clamps BELT Check for loose frayed or broken missing belt Belt hroken missing LIGHTS AND SIQALS Check all lights and tum signals for proper operation Lights INOP for nic Operation WARNING Electrolyte is extremely dangerous Wear eye protection when checking batteries Keep
13. A Figure 4 8 Boom Hoist Leer boom LOC Figure 4 9 Boom Telescope 29 Winch Lever lowers or raises load push to lower load pull to raise load Figure 4 10 29 MAIN WINCH Figure 4 10 Winch Lever 30 Turn Signal Lever activates right or left hand turn signals plus emergency flashers and is deactivated when blackout lights are on 4 11 Figure 4 11 Turn Signal Lever 31 Anti Two Block Panel is equipped with an audio visual anti two block warning system de signed to alert operator of impending two block conditions i e the hook or hook block is being drawn into boom point sheaves The vehicle is equipped with a shut off disconnect system on the control linkage It is activated when the hook block contacts the anti two block counterweight winch hoisting will cease and boom will not extend or lower raising and retracting boom and winch down functions will remain active Ap propriate counteraction should be taken to pre vent two blocking Figure 4 12 BY PASS EEEM WARNING Figure 4 12 Anti two Block Panel TM5 3810 305 10 Anti Two Block Warning Light is a visual warning light to indicate approaching two block condition Anti Two Block Audible Horn Warning Switch is used to deactivate the audible warning system while traveling Unwarranted use of BY PASS switch can result in damage to the LRT 110 Crane and cause DEATH or serious injury Anti Two Blo
14. BY PASS WARNING TWO Figure 5 9 Anti Two Block Panel 5 7 TM5 3810 305 10 11 Shut engine off Be aware of limited work area while lifting reaching and assembling the mast and lift arm The deck and fender surface is small and can become slippery in inclement weather Failure to follow this procedure could cause DEATH or serious injury 12 Install mast 3 on carrier as follows a With the aid of another person raise mast 3 from deck and lower it over square pivot bearing 9 Figure 5 10 located on right side of frame behind operator s cab Position stop on mast 3 towards center line of vehicle between stops Mast base ears should be over fender Align ears on top of mast with support ears on frame b lt Remove two truss rods 10 adjustable truss rod 11 and six pins 12 from stor age location A Figure 5 11 on right side of upperstructure c Install two truss rods 10 to top of carrier frame one on left side behind cab and the remaining one on right side of cab Install four pins 12 Figure 5 1 in connecting points Figure 5A Installing the Truss Rods 5 8 13 Install lift arm 16 as follows a With lift arm 16 still in storage location B on right side of boom pull out sheave pin 13 and remove sheave 14 from sheave bracket 15 Figure 5 11 b Temporarily lay sheave 14 aside Weight of the li
15. Description CAGEC and Part No hose extension h 11 h 11 h 10 label h 11 label torque multiplier 55719 P N GA184A 5 extesion drive 55719 P N GA184A 16 extension 3 4 drive 55719 P N LI22 breaker bar 3 4 drive 55719 P N 1226 57 36MM socket 55719 P N LDHM362 torque wrench 1 2 drive 81495 P N TQR250 adapter 3 4f to 1 2 MM 55719 GLA62 hammer 55719 P N BPN 16B tapered punch 55719 P N 1816A pliers 1495 P N 1226 3 rope 8149 P N 12178 144 adapter 1 2f to 3 4 M 55719 P N GLA12 wooden wedge 81495 P N 709 1985 extension bar 81495 P N 709 1977 metal bar 81495 P N 709 1977 wrench 6MM 81495 P N610 1039 bag 81495 P N 709 4324 lock pin 3942 8 P N 90174114 groove pulley 81495 P N 709A1565 space plate 81495 P N 709 1998 Usable on Code 106 106 106 106 Qty D 5 TM5 3810 305 10 D 6 22 23 24 25 26 27 28 3040 01 273 9314 5340 00 071 3836 4730 01 128 5831 5340 00 071 3834 5354 01 013 1040 4730 01 246 851 1 5340 01 239 8742 Appendix D connecting link 81495 P N 709 1877 protective cap 01276 P N 5657 10 protective plug 01276 P N5659 10 protective cap 01276 P N 5657 12 protective plug 01276 P N 5659 12 protective cap 01276 P N 5657 16 protective plug 01276 P N 5659 16 106 106 106 106 106 106 TM5 3810 305 10 Appendix E Additional Authorized List AAL Description NSN U M Qty 1 Helmut Construction 8415 00 889 3767 Ea 2 2 Gogles Protecti
16. Remove two coiled extension hoses Fig sure Turn dipstick 1 4 turn to ure 5 14 from tool box Their ends are safety notch to relieve pressure connected together by quick disconnects Failure to follow this procedure and are marked with ID tags reading H 10 could cause SERIOUS INJURY and H 11 Take them to right side of vehicle a Turn dipstick 1 4 turn to safety notch to relieve pressure b Disconnect two winch hoses tagged H 10 and H 11 Figure 5 13 attached to rotary manifold with quick disconnect fittings These hoses come down from winch on Figure 5 14 Extension Hoses COLLECTOR RING WIRE HARNESS TELESCOPE 1 Soff STOP PIN TELESCOPE BOOM HOIST RETRACT HOSE LOWER HOSE BOOM HOIST RAISE HOSE ROTARY MANIFOLD X x _ Figure 5 13 Rotary Manifold Hoses 5 10 TM5 3810 305 10 NOTE of earner Remove protective dust caps and connect male connectors of extension Be sure to keep the hoses and hose H 10 to H 10 winch hose and exten their quick disconnect ends clean sion hose H 11 to H 11 winch hose Fig during this procedure ure5 15 d Disconnect ends and uncoil hoses f Connect loose ends of H 10 and H 11 ex tension hoses to respective tagged fittings e Locate the two quick disconnect fittings The winch hoses are now attached from that extend down from two tees on winch valve to original winch hoses with these valve next to frame und
17. Using pins 23 stow post 19 at storage location D on upper structure post 20 at storage loca tion A Figure 5 11 on upperstructure and posts 21 and 22 at storage location E Figure 5 27 on frame Figure 5 27 Storage Location E 5 43 TM5 3810 305 10 f Start engine l Start engine Center boom over cab and raise boom to a 50 degree angle Lower hook g Swing boom to 2 o clock position and block down far enough to hook it into hook stow mast 3 on upperstructure storage block tieback on front of the LRT 110 Crane location D using additional Lower boom to travel position while taking pin from tool box up slack in cable h Shut engine off 2 Raise outriggers lowering the crane to ground Retract outrigger beams up to travel 3 Account for and clean all tools used in assem position Shut engine off bly procedures Put away all tools in tool box 3 Recheck stowage of all items used for assem bly of the LRT 110 Crane The crane is now Lower the LRT 110 Crane to the Ground ready for normal operation When attaching hook block to AC hook block tieback take up cable oo slowly while lowering boom to Si Ge at S prevent damage to windshield ex NS i Figure 5 4 Storage Location D 5 44 REF tA 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 21 TM5 3810 305 10 TOOLS AND PARTS FOR SECTIONALIZATION TOOL HOSE H 10 H 1
18. lever located at the right of the operator s sary When making turns make them as wide seat in the two wheel drive position to pre as possible no sharp turns at no more than 5 vent damage to the transmission during mph 8 km h towing CAUTION The tow bar MS500048 is the PINTLE HOOK only tow bar to be used on this vehicle If not available see or ganizational maintenance Fail ure to follow this procedure could cause damage to equip ment EUR 216 mm 10 5 in 267 mm i TIRE FOOT PRINT 92 50 in 2 35 m 34 29 in 871 mm RACK HOOK BLOCK TIEDOWN AND SLING POINT 2 TIEDOWN 4 10 760 Ib 4880kg 22 870 lb 12 110 Ib 5493 kg 10 374 kg 14 52 36 in 1 33 m Figure 4 60 Preperation for Travel 4 73 TM5 3810 305 10 Air Transport The overall height of the LRT 110 Crane allows for transport without disassembly by C 5 C 141 and C 130 aircraft Prepare the LRT 110 Crane as follows 1 Retract the boom and lower it over the rear of the carrier Figure 4 61 CAUTION Apply only enough tension to the cable to take up the slack Fail ure to follow this procedure could cause damage to equip ment TIEDOWN AND SLING POINT TIEDOWN OVERALL LENGTH 342 in 8 69 m OVERALL HEIGHT 93 in 2 36 52 56 in 1 34 m 2 Use the link in the tool box to connect the hook block to the pintle hook on the rear outrig ger With the winch take up the slack
19. Failure to follow this procedure could cause DEATH or serious injury c Operation and safety Always observe the following operation and safety procedures TM5 3810 305 10 before using a work platform Make certain the LRT 110 Crane is level and stable with outriggers fully extended on a solid level surface Make certain the operator is experienced and in good physical and emotional condition Make certain the operator does not leave his station While the work platform is in use the operator is to remain in the vehicle with the engine running All unauthorized personnel will leave the LRT 110 Crane working area while a work platform is in use All operations using a work platform must be planned by the operator along with supervisors signal personnel and personnel to be lifted prior to the operation The crane operator must avoid any sharp or sudden movements while a work platform is in use Never use a work platform near energized power lines or ground cables Failure to follow this procedure could cause DEATH or serious injury e Always maintain at least twice the distance from power lines required by OSHA 29CFR Part 1910 while a work platform is in use 1 45 TM5 3810 305 10 e Make certain the combined weight of the work platform plus any attachment devices personnel tools and equipment does not exceed 1 2 of the lifting capacity specified by the Capacity Chart refer to page 1 19 e N
20. However when this happens valley breaks will appear As soon as the first valley break is detected the rope should be removed immedi ately If preventive maintenance previously described is diligently performed the rope life will be prolonged and the operation will be safer Cut ting off a given length of rope at the end attach ment before the core deteriorates and valley breaks appear effectively eliminates these sections as a source of danger Equipment Inspection Any undetected fault on a sheave roller or drum be it of relatively major or minor significance can cause a rope to wear out many times faster than the wear resulting from normal operations As a positive means of minimizing abuses and other than normal wear the procedures here set forth should be adhered to Every observation and measurement should be carefully recorded and kept in some suitable and accessible file 1 Give close examination to the method by which the rope is attached both to the drum and to the load Make certain that the proper means of attachment is applied correctly and that any safety devices in use are in satisfac tory working order 2 Carefully check the groove and working surface of every sheave roller and drum to determine whether each groove and surface is as near to the correct diameter and contour as circumstances will permit and whether all surfaces that are in contact with the rope are smooth and free of corrugations
21. LRT 110 Crane until all operat ing instructions have been read and understood Knowledge of controls alone is inadequate preparation to operate this ve hicle Failure to follow this procedure could cause DEATH or serious injury To avoid many dangerous prac tices play it safe by following correct procedures Failure to follow these procedures could cause loads to fall causing DEATH or serious injury 1 27 TM5 3810 35 10 1 28 Be aware of limited work area while working on the deck area of the LRT 110 Crane The deck and fender surface is small and can become slippery in inclement weather Failure to follow this procedure could cause DEATH or serious injury Never disconnect hydraulic lines or fittings before venting pres sure Turn dipstick cap 1 4 turn to safety notch to relieve pres sure Failure to follow this procedure could cause SERIOUS INJURY Alert all personnel that the upperstructure is to be lifted off the carrier Keep all uninvolved personnel clear of the vehicle while hoisting and removal are taking place Check all pin connections cable alignment and machine bubble level before proceeding with the lift Failure to follow this procedure could cause DEATH or serious injury Keep hands and arms clear of all pinch points while checking the alignment of the upperstructure and the earner mounting surface Failure to follow this procedure could cause SERIOUS INJURY Keep arms and hands from und
22. Loops formed by overrun can cause kinks and dog legs in the cable resulting in damage and premature cable failure Figure 2 6 Securing Cable on Winch 8 Apply braking force to the reel flange to prevent overrun as the cable is being drawn off 4 Rotate the drum slowly to insure that first layer of cable is evenly wound onto drum 9 Using a timber or block apply force against the shipping reel flange to provide the re quired breaking force 2 4 TM5 3810 305 10 5 Install remainder of cable Tension cable by braking shipping reel and slowly operate winch in the raise mode to wind cable onto winch drum CAUTION Never use a steel hammer or pinch bar to move cable over on drum These tools can easily damage cable 6 Using a lead or brass hammer tap cable over against preceding turns making sure that ad jacent turns are tight against one another After cable is wound onto winch drum reeve cable as desired 2 5 2 6 blank TM5 3810 305 10 CHAPTER 3 GENERAL THEORY OF OPERATION The purpose of this chapter is to provide the operator with a general description of the LRT 110 Crane and an overall view of its components and their functions Title Page General Theory of Operation 3 2 Transmission Theory of Operation Axle Theory of Operation 3 3 Winch Theory of Operation 3 1 TM5 3810 305 10 General Theory of Operation The LRT 110 Crane is a self contained vehicle featuring 7 1 2 ton
23. Stop and refer to maintenance 6 Transmission Overheating Problem Remedy a Too high a gear ratio a Stop cool down and change gears b Low oil level oil below FULL line b Check and refer to maintenance c High oil level oil above FULL line c Stop and refer to maintenance 7 Control Lever s Inoperative or Erratic Problem Remedy a Low hydraulic oil level a Add hydraulic oil as required refer to b Anti two block system malfunction b Refer to maintenance c Lever or linkage damaged c Refer to maintenance 8 Boom Hoist or Extend Cylinders Inoperative or Erratic Problem Remedy a Low hydraulic oil level a Add hydraulic oil as required refer to b Load is too heavy b Consult Capacity Chart for maximum loads and reduce as required c Anti two block system malfunction c Refer to maintenance 4 16 TM5 3810 305 10 Section Ill Start Up Once the Checks Inspections and Observations Starting the Engine Exhaust gases can produce have been completed the engine maybe started 1 Make sure parking brake is on symptoms of headache dizziness 2 Move transmission shift lever to the neutral and loss of muscular control position DEATH permanent brain dam age or other serious injury may 3 Set throttle to one half speed be caused by exhaust gases 4 Turn ignition switch to the ON position If exhaust gases or exposure symptoms are observed ventilate CAUTION the area immediately and treat
24. Unus ual Operating ConditionS Special problems in maintenance and operation are caused by unusual conditions such as ex tremes in heat cold humidity high altitude salt water and dusty or sandy work sites When operating under such conditions special precau tions must be taken to prevent vehicle damage minimize wear and avoid component deteriora tion Extreme Cold In periods of extreme cold problems of freeze damage adequate lubrication and battery failure may become particularly troublesome With the onset of very cold weather it is advisable to winterize the LRT 110 Crane by servicing the cooling system and switching to the lubricant recommended for cold weather usage Follow recommendations in this manual when operating 4 64 the LRT 110 Crane under very extreme condi tions 1 Prevent freeze damage To prevent freeze damage to the cooling system and cracking of engine block or head drain and flush cooling system Clean radiator exterior making certain all air passages through core and cooling fins are free of foreign matter CAUTION Never use a chromate base corro sion inhibitor when coolant contains ethylene glycol Use only nonchromate base inhib itors Chromate base inhibitors reacting with ethylene glycol can produce chromium hydroxide commonly known as green slime This substance reduces the heat transfer rate and can cause serious engine overheating Refill cooling system Add an an
25. When idling engine for extended periods main tain an idle speed sufficient to prevent battery from being discharged a voltmeter reading of 26 V Before Moving the LRT 110 Crane CAUTION If traveling more than 5 miles on improved roads or 2 miles on rough terrain or unimproved roads remove anti two block weight and chain from the switch and secure it to the anchor point of the wedge socket located either on the boom head or hook block whichever is accessible Failure to follow this procedure could cause damage to the hook block switch The LRT 110 Crane is capable of both off road and on road travel The kind of travel under taken will determine how carrier is operated Before moving the LRT 110 Crane around work site or between sites carefully consider type of 4 18 terrain road conditions and any hazards likely to be encountered enroute Think the move through in advance and carry it out safely Pre Move Check List Before moving vehicle to and from job sites complete the following steps 1 Secure hook block to hook block tieback 2 Verify that tires are inflated properly refer to Recommended Tire Pressure Chart page 1 20 3 Check to be sure rear wheels are centered then switch to two wheel steer 4 Adjust seat and mirrors for clear vision Moving the Vehicle to a Job Site The general procedure for moving the LRT 110 Crane is as follows 1 Buckle seat belt 2 Start engine 3 Check to
26. a For use of a work platform suspended from a load line e An operable anti two block warning device which automatically deactivates the control function bringing about the two blocking condition e A boom angle indicator e Capacity Chart refer to page 1 19 eA boom extension indicator eA winch drum rotation indicator b For use of a work platform rigidly mounted to the boom e A boom angle indicator e Capacity Chart refer to page 1 19 e A boom extension indicator e A means to rigidly attach a Koehring supplied and or approved work platform to the boom tip TM5 3810 305 10 LRT 110 Crane Work Platform Requirements 1 Work platforms suspended from a load line or rigidly mounted to the boom shall comply with all applicable government and or indus try standards relating to design and manufac ture including but nor limited to ANSI A92 2 1979 a Design considerations for a work platform suspended from a load line include e Material and design safety factors e Construction including fasteners and welding e Flooring eHand rails eToe boards eSafety lanyard attachments e Gates eHoisting and tag line attachments eLoad limit occupant limit and work platform weight instructions on labels and warnings b Design considerations for a work platform rigidly mounted to the boom include e Material and design safety factors e Construction including fasteners and welding
27. a rope manufactured close to its nominal size may when it is subjected to loading undergo a greater reduc tion in diameter than that stipulated in the minimum diameter table Yet under these circumstances the rope would be declared unsafe although it may in actuality be safe As an example of the possible error at the other extreme we can take the case of a rope manufactured near the upper limits of allow able size If the diameter has reached a reduction to nominal or slightly below that the tables would show this rope to be safe But it should perhaps be removed Today evaluations of the rope diameter are first predicated on a comparison of the orig inal diameter when new and subjected to a known load with the current reading under like circumstances Periodically throughout the life of the rope the actual diameter should be recorded when the rope is under equivalent loading and in the same operating section This procedure if followed carefully reveals a common rope characteristic after an initial reduction the diameter soon stabilizes Later there will be a continuous albeit small decrease in diameter throughout its life Core deterioration when it occurs is revealed by a more rapid reduction in diameter and when observed it is time for removal Deciding whether or not a rope is safe is not always a simple matter A number of differ ent but interrelated conditions must be evalu ated It would be dan
28. adjustment is necessary consult the LRT 110 Capacity Chart before performing a lift Failure to follow this procedure could cause DEATH or serious injury TM5 3810 305 10 CAUTION Always consider possible ob structions which may be encoun tered during swings when vary ing boom height or length Think swing through consider ing all obstacles before making swing Failure to follow this procedure could cause damage to equipment When lifting with the LRT 110 Crane a signal man must always be used to direct the operation Limited visibility to the rear is caused by upper structure being in the operator s line of vision CAUTION Never hold controls in an acti vated position once hoist lower cylinder or extend retract cylin der has reached its limit of travel This can cause overheating of hydraulic oil 4 Swing boom over load Upperstructure and boom swing is controlled by swing lever To swing boom to the RIGHT push lever for ward To swing boom to LEFT pull lever back Swing speed increases as lever is moved further forward or back Swing speed also varies with engine speed 4 23 TM5 3810 305 10 Never lift and swing a load directly over operator s compart ment or over ground personnel in the work area Failure to follow this procedure could cause DEATH or serious injury CAUTION ALWAYS START AND STOP SWINGS GRADUALLY Stopping swing too abruptly will cause load to oscillat
29. and the shipping data plates for tiedown requirements LINK STORED IN TOOLBOX SHIPPING CUBAGE 1 767 cu ft 50 cu m OVERALL WIDTH 96 in 2 44 m Figure 5 45 Air Transport Tiedowns 5 48 TM5 3810 305 10 Rail Transport Prepare the LRT 110 Crane for rail transport as follows Weight of the hook block is approximately 235 Ib 107 kg Use adequate lifting equipment and properly support the hook block Do not lift over personnal or let personnel walk underneath suspended Failure to follow this procedure could cause DEATH or serious injury 1 Using hoist and sling remove the hook block from cable Store it in the tool box and block it to prevent it from moving 2 Retract the boom and lower it over the front Wind cable back on drum and wire socket down to prevent cable from loosening on winch drum 3 Install a 1 2 in 6x19 IWRC cable around load sheave and hook block tieback 4 Refer to TM55 3810 165 14 Transportability Guidance for the Crane 7 5 Toni Rough Terrain Koehring Type 1 NSN 3810 01 165 0646 Type 2 NSN 3810 01 165 0467 and the shipping data plates for tiedown requirements 5 Place the fuel shut off on the rear wall of cab in the off position Put the transmission shift lever in center neutral position and release the parking brake 6 Remove all loose tools and equipment from the operator s cab Stow and secure all tools and equipment in the tool box 7 Band the tool
30. cable are in alignment with boom Failure to follow this procedure could cause damage to equipment CAUTION Keep all hoses out of the way General Cautions when lowering upperstructure Make sure the winch extension In addition to personnel hazards the operator is hoses are not pinched against the also responsible for avoiding potential damage to outrigger beam as the upperstruc equipment ture is lowered This could result CAUTION When removing hook block from storage bracket pay out cable while raising boom to prevent damage to windshield CAUTION DO NOT use a torque wrench for removal purposes Failure to follow this procedure could cause damage to equipment in damage to the extension hoses CAUTION Do not allow outrigger beam located under upperstructure to contact winch hoses Failure to follow this procedure could cause damage to equipment CAUTION Make sure the base plate opening clears the connections on the rotary manifold Failure to follow this procedure could cause damage to equipment CAUTION When attaching hook block to hook block tieback take up cable slowly while lowering boom to prevent damage to windshield CAUTION Do not make directional changes between forward and reverse while vehicle is in motion Failure to follow this procedure could cause damage to equip ment CAUTION Do not attempt to move the vehicle with the parking brake engaged Failure to fo
31. caging of cable on winch drum Never operate equipment with personnel on the hook or a load Failure to follow this procedure could cause DEATH or serious injury Crane operators must always be prepared to take emergency action while a load is suspended in the air Never leave the operator s compartment with a load suspended Failure to follow this procedure could cause DEATH or serious injury 7 Lift load to desired height Do not lift higher than necessary The LRT 110 Crane is equipped with an anti two block system If hook or block is raised too close to boom head a warning light appears on panel If horn switch is activated an audible warning will sound This vehicle is also equipped with control disconnects to prevent winch from raising load and boom from extending or lower ing To reactivate the system disconnects retract or raise boom and or lower hook CAUTION Do not continue to pull block up after contact has been made with boom head This will result in damage to boom head and sheaves The cable may also be broken causing load to drop If the operator needs to raise hook block beyond point at which the anti two block is activated he may override the system by using anti two block BY PASS switch refer to page 4 7 CAUTION When spotting load it may be necessary to alter boom length or boom angle In making these adjustments the operator must guard against exceeding rated load as determ
32. e Flooring e Hand rails Toe boards Safety lanyard attachments Gates A means of adjusting and locking the work platform level Load limit occupant limit and work platform weight instructions on labels and warnings 2 Specifications for a work platform must be in writing and must describe the platform weight load and occupancy limit method of platforms inspection and maintenance and procedures for attachment to the LRT 110 Crane The above plus any appropriate pre cautionary information applicable to the platform must be permanently placed either in the vehicle or on the work platform Inspection Rigging Testing and Operating a Work Platform for the LRT 110 Crane 1 The inspection operation and safety require ments for a work platform suspended from a load line or rigidly mounted to the boom must at all times comply with PCSA Std No 4 and all appropriate government regulations 2 In addition all of the following limitations and minimum safety requirements apply 1 43 TM5 3810 305 10 Never use a work platform if inspection indicates a structural or mechanical fault of any kind Failure to follow this procedure could cause DEATH or serious injury a Inspection A complete inspection of the 1 44 LRT 110 Crane and the work platform must be performed prior to any operation Inspection is to be performed daily or each time the operator is replaced or the LRT 110 Crane is convert
33. hydraulic and water leaks and damage to the equipment that would require a more detailed inspection d Levers pins Jinkage etc not equipped with lubrication fittings shoule operate freely and be free of rust e Check for loose missing nuts bolts and cotter pins CQnipped cracked paint around nuts bolts may indicate loose hardware f Check for cracked broken welds Cracked or chipped paint may indicate a damaged weld g Listen for unusual noise from the aguipment and erratic c Perform walk around inspection of the vehicle Check for operation of controls equipment during operation Or damage Fill fuel tank m een a e a a e a EE EEEE ea a 1 e ENGINE a Check for oil leaks at the valve cover gasket and oil cooler Any class III oil leak b Check far daraged nisaing camponente Damage that renders a component ingcrable C Check for a cracked block head visually d Check the engine oil level Maintain the level between the Level below add 1 fadi qo Ot Mand mark on thecdipstick txithe dipstick 2 FUEL SYSTEM n Check injectors pump lines fittings and tank for leaks AIR CLEANER Check air cleaner element and service indicator for dirt CDNTROLS controls bind or won t engage Check controls for smooth movement no binding no excessive free play Oontrols bind or won t NO 10 11
34. position and release the parking brake 6 Remove all loose tools and equipment from the operators cab Stow and secure all tools and equipment in the tool box 7 Band the tool and battery box lids shut TM5 3810 305 10 4 75 TM5 3810 305 10 Transport For LRT 110 Crane For loading aboard ship the LRT 110 Crane may be slung in a horizontal attitude from the lifting eyes on the ends of the outrigger boxes Figure 4 66 shows the slinging geometry indicating the sling apex of the vehicle s center of gravity If provisions exist the LRT 110 Crane may be driven aboard the ship in a forward or backward direction Once aboard the LRT 110 Crane may be maneuvered into tight quarters by using the crab steering capability Tie down the vehicle as required using the tiedown lugs provided SLING APEX FOR LIFTING Lo CRANE IN HORIZONTAL ATTITUDE TRUE LENGTH OF FRONT N TRUE LENGTH OR REAR CINE a LINES 144 in 3 66 m TIEDOWN AND SLING POINT 2 GVW 22 870 Ib 10 374 kg Figure 4 66 Marine Transport 4 76 TM5 3810 305 10 CHAPTER 5 TYPE 1 SUPPLEMENT Section Title Page Sectionalization Preparation for and Sectionalization of the LRT 110 5 2 Type II Crane for External Air Transport EAT Preparation for and Assembly of Sectionalized LRT 110 Type II Crane After External Air Transport EAT Transportability Land Transport 5 46 Air Transport Rail Transport Ma
35. 11 valve fitting Stow plugs in tool box Winch hoses are now attached from valve to Figure 5 35 Quick Disconnet Fittings original winch hoses with these extensions 5 29 TM5 3810 305 10 Be aware of limited work area while lifting reaching and assembling mast and lift arm Deck and fender surface is small and can become slippery in inclement weather Failure to follow this procedure could cause DEATH or serious injury 4 Install mast 3 on carrier as follows 5 30 Weight of the mast is approxi mately 98 lb 44 kg Use two people to properly support and lift mast Failure to follow this procedure could cause DEATH or serious injury Storage Location D a Remove two pins 2 and mast 3 from storage location D on left side of upperstructure Store two pins 2 in tool box for future use b With the aid of another person raise mast 3 and lower it over square pivot bearing 9 Figure 5 10 located on right side of frame behind operator s cab Position stop on mast 3 towards center line of vehicle between stops Mast base ears should be over fender Align ears on top of mast with support ears on frame Figure 5 11 Assembling the Mast Storage Locations A and B c Remove two truss rods 10 adjustable truss rod 11 and six pins 12 from storage location A Figure 5 11 on right side of upperstructure Install two truss rods 1 O to top of carrier frame one o
36. 3 5 1 safety factor in accordance with SAE J 959 The winch drum capacity is such that when the crane is properly reeved three wraps of cable are maintained at all times on the hoist drum Boom Angle Indicator A mechanical boom angle indicator conforming to SAE J375 is provided for angular boom elevations Boom Lenght Markers Boom length markers are located on both sides of the inner boom to indicate retraced length of 21 75 ft 6 63 m ora fully extended boom length of 35 75 ft 10 90 m and are used in conjunction with Capacity Chart Figure 1 8 Boom Lenght Marker Section VIII List of Items Required NOT APPLICABLE Section IX Storage Data LRT 110 Cranes being placed in storage must be adequately protected from deterioration during extended periods of idleness Proper protection insures that the crane can be restored to service with minimum effort What specific preparation procedures are re quired depends upon the length of time the crane is to be stored Short Term Storage is defined as 1 24 30 days or less Extended Storage is defined as more than 30 days NOTE For a complete list of storage instruc tions for the LRT 110 Crane refer to Koehring Commercial Maintenance Instructions TM5 3810 305 10 Section X Tools and Test Equipment 8 EN g 11 10 24 amp o 20 19 18 13 cnc 5 ATE 35 a B I zi 16 32 29 3 3 5 33 36 Figure 1 9 Tools and Test Eq
37. 32 degrees F O de grees C and required at temperatures of 10 degrees F 12 degrees C and below 4 65 TM5 3810 305 10 To install cold start cylinder a Remove cylinder from tool box and remove cap from top of cylinder Figure 4 57 Figure 4 57 Cold Start Cylinder b Remove protector cap from valve or if empty cylinder is in place loosen clamp and unscrew cylinder c Invert cylinder and thread into cold start mounting valve d Secure cylinder with clamp Before starting engine using the cold start device be sure to inspect engine oil and transmission oil filters for bulges and rup tures The applicable Preventive Maintenance Checks and Services are also to be completed refer to If temperature is below O degrees F 18 degrees C briefly turn ignition switch ON to check battery voltage If battery voltage is below 24 volts the LRT 110 Crane will require a slave start refer to page 4 68 Headlights are to be turned on for 3 minutes to warm the batteries then all switches and accessories are to be turned off 4 66 To use the cold start device a Pull cold start knob out and wait 3 to 5 seconds for ether to fill charging valve Omit this step if temperature is above O degrees F 18 degrees C b Push cold start knob in and wait 3 to 5 seconds for ether to spray into intake manifold Omit this step if temperature is above 0 degrees F 18 degrees c Repeat steps a and b
38. 3810 305 10 C 1 Load Ratin n Tir NOTES 1 For Pick and Carry Operation boom must be centered over the front of the machine 2 The load should be restrained from swinging 3 Creep Speed is crane movement of less than 200 ft 61 m in a 30 minute period and not exceeding 1 0 mph 1 6 km h RECOMMENDED TIRE PRESSURE iR225 STATIONARY TRAVEL ON TIRES 12R22 5 LR H t STATIONARY 2 6 MEN 360 __ST OVER FRONT 5 800 11 000 8 400 7 400 4 100 7 500 6 800 6 000 2 00 4 700 1 900 3 400 3 400 3 400 2 1 600 2 800 2 800 2 800 21 1 400 2 600 2 600 2 600 Notes for On Tires Capacities A For Pick and Carry operation boom must be centered over the front of the machine B The load should be restrained from swinging SL xe oh o o Creep Speed Is crane movement of less than 200 ft 61 m ina 30 minute period and not ex ceeding 1 0 mph 1 6 km h D Refer to General Notes for addi tional information o BEEBEBEH jsjsjsjsjals a ec o o 1 20 TM5 3810 305 10 MAXIMUM PERMISSIBLE HOIST LINE LOAD NI Rt j E o a i Line Parts I 2 3 Maximum Load 6 000 Ib 12 000 Ib 15 000 Ib 2 722 kg 5 443 kg g Hook Block I D I I 1 2 D Cable to sheave position and dead end Sheaves are numbered left to right Wire Rope 19 Class 23 000 Ib 10 433 kg minimum breaking streng
39. Army 0025801 DISTRIBUTION To be distributed in accordance with the initial distribution requirements for IDN 255732 TM 5 3810 305 10 TM 5 3810 305 10 C 1 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY TM 5 3810 305 10 WASHINGTON DC 1 November 2000 OPERATOR S MANUAL FOR CRANE WHEEL MOUNTED HYDRAULIC LIGHT 7 1 2 TON ROUGH TERRAIN MODEL LRT 110 CONSISTS OF Type I General Purpose NSN 3810 01 165 0646 Type 11 Airborne Airmobile 3810 01 165 0647 REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS 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 Submit your DA Form 2028 2 Recommended Changes to Equipment Technical Publications through the internet on the Army Electronic Product Sup port AEPS website The internet address is http aeps ria army mil If you need a password scroll down and click on ACCESS REQUEST FORM The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program You may also mail fax or e mail your letter DA Form 2028 or DA Form 2028 2 direct to Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 The e mail address is amsta ac nml ria army mil The fax number is DSN 793 072
40. Back 4 65 5 37 2028 Front 4 66 5 38 2028 Back 4 67 5 39 2028 Front 4 68 5 40 2028 Back 4 69 5 41 2028 Front 4 70 5 42 2028 Back 4 71 5 43 4 72 5 44 4 73 5 45 4 74 5 46 4 75 5 47 4 76 5 48 5 1 5 49 5 2 5 50 5 3 1 5 4 2 5 5 2 5 6 3 5 7 4 5 8 1 5 9 C 2 5 10 D 1 5 11 D 2 5 12 D 3 5 13 D 4 5 14 D 5 5 15 D 6 5 16 E 1 5 17 E 2 5 18 F 1 5 19 F 2 5 20 F 3 TM 5 3810 305 10 C 1 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON DC 1 November 2000 CHANGE NO 1 OPERATOR S MANUAL CRANE WHEEL MOUNTED HYDRAULIC LIGHT 7 1 2 TON ROUGH TERRAIN MODEL LRT 110 CONSISTS OF Type General Purpose NSN 3810 01 165 0646 Type Il Airborne Airmobile 3810 01 165 0647 TM 5 3810 305 10 9 August 1991 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 3 Added or revised illustrations are indicated by a vertical bar adjacent to the illustration Remove Pages Insert Pages List of Effective Pages iand ii lii 1 7 thru 1 8 1 7 thru 1 8 1 19 thru 1 20 i1 19 thru Approved for public release distribution is unlimited File this sheet in the front of the publication for reference purposes By Order of the Secretary of the Army ERIC K SHINSEKI General United States Army Official Chief of Staff JOEL B HUDSON Administrative Assistant to the Secretary of the
41. Introduction General Warnings General Cautions Safety Decals Minimum Safety Requirements For Work Platforms Suspended From Load Line or Rigidly Mounted On Boom Page 1 2 TITT nli WIN b 1 En 1 DOP 1 lli ii am 1 1 1 1 1 1 1 GI N N N N ON xa anan A n P 1 4 N TM5 3810 305 10 Section Purpose and Function HYDRAULIC WINCH UPPERSTRUCTURE A Ex BOOM COUNTERWEIGHT PLEX BOOM HOIST CYLINDER TT NC 4 N HOOK BLOCK 9 j Yo OUTRIGGER ENGINE TRANSMISSION ERN OUTRIGGER OPERATOR S CAB Figure 1 1 Major Component Locations Left Side 2 HYDRAULIC BATTERY RESERVIOR Do i COMPARTMENT sid TOOL COMPARTMENT Figure 1 2 Major Component Locations Right Side 1 3 TM5 3810 305 10 General The purpose of this manual is to familiarize operators with the operation and maintenance of the LRT 110 Crane This manual provides information and data for operation and lubric ation The operator of the LRT 110 Crane must not attempt to operate the vehicle before he has obtained a thorough understanding of the manual contents The LRT 110 Crane is a wheel mounted self contained two and four wheel drive two and four wheel steering crane A diesel engine powers the LRT 110 Crane driving through a powershift transmission with tandem pump hydraulic power for operation of the crane outriggers fully revolving upperstr
42. On Tires portion of the Capacity Chart are based on the following conditions l Boom shall be carried straight over front of vehicle Travel speed shall be reduced to suit condi tions Specified tire pressure shall be maintained 4 25 TM5 3810 305 10 4 Sudden starts and stops shall be avoided 5 Tag or restraint lines shall be provided to snub swinging of load CAUTION Traveling over uneven terrain with rear axle oscillation locked out can result in instability Excessive boom length can also cause instability depending on terrain and wind pressure 6 Load shall be carried as near to ground as possible with necessary minimum boom length Carry straight over front since rear axle oscillation is locked out when boom moves off center more than 5 degrees 4 26 TM5 3810 305 10 ignal for the LRT 11 ran rauon The following are hand signals and their meaning for the operation of the LRT 110 Crane Both opera tor and person indicating the necessary movement of the LRT 110 Crane must be familiar with all hand signals and their interpretation Figure 4 16 HAND SIGNALS FOR CRANE OPERATIONS HOIST With forearm vertical forefinger pointing up move hand in smail horizonta circle LOWER BOOM Arm extended fingers closed thumb point ing downward aN 5 Ad d STOP Arm extended palm Gown move arm back and forth horizontally TRAVEL One Track Lock the track on side indica
43. Switch provides on off opera tion of service drive lights stop lights blackout marker and blackout drive lights 16 Dash Light Switch turns dash panel and instrument lights on 17 Outrigger Switch Front activates valve for independent operation of front left or right outriggers 18 Outrigger Switch Rear activates valve for independent operation of rear left or right outrig gers 19 Steering Selector has three positions four wheel is full clockwise position two wheel is center position and crab is full counterclockwise position Switch to crab or four wheel steering only when axles are centered axle center indica tor light is out or steering will be limited and may be locked Figure 4 4 If wheels should become locked switch to two wheel steering turn front wheels switch back to crab or four wheel steering and center rear wheels 20 Outrigger Control Lever raises or lowers outrigger beams Each beam operates independ ently with control switches pull to raise push to lower Figure 4 5 TM5 3810 305 10 21 WORK LIGHTS Figure 4 6 Swing Lever 2 OUTRIGGER Figure 4 3 Side Sloping Dash Panel STEERING SELECTOR 12400 231 Figure 4 4 Steering Selector 21 Swing Lever contols rotation of upperstruc ture push to swing right pull to swing left When the upperstructure is 5 degrees off front center rear axle pivot cylinders are locked into position to maintain sta
44. adjusted the crane cannot drive through it in third gear 4 8 36 Brake Pedal activates hydraulic service brakes 37 Heater Switch turns fan ON or OFF and is located on top of heater behind operator s seat 38 Seat Adjust Lever adjusts seat front to rear and is located under left hand comer of seat 39 Heater Shut Off Valve shuts off flow of heated coolant and is located below the left side of heater behind operator s seat 40 Boom Angle Indicator indicates angle of boom from 0 thru 75 degrees elevation in 1 degree increments 4 Fire Extinguisher is located on left hand side of cab on rear wall for emergency fires 42 Defroster Fan is mounted on upper right comer of cab and is controlled by ON OFF switch on mounting base 43 Boom Length Markers are located on side of boom and are used to indicate boom length 44 Capacity Chart is located in cab on left hand side and is used to determine proper lift capacity 45 Steering Wheel controls direction of vehicle Figure 4 1 Control and Instrument Identification TM5 3810 305 10 4 9 TM5 3810 305 10 Section Il Initial Adjustments and Control Settings Checks and Inspections The following items should be checked each day before start up and start of operations Check all fluid levels with vehicle parked on level ground Cooling system is pressurized Use extreme caution and proper protection when removing radiator cap after operating
45. an inner rope of 7x7 left lang lay 18x7 construction with 12 strands in right regular lay The rotation resistant property that characterizes this highly specialized construction is a result of the counter torques developed by the two layers When the steel wire core strand is replaced by a fiber core the description becomes 18x7 When a center wire is replaced by a strand it is considered as a single wire and the rope classification remains unchanged There are of course many other types of wire rope but they are useful only in a limited number of applications and as such are sold as specialties They are usually designated accord ing to their actual construction 4 29 TM5 3810 305 10 Wire Rope Installation Checking The Diameter It is most important to check the diameter of the delivered rope before installation This is to make certain that the rope diameter meets the specified requirements for the given machine or equipment With an undersize diameter rope stresses will be higher than designed for and the probability of break ing the rope will be increased an oversize diameter rope will wear out prematurely This happens because of abuse to the rope caused by pinching in the grooves of the sheave and drum In checking however the true rope diameter must be measured And this is defined as the diameter of the circum scribing circle i e its largest cross sectional dimension To insure accuracy this measurement
46. and backward to check for frozen brakes and tires m Check brakes and steering functions before exceeding 5 mph 8 km h ALLOW THE ENGINE TO WARMUP so that optimum engine power is obtained at low speed for the protection of the hydrau lic system 7 Special attention must be given to the hy draulic oil TM5 3810 305 10 CAUTION BE ALERT FOR SIGNS OF PUMP CAVITATION The hydraulic oil provides lubrication for pumps When too heavy or stiff it will not flow fast enough to meet pump demand and a vacuum or cavitation will be created A screaming noise indicates inadequate pump lubrication and if allowed to continue for more than a short period will result in serious damage to pumps If cavitation noise is noticed hydraulic oil must be warmed To do this actuate a func tion allow the cylinders involved to reach the limits of their travel and hold control in engaged position for 10 minutes When running hydraulic oil over relief to warm it be sure to restrict flow by turning engine at as slow a speed as possible Increase engine speed gradually allowing sufficient time for oil to run through the system before commencing operation If cavitation noise is still noticed repeat the procedure listed above Refer to the lubrica tion chart for recommended oil viscosity for the winter season 4 67 TM5 3810 305 10 8 Slave start engine when necessary Maintain batteries at full 24 volt charge
47. are burred There is ample evidence to support the rule that sheaves with broken flanges must be replaced immediately A sheave or drum with a flat spot can induce a whip into the line This whip or wave travels until it is stopped by the end terminal at which point the rope may bend severely This condition helps to accelerate the fatigue breakage of wires Sometimes the reeving is such that the whip or 4 44 wave is arrested by a sheave or the drum itself In these circumstances the whipping will cause wire breaks along the crowns of the strands Obviously sheaves or drums that excite vibra tions of this sort must be repaired or replaced Guideline to Inspections and Reports for Equipment wire Rope and Wire Rope Slings 1 Maintain all inspection records and reports for the length of time deemed appropriate 2 Prior to each daily use the following proce dure should be followed a Check all equipment functions b Lower load blocks and check hooks for deformation or cracks c During lowering procedure and the follow ing raising cycle observe the rope and the reeving Particular notice should be paid to kinking twisting or other deformities Drum winding conditions should also be noted d Check wire rope and slings for visual signs of anything that can cause them to be unsafe to use 1 e broken wires excessive wear kinking or twisting and marked corrosion Particular attention should be given t
48. batteries 3 Check cables Corroded cables must be cleaned tightened and coated with grease Batteries should be clean and free of damage Check tire condition refer to page 4 11 Visually inspect the LRT 110 Crane Inspect structural members and welds for cracks align ment and wear Visually inspect hook block Inspect hook block for damage and wear to sheaves and tubes Check hydraulic cylinders and rods Inspect cylinders for damage and leaks Inspect rods for nicks burrs and scratches Lubricate control disconnects refer to lubric ation chart Appendix B Lubricate sheaves Type II refer to lubrication chart Two Week Check or Every 80 100 Hours of Service Perform Daily and Weekly Checks Perform Daily Weekly and Two Week lubrica tion refer to lubrication chart Appendix Verify that wheel nuts have been torqued to 450 to 500 lb ft 610 to 678 N em Check engine belt Visually inspect belt for glazing cracks and fraying Visually check the condition of the hydraulic oil Thickening of oil or a change in its appearance such as darkening may serve as an indicator of when an oil change is needed Clean radiator exterior Wash radiator with soap and water to remove dirt and foreign material from fins of radiator Operator Troubleshooting 1 Engine Does Not Crank Problem a Ignition switch OFF b Transmission shift not in neutral c Loose battery cables d Low battery vo
49. be exposed to the deteriorating effects of salt moisture or both To protect exposed metallic surfaces wiring hoist rope paint and other items keep them dry and well lubricated Follow the recommendations below when operating in these conditions Check for deterioration Make frequent inspections for rust and corrosion Remove them as soon as they are detected Dry and paint exposed surfaces after rust and corro sion have been removed TM5 3810 305 10 Where paint may not be applied such as on polished or machined surfaces coat the area with grease to repel water Keep bearings and their surrounding surfaces well lubricated to prevent the entry of water Cable must be kept well lubricated to prevent moisture and salt from penetrating the cable strands Fording There are no special preparation or maintenance vehicle requirements to ford up to 30 in 762 mm of water Section VII Shutdown Vehicle Shutdown Procedures Before securing the LRT 110 Crane make sure of the following 1 Fully retract boom and center it over the front of the LRT 110 Crane CAUTION When attaching hook block to hook block tieback take up cable slowly while lowering boom to prevent damage to windshield 2 Secure hook block to hook block tieback 3 Lower boom to travel position 4 Make certain all outriggers are in the up position 5 Place transmission shift lever in neutral 6 Apply parking brake 7 Turn ignit
50. be sure engine oil pressure is in normal operating range 30 psi 207 kPa engine idling to 55 psi 380 kPa governed no load 4 Shift into two wheel drive 1st gear This is recommended for normal travel conditions CAUTION Do not attempt to move the vehicle with the parking brake engaged Failure to follow this procedure could cause damage to equipment 5 Release parking brake 6 Shift into forward travel Good judgment in selection of gear range and route of travel is essential when operating off road Though designed primarily for use in off road conditions there may be instances when highway travel is necessary In such instances the LRT 110 Crane is subject to the same regulations governing the operation of other heavy equip ment on public roads Adequate lighting flares flags and safety equipment must be on the ve hicle at all times CAUTION When operating on hard surfaces use two wheel drive only Fail ure to do so may result in severe drive line wind up and compo nent failure 7 Accelerate engine by depressing accelerator pedal until LRT 110 Crane starts to move CAUTION Speed is not to exceed 25 mph 40 km h Failure to follow this procedure could cause damage to equipment The operator may start to travel from idle in either forward or reverse and in 1st gear TM5 3810 305 10 In addition to conditions of terrain gear selection while traveling is also determined by transmi
51. bearing if Be sure to keep the hoses and necessary where upperstructure will be their quick disconnect ends clean bolted down during this procedure b Disconnect ends and uncoil hoses ROTARY MANIFOLD Ab TORQUE ARM BRACKET Figure 5 32 Rear Axle Oscillation f Figure 5 20 Location of Boom HoistCylinder_Hoses After Disconnection 5 28 TM5 3810 305 10 Never disconnect hydraulic lines or fittings before venting pressure Turn dipstick cap 1 4 turn to the safety notch to relieve pressure Failure to ie NSE follow this procedure could cause SERIOUS INJURY Turn the face during the following procedure to avoid having hydraulic oil splash in face or eyes Failure to follow this procedure could cause SERIOUS INJURY Figure 5 14 Extension Hoses NOTE During reconnection of hydraulic quick disconnects pressure build up may prevent reconnec tion Striking the cone at the center of the disconnect will relieve the pressure Turn dipstick cap 1 4 turn to safety notch to relieve pressure d Locate two quick disconnect fittings that extend down from two tees on winch valve next to frame underneath right side of carrier Remove protective dust caps and connect male connectors of extension hose H 10 to H 10 winch hose and extension hose H 11 to H 11 winch hose Figure 5 35 Attach female connectors of exten sion hose H 10 to H 10 valve fitting and extension hose H 11 to H
52. coolant Engine Oil 4 6 Fuel Fuel Water Separator Hydraulic System Leakage Lubrication Safety Equipment Tires 4 43 Transmission Oil 4 6 Checks and Services Preventive Maintenance Circuit Breakers Clips Wire Rope Fist Grip U Bolt TM5 3810 305 10 1 1 AI oi r2 Col Lonfico y r2 e tA EN 1 1 0 a a oo olojo 1 1 colo FREN Lae P c Alle INDEX 1 TM5 3810 305 10 Cold Start Cold Extreme Completion of Upperstructure Assembly Construction of Wire Rope Identification and Control and Instrument Identification Control Settings Initial Adjustments and Converter Torque Coolant Checks and Inspections Counterweight Cranes New Break In Requirements Cutting Wire Rope Cylinder Boom Dash Lights Dash Light Switch Decals Safety Decible Level Chart Definition of Load Rating References Freely Suspended Load Operating Radius Side Load Working Arc Defroster Fan Diagnostic Connector Panel Diagnostic Guide to Common Wire Rope Abuses Dimensions Equipment Specifications Dimensions General Drawbar Drive Shafts Drums Plain Smooth for Wire Rope INDEX 2 E EN nN eel ie E N O2 ony oo R iN a E 1 gt T O2 CA 1 l 1 Aca je 11 1
53. for the combined weight of lifting attachments platform personnel and tools No personnel are permitted on the work platform during the performance of any test Do not allow personnel on work plat form if any test procedure indi cates a malfunction in equip ment Failure to follow this procedure could result in DEATH or serious injury Testing The following daily test proce dures are to be performed on the LRT 110 Crane and the work platform whenever the operator changes or a significant change in lifting conditions occurs To test the work platform and equipment use the following procedure 1 Load the work platform with ballast at least 2 times the weight of intended load CAUTION Acceleration and deceleration must be smooth and controlled Failure to follow this procedure could cause damage to equip ment 2 Raise and lower the load at maximum line speed 3 Test the control braking function by bringing the load to a smooth stop 4 The specific operation to be undertaken shall be performed in its entirety 5 When the test is completed inspect the work platform and equipment for any evidence of damage or defect All limiting and warning devices shall be acti vated by each control function which may create a two blocking condition No operations with a work platform are authorized On Tires Always make certain the LRT 110 Crane is on a stable surface with the outriggers fully extended
54. ft 5 49 m from winch to reach up to sheave clevis at top of lift arm 16 Figure 5 36 Using wedge block wedge cable to prevent cable unspooling Figure 5 6 3 Take loose sheave 14 Figure 5 36 that was removed from lift arm 16 in step 5 a of Preparation for Assembly and insert it in slack of cable Check that all pins and pinlocks are installed and secured prop erly DEATH or serious injury may result if upperstructure comes loose Raise sheave 14 and cable up into clevis on lift arm 16 and using sheave pin 13 install sheave 14 in clevis Swing lift arm 16 over upperstructure Maintain tension on end of cable and remove wedge block from cable spool Operate winch until hook block is secured to boom head Figure 5 6 Wedge Block in Winch Drum Figure 5 36 Preparing Upperstructure for Lift 5 32 Remove tether rope from tool box and knot rope to boom head quick reeving pin 5 24 Hold on anti two block BY PASS switch and use winch to slowly hoist upperstructure until support bracket clears ground Remove three pins 23 Figure 5 37 from boom support that connects it to upperstruc ture and remove boom support Set aside for later disassembly and storage Remove protective bag from base plate of up perstructure and place in tool box TM5 3810 305 10 Lifting Upperstructure onto Carrier Stay clear of hoisted upperstruc ture while it is being positioned over car
55. in tool box Connect one end of posts 19 and 20 to ends of post 21 with two pins 23 Swing remaining ends of posts 19 and 20 up and attach to ears on side of Figure 5 26 Storage Location D Sa QU AN M x CSS A M MW 4 AN A AY n Y Y Figure 5 27 Storage Location 5 20 boom with two pins 23 Figure 5 29 Connect one end of post 22 to center of post 21 with pin 23 then swing other end of post 22 up and attach to ears underneath boom with pin 23 Attach tube 24 to posts 21 and 20 with two pins 2 Figure 5 28 Storage Location A Figure 5 29 Support for Front of Boom NOTE Make sure hook is turned side ways and trunnion rotated so that bottom of hook block sets level on ground Use tether rope around hook to hold hook in place while lowering TM5 3810 305 10 Lower upperstructure on to front support between outriggers Position of lift arm 16 should be straight out from side of carrier frame Figure 5 30 Figure 5 30 Lowering Upperstructure on Support 5 21 TM5 3810 305 10 Removing and Stowing Parts Used for Separation 1 When upperstructure is down continue to pay out approximately 18 ft 5 49 m to remove tension on hoist cable 2 Shut engine off 3 Block cable at winch drum with a wooden wedge Figure 5 6 to prevent cable from un winding 4 Dismantle and rest
56. lll NAT MIL L 46187 BELOW 10 F fox oe t 38r 2 cn 25559 AND ABOVE five PURGE a 65 F TO 250 F 65 F AND ABOVE 8 65 F TO 250 F jwe 22 ox cox suaves 23 HOOK BLOCK TRUNNION 65 F AND ABOVE Tus 1 1 25 as meoo 4 29 smtcAaues Pins asmeoo 4 amp 7866 GREASE pu pao eins wee wow fasano a posee enot ion Tus PT Pa fesses rreen oncvfas 65 TO 250 F Ol SOE OLSE SINL APPENDIX C TM5 3810 305 10 PUBLICATION REFERENCES PUBLICATION INDEXES DA Pam 25 30 FORMS Consolidated Index of Administration Publications Refer to DA Pam 738 750 The Army Maintenance Management System TAMMS for instructions on the use of maintenance forms pertaining to the vehicle PUBLICATION REFERENCES General FM 90 3 90 6 HTF MIL M 63042C TM TG 2b 7 2 es we TM 5 331 TM 9 238 TM 43 0139 Vehicle FM 21 306 LO 5 2350 262 12 TB 750 651 TM 5 2350 262 10 HR IM 55 3810 01 165 141 TB 5 3810 305 15 Identification and Distribution of DA Publications and Issue of Agency and Co
57. load overburden change frozen or stuck sheaves soft rollers sheaves or drums excessive fleet angle misalignment of sheaves kinks improperly attached fittings grit and sand objects imbedded in rope improper grooving Check on all the above conditions for mechanical abuse or either abnormal or accidental forces during installation Check on all the above conditions for mechanical abuse or either abnormal or accidental forces during installation Check on all the above conditions for mechanical abuse or either abnormal or accidental forces during installation Indicates improper lubrication or storage A long term condition normal to the operating process A long term condition normal to the operating process produces a chisel shape 4 50 Figure 4 44 Interstrand and Core to Strand Figure 4 46 Damaged Reel TM5 3810 305 10 Illustrated Examples of Possible Wire Rope Damage 1 Interstrand and core to strand nicking A strand has been removed from the rope to show the equivalent lines of nicking where strands are in contact with one another as well as with the core Figure 4 44 2 Cork screwed rope This condition results from rope being pulled around an object having a small diameter Figure 4 45 3 Damaged reel When a reel has been dam aged in transit it is a safe assumption that ir reparable damage has been done to the rope Figure 4 46 4 51 TM5 3810 305 10 4 Sh
58. of rotary manifold centered in notch c Maneuver carrier over toward upperstruc ture positioning right front outrigger beam in under upperstructure Figure 5 34 Vehicle must be level to prevent OUTRIGGER possible loss of control of upper structure when lifting off of ground DEATH or serious Figure 5 34 Positioning Qutrigger injury may result if upperstruc ture gets out of control d With carrier in place extend outrigger beams raising carrier off ground at all four corners Level carrier using bubble level on right side of console 5 27 TM5 3810 305 10 e Align left edge of wrench i Remove all dust caps and plugs from con with right side of lockout valve Using a nectors on hoses and rotary manifold in 36 mm socket and breaker bar remove center of swing bearing two capscrews and four washers attaching Stow caps and plugs in tool box wrench to swing bearing and rotary mani fold Remove wrench and stow in tool 3 Attach winch extension hoses as follows box Capscrews and washers will be installed at a later time a Remove two coiled extension hoses Fig ure 5 14 from tool box Their ends are f Shut engine off connected together by quick disconnects and are marked with ID tags reading H 10 g Remove remaining 16 capscrews and 32 and H 11 Take them to right side of washers from top of swing bearing Set carrier them aside for reinstallation at a later time NOTE h Check and clean top of swing
59. on upperstructure Figure 5 11A Installing the Truss Rods 5 23 TM5 3810 305 10 b Lift mast 3 up off pivot bearing and stow 5 24 Weight of mast is approximately 98 Ib 44 kg Use two people to properly support and lift mast Failure to follow this procedure could cause DEATH or serious injury in storage location D Figure 5 4 on upperstructure Disconnect H 10 and H 11 winch exten sion hoses from both upperstructure and underneath carrier Install dust caps on disconnect fittings at winch valve on right side of carrier Roll up hoses H 10 and H 11 and connect ends together Figure 5 14 Return them to tool box Figure 5 4 Storage Location D Remove dust caps and plugs from tool box three sizes two of each Plug or cap open hose ends and all open fittings on rotary manifold_ Figure 5 20 Lock dip stick cap on hydraulic tank Maintain normal rear axle oscillation with rotary manifold disconnected from upper structure Remove wrench from tool box and using two mounting capscrews and four washers install wrench with pin end engaged in hole of torque arm bracket on rotary manifold Use breaker bar and 36 mm socket to tighten two mounting capscrews _ Thread remaining 16 mounting capscrews and 32 washers back into threaded holes of swing bearing Figure 5 14 Extension Hoses Preparation of Carrier for Transport 1 Lower carrier to ground using the follo
60. open flames sparks and other heat sources away fram batteries Should electrolyte get splashed into eyes flush immediately with water and seek medical attention ASAP If electrolyte contacts skin wasb immediately BATTERIES a Check electrolyte level contact maintenance if battery Batteries will not crank electrolyte is required engine b Check battery box and cables for corrosion cleanliness Qontact maintenance to remove batteries if required a Visually check tires for severe cuts and obvious low pressure Ref TM 9 2610 200 20 Chapter 2 Tire pressure is 90 PSI WARNING Place transmission in neutral before starting engine NOTE Transmission temperature must be 1609F to 190 F to check fluid level TRANSMISSION a Check transmission fluid level Maintain level Fluid below add mark between Add Full mark b Check transmission and oil cooler for leaks Class III leak F5 TM5 3810 305 10 APPENDIX F OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B BEFORE F 6 D OURING A AFTER W WEEKLY ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND HAVE REPAIRED FILLED OR ADJUSTED AS NEEDED WARNING Do not attempt to move the vehicle with the parking brake engaged Check parking brake operation Vehicle must not move with the brake engaged engine at an idle and engine in forward gear BRAKES a Check reservoirs fluid level Must be between Max and Min marks Use silicone b
61. operation in dust or sand Daily Check or Every 8 Hours of Service Check hydraulic reservoir fluid level refer to lubrication chart Appendix B and page 4 10 Fill fuel tank refer to page 4 10 Check engine oil level refer to page 4 10 Check coolant level refer to page 4 10 Check air cleaner refer to page 4 11 Check hydraulic components Make overall visual inspection including ground for leakage Check brake fluid refer to page 4 11 Verify that tires are inflated properly refer to page 1 20 Check for dirt accumulation in outrigger box Drain fuel water separator refer to page 4 10 TM5 3810 305 10 CAUTION If any gauge fails to operate shut engine off and notify mainte nance Failure to follow this procedure could cause damage to equipment Check instruments gauges and safety equipment using the following procedure Start engine Check to see if all gauges are operational 2 Check all lights warning horns mirrors and turn signals 3 Check all controls for proper operation Con trols should move smoothly without binding or excessive free play 4 Check transmission oil level refer to page 4 10 Check anti two block system refer to page 4 11 Check cable and related equipment refer to page 4 11 Lubricate rear axle pivot and axle lockout cylin ders Raise crane on outriggers before greasing refer to lubrication chart Appendix B Lubri
62. practice B c Rope slides over or against itself C d Flexing the rope exposes broken wires hidden in valleys between strands This is known as valley type fatigue breaks D Figure 4 51 Wearing of Wire Ropes Rope Inspection Summary Any wire rope that has broken wires deformed strands variations in diameter or any change from its normal appearance must be considered for replacement It is always better to replace a rope when there is any doubt concerning its condition or its ability to perform the required task The cost of wire rope replacement is quite insignificant when considered in terms of injuries to personnel the cost of down time or the cost of replacing broken structures 4 54 Wire rope inspection includes examination of basic items such as 1 Rope diameter reduction 2 Rope lay 3 External wear 4 Internal wear 5 Peening 6 Scrubbing 7 Corrosion 8 Broken wires Some sections of rope can breakup without any prior warning Already discussed in some detail as to cause and effect sections where this occurs are ordinarily found at the end fittings and at the point where the rope enters or leaves the sheave groove of boom hoists suspension systems or other semi operational systems Because of the working that takes place at these sections no appreciable wear or crown breaks will appear Under such an operation the core fails thereby allowing the strands to notch adjacent strands
63. refer to Appendix B Diesel fuel and other combustible materials are used in the opera tion and maintenance of this equipment Do not smoke or allow open flames in areas where combustible materials are stored or used Failure to follow this procedure could cause DEATH or serious injury Fuel Water Separator Drain water from fuel water separator mounted on outer fuel filter Fuel Check fuel gauge Engine fuel should be adequate for sustained operations When adding fuel use ASTM NO 2 or 2D climatized Diesel Fuel ADD 1 QT E Figure 4 15 Engine Oil Level Air Cleaner With engine running check air cleaner restriction indicator located on outside of hood support assembly yellow is normal red requires service Reset indicator each time hood is opened by pushing the button on the bottom of the indicator If it does not reset notify mainte nance Tires Check for proper pressure before travel ing Tires should only be checked when cold refer to Recommended Tire Pressure Chart page 1 20 Check for severe cuts and foreign objects imbedded in tread Cable and Blocks Inspect hoist cable hoist block hook latch and boom attachment for readiness Boom Head Inspect cable retention pins and hair pin totters at boom head for correct installa tion CAUTION Keep tension on cable to prevent damage from slack Cable Reeve hoist cable as required Anti Two Block System Inspect anti two block
64. sound levels above 85 dB measured on the A scale for prolonged periods can result in permanent hearing loss In order to avoid hearing loss ear plugs or other suitable protective devices should be worn when working within the 85 dBA envelope 40 ft maximum from the nearest surface of the crane as shown on Figure 1 3 Sound levels in the operators cab can reach 87 dBA with the cab closed and therefore operators should wear hearing protection while operating the LRT 110 Crane 85 dB PROFILE RADIUS DIMENSIONS RIGHT SIDE 24 FT 7 3 M RIGHT REAR 32 FT 9 8 M RIGHT FRONT 10 FT 3 0 M FRONT 10 FT 3 0 M iya T 20 FT 6 1 M 25 FT 7 6 M 1 30 FT 9 1 M LEFT FRONT 12 FT 3 7 M 35 10 7 40 FT 12 2 LEFT SIDE 22 FT 6 7 M 45 FT 13 7 M LEFT REAR 40 FT 12 2 M Figure 1 3 Decibel Level Chart 85 dB Profile Weights Vehicle Weight Distribution Front Rear Total Hook Block One sheave Dimensions Winch Drum Diameter Drum Length Flange Diameter Cylinders Boom Extend Boom Hoist Section IV Equipment Specifications 10 760 Ib 4 881 kg 12 110 1b 5 493 kg 22 870 Ib 10 374 kg 235 Ib 107 kg 8 5 in 216 mm 12 25 in 311 mm 14 56 in 370 mm Bore 4 0 in 102 mm Stroke 168 in 4 27 m Rod 3 in 76 mm Bore 8 5 in 216 mm Stroke 39 3 in 998 mm Rod 3 in 76 mm TM5 3810 305 10 Type Il Diffe
65. switch found on boom head for damage Check for free movement of the counterweight attached to switch Be sure counterweight is secured around correct line of hoisting cable in proper manner Inspect all electrical connections and wires as well as the entire length of cable at tached to the cable reel and its connections for evidence of excessive wear damage or improper installation Check cable reel for proper tension and to insure that reel is free to rotate Verify visual and audible warning devices operation by lifting counterweight TM5 3810 305 10 CAUTION If disconnects malfunction and hook block is drawn into the boom point vehicle may be damaged Care should be taken when performing disconnect test NOTE A warning light will appear on anti two block panel and an audible signal will be heard if horn switch is in ON position The LRT 110 Crane is equipped with disconnects on control linkage A check of this system should be made prior to lifting Hoist hook block so that actual contact between block and anti two block counterweight is made If all functions are operating properly winch hoisting will cease and boom will not extend or lower Should any of these functions continue disconnects are not working and a complete system check must be made Boom retract boom raise and winch down functions remain active and will be unaf fected by anti two block system Brake Fluid Check reservoirs on front of dash F
66. to bending stresses or vibration If the diameter of the sheaves rollers or drum cannot be increased a more flexible rope should be used But if the rope in use is already of maximum flexibility the only remaining course that will help prolong its service life is to move the rope through the system by cutting off the dead end By moving the rope through the system the fatigued sections are moved to less fatiguing areas of the reeving This technique is most frequently used in rotary drilling Broken Wires The number of broken wires on the outside of a wire rope are considered an index of its general condition and whether or not it must be considered for replacement Frequent inspection will help determine the elapsed time between breaks Ropes should be replaced as soon as the wire breakage reaches the numbers given in Table 7 Such action must be taken without regard to the type of fracture On occasion a single wire will break shortly after installation However if no other wires Table 7 When to Replace Wire Rope Based on Number of Broken Wires Number Broken Wires In Running Ropes Number Broken Wires In Standing Ropes ANSI In One In One In One At End No Equipment Rope Lay Strand Rope Lay Connection B30 5 Crawler Locomotive amp Truck Cranes 6 3 3 2 4 48 break at that time there is no need for con cern On the other hand should more wires break the cause should be carefully investi gated On any in
67. up with the axis of the rope in lang lay rope the wires form an angle with the axis of the rope 4 28 This difference in appearance is a result of variations in manufacturing techniques regular lay ropes are made so that the direction of the wire lay in the strand is opposite to the direction of the strand lay in the rope lang lay ropes C and D are made with both strand lay and rope lay in the same direction Finally the last rope illustrated E called alternate lay consists of alternating regular and lang lay strands Wire rope nomenclature also defines length size i e diameter type direction of lay grade of rope type of core and whether it is preformed p f or non preformed rip f If the direction and type of lay are omitted from the rope de scription it is presumed to be a right regular lay In addition if no mention is made as to pre forming this will be presumed as a requirement for preforming On the other hand an order for elevator rope requires an explicit statement since p f and rip f ropes are used extensively An example of a complete description would appear thus 600 ft 3 4 in 6x25 FW Left lang lay Improved plow IWRC Rope described above would be made PRE FORMED There are four basic constructions around which standard wire ropes are built Figure 4 18 090 eg 6 CA d 6x21 SEALE 6x31 WARRINGTON WITH IWRC SEALE WITH IWRC LM 6x43 FILLER WIRE SEALE 6x46 SEALE FILL
68. 1 11 OO oo By 1 gt A 1 1 o9 CA 99 NIE 1 1 AR N Electrical System Emergency Load Lowering Procedure Attach Supply Hose Lower the Boom Lower the Crane off the Outriggers Lower the Load with the Winch Prepare the Equipment Retract the Boom Secure the Hook Block Swing the Crane Mechanically Emergency Window Removal End Fittings and or Attachments for Wire Rope Engine Oil Pressure Gauge Engine Oil Checks and Inspections Engine Temperature Gauge Engine Operating Starting Stopping Environmental Requirements Equipment Inspection Wire Rope Dimensions Load Rating on Outriggers Load Rating on Tires Maximum Permissible Hoist Line Load Chart Radius from Centerline of Rotation Chart Weights Working Area Diagram Extreme Heat Extreme Cold E n T CA I Oy In ON 4 22 2 A oo P ON AB ON NO BE I n A T T UM TI 1 N gt T 1 j pe m to XO Oo 07 SS d QN E Fire Extinguisher Flexibility of Wire Rope Forward Neutral Reverse Lever Fuel Gauge Fuel Checks and Inspections Fuel Water Separator Checks and Inspections G Gear Ranges General Theory of Operation General Cautions Dimensions Warnings Guidelines to
69. 1 TORQUE MULTIPLIER w reaction bar 3 4 drive 1 2 input SHORT EXTENSION 3 4 drive LONG EXTENSION 3 4 drive EXTENSION BAR 36 mm SOCKET TORQUE WRENCH 1 2 drive REDUCER 3 4 f to 1 2 m HAMMER TAPERED PUNCH PLIERS ROPE ADAPTER 1 2 f to 3 4 m WOODEN WEDGE BREAKER BAR 3 4 PLASTIC CAP 10 PLASTIC PLUG 10 PLASTIC CAP 12 PLASTIC PLUG 12 PLASTIC CAP 16 PLASTIC PLUG 16 BAG WRENCH PLATE PIN HAIR ALLEN WRENCH 6 mm TUBE USE Winch extension hoses 4 to 1 mechanical advantage for torquing swing bearing capscrews Use with torque multiplier Use with torque multiplier Use with breaker bar and torque wrench Swing bearing capscrews Torquing swing bearing capscrews Adapt extension to torque multiplier All purpose use All purpose use All purpose use Tether boom tip Adapt torque wrench to extensions Wedge winch cable Removing swing bearing capscrews Cap hoist connectors on manifold Plug hoist hoses Cap extend retract connectors on manifold Plug extend retract hoses Cap winch connectors on manifold Plug winch hoses Base plate protector Axle oscillation Hook block Secure extension bar to breaker bar torque wrench Anti two block counterweight Boom support assembly Also use the basic issue tools as required from pages 1 23 and 1 26 of this manual 5 45 TM5 3810 305 10 Section Transportability As required by the procurement specificatio
70. 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 Centimeters 2 540 Feet i 4L eet Gast ana 0 305 Yards sequ UA faces weeks Meters ce uad RET UN 0 914 Miles iv br ees 1 609 Square Inches Square Centimeters 6 451 Square Feet Square Meters 0 093 Square Yards Square Meters 0 836 Square Miles Square Kilometers 2 590 E Square Hectometers 0 405 Cubic Cubic Meters 0 028 Cubic Yards Cubic Meters 0 765 Fluid Milliliters uuuuuuuu 29 573 MSs oro dapat NEEDS EIS cea e aa 0 473 BIiS liters ra erg x ed 0 946 lll ege itu Ditet Sio eeina 3 785 O nce Sooden ee ee ta IQ I RN 28 349 Kilograms 0 454 Short
71. 10 Section Title Wedge Sockets Drums Plain Smooth Flexibility of Wire Rope Breaking in a New Wire Rope Wire Rope and Operation Inspection Guideline to Inspections and Reports for Equipment Wire Rope and Wire Rope Slings Wire Rope Inspection Illustrated Examples of Possible Wire Rope Damage Rope Inspection Summary Equipment Inspection Cable Lubrication VI Operation Under Emergency and Abnormal Conditions Emergency Load Lowering Procedure Unusual Operating Conditions Shutdown Vehicle Shutdown Procedures VIII Transportability 4 2 Land Transport Air Transport Rail Transport Marine Transportation TM5 3810 305 10 Section Use of Operator s Controls and Indicators Figure 4 1 Control and Instrument Identification The controls and instruments are illustrated from operator s view point with the machine in travel posi tion 4 3 TM5 3810 305 10 Controls and Instruments Figure 4 2 Dash Panel 1 Tachometer Hour Meter indicates engine rpm normal idle 800 rpm governed 2 950 rpm and operating hours of engine Figure 4 2 2 Dash Lights illuminate dash panel and side sloping dash panel 3 Rear Axle Centering Indicator light is off when axle is centered with wheels parallel to line of travel for two wheel steering Light is on when wheels are off center When light is off switch to two wheel steering Figure 4 2 4 Horn is activated when pushed and
72. 10 305 10 Check fuel in the fuel tank Check hydraulic oil level in the reservoir Check all hydraulic components and fittings for oil leaks Check batteries for electrolyte level and that all battery connections are tight and not corroded Check brake fluid in brake reservoir Lubricate the LRT 110 Crane according to the lubrication chart found in Appendix B up to and including the two weeks 80 to 100 hours Start the engine and check the gauges while running at low idle rpm When engine tempera ture reaches the operating temperature of 190 degrees F 88 degrees C increase the rpm and continue to monitor the gauges making sure everything is functioning properly Shut engine off If not already on the LRT 110 Crane install the cable hook block and anti two block counter weight according to the instructions found in Chapters 2 and 4 When all checks are com pleted and the LRT 110 Crane is reeved the operator should familiarize himself with the controls and operate the LRT 110 Crane at half throttle to gain experience A 2 Special Break in Requirements for New LRT 110 Cranes These requirements are to be performed after indicated hours of service 8 hours Torque wheel nuts to 450 to 500 lb ft 610 to 678 N m for a 2 week period 20 hours Drain change filter and refill the transmission with new fluid 40 hours Make an initial replacement of the hy draulic return line filter 100 hours Do the fo
73. 110 Crane is in motion Failure to follow this procedure could cause damage to equipment CAUTION Downshifts should not be made when vehicle speed exceeds maximum speed of next lower range Downshifting at exces sive speeds will overspeed drive train components and cause damage to drive shafts CAUTION Do not operate for extended periods with wide open throttle at speeds below minimums shown Failure to follow this procedure could cause damage to equipment CAUTION Under emergency or extreme traveling circumstances it is possible to stop the LRT 110 Crane with the parking brake However this results in rapid brake wear After stopping 3 or 4 times by this method parking brake adjustment should be made Failure to follow this procedure could cause damage to equipment CAUTION A dirty cab can result in damage to instruments and controls Always consider possible ob structions which may be encoun tered during swings when vary ing boom height or length Think swing through consider ing all obstacles before making swing Failure to follow this procedure could cause damage to equipment CAUTION Never hold controls in an acti vated position once hoist lower cylinder or extend retract cylin der has reached its limit of travel This can cause overheating of hydraulic oil CAUTION ALWAYS START AND STOP SWINGS GRADUALLY Stopping swing too abruptly will cause load to oscillate a
74. 2 09 m 8 ft 2 44 m 12 ft 4 9 in 3 78 m 13 ft 7 9 in 4 16 m Capacities Cooling System Fuel Crankcase Hydraulic System Hydraulic Oil Reservoir Transmission Capacity Refill Axle Hub es Differential Swing Reduction Unit Winch TM5 3810 305 10 28 qt 26 5 L 44 gal 166 5 L 11 qt 10 4 L 45 gal 170 3 L 23 8 gal 90 1 L 20 5 qt 19 41 12 qt 11 4L 3 qt 2 8 L 14 qt 13 2 L 3 qt 2 8 L 2 qt 1 9L TM5 3810 305 10 i hart N e Never lift or swing load directly over operator s compartment or over ground personnel in the work area Failure to follow this procedure could cause DEATH or serious injury All notes on the Capacity Chart must be treated as WARNING S Failure to follow these procedures could cause DEATH or serious injury NOTE The following is a direct copy of the notes on the Capacity Chart found on the machine For clari fication of the notes refer to GENERAL 1 Crane load ratings as determined by boom length radius and boom angle apply to this crane only as originally manufactured and equipped THEY ARE MAXIMUM LOAD RATINGS The crane and its load ratings are in accor dance with Power Crane and Shovel Associa tion Standard No 4 SAE Crane Load Stabil ity Test Code J 765a SAE Method of Test for Crane Structure J 1063 and Safety Code for Cranes Derricks and Hoists ANSI B30 5 1982 I
75. 3 TM5 3810 305 10 The size of the groove is not the only critical item to be examined closely The condition of the groove is also an important factor of concern Is it smooth or imprinted If the groove is imprinted then it must be re machined or if it is imprinted too deeply it means that sheave roller or drum must be replaced If replacement is indicated a larger sheave or drum should be installed if possible or a harder material should be specified for the replacement Groove examination should also concern itself with how the groove is wearing If it is worn off center thereby forcing the rope to undercut or to rub against the flange it then becomes necessary to correct the alignment of the reeving system and to specify a harder material When checking the grooves the bearings of the sheaves and rollers should also be examined They should turn easily If not each bearing must be properly lubricated Wobble in the sheave from broken or worn bearings is not acceptable Bad bearings will set up vibrations in the wire rope that can cause rapid deterioration unless the condition is remedied Bad bearings also increase the force on the rope that is needed to move a given load since friction forces will be greatly increased Sheaves with broken flanges may allow the rope to jump from the sheave and become fouled in the machinery When this happens the rope is cut curled and the crowns of the wires in the strands
76. 495 P N709 1270 78 retaining pin 96652 P N 1200 03125 02000 hosea assy 81495 P N 709 1270 142 hyd ram pump 19184 P N HP 121 DA TL adapter 57760 0203 4 6 hose assy 81495 P N 709 1272 18 pipe to tube elbow 81343 P N 6 4070202 pipe plug 81492 P N 1219 137 4 protective cap plug 23540 P N 249 2 special adapter 81495 709 4227 link 81495 P N 37881 engine cartridge 53203 P N 020030 105 106 105 106 105 106 TM5 3810 305 10 3 105 106 2 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 105 106 D 3 TM5 3810 305 10 Appendix D D 4 11 26 gt O 12 21 95 0 28 7U 0 TypellSectionalization Tool Kit Appendix D Basic Issue Items Crane Wheel Mounted Hydraulic NSN 3810 01 165 0647 Sectionalized Type 1 TM5 3810 305 10 Type II Basic Issue Items BII include the BII for the Type LRT 110 in addition to the below listed BII Illust No 1 20 21 NSN 4720 01 274 1841 A 9905 01 268 7581 B 9905 01 268 7582 5120 00 509 9092 5120 01 030 1187 5120 00 227 8079 5120 01 278 7281 5120 01 119 4806 5120 01 276 7016 5120 01 133 8880 5120 00 272 8985 5120 00 223 7396 4020 01 28 6173 5120 00 144 5207 5510 01 276 9242 8105 01 286 0935 5315 01 284 9813 3020 01 26l 6856 5365 01 276 7509
77. 5 3810 305 10 Figure 4 38 Installing the Wedge Sock et Figure 4 39 Clamping the Dead End of the Wire Rope 4 41 TM5 3810 305 10 Drums Plain Smooth Installation of a wire rope on a plain smooth face drum requires a great deal of care The starting position should be at the drum end so that each turn of the rope will wind tightly against the preceding turn Figure 4 40 Close supervision should be maintained all during installation This will insure the following 1 The rope will be properly attached to the drum 2 Appropriate tension will be maintained on the rope as it is wound on the drum L f UNDERWIND LEFT TO RIGHT USE LEFT LAY ROPE LEFT LAY UNDERWOUND START ROPE AT LEFT FLANGE OVERWIND LEFT TO RIGHT USE RIGHT LAY ROPE RIGHT LAY OVERWOUND USE RIGHT LAY ROPE 3 Each turn will be guided as close to the pre ceding turn as possible so that there are no gaps between turns 4 There will beat least two dead turns on the drum when the rope is fully unwound during normal operating cycles By holding the right or left hand with index finger extended palm up or palm down the proper procedure for installing left and right lay rope on a smooth drum can be easily determined OVERWIND RIGHT TO LEFT USE LEFT LAY ROPE LEFT LAY OVERWOUND START ROPE AT RIGHT FLANGE L UNDERWIND RIGHT TO LEFT i RIGHT LAY UNDERWOUND Figure 4 40 Drum Winding and Appropriate Hand Si
78. 6 or Commercial 309 782 0726 This technical manual is an authentication of the manufacturers commercial literature and does not conform with the format and content specified in AR 25 30 Military Publications This techni cal manual does however contain information that is essential to the operation and mainte nance of the equipment TABLE OF CONTENTS TM5 3810 305 10 Title Page CHAPTER 1 INTRODUCTION Section I Purpose and Function Section II Capabilities 1 5 Section III Performance Characteristics 1 5 Section IV Equipment Specifications 1 1 Section V Power and Utility Requirements Section VI Environmental Requirements 1 24 Section List of Items Furnished 1 24 Section VIII List of Items Required Section IX Storage Data 1 24 Section X Tools and Test Equipment Section XI Warranty Information 1 2 Section Safety Precautions CHAPTER 2 PREPARATION FOR USE GENERAL THEORY OF OPERATION CHAPTER 4 OPERATION INSTRUCTIONS AND FUNCTIONS Section I Use of Operator s Controls and Indicators 4 3 Section II Initial Adjustments and Control Settings Section Start up 4 17 Section Operation Under Normal Conditions Section V Wire Rope Instructions Section VI Operation Under Emergency or Abnormal Conditions 4 56 Section VII Shutdown 4 72 Section VIII Transportability CHAPTER 5 TYPE II SUPPLEMENT Section I Sectionalization Section II Transportability APPENDIX A EQUIPMENT PREPARATION APPENDIX B LUBRICATION INST
79. 7 mm 47 8 mm 25 4 mm 30 2 mm 28 7 mm 22 4 mm 48 5 mm 57 9 mm 292 mm 88 N m 34 kg 100 From the Crosby Group 4 38 NOTE Rope will stretch and shrink in diameter when loads are applied 4 Apply the initial load and retighten nuts to the recommended torque Inspect periodically and retighten A termination made in accordance with the above instructions and using the number of clips shown has an approximate 80 effi ciency rating This rating is based upon the catalog breaking strength of wire rope If a pulley is used in place of a thimble for turning back the rope add one additional clip NOTE The following information is based upon the use of U bolt clips on new rope The number of clips shown is based upon using right regular or lang lay wire rope 6x19 class or 6x37 class fibre core or IWRC IPS or XIPS If Scale construction or similar large outer wire type construction in the 6x19 class is to be used for sizes 1 in and larger add one additional clip The number of clips shown also applies to right regular lay wire rope 8x19 class fibre core IPS size 1 1 2 in and smaller and right regular lay wire rope 18x7 class fibre core IPS or XIPS sizes 1 3 4 and smaller For other classes of wire rope not mentioned above it may be necessary to add additional clips to the number shown If a greater number of clips are used than shown in the table the amount of rope turnback should be increased proportionat
80. 730 00 079 8814 straight adapter 90906 P N MS51500A6 83 105 106 1 8 to 6 9 5310 01 212 6134 plain nut 01276 P N 210292 45 105 106 1 4 10 4730 00 706 8711 tube reducer 01276 P N 221501 6 4S 105 106 1 6 to 4 11 4730 00 203 5266 pipe tee 01276 P N 2090 8 8S 105 106 1 8 12 4730 01 271 3751 tube plug ftg 01276 P N 900599 4 105 106 1 13 4730 01 247 2611 tube plug ftg 01276 900599 6S 105 106 1 6 14 5365 01 280 6488 machine plug 17335 P N 2408 10 105 106 1 o 15 4730 01 270 9651 tube plug ftg 57760 P N 03CP 12 105 106 3 2 16 coupling half 01276 P N FD 90 1021 04 04 105 106 2 20 21 22 23 24 25 20 27 28 29 30 31 32 33 34 35 36 4730 00 955 1559 4720 01 267 4258 4730 00 781 6089 5310 00 257 6177 4730 00 647 3311 4730 01 297 9072 5120 00 198 5409 5120 00 198 5392 4720 01 262 5215 5315 01 267 2927 4720 01 266 4240 4320 01 126 0014 4720 01 262 5211 4730 00 812 7999 4730 01 266 1369 5340 01 269 1701 2590 01 267 1359 3040 01 285 2914 2910 00 646 9727 straight adapter 96906 P N MS51500A6 6 to 4 hose assy 81495 709 1272 166 tube nipple 96906 P N MS51501A65 6 to 6 plain nut 01276 P N 210292 65 tube cap 87373 P N 306CP 12 12 straight adapter 57760 P N 0103 8 12 12 to 8 Socket key wrench 57719 P N ALW10 5 16 socket key wrench 16786 P N P848000210 5 32 hose assy 81
81. 8 rpm 10 000 Ib 4 536 kg 40 000 Ib 18 144 kg Flipper 7 in 178 mm lift on 12 00 x 22 5 14 PR standard tires D REMEDIUM CGU ND MN C D KE URN UU MC cT RR M M P M PH QH nr 1 8 TM5 3810 305 10 Extend Time per Outrigger Retract Time per Outrigger Construction Point Sheaves Retraction Base and Tip Sections Winch Maximum Line Speed NO LOAD Drum Capacity Rope Size Boom Cylinders NOTE All cylinders contain pilot check valves 4 50 sec 4 00 sec Standard two section 35 75 ft 10 90 m All welded box beam Cast ductile iron mounted on non friction bearings Two sheave boom head To 21 75 ft 6 63 m PCSA Standards 70 000 psi 483 N mm2 material First layer 177 ft 53 95 m per min Third layer 216 ft 65 84 m per min 350 ft 107 m Five layers 1 2 in 6 x 9 Independent Wire Rope Core IWRC Improved Plow Steel IPS Preformed Boom Hoist Time 28 5 sec Boom Down Time 25 3 sec Telescope Extend Time 27 2 sec Telescope Retract Time 22 7 sec Counterweight 1 9 TM5 3810 305 10 Decibel Level Chart Within the 85 dB envelope hearing protection is required Failure to follow this procedure could cause SERIOUS INJURY NOTE Radius dimensions illustrated in Decibel Level Chart are from center of rotation Points on the profile are from nearest surface of the crane Exposing the unprotected human ear to
82. Approximate Efficiencies are based on nominal strengths Method of attachment Wire Rope Socket Spelter or Resin Attachment Swagged Socket Mechanical Spliced Sleeve 1 in 25 40 mm Diameter and Smaller Loop or Thimble Splice Hand Spliced Tucked Carbon Steel Rope 1 2 in 12 70 mm Loop or Thimble Splice Hand Spliced Tucked Stainless Steel Rope 1 2 in 12 70 mm Wedge Sockets Depending on Design Clip s Number of Clips Varies with size of Rope IWRC Independent Wire Rope Core FC Fiber Core Socketinq Improperly attached wire rope terminals lead to serious or possibly unsafe conditions Failure to follow this procedure could cause DEATH or serious injury Efficiency Rope with IWRC Rope with FC 100 100 95 Not Established 95 92 5 86 86 76 75 95 75 95 80 80 Typical values when applied properly Refer to fittings manufacturers for exact values and method All wire rope elements must be held securely by the terminal If this is not accomplished the strands will loaf on the job and there is every likelihood that a strand will become high Figure 4 33 Selective abrasive wear of the loose strand will necessitate early removal of the rope 4 36 Figure 4 33 A High Strand To avoid many dangerous prac tices play it safe by following correct procedures Failure to follow these procedures could cause loads to fall c
83. BOOM Arm extended lingers closed thumb point ing upward SWING Arm extended paint with finger in direction ol swing of boom TRAVEL Both Tracks Use both fists in Iront of body making a circular motion about each other indicating direction ol travel forward backward land cranes only i RETRACT BOOM ing Boom One Hand Signal One tisi 0 tront of chest thumb pointing outward and heei of f st tapping ches 12400 292 4 27 TM5 3810 305 10 Section V Wire Rope Instructions Rope Identification and Construction Wire rope is identified not only by its component parts but also by its construction i e by the way the wires have been laid to form strands and by the way the strands have been laid around the core The following illustration is a comparison of typical wire rope lays Figure 4 17 2 Figure 4 17 a Right Regular Lay b Left Regular Lay Right Lang Lay d Left Lang Lay e Right Alternate Lay In illustrations A and C show strands as normally laid into the rope to the right in a fashion similar to the threading in a right hand bolt Conversely the left lay rope strands illustrations B and D are laid in the opposite direction Again in Figure 4 17 the first two illustrations A and B show regular lay ropes Following these are the types known as lang lay ropes Note that the wires in regular lay ropes appear to line
84. ER WITH FIBER CORE WIRE WITH IWRC Figure 4 18 Basic Design Construction TM5 3810 305 10 Illustrated below are a few combinations of basic design constructiohs Figure 4 19 Wire rope is iden tified by reference to its number of strands as well as the number and geometric arrangement of wires in the strand Figure 4 20 m iere en i ege 6x7 6x9 WARRINGTON 6X19 SEALE 6X25 FW Figure 4 19 Basic Constructions Figure 4 20 A Single Wire Rope Strand Table 1 Wire Rope Classification Based on the normal number of wires in each strand Classification Containing 6 strands that are made up of 3 through 14 wires of which no more than 9 are outside wires 6x7 6x19 Containing 6 strands that are made up of 15 through 26 wires of which no more than 12 are outside wires Containing 6 strands that are made up of 27 through 49 wires of which no more than 18 are outside wires 6X61 Containing 6 strands that are made up of 50 through 74 wires of which no more than 24 are outside wires 6x91 Containing 6 strands that are made up of 75 through 109 wires of which no more than 30 are outside wires 6x127 Containing 6 strands that are made up of 110 or more wires of which no more than 36 are outside wires 8x19 Containing 8 strands that are made up of 15 through 26 wires of which no more than 12 are outside wires 19x7 Containing 19 strands each strand is made up of 7 wires It is and manufactured by covering
85. Horizontal Re reeling 4 32 2 Method B Mount the reel on an unreeling stand Figure 4 24 It is then unwound in the same manner as described in Method A In this case however greater care must be exercised to keep the rope under tension sufficient to prevent the accumulation of slack a condition that will cause the rope to drop below the lower reel head 3 Method C Hold the end of the rope while the reel itself is rolled along the ground With this procedure the rope will pay off properly however the end being held will travel in the direction the reel is being rolled As the difference between the diameter of the reel head and the diameter of the wound rope increases the speed of travel will increase When re reeling wire rope from a horizontally supported reel to a drum it is preferable for the rope to travel from the top of the reel to the top of the drum Figure 4 25 Re reeling in this manner will avoid putting a reverse bend in the rope as it is being installed If a rope is installed inducing a reverse bend it may cause the rope to become livelier and consequently harder to handle When unwinding wire rope from a coil there are two suggested methods for carrying out this procedure in a proper manner 1 Method A Place the coil on a vertical unreel ing stand The stand consists of a base with a fixed vertical shaft On this shaft there is a swift consisting of a plate with inclined pins positioned so th
86. Inspections and Reports of Equipment Wire Rope and Wire Rope Slings Hand Signals for Crane Operation Heat Extreme Heater Shut Off Switch Helicopter Transport Type II High Humidity or Saltwater Hoist Line Load Chart Maximum Permissible Hoist Line Reeving Hook Block Hook Pintle Horn Hydraulic System PIS N BIN z T 1 1 1 1 NIN SILO I IR pH OIN Tn Nie Nyt EN R do lalelo N Hydraulic System Checks and Inspections Identification and Construction of Wire Rope Ignition Switch Initial Adjustments and Control Settings Inspection Summary of Wire Rope Inspection Cable Inspections Checks and Installing Cable on Winch Upperstructure on Carrier Wedge Socket on Cable Instrument Identification Control and Items Furnished List of Items Required List of Job Site Moving to a Land Transport Type I Land Transport Type II Leakage Checks and Inspections Lift Procedure on Outriggers on Tires Lift Preparing Upperstructure for Lifting Upperstructure onto Carrier TM5 3810 305 10 T E N oo A CA AI i ta Cc T E 1 o2 CA 1 1 Ye jD 1 oo 5 l N 1 QN P INDEX 3 TM5 3810 305 10 List of Items Furnished Boom Angle Boom Length Marke
87. LEASE LEVER PRESSURE HOSE HAND PUMP Figure 4 53 Quick Disconnect on Supply Hose 4 57 TM5 3810 305 10 Lower Load with Winch 8 Using a wrench on the swing box rotate up perstructure back to the travel position NOTE Retract Boom If there is no load on hook proceed to Retract Boom A WARNING 1 Bring hand pump pressure hose up to winch Never disconnect hydraulic lines and remove smallest cap on the connector tee or fittings before venting pres sure Turn dipstick cap 1 4 turn 2 Disconnect the brake hose from the tee in the to safety notch to relieve pres lowering port on the winch motor sure Failure to follow this procedure could cause SERIOUS 1 Turn dipstick 1 4 turn to safety notch to Entry of air into lowering port relieve pressure will cause winch motor to cavi tate The winch motor lowering port tee must be capped to pre vent load from free falling when hand pump pressure is applied 3 Failure to follow this procedure could cause DEATH or serious 2 Locate counterbalance valve on top of boom extend cylinder at base of boom Loosen jam nut on counterbalance valve ex tending up from valve block and turn the Ke adjusting screw in until it bottoms Figure 4 Hus 54 Keep track of number of turns required to bottom out screw 3 Install cap on winch motor lowering port tee 4 Connect connector tee to winch brake hose When working the hand pump clear all personnel from t
88. LLECTOR RING WIRE HARNESS TELESCOPE EXTEND HOSE TELESCOPE RETRACT HOSE BOOM HOIST LOWER HOSE i BOOM HOIST ROTARY mem RAISE HOSE MIS Mz Figure 5 19 Rotary Manifold Hoses TM5 3810 305 10 Preparation for Removing Upperstructure from Carrier 1 Swing mast and lifting arm around from beside cab and position it over lifting point of boom between toggle sheaves Figure 5 21 2 Start engine Lower hook block to ground and begin paying out cable to form slack from toggle sheaves up to clevis on lift arm Main tain tension on cable to prevent unspooling 3 Insert wedge block between winch cable and winch brace at counterweight Figure 5 6 Figure 5 6 Wedge Block in Winch Drum Figure 5 21 Positioning of Mast and Lifting Arm TM5 3810 305 10 4 Take loose sheave 14 Figure 5 22 that was removed from lift arm 16 in step 13 a of Preparation for Separating Upperstructure from Carrier and insert it in slack of cable 5 Raise sheave 14 and cable up into clevis on lift arm 16 and using sheave pin 13 install sheave 14 in place in clevis CAUTION Make sure three sheaves and cable are in alignment with boom Failure to follow this procedure could cause damage to equipment 6 Remove wedge block and raise hook block to boom head and draw cable tight Maintain tension on cable to prevent unspooling The tightened cable will help support boom and upperstructure whi
89. Lever Lift Procedure Load Chart Load Rating Performance Characteristics Switch Front Switch Rear Oversize Limits of Wire Rope Diameters EN e IB e TA oo 4 Pe N E A EN CA D in oo I s CA 1 1 CA js Nn CA T O2 Parking Brake Lever Parts Used for Assembly Removing and Stowing Parts Used for Separation Removing and Stowing Performance Characteristics Electrical System Engine Outriggers Torque Converter Transmission Pintle Hook Power and Utility Requirements Pre Move Check List Precautions Safety Preparation for Use Hoist Line Reeving Installing Cable on Winch Installing Wedge Socket on Cable Spooling Cable on Drums Preparation for and Assembly of Carrier and Upperstructure of Carrier for Transport for Removing Upper structure from Carrier for Separating Upper structure from Carrier of Upperstructure for Lift of New Crane for Operation Preventive Maintenance Checks and Services PMCS Purpose and Function General Major Component Nomenclature 1 1 oo gy tA N Jv N GEG ELSE voljo ES INE Ell oo SIEN e a 5 ae 1 bo AA two el B F3 1 O2 J A Ao R Radius from Centerline of Rotation Chart Rail Transport Type I Rail Transport Type 11 Rail Transport Ma
90. ON disconnect the driveshaft or to run engine will cause internal 1 Position the boom over the front in the travel position to prevent engagement of the rear axle lockout When attaching hook block to damage to the transmission as the hook block tieback take up cable vehicle is towed slowly while lowering boom to prevent damage to windshield 3 Disconnect the driveshaft by removing four capscrews and two caps Figure 5 43 The 2 Attach the hook block to the hook block driveshaft must be disconnected from the tieback with enough tension to take the slack front axle and secured to a frame cross out of cable member to prevent it from contacting the 5 46 rotating axle input yoke or ground while the vehicle is being towed The spider bearing caps must be taped or wired together to prevent them from falling off and being lost 4 Place the two wheel four wheel drive shift lever located at right of operator s seat in the two wheel drive position to prevent damage to the transmission during towing TM5 3810 305 10 CAUTION The tow bar MS500048 is the only tow bar to be used on this vehicle If not available see or ganizational maintenance Fail ure to follow this procedure could cause damage to equip ment 5 Attach tow bar to lugs on outrigger and to towing vehicle CENTERLINE OF ROTATION TIEDOWN LUGS 4 TOW LUGS 2 GVW 24 230 11 710 10 991 kg 5312 kg 97 00 in 2 46 m POINTS 4
91. Omit this step if temperature is above O degrees F 18 degrees C CAUTION Do not crank engine for periods longer than 30 seconds if tach ometer indicates less than 250 rpm and no longer than 1 minute if tachometer indicates over 250 rpm Failure to follow this pro cedure could cause damage to equipment d Pull cold start knob out and wait 3 to 5 seconds Turn ignition switch ON and press start button Then push cold start knob in while holding start button Hold accelerator pedal all the way down while cranking engine e Pull cold start knob out and wait 3 to 5 seconds for ether to fill charging valve f Push cold start knob in and wait 3 to 5 seconds for ether to spray into intake manifold Inject additional ether as necessary to attain and then maintain a minimum of 500 rpm ga h Continue to hold start button until tach ometer indicates 500 rpm or minute of time is reached i Check oil pressure gauge for 10 psi 69 kPa or higher at idle 720 to 880 rpm Operate engine at 1 000 to 1 500 rpm until engine temperature reaches 120 to 140 degrees F 49 to 60 degrees C NOTE Minor oil leakage of filters is normal and can be as much as 3 tablespoons per minute for the first 5 minutes of operation k Inspect engine oil filter and transmission oil filter for leaks There should be no leaks present after 5 minutes of operation Close engine hood l Attempt to move the LRT 110 Crane for ward
92. RUCTIONS Appendix C References Appendix D Components Of End Item and Basic Issue Item List Additional Authorization List Appendix F Operator Crew PMCS pm p i Kip N m ii TM5 3810 305 10 CHAPTER 1 INTRODUCTION The purpose of this chapter is to introduce the operator to the LRT 110 Crane functions capabilities performance data and specifications A special section on safe operation of the equipment is also in cluded at the end of the chapter Section Title Page I Purpose and Function 1 3 General Major Component Nomenclature II Capabilities Performance Characteristics General 1 5 Engine Electrical System 1 6 Transmission Torque Converter 1 7 Wheels Axles Brakes 1 7 Suspension Steering 1 7 Hydraulic System Swing System 1 8 Drawbar Pintle Hook Outriggers Boom Winch Boom Cylinders Counterweight 1 10 Decibel Level Chart IV Equipment Specifications Weights 1 11 Dimensions Capacities Capacity Chart Notes Load Ratings on Outriggers TM5 3810 305 10 Section 1 2 VIII IX XII Title Load Ratings on Tires Maximum Permissible Hoist Line Load Radius From Centerline of Rotation Working Area Diagram Power and Utility Requirements Environmental Requirements List of Items Furnished Hook Block Cable Boom Angle Indicator Boom Length Markers List of Items Required Storage Data Tools and Test Equipment Warranty Information Safety Precautions
93. TECHNICAL MANUAL OPERATOR S MANUAL FOR CRANE WHEEL MOUNTED HYDRAULIC LIGHT 7 1 2 TON ROUGH TERRAIN CRANE MODEL LRT 110 CONSISTS OF Type General Purpose 3810 01 165 0646 Type 11 Airborne Airmobile 3810 01 165 0647 This technical manual is an authentication of the manufacturers commercial literature and does not conform with the for mat and content specified in AR 25 30 Military Publications This technical manual does however contain available information that is essential to the operation and maintenance of the equipment Distribution Restriction Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY 9 AUGUST 1991 WARNING If NBC exposure is suspected all air filter me dia should be handled by personnel wearing protective equipment Consult your unit NBC Officer or NBC NCO for appropriate handling or disposal instructions WARNUNG IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PERSONNEL WEARING FULL NBC PROTECTIVE EQUIPMENT SEE OP ERATOR MAINTENANCE MANUAL 7690 01 114 3702 To order this NBC decal use National Stock Number NSN 7690 01 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 TM 5 3810 305 10 INSERT LATEST UPDATED PAGES WORK PACKAGES DESTROY SUPERSEDED DATA LIST OF EFFECTED PAGES WORK PACKAGES Note The portion of text or illustration effected b
94. The slave receptacle on side of battery compartment may be used for charging batteries or slave starting engine from an external power source Figure 4 58 Mx SLAVE RECEPTACLE Figure 4 58 Slave Receptacle If slave starting make sure when connecting slave start cables that ignition switch is OFF transmission is in neutral and parking brake is applied Connect external power source cable plug to slave receptacle The LRT 110 Crane is a 24 volt negative ground system CAUTION Do not crank engine for periods longer than 30 seconds if ta chometer indicates less than 250 rpm and no longer than 1 minute if tachometer indictes over 250 rpm Failure to follow this procedure could cause damage to equipment 4 68 Turn ignition switch ON and engage starter until engine starts After starting allow engine speed to return to idle for engine warm up and remove slave power cable connection Cold weather shutdown procedure Park the LRT 110 Crane on prepared surface if pos sible free of snow ice and water to prevent tires from freezing to surface Be sure slave receptacle is accessible Remove all ice and or snow accumulations from the vehicle and proceed as follows a Turn off all accessories 1 e heater fan etc b Check transmission fluid level c Check voltmeter If voltmeter reads below 24 volts indicating insufficient charge in battery for unassisted start notify organ izational mainten
95. _ affected personnel Do not engage starter motor for more than 30 seconds at a time eAdminister artificial Should engine fail to start within respiration if required 30 seconds allow starter motor to cool for 2 minutes before e Expose affected personnel to attempting to start engine again fresh air Failure to follow this procedure could cause damage to equip eKeep affected personnel warm ment eDo not permit physical 5 Push starter button to start engine Release exertion starter button as soon as engine starts If engine stalls during start up procedure allow eRefer to FM21 11 First Aid engine to stop revolving before re engaging For Soldiers for a more detailed starter description of treatment procedures 6 Move throttle back to idle as soon as engine starts Idle speed range is 720 to 880 rpm 7 With engine running check oil pressure gauge If gauge does not register minimum readings of 10 psi 69 kpa idle to 30 psi 207 kPa governed speed no load within 15 sec onds stop engine and refer to maintenance 4 17 TM5 3810 305 10 Section IV Operation Under Normal Conditions Operating the Engine When engine reaches operating temperature of 140 degrees F 60 degrees C operations may begin While engine is running check gauges at frequent intervals and be alert for any abnormal engine sounds or faulty engine performance NOTE Maintaining battery in a fully charged state is important for starting engine
96. acks takes place over an extended time This results from normal wear fatigue etc On b Hoist drum for wear or cracks the plotted curve stretch vs time this portion would almost be a horizontal c Structural members for cracks corrosion straight line inclined slightly upward from and distortion its initial level d For loose structural connections such as c Thereafter the stretch begins to increase at bolts rivets and weldments a quicker rate This means that the rope is reaching the point of rapid deterioration a Wire Rope Inspection result of prolonged subjection to abrasive wear fatigue etc This second upturn of The following is a fairly comprehensive listing of the curve is a warning indicating that the critical inspection factors It is not however rope should soon be removed presented as a substitute for an experienced inspector It is rather a user s guide to the ac ali cepted standards by which ropes must be judged E 5 hed LOIS BISG 1818 1 Abrasion abrades when it moves EL through an abrading medium or over drums w 9 and sheaves Most standards require that rope is to be removed if the outer wire wear 6 f ceeds 1 3 of the original outer wire diameter ej i This is not easy to determine and discovery Z relies upon the experience gained by the as inspector in measuring
97. al load and retighten nuts to the recommended torque Inspect periodically and retighten A termination made in accordance with the above instructions and using the number of clips shown has an approximate 80 effi ciency rating This rating is based upon the catalog breaking strength of wire rope If a pulley is used in place of a thimble for turning back the rope add one additional clip The number of clips shown is based upon using right regular or lang lay wire rope 6x19 class or 6x37 class fibre core or IWRC IPS or EIPS If Scale construction or similar large outer wire type construction in the 6x19 class is to be used for sizes 1 in and larger add one additional clip NOTE The following information is based upon the use of fist grip clips on new rope The number of clips shown also applies to right regular lay wire rope 8x19 class fibre core IPS sizes 1 1 2 in and smaller and right regular lay wire rope 18x7 class fibre core IPS or EIPS sizes 1 1 2 and smaller For other classes of wire rope not mentioned above it may be necessary to add additional clips to the number shown 4 40 If a greater number of clips are used than shown in the table the amount of rope turnback should be increased proportionately Wedge Sockets One of the more popular end attachments for wire rope is the wedge socket For field or on the job attachment it is easily installed and quickly dismantled Failure to inst
98. all wedge sockets in accordance with the following instructions could cause DEATH or serious injury The recommended method for the installation of wedge sockets is as follows 1 Inspect the wedge and socket All rough edges or burrs that might damage the rope should be removed 2 If the end of the rope is welded the welded end should be cut off This will allow the dis tortions of the rope strands caused by the sharp bend around the wedge to adjust themselves at the end of the line If the weld is not cut off the distortions will be forced up the working line This may result in the development of high strands and wavy rope 3 Place the socket in an upright position and bring the rope around in a large easy to handle loop Care must be taken to make certain that the live loaded side of the rope is in line with the ears Figure 4 38 Clamp the dead end close to the socket to prevent the rope and wedge from disengaging from the socket Failure to follow this procedure could cause DEATH or serious injury 4 Clamp the dead end of the rope Figure 4 39 2 refer to page 2 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 into position with tension sufficiently tight to hold them in place After final pin connections are made increase the loads gradually until the wedge is prop erly seated Avoid sudden shock loads TM
99. ance d Perform vehicle shutdown refer 4 71 e Drain water from fuel separator by open ing drain valve and pumping handle on lift pump Close drain valve when procedure is completed f Restart engine and check to insure all controls are properly positioned for starting Run engine for 3 to 5 minutes to charge battery g Turn ignition switch OFF and service vehicle Emergency Window Removal If it is necessary to rescue an operator that is trapped in the cab remove the front glass Using any available pointed object such as a knife screwdriver or stick pry out the seal lip of the weatherstripping Pry in under the glass to raise it so that it can be removed This same method can be used on any of the side or rear windows for emergency purposes An able and conscious operator can also exit the cab by placing his feet against the glass and with moderate force push the glass out of front or rear windows Extreme Heat Like extreme cold extreme heat requires that precautions be taken with respect to the cooling system battery and lubrication Protect the vehicle by performing the following recom mended procedures 1 Lubricate with correct lubricants High tem peratures necessitate the use of lubricants which are both higher in viscosity and resist deterioration at higher operating tempera tures Refer to the Lubrication section Appendix B and use the lubricants recom mended for the ex
100. and battery box lids shut 5 49 TM5 3810 305 10 Marine Transport Helicopter Transport For loading aboard ship the LRT 110 Crane may 1 The LRT 110 Crane must be sectionalized be sung in a horizontal attitude from lifting eyes in two sections according to the instructions on ends of outrigger boxes Figure5 46 shows found in Chapter 5 Section 1 slinging geometry indicating sling apex of the vehicle s center of gravity If provisions exist 2 Attach the slings to the lifting eyes provided the LRT 110 Crane may be driven aboard the on the outrigger beams of the carrier and on ship in a forward or backward direction Once the boom and upperstructure aboard the LRT 110 Crane may be maneuvered into tight quarters by using the crab steering ca pability Tie down the vehicle as required using tiedown lugs provided 3 After delivery reassemble the LRT 110 Crane following instructions found in Chap ter 5 Section I SLING APEX FOR Lit LING CRANE IN HORIZONTAL ATTITUDE N Af TRUE LENGTH OF FRONT LINES 122 in 3 10 m TRUE LENGTH OF FRONT LINES 122 in 3 10 m Ny 77 in 1 96 m _ 4 SLING POINT 4 TIEDOWN 4 GVW 24 230 Ib 10 991 kg TIEDOWN 6 Figure 5 46 Marine Transport 5 50 TM5 3810 305 10 APPENDIX A Preparation of a New LRT 110 Crane for Conduct the following checks before putting a new crane into operation Figure A 1 Engine Check the oil level coo
101. ank Add diesel fuel to bring level up to the 3 4 full mark NOTE Prior to air lifting carrier rear axle must be in locked position Start engine Rotate swing bearing 10 or more degrees from unlocked position refer to step 1 b Cam roller on valve must be out of notch on rotary manifold Shut engine off The vehicle is now sectionalized Preparation for and Assembly of Sectionalized LRT 110 Type Il Crane After External Air Tranport EAT Preparation for Assembly Carrier is to be positioned parallel to upperstruc ture on operator s right side with boom tip to rear and counterweight to front Front outrigger beam is to be positioned approximately even with upper hose clamp Figure 5 34 1 Install pads on outrigger beams a Remove two cotter pins 26 and rod 25 that stow pads on right side of boom Figure 5 33 Remove pads for installa tion and reinstall rod 25 and pins 26 on side of boom b Remove nuts washers and bolts from ends of outrigger beams and install pads Reinstall bolts washers and nuts to ends of outrigger beams Torque nuts to 240 Ib ft 325 N m Figure 5 33 Secure Pads on Boom 5 26 TM5 3810 305 10 2 Start engine Position carrier next to upper structure as follows a Extend outrigger beams and pads down close to ground HOSE CLAMP b Using swing lever rotate swing bearing to unlocked position with cam roller on axle lockout valve located at rear bottom
102. ank Engine Oil Pressure High or Low Engine Overheating Transmission Overheating Turn Signals Two Wheel Four Wheel Drive Lever u Unreeling and Uncoiling Wire Rope Unusual Conditions Time Intervals Upperstructure Completion of Assembly Installing on Carrier Lifting onto Carrier Preparing for Lift Use of Operator s Controls and Indicators Nn ah Nn rd a amp 1 EN QN 1 CA 1 OY Ov CA im E ON D T infi w T Em uo OO 1 o2 Cn CA 1 0 O2 l 09 N ER TM5 3810 305 10 Utility Requirements Power and V Vehicle Lights Switch Vehicle Shutdown Procedures Voltmeter Warnings General Warranty Information Wedge Socket on Cable Installing Wedge Sockets for Wire Rope Weights Equipment Specifications Wheels Winch Winch Lever Winch Theory of Operation Window Removal Emergency Windshield Wiper Switch Wire Rope Classifications Wire Rope Clips Fist Grip U Bolt Wire Rope Damage Illustrated Examples Wire Rope Identification and Construction Wire Rope Inspection for Abrasion Bird Caging Broken Wires Corrosion Damaged End Attachments Fatigue Failure Heat Damage Kinks Localized Conditions 1 2 m EN 1 1 AIO 1 1 NO T 5 ON o2 ARE CIPRO CA ON Co
103. appear grainy Tension Wire break reveals predominantly cup and cone fracture with some 45 degree shear breaks Abrasion Wire break mainly displays outer wires worn smooth to knife edge thinness Wire broken by abrasion in combination with another factor will show a combination break Cut or Gouged Wire ends are pinched down mashed and or or Rough Wire cut in a rough diagonal shear like manner Torsion or Wire ends show evidence of twist and or cork Twisting screw effect Mashing Wires are flattened and spread at broken ends Corrosion Wire surfaces are pitted with break showing evidence either of fatigue tension or abrasion Abrasion plus Fatigue Reduced cross section is broken off square thereby producing a chisel shape Reduced cross section is necked down as in a cup and cone configuration Tensile break Abrasion plus Tension Check for rope bent around too small a radius vibration or whipping wobbly sheaves rollers too small reverse bends bent shafts incorrect rope construction improper installation poor end attachments All running rope if left in service long enough will fail by fatigue Check for overloads sticky grabby clutches jerky conditions loose bearing on drum fast starts fast stops broken sheave flange wrong rope size and grade poor end attachments Check for too great a strain on rope after factors of deterioration have weakened it Check for change in rope or sheave size change in
104. at the coil may be placed over them The whole swift and coil then rotate as the rope is pulled off This method is particularly effective when the rope is to be wound on a drum TM5 3810 305 10 2 Method B the most common as well as the easiest uncoiling method Hold one end of the rope while rolling the coil along the ground like a hoop Figure 4 26 Incorrect methods of unreeling and uncoiling wire rope will most likely result in kinks 4 27 and 4 28 Such improper procedures should be strenuously avoided in order to prevent the occurrence of loops These loops when pulled taut will inevitably result in kinks No matter how a kink develops it will damage strands and wires and the kinked section must be cut out Proper and careful handling will keep the wire rope free from kinks Figure 4 26 ncoiling Wire Rope Figure 4 27 Incorrect Method of Unreeling Wire Rope Figure 4 28 ope 4 33 TM5 3810 305 10 Seizing Wire Rope While there are numerous ways to cut wire rope in every case certain precautions must be ob served Proper seizings are always applied on both sides of the place where the cut is to be made In a wire rope carelessly or inadequately seized ends may become distorted and flattened and the strands may loosen Subsequently when the rope is put to work there may be an uneven distribution of loads to the strands This condi tion will significantly shorten the life of the rope The
105. ausing DEATH or serious injury When preparing a wire rope for socketing it is of extreme importance to follow recommended procedures refer to page 4 40 Procedures other than those stipulated here may develop the required strength but this cannot be predeter mined without destructive tests It is far safer and ultimately less costly to follow well estab lished practices There are many ways to go wrong in socketing procedures Some of the more common PIT FALLS THAT SHOULD BE GUARDED AGAINST include 1 Turning back the strands inward or outward before the broom is inserted into the socket 2 Turning back the strands and seizing them to the body of the rope 3 Turning back the strands and tucking them into the body of the rope 4 Tying a knot in the rope 5 Driving nails spikes bolts and similar objects into the socket after the rope is in so as to jam it tight this is particularly dangerous and ruinous TM5 3810 305 10 Wire Rope Clips Wire rope clips are widely used for attaching wire rope to haulages mine cars and hoists and for joining two ropes Clips are available in two basic designs the U bolt and fist grip Figure 4 34 The efficiency of both types is the same FIST GRIP Figure 4 34 Basic Designs of Wire Rope Clips 4 37 TM5 3810 305 10 U Bolt Clips 2 Apply the next clip as near the loop as pos sible Turn nuts firmly but do not tighten Refer t
106. b Table 5 arid Figure 4 35 for specifica tions of U bolt clips 3 Space additional clips if required equally between the first two Turn nuts take up rope The recommended method of applying U bolt slack and tighten all nuts evenly on all clips to clips to get maximum holding power of the clip recommended torque Is as follows When using U bolt clips extreme care must be exercised to make certain that they are attached correctly Failure to follow this procedure could cause DEATH or serious injury Failure to make a termination in accordance with the following instructions or failure to periodically check and retighten to the recommended torque will cause a reduction in efficiency rating which could cause DEATH or serious injury RIGHT WAY FOR MAXIMUM ROPE STRENGTH 1 Turn back the specified amount of rope from the thimble Apply the first clip one base width from the dead end of the wire rope U bolt over dead end live end rests in clip saddle The U bolt must be applied so that the U section is in contact with the dead end of the rope Figure 4 36 Tighten nuts evenly to recommended torque WRONG WAY CLIPS REVERSED Figure 4 36 U bolt Clip Dimensions Table 5 U Bolt Clip Specifications Min Amount Clip no of of rope to Torque Weight Size A B D E F G H clips X tum back 1 2 in 0 50 in 1 88 in 1 00 in 1 19 in 1 13 in 0 88 in 1 91 in 2 28 in 3 11 5 in 65 lb ft 75 10 100 12
107. battery Increased evaporation rates will cause the battery electrolyte level to fall more rapidly during very hot weather Check the level frequently and add distilled water as required to maintain the proper level 4 Keep air circulation free Air circulation around the engine and battery must not be restricted Keep air intake and exhaust openings clear of leaves paper and other foreign matter which may restrict air flow Keep the engine clean of dirt grease and other substances which inhibit heat dissipa tion Use sound judgment in operating the engine Avoid the two extremes of racing and lug ging Advance the throttle only enough to handle the load yet be certain that the engine speed is high enough to maintain adequate fan speed for cooling Run the engine only when engaged in work operations or when traveling the vehicle Avoid prolonged periods at idling and shut the engine down if operations are interrupted Sandy or Dusty Work Sites The presence of large amounts of sand or dust at the work site can contribute to accelerated component wear Either substance will act as an abrasive when deposited on moving parts The problem is combated by more frequent lubrica tion and by the servicing of breathers and filters at shorter intervals Follow the recommendations below when operating in sand or dust on a regular basis 4 70 Check the filler caps filters breathers air cleaner and grease fittings Kee
108. bility for crane work Figure 4 6 4 5 TM5 3810 305 10 CAUTION Do not make directional changes between forward and reverse while vehicle is in motion Failure to follow this procedure could cause damage to equip ment 22 Forward Neutral Reverse Shift Lever selects direction of travel Must always be in neutral when starting engine and making crane lifts Figure 4 7 23 Transmission Speed Shift Lever has four transmission speeds from 1 thru 4 in either forward or reverse travel Start travel in Ist gear O BREAKERS i IN auT HEATER racen a Qv M Oye D AG AND EYA IA TWO sa Nm BLOCK 10 PEA TOTO w imi raog KOROKI a4 Figure 4 7 Right Hand 4 6 24 Two Wheel Four Wheel Drive Shift Lever selects drive mode two wheel drive for hard surface travel and four wheel drive for off road use It may be necessary to creep to get gears to align 25 Bubble Level indicates if vehicle is level prior to making a lift level is with bubble in center of circle 26 Circuit Breakers protect electrical circuits during minor electrical malfunctions Circuit breakers must be reset if tripped 27 Boom Hoist Lever raises or lowers boom pull to raise boom push to lower boom 4 8 28 Boom Telescope Lever extends or retracts boom push to extend boom pull to retract boom Figure 4 9 27 BOOM HOIST Fy MSS TELESCOPE
109. cate turntable gear and pinion gear teeth refer to lubrication chart Appendix B Weekly Check or Every 40 Hours of Service Perform the Daily Check Perform Daily and Weekly lubrication refer to lubrication chart TM5 3810 305 10 Battery gases can explode Do not smoke or allow sparks or open flames near batteries Wear safety glasses or goggles when checking the batteries Failure to follow this procedure could cause DEATH or serious injury Sulfuric acid contained in batteries can cause serious burns If battery corrosion or electrolyte makes contact take immediate action to stop the burning effects EYES Flush with cold water for no less than 15 minutes and seek medical attention immediately SKIN Flush with large amounts of cold water until all acid is removed Seek medical attention as required INTERNAL If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magnesia beaten egg or vegetable oil Seek medical attention immediately CLOTHING EQUIPMENT Wash area with large amounts of cold water Neutralize acid with baking soda or household ammo nia Failure to follow this procedure could cause DEATH or serious injury Check battery condition l Check electrolyte level Fill battery cells to 0 75 in 19 1 mm above the separator plates with distilled water 2 Check battery box It should be clean and dry with no signs of leakage from
110. ch Theory of Operation The winch is made up of four basic assemblies winch base hydraulic motor and brake valve brake cylinder and motor support and drum assembly The hydraulic motor turns the gears in the drum assembly working the cable The winch has a dual braking system a dynamic brake and a static brake These two types of brakes work together to control the speed of the drum assembly The dynamic brake uses hy draulic pressure to operate the brake valve which controls the flow of hydraulic oil to the hydraulic motor The static brake is made of multiple friction discs a brake clutch assembly and a hydraulic piston and cylinder The static brake is automatically applied unless it is released by brake valve pilot pressure at a level lower than that required to open the pilot operated spool valve Either brake system does not affect the winch during hoisting operations When the operator s control is placed in neutral rollers between the cam and outer race wedge to prevent the drum assembly from turning The brake valve stops oil flow from the hydraulic motor For lowering a load slowly the operator can allow only enough oil to release the brake without engaging the hy draulic motor The heat build up is dissipated by the hydraulic oil For faster lowering the hy draulic pressure is increased by the operator to both release the brake and engage the hydraulic motor TM5 3810 305 10 3 3 3 4 blank TM5 3810 305 10
111. ck BY PASS Switch allows an operator to override the anti two block system This then allows hook or block to be drawn closer to boom point It is recommended that the BY PASS switch be used only in cases of ex treme emergency The operator must exercise sound judgment 32 Diagnostic Connector Panel is located in rear of operator s cab to plug in Vehicle Test Module VTM to run STE ICE tests Fuel shut off switch is part of STE ICE system and always remains on unless it is used for STE ICE tests Figure 4 13 Panel also has lubrication fitting for turntable bearing For lubrication instructions refer to RESISTOR MODULE STE ICE DIAGNOSTIC TURNTABLE BEARING LUBE x F D Figure 4 13 Diagnostic Connector Panel 4 7 TM 5 3810 305 10 33 Speedometer indicates travel speed in mph and km h An audible warning will sound at 25 mph 40 km h Figure 4 14 Figure 4 14 Speedome ter 34 Accelerator Pedal increases fuel flow and engine speed CAUTION Do not attempt to move the vehicle with the parking brake engaged Failure to follow this procedure could cause damage to equipment 35 Parking Brake Lever activates parking brake push down to engage parking brake pull up to release Always engage parking brake before leaving vehicle Minor adjustments may be made by turning the knob on the end of the parking brake lever clockwise to tighten the brake When the parking brake is properly
112. could endanger your safety or could result in damage to equipment TM5 3 F 2 APPENDIX F 810 305 10 WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well ventilated area Avoid allowing solvent to contact skin eyes and clothes and do not breathe vapors Do not use near open flame or excessive heat If you become dizzy while using cleaning solvent get fresh air immediately and get medical aid If solvent comes in contact with skin or clothing wash with water If solvent gets in your eyes flush with water and get medical aid immediately Flash point of solvent is TISSE 59 Cs a Keep it clean Dirt grease oil debris only get in the way and may cover up a serious problem Clean as you work and as needed Use dry cleaning solvent P D 680 to clean metal surfaces Use soap and water when you clean rubber or plastic material b Bolts nuts and screws Check that they are not loose missing bent or broken You can t try them all with a tool or course but look for chipped paint bare metal or rust around bolt heads Tighten any bolt nut or screw that you find loose c Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to unit maintenance d Electric wires and connectors Look for cracked or broken insulation bare wires and lo
113. ction 111 Performance Characteristics General The following are performance specifications for the LRT 110 Crane Engine Type Cummins 4B3 9 Four cylinder Bore and Stroke 4 02 x 4 72 in 102 x 120mm Displacement 239 3 in 3 92 L Maximum Gross Horsepower 80 hp 60 kw at 2 800 rpm TM5 3810 305 10 Maximum Gross Torque 184 lb ft 249 N m at 2 800 rpm Net Power 60 hp 44 7 kw at 2 800 rpm Air Filter Dry type Electrical System Alternator 24 V 40 amp Battery 440 cold cranking amp at 24 V Transmission Type Funk Powershift Four speeds forward reverse Forward reverse lever Shift Controls Gear speed 1 thru 4 select lever Two four wheel drive select lever Gear Ranges 1 6 Forward Two or Four Wheel Drive Maximum Speed 3 3 mph 5 3 km h 6 2 mph 9 9 km h 11 4 mph 18 3 km h 22 0 mph 35 4 km h Maximum Tractive Effort 18 830 Ib 8 54 1 kg 9 930 Ib 4 504 kg 5 400 Ib 2 449 kg 2 900 16 1 315 kg Gradeability At Stall TM 5 3810 305 10 C 1 Torque Converter Type Wheels Type Tires Axles Type Brakes Type Suspension Type Driving Mode Steering Type Modes Turning Radius Single stage three element Free wheel stator Size 11 75 STR 29 Disc 8 25 x 22 5 210 x 572 mm 108 in wheelbase 2 743 mm 12 0x 22 5 14 PR Radial 115 psi 793 kPa pressure Soma planetary Model 3 Ratio total r
114. d with minimum parts of line required for the load being lifted 3 PART LINE MAX LOAD 15 000 LB Installing Wedge Socket on Cable CAUTION Be certain correct socket and wedge as supplied are used Failure to follow this procedure could cause damage to equip ment When installing wedge type sockets on cable use the following procedure 1 Lead cable through socket and forma large loop Draw cable end back through socket approximately 2 in 50 8 mm Figure 2 2 Figure 2 2 Cable Loop 2 Insert wedge and allow cable strands to adjust around it Figure 2 3 Inserted Wedge 3 Seat wedge and loop just tightly enough to allow handling by attaching socket to a strong support and engaging winch to take a strain on cable TM5 3810 305 10 4 Make lifts of gradually increased loads until wedge is finally seated Avoid imposing shock loading on cable until wedge is firmly in place 5 With no more than 2 in 50 8 mm of cable protruding clamp dead end of cable with a cable clamp Figure 2 4 Clamped Cable Spooling Cable on Drums Care must be exercised when installing cable on winch drum Improper spooling can result in cable damage through crushing kinking dog legs abrasion and cutting Poorly installed cable will also adversely affect operating characteris tics of machine by causing uneven application of force and motion This in turn can cause pre mature fatiguing and failure o
115. drum to perform each different craning application of this vehicle Provide for no less than three wraps of cable remaining on winch drum as specified in all applicable crane operating safety standards The increased possibility of inadequate wraps remaining on winch drum occurs when operating with a higher number of line parts than are required for load being lifted particularly at longer boom lengths and high boom angles Sufficient cable is initially provided to allow the hook block to reach ground level when reeved for the required parts of line indicated on the Capacity Chart for all given loads Reeving with more parts of line than required may result in all of the cable being payed off the winch drum CAUTION Keep tension on cable to prevent damage from slack 3 Raise boom to required angle consulting the boom angle indicator for the boom angle The boom elevation is controlled by a hand lever To LOWER boom push lever forward To RAISE boom pull lever back Improved control is obtained by operating engine at low speed while metering controls Always operate and release controls slowly to minimize dynamic effects of load During a lift where precise control of load is required do not attempt to use more than one function at a time Always use a qualified signalman and observe load while the equipment is in operation When spotting a load it may become necessary to alter the boom angle or length If
116. e MISCELLANEOUS Check for damage to the equipment and fluid leaks Class leak Damage causing the equipment to be inoperable WARNING Do not use high pressure steam on electrical components 27 VEHICLE Clean wash vehicle as required 28 6 EXHAUST SYSTEM Check muffler pipes clamps amp gaskets 29 FUEL WATER SEPERATER Drain fuel water seperator daily and check for contamination Drain Approx 1 pt oe PPP SEA F 8 Accelerator Pedal Air Cleaner Checks and Inspections Air Transport Type I Air Transport Type II Anti Two Block Panel Anti Two Block System Checks and Inspections Attachments for Wire Rope End Fittings and or Axle Theory of Operation Axles Boom Boom Angle Indicator Boom Angle Indicator Boom Cable Retention Pins Checks and Inspections Boom Cylinder Boom Hoist Lever Boom Length Markers Boom Telescope Lever Brake Fluid Checks and Inspections Brake Pedal Brakes Break In Requirements for New Cranes Breaking in New Wire Rope Bubble Level INDEX Cable Inspection Installing on Winch Items Furnished 4 7 Lubrication Specifications Spooling on Drums Capabilities Capacities Cautions General Centerline of Rotation Chart Radius from Characteristics Performance Check List Pre Move Im me E m Pad Sd Ba Checks and Inspections Air Cleaner Anti Two Block System Boom Pin Brake Fluid Cable 4 6 Cable and Blocks
117. e If not available see organizational maintenance Failure to follow this procedure could cause damage to equip ment CAUTION Be certain correct socket and wedge as supplied are used Failure to follow this procedure could cause damage to equip ment CAUTION Loops formed by overrun can cause kinks and dog legs in the cable resulting in damage and premature cable failure CAUTION Never use a steel hammer or pinch bar to move cable over on drum These tools can easily damage cable CAUTION If traveling more than five miles on improved roads or two miles on rough terrain or unimproved roads remove anti two block weight and chain from the switch and secure it to the anchor point of the wedge socket located either on the boom head or hook block whichever is accessible Failure to follow this procedure could cause damage to the hook block switch TM5 3810 305 10 Safety Decals Read and follow all safety decals Failure to follow this procedure could cause DEATH or serious injury ACAI TO PREVENT SERIOUS BODILY INJURY KEEP CAUTION HEARING PROTECTION REQUIRED AD ANGER WITHIN 40 OEATH OR INJURY CAN RESULT FROM CON TACTING ELECTRIC POWER LINES ALWAYS CONTACT THE ELECTRIC POWER LINE OWNER THE ELECTRIC POWER SHALL BE OISCONNECTED OR THE POWER LINES MOVED OR INSULATED BEFORE MACHINE OPERATIONS BEGIN Keep clear of Swinging upper to prevent serious bodily injury
118. e and impose side loads on boom This will cause damage to boom When ready try for a smooth controlled safe swing The swing should be SLOW Start SLOWLY and allow load to buildup just enough momentum to carry it through to the point where it is to be lowered Begin slowing swing in advance of point where load is to be lowered Slow swing GRADUALLY enabling it to coast to a stop over desired spot If properly executed load will hang motionless when swing is terminated If load is oscillating swing was made too rapidly and or stopped too abruptly 5 Extend boom to desired length refer to the Capacity Chart EXTEND boom by pushing extend retract lever forward and RETRACT by pulling lever back CAUTION Never pull to the side with a crane boom Crane booms are not designed for excessive side pull and may collapse if sub jected to excessive side loading 4 24 6 Lower hook block to load and fasten hook Make sure hook is properly engaged in slings or lifting device employed to make the lift Be certain hook latch is not supporting any of the load refer to warning decal on hook block Hoisting or lowering load with winch is con trolled by winch lever To LOWER load push lever forward To RAISE load pull lever back Improved control is obtained by operating engine at low speed while metering control Always actuate and release this lever slowly to minimize dynamic effects on load and to prevent bird
119. ed for use with some commonly used Wire ropes Table 3 Seizing Suggested Diameters and Lengths Rope Diameters Seizing Wire Diameters in mm in 3 8 9 1 6 9 5 14 3 0 048 Seizing Lengths mm in mm 1 2 0 5 13 Cutting Wire Rope Using an axe or hatchet to cut wire rope may be dangerous If necessary to use proceed with great caution Failure to follow this procedure could cause SERIOUS INJURY Portable hydraulic and mechanical rope cutters are available In remote areas however it may at times be necessary to use less desirable cutting methods Wire rope is cut after being properly seized Figure 4 3 1 Cutting is a reasonably simple operation provided appropriate tools are used There are several types of cutters and shears commercially available These are specifically designed to cut wire rope End Fittings and or Attachments There are many available designs of end fittings and attachments some of which were developed for particular applications The most common ones are illustrated in Figure 4 32 NONPREFORMED BEFORE CUTTING SEGUE GUESS s AFTER CUTTING PREFORME SAAT AA AAR RON AREAS AS NONENENENNNQNEN INE NOR RRN EN OREHUNEA WIRE ROPE SOCKET SPELTER OR RESIN Attachment WIRE ROPE SOCKET SWAGED LOOP OR THIMBLE SPLICE HAND TUCKED Figure 4 32 End Fittings and Attachments 4 35 TM5 3810 305 10 Table 4 Terminal Efficiencies
120. ed from material to personnel handling Inspection must include the boom and all mechanical and rigging equipment vital to the safety of work platform operation Before a work platform suspended from a load line may be used the following additional inspections must be performed Inspection of hook and wire rope Daily inspection of load line The anti two block device must be calibrated to sound a warning and deactivate the control function bringing about the two blocking condition whenever the hook block assembly platform or fall ball assembly is less than 3 ft 914 mm from the boom tip Inspect hook latches on fall ball assemblies and sheave block assemblies making certain they close and lock eliminating hook throat openings and are full load bearing hook latches with manual trigger releases As an alternative shackles with bolts nuts and retaining pins may be used Inspect wire rope ends making certain they are properly anchored to boom fall ball hook blocks and drums refer to page 2 3 e With the boom at maximum elevation and the work platform on the ground or at its lowest operational level inspect the hoist drum making certain at least three wraps of wire rope remain Make certain the minimum safety factors for wire rope are adhered to at all times Use 7 1 as the minimum safety factor for manufacturer s specified wire rope and 10 1 as the minimum safety factor for rotation resistant rope
121. eduction of 19 61 1 Hydraulically boosted hydraulic dual system with front to rear split Oscillating rear axle Automatic hydraulic lockout Two wheel rear drive for hard l surfaces at high speeds Four wheel drive for off road rough terrain Full fluid linked power steering Auxiliary steering pump driven by wheel rotation provides steering and braking during power loss Two wheel steering four wheel steering crab steering Two wheel 32 ft 2 in 9 80 m Four wheel 18 ft 4 in 5 59 m TM 5 3810 305 10 C 1 Hydraulic System Hydiaulic Pump Drive Steering Brake and Swing Circuit Winch Circuit Boom Hoist Telescope and Outiigger Circuit Hydraulic Valve Bank Hoist Telescope Swing Outrigger Winch Valve Oil Filtration Swing System Type Speed Drawbar Continuous Pull Pintle Hook Towing Capacity Outriggers Type One tandem hydraulic pump driven off transmission at 0 87 times engine rpm Pump 21 gal 79 5L per min operating at 2 440 rpm and 2 650 psi 18 272 kPa Priority flow 10 gal 37 8 L per min 2 500 psi 17 238 kPa 18 gal 68 1 L min operating at 2 440 rpm and 2 650 psi 18 272 kPa 21 gal 79 5 L per min operating at 2 440 rpm and 2 750 psi 18 961 kPa Foui spool two way valve Single spool two way valve Full flow system with 100 mesh 140 micron screen and 10 micron return filter Worn gear reduction unit powered by hydraulic motor No load 3 0
122. ely TM5 3810 305 10 Fist Grip Clips Failure to make a termination in accordance with the following instructions or failure to periodi tally check and retighten to the recommended torque will cause a reduction in efficiency rating which could cause DEATH or serious injury Refer td Figure 4 37 and Table 6l page 4 40 for specifications of fist grip clips The recommended method of applying fist grip clips is as follows 1 Turn back the specified amount of rope from the thimble Apply the first clip one base width from the dead end of the wire rope Tighten nuts evenly to recommended torque 2 Apply the next clip as near the loop as pos sible Turn nuts firmly but do not tighten 3 Space additional clips if required equally between the first two Turn nuts take up rope slack and tighten all nuts evenly on all clips to recommended torque Figure 4 37 Fist Grip Clip Dimensions 4 39 TM5 3810 305 10 Table 6 Fist Grip Clip Specifications Clip Size B C D E F l2in 0 5010 1 88 in 0 56 in 1 25 in 0 50 in 1 00 in 2 19 in 0 28 in 2 75 in 0 88 in 2 19 in 3 Min Amount L no of rope to Torque Weight H approx M N clips turn back 11 in 65 lb ft 60 10 100 12 7 mm 47 8 mm 14 2 mm 31 8 mm 12 7 mm 25 4 mm 55 6 mm 71 mm 69 9 mm 22 4 mm 55 6 mm 279 mm 88 N 27 kg 100 From the Crosby Group NOTE Rope will stretch and shrink in diameter when loads are applied 4 Apply the initi
123. ent damage to windshield Raise boom to a 50 degree elevation keeping hook block in vertical position Unhook hook block from storage bracket Lower boom to horizontal position while raising hook block Before making a LRT 110 Crane lift be sure hook is properly engaged with slings The lifting device should be employed to make lift Be certain hook latch is not supporting any of the load refer to the warning decal on the hook block 4 22 An operator must be guided by the Capacity Chart mounted on vehicle when considering load weights Rated loads must never be exceeded Failure to follow this procedure could cause DEATH or serious injury 2 Use the Capacity Chart attached to the LRT 110 Crane to interpret conditions and limita tions that exist when making a lift The deter mining factors are lifted load radius boom angle working position and hoist line reeving Use load ratings from the Capacity Chart at tached to the LRT 110 Crane when making all lifting calculations The intent of the following information is to prevent any possibility of either reverse winding of the rope on the winch drum causing breakage of winch cable or the unseating of cable from winch drum resulting in uncontrolled fall of the hook block and load Failure to follow this procedure could cause DEATH or serious injury Always consider anticipate and or determine by trial the maximum amount of cable that will be payed off the winch
124. er upperstructure Failure to follow this procedure could cause SERIOUS INJURY Vehicle must be level to prevent possible loss of control of upper structure when lifting off of ground DEATH or serious injury may result if upperstruc ture gets out of control Check that all pins and pin locks are installed and secured prop erly DEATH or serious injury may result if upperstructure comes loose Stay clear of hoisted upperstruc ture while it is being positioned over carrier Failure to follow this procedure could cause DEATH or serious injury Turn the face during the follow ing procedure to avoid having hydraulic oil splash in face or eyes Failure to follow this procedure could cause SERIOUS INJURY Weight of component is ap proximately XX Ib XX kg Use two people to properly support and lift component Failure to follow this procedure could cause DEATH or serious injury Unwarranted use of BY PASS switch can result in damage to the LRT 110 Crane and cause DEATH or serious injury Cooling system is pressurized Use extreme caution and proper protection when removing radiator cap after operating temperature is reached When removing cap loosen it slowly to the left then pause a moment Steam and hot gases will be escaping through the radiator cap avoid being burned by these gases Continue to turn cap until it can be removed Failure to follow this procedure could cause SERIOUS INJURY Battery ga
125. erneath right side extensions EXTENSION HOSES Figure 5 15 Quick Disconnect Fittings 5 11 TM5 3810 305 10 CAUTION DO NOT use a torque wrench for removal purposes Failure to follow this procedure could cause damage to equipment 17 Remove 10 upperstructure mounting cap screws and 20 washers from inside upper structure by using a 36 mm socket two adapters torque multiplier short and long ex tensions breaker bar and extension bar Figure 5 16 All these tools are found in tool box refer to Tools for Sectionalization page 5 45 Set mounting capscrews and washers aside where they will not be kicked off deck as they will be reinstalled shortly TOOLS REQUIRED BY TOOL NUMBER REFER TO PAGE 5 45 NIN N Figure 5 16 Tools Used for Remwal of Mountin aps crews 5 12 TM5 3810 305 10 18 With a 36 mm socket remove stop pin and lockwasher from torque arm bracket on side of rotary manifold Stem stop pin and lock washer in tool box 19 Disconnect wire harness Figure 5 17 con nected to electrical collector ring 20 Relieve pressure in extend retract valve circuit by turning ignition switch ON hold ing on anti two block BY PASS switch and operating boom telescope lever in both direc tions several times until pressure is released Turn ignition switch OFF and proceed as fol lows a Disconnect boom extend retract hose quick d
126. event damage to windshield b Raise boom to a 50 degree elevation keeping hook block in vertical position Unhook hook block from storage bracket Lower boom to horizontal position while raising hook block c Shut engine off 2 Remove anti two block counterweight as follows a Using 6 mm hex allen wrench open and split the anti two block counterweight hanging down from boom tip around hoist cable b Separate and remove counterweight halves from cable Using capscrews reassemble counterweight halves after removal c Remove counterweight from anti two block switch by removing thumbscrew from clevis holding chain to anti two block switch d Remove counterweight and chain Stow in tool box Reinstall clevis on anti two block switch with thumbscrew TM5 3810 305 10 ANTI TWO ANTETWO BLOCK SWITCH LOCK COUNTERWEIGHT 2 PART HOIST LINE HOOK BLOCK Figure 5 2 Anti Two Block Counterweight Switch and Hook Block 5 3 TM5 3810 305 10 Observe length of cable end protruding from cable socket and clamp If cable end extends more than 2 in 51 mm adjust cable so no more than 2 in 51 mm protrude Excessive cable protrusion can push cable out of socket when hook block is hoisted with plate to boom head Failure to follow this procedure could cause DEATH or serious injury NOTE When counterweight has been removed from anti block switch the switch is shut off and LRT 110 Crane control di
127. ever travel the LRT 110 Crane while a work platform is occupied e Make certain that no more than one crane function at a time is operated while the work platform is in use e Make certain personnel have radio or telephone communication with the crane operator at all times while the work platform is in use In the event of a communication failure per sonnel on the work platform must be returned to the ground immediately using hand signals No operations using a work platform are to performed without functioning communica tion equipment If other cranes or equipment are in the area of a work platform operation communication between all machine operators will also be maintained e Make certain work platforms are not used in winds on excess of 10 mph 16 km h rain snow ice sleet electrical storms or other adverse conditions Make certain personnel never stand on top rail midrail or toe board of work platform 1 46 e Make certain personnel keep all parts of the body tools and other equipment inside the work platform area during raising or lowering operations Before positioning a work platform make certain the vehicle is away from any overhead obstacles e Before a work platform is raised or lowered make certain all ropes electrical cords hoses etc are free from entanglement e After positioning a work platform make certain all locks are set before any work is performed e When off the gr
128. f cable 1 Inspect and clean winch thoroughly before proceeding with installation 2 Check lagging and drum flanges for cracks breaks and excessive wear 3 Check for deformed or outsized drum and excessive undercutting at base of flange These indicate that repair or replacement of drum is necessary 2 3 TM5 3810 305 10 4 After correcting any defects revealed by in spection and determining that the winch is in good operating condition spool cable refer to Chapter 4 Section V Wire Rope Instruc tions page 4 28 Place a pipe or bar through the reel center Mount the cable shipping reel with the bar horizontal on jacks or a suitable supporting Installing Cable on Winch Install cable on winch drum in accordance with the following procedure 1 Position cable over boom tip sheave and route back to winch drum 2 Position winch drum with cable anchor pocket on top structure Figure 2 5 3 Insert cable into small opening of cable 7 Draw the cable from the top of the reel in pocket Loop cable around clamp and back order to avoid reverse bending as it is spooled into pocket about 3 4 of the way through the onto the winch drum pocket Use cable clamp for 1 2 in cable refer to Koehring Commercial Parts Man ual Insert small end first Pull on cable and the clamp will slip into the pocket securing the cable Figure 2 5 Spooling Cable on Winch Drum CAUTION
129. fluid levels as required on your PMCS Class Ill leaks should be reported to your supervisor or unit maintenance Equipment is not ready available if any gasoline leak is present whether Class I Il or IIl eference AR 385 55 F 3 TM5 3810 305 10 APPENDIX F OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B BEFORE D DURING AFTER W WEEKLY M MONTHLY EQUIPMENT IS NOT READY AVAILABLE IF INTERVAL ITEM TO BE INSPECTED A PROCEDURE FOR AND HAVE REPAIRED FILLED ADJUSTED AS NEEDED All Preventive Maintenance Checks and Services PMCS listed are based on DA PAM 750 40 Reliability Centered Maintenance ROM logic Perform WEEXLY as well as BEFORE PMCS if a You the assigned operator but have not operated the equipment since the previous week b You are operating the equipment for the first time During the warranty period vou must perform the PMCS in the i manufacturer s commercial manual in addition to this PMCS APPENDIX WARNING safety and the safety of others around you despends upon you good judgement and a thorough knowledge in the operation a ius Know the position and functions a all controls before ting to start operate the equipment TT ld 3 ve ily weekly lubrication in accordance with IAW the 1 ube chart APPENDIX C b When checking fluid levels insure the equipment is on a level surface fuel oil
130. follow these proce dures could cause DEATH serious injury Diesel fuel and other combustible materials are used in the opera tion and maintenance of this equipment Do not smoke or allow open flames in areas where combustible materials are stored or used Failure to follow this procedure could cause DEATH or serious injury No personnel are permitted on the deck while rotating upper structure Failure to follow this procedure could cause DEATH or serious injury Improperly attached wire rope terminals lead to serious or possibly unsafe conditions Failure to follow this procedure could cause DEATH or serious injury When using U bolt clips ex treme care must be exercised to make certain that they are at tached correctly Failure to follow this procedure could cause DEATH or serious injury A WARNING Failure to make a termination in accordance with the instructions or failure to periodically check and retighten to the recom mended torque will cause a reduction in efficiency rating which could cause DEATH or serious injury A WARNING Failure to install wedge sockets in accordance with the instruc tions could cause DEATH or serious injury Clamp the dead end close to the socket to prevent the rope and wedge from disengaging from the socket Failure to follow this procedure could cause DEATH or serious injury TM5 3810 305 10 During the execution of this procedure the danger exists of uncont
131. freeze damage if not kept fully charged Its electrolyte will freeze at a higher temperature than a fully charged battery Be certain battery is charging when engine is running Use an external charger to restore full charge when the vehicle is not being operated The battery can discharge if snow or ice short circuits the terminals Keep battery posts and cable connectors clean and dry Remove any corrosion with a solution of baking soda and water During extremely cold weather when the vehicle is to remain idle overnight or for any extended period it is advisable to remove and store battery in a heated area For cold start at 25 degrees F 32 degrees C the batteries have sufficient charge for only one start attempt TM5 3810 305 10 Idle vehicles must be properly stored refer to maintenance At the end of work period or whenever vehicle is to be left idle for ex tended periods park it on a wood concrete asphalt or mat surface This will prevent it from being frozen to the ground For cold weather starting use the cold start device Starting fluid is toxic and highly flammable Container is pressur ized to act as an expellent Do not heat container and do not discharge starting fluid in con fined areas or near an open flame Failure to follow this procedure could cause SEVERE INJURY It is recommended that the cold start device be used for starting the LRT 110 Crane in am bient temperatures below
132. ft arm is approximately 95 Ib 43 kg Use two people to properly support and lift the lift arm Failure to follow this procedure could cause DEATH or serious injury c Remove lift arm 16 and pins 17 and 18 from storage brackets Place pin 18 in tool box for future use d With sheave bracket 15 down connect lift arm 16 to base of mast 3 with pin 17 Figure 5 12 TM5 3810 305 10 e Using two pins 12 attach adjustable truss rod 11 to top of mast 3 and top of lift arm 16 The mast and arm assembly is now complete f Temporarily swing mast and arm assembly out of the way 14 Start engine Raise boom until a minimum boom angle of 45 degrees is observed on boom angle indicator 15 Shut engine off The crane winch is used to hoist and separate upperstructure from carrier Extension hoses are added to winch hydraulic circuit supplying power to winch to hoist upperstructure off carrier and lower it to ground The rotary manifold is located internally in center of upperstructure Access to rotary mani fold is through opening under boom and through cutout on sides of upperstructure Figure 5 12 Assembling the Mast 5 9 TM5 3810 305 10 16 Prepare crane winch for hoisting as follows right side of upperstructure and run in through hole to rotary manifold Reach in and release attaching disconnects on these hoses Never disconnect hydraulic lines or fittings before venting pres
133. gerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimum arbitrarily established in a table if at the same time other observa tions lead to an opposite conclusion Because criteria for removal are varied and because diameter in itself is a vague crite rion the table of minimum diameters has been deliberately omitted from this manual Corrosion Corrosion while difficult to evaluate is a more serious cause of degrada tion than abrasion Usually it signifies a lack of lubrication Corrosion will often occur internally before there is any visible external evidence on the rope surface Pitting of wires is a cause for immediate rope removal Not only does it attack the metal wires but it also prevents the rope s component parts from moving smoothly as it is flexed Usually a slight discoloration because of rusting merely indicates a need for lubrication Severe rusting on the other hand leads to premature fatigue failures in the wires neces sitating the rope s immediate removal from service When a rope shows more than one wire failure adjacent to a terminal fitting it should be removed immediately To retard corrosive deterioration the rope should be kept well lubricated In situations where extreme corrosive action can occur it may be necessary to use galvanized wire rope Kinks Kinks are permanent distortions caused by loops drawn too
134. gnals Flexibility of Wire Rope The term flexibility is frequently thought of as being synonymous with resistance to bending fatigue This is not true Flexibility refers to the capability of flexing or bending While a high degree of fatigue resistance may sometimes accompany the flexibility characteristic it does not necessarily follow that this is so A fiber core rope for example is more flexible than an IWRC rope Yet when the IWRC rope is bent around undersize sheaves at relatively high loads it will usually perform better than the more 4 42 flexible fiber core rope The reason for this lies in the ability of IWRC rope to retain its round ness and freedom of internal movement Under the same conditions a fiber core rope will flatten and inhibit free internal adjustment thereby leading to early failure As noted earlier a design choice is almost invariably the result of compromise Ultimately what is sought is an efficient economical solu tion hence whatever the compromise it must help achieve this goal Breaking in a New Wire Rope A new wire rope requires careful installation and close adherence to all the appropriate procedures previously noted After the rope has been in stalled and the ends secured in the correct man ner the mechanism should be started carefully and then permitted to run through a cycle of operation at very slow speed During this trial operation a very close watch should be kept on al
135. he area Failure to follow this procedure Figure 4 54 Holding Valve Adjusting Screw could cause DEATH or serious injury 4 Turn ignition switch ON and pull back on boom telescope lever until boom is fully re 5 Close pressure release lever on pump Pump tracted slowly until winch brake is released The load will lower slowly to the ground NOTE 6 With the load safely down open pressure If boom retracts proceed to step release lever on hand pump 12 7 Disconnect brake hose from connector tee and 5 Remove hose from retract port adapter on reattach to lowering port tee Install cap on control valve extend retract section first Gonfiector tee section from the left side refer to Figure 4 53 4 58 6 Take cap off largest adapter on connector tee and put it on valve adapter 7 Attach connector tee to the retract hose NOTE Another person is required in the cab to pull back on boom tele scope lever to open valve and allow oil to flow thru valve while pumping is taking place 8 Pull back on boom telescope lever EST BIB CH QUICK DISCONNECT RESERVOIR SUPPLY PORT 5 3810 305 10 9 Close pressure release lever on hand pump and pump until boom is fully retracted 10 When boom is retracted open pressure release lever on pump and disconnect con nector tee from retract hose 11 Connect retract hose to boom retract cylinder port adapter 12 Back out adjusting screw o
136. ight and reach of the crane and erect a suitable barricade around all power sources Warn all personnel in the work area of the power source and electrocution hazard If contact with a power source does occur DO NOT STEP OFF THE CRANE Stay on the vehicle until the power is turned off or the equipment is lowered and clear of the power source If fire or other conditions force the operator to leave the crane jump off and away keeping all parts of the body clear of the equipment Failure to follow these proce dures could cause DEATH or serious injury Keep all parts of body and tools away from moving cable Fail ure to follow this procedure could cause DEATH or serious injury In making lifts the operator must successfully coordinate several functions These include the boom raise lower boom extend retract load hoist flower and swing functions Although experienced operator tends to operate two or more of these functions simultaneously the lift procedure can be broken down into the following sequence of operations TM5 3810 305 10 The operator must exercise sound judgment in positioning outriggers The outriggers should not be set near holes on rocky ground or on extremely soft ground Setting outriggers in such locations may result in vehicle tipping causing DEATH or serious injury The LRT 110 Crane must be level prior to extending boom or lifting loads To achieve this condition outriggers
137. ill to FULL line on reservoirs Safety Equipment Check safety equipment including tall lights parking brake hazard warn ing devices and fire extinguisher Operator Observations As the operator it is your responsibility to observe and report any unusual sounds odors or other signs of abnormal performance that could indicate trouble ahead On a routine basis during the days operations the following items should be checked 4 11 TM5 3810 305 10 Visual inspection Check complete vehicle for any unusual condition 2 Check for any leaks or damage to the hydrau lic system 3 Check engine compartment for Tension and wear of belt level Air cleaner restriction indicator intake piping condition Muffler and exhaust pipe condition 4 Check dash gauges for proper operation 5 Check hydraulic reservoir dipstick level 6 Check crane boom for Wear damage to hook block Wear on cable retention pin at boom head Proper function of anti two block system Proper cable spooling on winch Wear of cylinder pin connections 7 Check tires axles and drive lines for wear or damage 8 Check cab for Properly functioning instruments Properly operating controls Clean windows Properly functioning safety equipment Properly working lights Cleanliness free of mud and debris Time Intervals Unusual Conditions The LRT 110 Crane will require ext
138. in 12 from adjustable truss rod c Remove plate 1 from top of hook block 11 at top of mast 3 and lower lift arm Figure 5 3 and stow in tool box 16 to deck Remove pin 12 from adjustable truss rod 11 and set adjustable d Shut engine off truss rod 11 aside temporarily Remove pin 17 from lift arm 16 at base of mast 3 Figure 5 42 b Remove lift arm 16 and stow in location B using one pin from tool box Install sheave 14 back in clevis on lift arm 16 with pin 13 Index sheave pin 13 and lock sheave bracket to side of lift arm 16 Figure 5 11 Figure 5 3 Preparation for Raising the Hook Block Figure 5 42 Disassembling the Mast 5 42 c Remove two truss rods 10 from mast 3 Figure 5 42 and stow two truss rods 10 and adjustable truss rod 11 Figure 5 11 in location A on upperstructure Weight of mast is approximately 98 lb 44 kg Use two people to properly support and lift the mast Failure to follow this procedure could cause DEATH or serious injury d Remove mast 3 Figure 5 42 and lay on deck Figure 5 11 Storage Locations A and B Figure 5 29 Support for Front of Boom TM5 3810 305 10 Disassemble and stow boom support that was removed in step 8 of Preparing the Upperstructure for Lift Remove two pins 2 and tube 24 Figure 5 29 and store in tool box Remove three remaining pins 23 that connect posts 19 20 and 22 to post 21
139. in the cable Refer to TM55 3810 165 14 Transportability Guidance for the Crane 7 5 Ton Rough Terrain Koehring Type 1 NSN 3810 01 165 0646 Type 2 NSN 3810 01 165 0467 and the shipping data plates for tiedown requirements LINK STORED IN TOOL BOX TIEDOWN AND SLING POINT SHIPPING CUBAGE 1767 cu ft 50 04 cu m OVERALL WIDTH 96 in 2 44 m Figure 4 61 Air Transport Tiedowns 4 74 Rail Transport Weight of hook block is approxi mately 235 Ib 107 kg Use ade quate lifting equipment and always properly support hook block Do not lift over personnel or let personnel walk underneath suspended load Failure to follow this procedure could cause DEATH or serious injury 1 Using hoist and sling remove the hook block from the cable Store it in the tool box and block it to prevent it from moving 2 Retract the boom and lower it over the front Wind the cable back on the winch drum and wire the socket down to prevent the cable from loosening on the winch drum 3 Install a 1 2 in 6x19 IWRC cable around the load sheave and the hook block tieback 4 Refer t TM55 3810 01 165 14 Transpor tability Guidance for the Crane 7 5 Ton Rough Terrain Koehring Type 1 NSN 3810 01 165 0646 Type 2 NSN 3810 01 165 0467 and the shipping data plates for tiedown requirements Place the fuel shut off on the rear wall of the cab in the off position Put the transmission shift lever in the center neutral
140. ined by the Capac ity Chart Failure to follow this procedure could cause damage to equipment 8 Swing and spot load over the location where it is to be placed When lowering light loads be sure to maintain sufficient cable tension preventing cable from becoming loose on cable drum Loose cable can slip and bind suddenly causing jerky lowering and shock loading of boom Loose wraps may form loops which can be overlaid when cable is wound onto winch drum These conditions may result in personal injury or property damage 9 Lower load and unfasten hook TM5 3810 305 10 CAUTION When attaching hook block to hook block tieback take up cable slowly while lowering boom to prevent damage to windshield 10 Center boom over cab and raise boom to a 50 degree angle Lower hook block down far enough to hook it into hook block tieback on front of the LRT 110 Crane Lower boom to travel position while taking up slack in cable Lift Procedure Tires CAUTION Insufficient tire pressure reduces the On Tires capacity Attempts to pick rated capacity without properly inflated tires may cause vehicle to tip and or result in damage to tires and rims following precautions are necessary to prevent a pendulum effect of a swinging load Failure to follow these precautions can result in vehicle tipping over Listed below are special precautions for On Tires lifts Load Ratings shown in the
141. ining Set Chemical Agent Identifi cation Simulants M72A2 TM 43 0001 26 1 Army Equipment Data Sheets Chemical Defense Equip ment Communications SB11 131 Vehicular Radio Sets and Authorized Installations TM 11 5820 498 12 Operator s and Organizational Maintenance Manual Radio Sets AN VRC 53 AN VRC 64 AN VRC 125 and AN GRC 160 TM 11 5820 498 12 HR Hand Receipt Manual Covering End ltem Components of End Item Basic Issue Items BII and Addi tional Authorization List AAL for Radio Sets AN VRC 53 AN VRC 64 AN GRC 125 and AN GRC 160 TM5 3810 305 10 APPENDIX D BASIC ISSUE ITEMS TYPE I TYPE II 20 19 18 13 16 32 29 2 por Persas i 33 TM5 3810 305 10 APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST Crane Wheel Mounted NSN 3810 01 165 0646 Non Sectionalized Type 1 amp 2 ILLUST NO NSN DESCRIPTION CAGEC and PART NO USABLE ON CODE 1 5120 01 145 7452 ratchet wrench 55719 P N R2428 105 106 1 3 4 X7 8 2 5120 00 277 8301 end wrench 55719 P N 52022 B 105 106 1 9 16 X5 8 3 wrench 55719 P N V02022 105 106 1 5X8 x 11 16 4 5120 00 240 5609 Open end wrench 19207 P N 11655789 4 105 106 1 3 4 X7 8 5 5120 00 264 3796 adj wrench 55719 P N DA212 105 106 1 12 6 5120 00 293 1289 socket wrench 09386 P N 18806 105 106 1 7 5120 00 266 1927 spanner wrench handle 03683 P N 17899 105 106 1 8 4
142. ion before loading to the center of the vertical hoist line or tackle with load applied 26 Freely Suspended Load Load hanging free with no direct external force applied except by the hoist rope 27 Side load Horizontal force applied to the lifted load either on the ground or in the air 28 Working Arc Areas measured in a circular arc around the centerline of rotation as shown on the working area diagram CLARIFICATIONS All notes on the Capacity Chart must be treated as WARNINGS Failure to follow these procedures could cause DEATH or serious injury NOTES 4 amp 8 The Service manual and Operator s manual are the same Operation manual Operator s manual refer to section XII NOTE 7 Consult this manual page 1 20 Load Ratings on Tires tire pressure must be maintained at 90 psi NOTES 5 8 amp 10 Consult Hoist Line Reeving refer td page 2 2 and Wire Rope Instructions refer to NOTE 13 The use of clamshells magnets or work platforms which are not provided with the ma chine is not permitted TM 5 3810 305 10 C 1 LOAD RATINGS ON OUTRIGGERS ON OUTRIGGERS BOOM LENGTH BOOM LENGTH 21 75 Ft 35 75 Ft Retracted Extended RADIUS FRONT RADIUS 15 000 12 as s000 15 000 65 15 000 15 0007 3 000 RINT DOT f Re 14 100 13 000 14 100 13 200 P20 105300 7 900 PT 1 38 7 700 5 400 O 6 300 4 500 5 700 4 000 30 1 19 TM 5
143. ion switch OFF 4 71 TM5 3810 305 10 Section VIII Transportability As required by the procurement specification provisions are included on the LRT 110 Crane for highway air marine and rail transportation Figure 4 60 illustrates the weight distribution and location of slinging eyes tiedown lugs and towing lugs Land Transport The LRT 110 Crane may be driven on public roads refer to Vehicular Operation page 4 18 Normal transport over highways should be accomplished by hauling on a flatbed truck or trailer LRT 110 Crane Towing Procedure for Emergency Recovery Only This towing procedure is to be used for emer gency recovery only such as a dead engine or any other breakdown unabling the LRT 110 crane to be moved under its own power Refer to of this manual for Emergency Load Lowering to return the LRT 110 Crane to a travel mode for towing purposes Do not tow the LRT 110 Crane in any convoy or troop move ment by this procedure For convoy or troop movement transport on a flatbed truck or trailer To prepare the vehicle for towing 1 Position the boom over the front in the travel position to prevent engagement of rear axle lockout CAUTION When attaching hook block to hook block tieback take up cable slowly while lowering boom to prevent damage to windshield 4 72 FRONT AXLE Figure 4 59 Driveshaft 2 Attach the hook block to the hook block tieback with enough tension
144. ipping damage Wire rope abuses during 6 Incorrect handling results indifferent types of shipment create serious problems Figure 4 damage to wire rope Figure 4 49 47 One of the more common causes is improper fastening of rope end to reel e g a Rope damaged by being rolled over some nailing through the rope end These illustra sharp object A tions show two acceptable methods b Damage resulting from bad drum winding Drum crushing is evidence of bad winding conditions C d Damage resulting from a deeply corru gated sheave D a One end of a wire noose holds the rope and the other end is secured to the reel A b The rope end is held in place by a J bolt or U bolt that is fixed to the reel B 5 High strand wire rope The excessive wear of a single strand is caused by improper sock eting Figure 4 48 Figure 4 48 High Strand Wire Rope 4 52 TM5 3810 305 10 7 There are different types of wire rope damage Figure 4 50 a Dog leg A b Popped core B c Bird caging C d Snagged strand wires D e Spiraling that is brought about when rope jumps from the sheave E f A tension break resulting from overload ing F Figure 4 50 Types of Wire Rove Damage TM5 3810 305 10 8 There are different types of wearing of wire rope Figure 4 5 1 a From excessive bending A b Localized wear brought about by poor cut off
145. is deacti vated when blackout lighting is used 5 Engine Water Temperature Gauge indicates engine coolant temperature temperature range is 140 to 220 degrees F 60 to 104 degrees C approximately 190 degrees F 88 degrees C is normal operating temperature 6 Engine Oil Pressure Gauge indicates engine oil pressure idle of 10 psi 69 kpa minimum to governed speed no load of 55 psi 379 kPa cold oil may read 90 psi 621 kPa 7 Fuel Gauge indicates amount of fuel in fuel tank 4 4 WORK LIGHTS Z0 LEFT OUTRIGGERS Rieng FRONT Arm fd Figure 4 3 Slide Sloping Dash Panel 8 Cold Start is recommended for ambient tem peratures below 32 degrees F O degrees C and required at 10 degrees F 12 degrees C and below 9 Transmission Temperature Gauge indicates oil temperature out of convertor normal range is 160 to 190 degrees F 71 to 88 degrees C cool down is required above 250 degrees F 121 degrees C 10 Voltmeter indicates battery condition 24 volts is normal indication 11 Ignition Switch turns electrical circuits ON and OFF and stops engine in the OFF position Figure 4 3 NOTE Starter will not activate unless transmission is in neutral 12 Starter Button starts engine 13 Windshield Wiper Switch has three posi tions OFF LO and HI 14 Work Light Switch turns three flood lights on and off and is deactivated when blackout lighting is used 15 Vehicle Light
146. isconnect port on top of hydraulic reservoir Remove 8 Repeat steps 5 thru 7 for each outrigger as cap and connect other end of emergency necessary return hose to outrigger extend hose 4 56 SINGLE RETURN HOSE EXTEND HOSES CS EMERGENCY RETURN HOSE PUMP SUPPLY HOSE PRESSURE HOSE Z DISCONNECT PORT am PRESSURE RELEASE LEVER E Figure 4 56 Lowering the LRT Crane off the Outriggers 4 62 TM5 3810 305 10 9 Remove pressure hose emergency return hose 11 Remove pin from pump handle and store in and pump supply hose replace caps and place tool box in tool box 12 Install pinion cover 7 deck plate 6 five washers 5 bolts 4 three washers 3 bolt 10 Connect outrigger hoses 2 and three nuts 1 Figure 4 52 Figure 4 52 Swing Drive Box 4 63 TM5 3810 305 10 Secure Hook Block 1 If cable and hook block are lying on the ground after completing these emergency pro cedures tighten cable and install wood block on winch to retain tension on cable Remove cable from hook block socket and secure cable to vehicle Weight of the hook block is approximately 235 Ib 107 kg Use adequate hoist and sling to lift hook block Do not lift over personnel or let personnel walk underneath suspended load Failure to follow this procedure could cause DEATH or serious injury 2 Using hoist and sling lift hook block to tool box for carrying purposes
147. isconnects from rotary manifold b Remove two plugs size 12 from tool box and plug hoses c Roll both hoses back to rear opening and hang the right extend hose over lip of s J COLLECTOR RING MEE HARNESS TELESCOPE 2 opening Hang left retract hose over right extend hose and under tab Figure 5 18 NOTE Make sure that all capscrews and stop pin are removed from inside upperstructure and wire harness is disconnected from electrical collector ring Start engine Lower hook block 12 in 305 mm from boom head and proceed as fol lows a Lower boom to horizontal position b Shut engine off Figure 5 18 Location of Boom Extend Retract Hoses After Dis connection EXTEND HOSE TELESCOPE RETRACT HOSE BOOM HOIST LOWER HOSE 5 13 TM5 3810 305 10 22 Relieve pressure in boom hoist circuit by turning ignition switch ON holding on anti two block BY PASS switch and operating boom hoist lever in both directions several times until pressure is released Turn ignition switch OFF and proceed as follows a Disconnect two boom hoist cylinder hoses Figure 5 19 from manifold Access is through cutout in front of upperstructure b After disconnecting pull hose ends out through front hole to keep them out of the way Remove two plugs size 10 from tool box and plug hose ends Figure 5 20 Figure 5 20 Location of Boom Hoist Cylinder Hoses After_ Disconnection CO
148. l working parts sheaves drums rollers to make certain that the rope runs freely and without any possible obstructions as it makes its way through the system If no problems appear in running the rope the next step should include several run throughs of the normal operational cycle under light load and at reduced speed This procedure allows the component parts of the new rope to make a gradual adjustment to the actual operation conditions Wire Rope and Operations Inspection To insure a high level of safety while keeping the annual cost of wire rope at a reasonably low level it is essential to maintain a well planned program of periodic inspection Frequently there are statutory and or regulatory agencies whose requirements must be adhered to but whether or not these exist in a given locale the wire rope user can be guided by the suggested procedures that follow Abrasion bending and crushing represent the ABC s of wire rope abuse and it is the primary goal of good inspection practice to discover such conditions early enough so that corrections can be made or ropes replaced safely and with mini mum effort When any degradation indicates a loss of original rope strength a decision must be made quickly as to allowing the rope to remain in service But such a decision can only be made by an experienced inspector And this determi nation will be based on TM5 3810 305 10 l Details of the equipment s operation Will
149. lant level and that all clamps on the air intake system are tight Check that all filters are installed Look for oil leaks around the engine Oil level is to be main tained between ADD and FULL as indicated on the dipstick Transmission Check transmission oil level dip stick Oil level is checked with the engine running at idle speed transmission in neutral and oil warm 160 to 190 degrees F 71 to 88 degrees C Oil should be at FULL line on dipstick AXLE ATTACHING BOLTS COOLANT LEVEL ENGINE OIL LEVEL ENGINE FUEL FILTERS DIFFERENTIAL TRANSMISSION OIL LEVEL FUEL PARKING TANK AXLE ATTACHING BOLTS Drive Shafts Visually check the connecting capscrews and drive shafts for damage Examine the parking brake disc and brake pack Check the function of the brake Axles Visually check all attaching bolts Check the differentials and hub drives for lubricant levels Visually check the steering cylinders and tie rods for damage Check to be sure the torque on all wheel nuts is 450 to 500 1b ft 610 to 678 N em Visually check tires for damage and verify tire pressure Tire pressure should be 90 psi 620 kPa Swing Gear Box Check lubricant level in the swing gear box Winch Check oil level and that the vent is free to open ENGINE OIL FILTER AIR INTAKE SYSTEM BATTERIES SWING GEAR BOX HYDRAULIC OIL LEVEL Figure A 1 Loaction of check Points TM5 38
150. le removing remaining capscrews 14 7 Shut engine off Figure 5 22 Lifting the Upperstructure 5 16 8 Remove 8 remaining mounting capscrews and 16 flat washers on outside of upperstructure using a 36 mm socket two adapters torque 25 multiplier short and long extensions breaker bar and extension bar TM5 3810 305 10 TOOLS REQUIRED BY TOOL NUMBER REFER TO PAGE 5 45 8 15 25 5 5 8 15 25 5 8 4 15 2 5 2 8 15 12 6 3 2 8 15 25 6 2 ia ae 8 4 15 2 5 2 8 15 2 5 2 8 15 25 5 6 oor Figure 5 23 Tools Used for Removal of Mounting Capscrews 5 17 TM5 3810 305 10 Removing Upperstructure from Carrier Alert all personnel that the upperstructure is to be lifted off the carrier Keep all uninvolved personnel clear of the vehicle while hoisting and removal are taking place Check all pin connections cable alignment and machine bubble level before pro ceeding with the lift Failure to follow this procedure could cause DEATH or serious injury 1 Remove tether rope from tool box and knot rope to boom head quick reeving pin 5 24 NOTE Two personnel are required on the deck next to upperstructure one on each side to observe up perstructure separation Another person is required on the ground to handle the tether rope 2 Start engine Hold on anti two block BY PASS switch and slowly hoi
151. line called for by the Capacity Chart Failure to follow this procedure could cause DEATH or serious injury Within the 85 dB envelope hearing protection is required Failure to follow this procedure could cause SERIOUS INJURY A WARNING All notes on the Capacity Chart must be treated as WARNINGS Failure to follow these proce dures could cause DEATH or serious injury When use of a work platform is least hazardous to personnel and is the only practical means of accomplishing a task make certain all personnel follow minimum safety procedures Failure to follow these proce dures could cause DEATH or serious injury Read and understand all safety precautions before attempting an operation using a work platform Failure to follow this procedure could cause DEATH or serious injury All safety procedures and criteria established are the MINIMUM requirements for use of a work platform on the LRT 110 Crane Applicable government and industry standards must also be adhered to Failure to follow this procedure could cause DEATH or serious injury Never use a work platform if inspection indicates a structural or mechanical fault of any kind Failure to follow this procedure could cause DEATH or serious injury No personnel are permitted on the work platform during the performance of any test Do not allow personnel on work plat form if any test procedure indi cates a malfunction in equip ment Failure to foll
152. llow this procedure could cause damage to equipment CAUTION Never operate engine with oil level below the ADD 1 QT mark or above the FULL mark Fail ure to follow this procedure could cause damage to equip ment CAUTION Keep tension on cable to prevent damage from slack TM5 3810 305 10 CAUTION If disconnect system malfunc tions and hook block is drawn into the boom point vehicle may be damaged Care should be taken when performing discon nect test CAUTION If any gauge fails to operate shut engine off and notify mainte nance Failure to follow this procedure could cause damage to equipment CAUTION Release starter button as soon as the engine starts If engine stalls during start up procedure allow engine to stop revolving before re engaging starter Failure to follow this procedure could cause damage to equipment CAUTION When operating on hard surfaces use two wheel drive only Fail ure to do so may result in severe drive line wind up and compo nent failure 1 37 TM5 3810 305 10 1 38 CAUTION Speed is not to exceed 25 mph 40 km h Failure to follow this procedure could cause damage to equipment CAUTION Traveling with high transmission temperature above 250 degrees F 121 degrees C can cause damage to vehicle Do not shut engine off when transmission is overheating CAUTION Never shift between forward and reverse while the LRT
153. llowing 1 Drain and change winch lubricant 2 Tighten the swing bearing capscrews The 18 capscrews in the outer race hold the upper structure to the bearing The 22 capscrews in the inner race hold the bearing to the carrier Torque all 40 capscrews to 722 lb ft 979 N m Torque winch base mounting cap screws to 249 Ib ft 338 N m Torque cap screws of counterweight to 845 Ib ft 1 146 TM5 3810 305 10 APPENDIX B Lubrication Instructions Oil levels are to be checked with the LRT 110 Crane parked on a level surface in transport posi tion Check while the oil is cold unless other wise specified On plug type check points the oil levels are to be at the bottom edge of the check port Over lubrication of nonsealed fittings will not harm the fittings or components Under lubrication will lead to a shorter lifetime On sealed U joints care must be exercised to prevent rupturing seals Fill only until expansion of the seals becomes visible Items not equipped with grease fittings such as linkages pins and levers should be lubricated with lubricating oil MIL L 2104 once a week Oil applied sparingly will provide the necessary lubrication and help prevent the formation of rust Grease fittings that are worn and will not hold the grease gun or those that have a stuck check ball must be replaced Where slide pads are used cycle the boom and relubricate to insure complete lubrication of the entire wear area
154. ltage 2 Engine Cranks But Does Not Start Problem a Out of fuel b STE ICE fuel switch OFF c Temperature below 32 degrees F O degrees C d No fuel at engine 3 Electrical Circuit Non Functional Problem a circuit breaker tripped b Lights will not come on c Low battery voltage below 22 V d High battery voltage above 29 5 V TM5 3810 305 10 Periodic testing of oil is the safest most accurate method of determining the condition of the oil An oil sample may be taken through the fitting on inlet end of the reservoir return filter Obtain hydraulic oil sample for analysis every 100 hours of service Remedy a Turn ON b Shift into neutral c Refer to maintenance d Refer to maintenance Remedy a Check guage and fill tank refer to page 4 10 b Turn ON c Use cold start assist d Check fuel solenoid wire connection If loose refer to maintenance Remedy a Check and reset b Check for blackout mode and correct c Increase engine speed and observe voltmeter If no response refer to main tenance d Refer to maintenance TM5 3810 305 10 4 Engine Overheating Problem Remedy a Low coolant level a Cool down and check radiator refer to b Broken fan belt b Refer to maintenance c Radiator fins plugged c Stop engine check and clean 5 Engine Oil Pressure Problem Remedy a Low below 10 psi 69 kPa a Stop engine check and add oil refer to b High above 90 psi 621 kpa b
155. ly actuated multiple disc clutches The clutches are power absorbing allowing shifts under full engine power in both forward and reverse The clutches are hydraulically controlled and spring released Hydraulic control makes the clutches self adjusting Each clutch is made of friction plates and polished steel reaction plates The transmission receives power from the engine through the torque converter The torque con verter is fluid driven creating a smooth and shock free drive Fluid drive also eliminates engine stalling and lugging when vehicle has a heavy load With light loads the torque con verter is able to transmit engine power directly to the transmission at most engine speeds with no torque multiplication This provides variable and automatic speed ratios reducing need for shifting gears Axle Theory of ration The front and rear axles have remote breathers to allow operation in up to 30 in 762 mm of water The rear axle has lockout cylinders to provide increased stability during hoisting Steering for each axle is enhanced by dual acting hydraulic cylinders which are tied together by a single tie rod which provides smooth sharp synchronized turning with minimum alignment and adjustment requirements The service brakes are shoe type hydraulic units and are part of the axle The front axle has a disc brake that can be used either as a parking brake or as an emer gency brake Each axle has its own differential Win
156. maximum lifting capacity optional four wheel drive outriggers for added stability during lifting operations and three different steering modes front wheel steering for normal driving crab steering for diagonal moves and four wheel steering for minimum radius turns Power originates from an in line four cylinder diesel engine mounted at the rear of the vehicle The transmission is mounted directly on the engine and is used to turn drive shafts and to power the tandem hydraulic pump One half of the tandem hydraulic pump supplies hydraulic pressure to the winch and the other half supplies hydraulic pressure to actuate the boom telescope cylinder boom hoist cylinder boom swing motor outrigger cylinders axle lockout cylinders and steering controls and to provide hydraulic assistance for the brake system The boom is a two section telescope type with a rotating boom support Two large diameter double acting hydraulic cylinders telescope and hoist the boom assembly The hydraulic swing motor and worm gear rotate the upperstructure The cable and hook block assembly are operated by the hydraulic winch The hydraulic and electrical systems on the upperstructure are con nected to the rest of the vehicle by the hydraulic rotary manifold and electrical collector ring Transmission Theory of Operation The transmission is capable of four speed shift ing in both forward and reverse Direction and speed are selected through hydraulical
157. mmand and Administrative Publications Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items The Army Maintenance Management System TAMMS Camouflage Operation and Maintenance of Army Materiel in Extreme Cold Weather 0 to 65 F TO 36 1 40 Vehicle Recovery Operations First Aid for Soldiers Visual Signals Basic Cold Weather Manual Northern Operations Desert Operations How to Fight Mountain Operations How to Flight Manuals Technical Procedures for Obstruction of Equipment to Prevent Enemy Use Training Management Skills Unit Development Utilization of Engineer Construction Equipment Volume A Earthmoving Compaction Grading and Ditching Equipment Deepwater Fording of Ordnance Materiel Painting Instructions for Field Use Manual for Tracked Combat Vehicle Driver Lubrication Order for Armored Combat Earthmover ACE 9 Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems Hand Receipt Manual Covering End hem Components of End Item COEI Basic Issue hems BII and Additional Authorization List AAL for Armored Combat Earthmover ACE M9 Transportability Guidance For The Crane 7 5 Ton Rough Terrain Koehring Type 1 NSN 3810 01 165 0646 Type 2 NSN 3810 001 165 0647 Warranty Technical Bulletin For Crane 7 5 Ton Rough Terrain Koehring Type 1 and 2 C 1 TM5 3810 305 10 APPENDIX C TM 9 6140 200 14 Operator s Organizati
158. mproperly operated or maintained equipment can be dangerous The operator and other personnel should read and fully understand the Operator s Manual furnished by the manu facturer before operating or maintaining this 1 16 machine Rules for safe operation of equip ment should be adhered to at all times If either manuals or lift chart are missing they should be ordered by machine serial number through the distributor Operators and supervisors must fully under stand Safety Standards for Mobile Hydraulic Cranes ANSI B30 5 or latest and be familiar with Federal State and local safety regula tions Consult section of Operator s and Service Manual for more exacting description of the use of this lift chart SET UP 5 Crane load ratings are based on the machine being leveled and standing on a firm uniform supporting surface Crane load ratings on outriggers are based on all outrigger beams fully extended and the tires raised free of the supporting surface Crane load ratings on tires depend on appro priate inflation pressure and tire conditions Caution must be exercised when increasing air pressure in tires Consult Operator s Manual for precautions Consult appropriate section of Operator s and Service Manual for more exact description of hoist line reeving The use of more parts of line than required by load may result in having insufficient rope to allow the hook block to reach the grou
159. n provisions are included on the LRT 110 Crane for land air marine and rail transportation Figure 5 44 illustrates the weight distribution and location of slinging eyes tiedown lugs and towing lugs Land Transport The LRT 110 Crane may be driven on public roads refer to Vehicular Operation 4 18 Normal land transport should be accomplished by hauling on a truck or trailer FRONT AXLE MARS LRT 110 Crane Towing Procedure for Emergency Recovery Only Figure 5 43 Drive Shaft CAUTION This towing procedure is to be used for emer gency recovery only such as a dead engine or If the LRT 110 Crane is to be any other breakdown unabling the LRT 110 Crane to be moved under its own power Refer to page 4 56 for Emergency Load Lowering to return the LRT 110 Crane to a travel mode for towing procedures Do not tow the LRT 110 Crane in any convoy or troop movement by this procedure For convoy or troop movement transport on a flatbed truck or trailer To prepare the vehicle for towing towed a distance of more than 1 mile 1 6 km and or at speeds greater than 3 mph 4 8 km h the front driveshaft must be dis connected from the front axle As an alternative to disconnect ing the driveshaft if engine is operable engine may be started and allowed to idle during the towing process This will circu late lubricant in the transmission lubricating the clutches during the towing operation Failure to CAUTI
160. n left side behind cab and the remaining one on right side of cab Install four pins 12 in connecting points Figure 5 114 5 Install lift arm 16 as follows a With lift arm 16 still in storage location B on right side of boom pull out sheave pin 13 and remove sheave 14 from sheave bracket 15 Figure 5 11 b Temporarily lay sheave 14 aside A WARNING Weight of the lift arm is approxi mately 95 lb 43 kg Use two people to properly support and lift the lift arm Failure to follow this procedure could cause DEATH or serious injury Figure 5 11A Installing the Truss Rods TM5 3810 305 10 Remove lift arm 16 and pins 17 and 18 from storage brackets Place pin 18 in tool box for future use With sheave bracket 15 down connect lift arm 16 to base of mast 3 with pin 17 Figure 5 12 NOTE Adjustable truss rod 11 has been permanently adjusted for the LRT 110 Crane and should never require adjustment Using two pins 12 attach adjustable truss rod 11 to top of lift arm 16 and then to top of mast 3 Mast and arm as sembly is now complete Swing assembly around and position over rear fender Figure 5 12 Assembling the Mast 5 31 TM5 3810 305 10 Preparing the Upperstructure for Lift 1 Remove wedge block from tool box and locate it near winch 2 Start engine Lower hook block to ground Pay out a loop of cable approximately 18
161. n extend cylinder counter balance valve to its exact original ad justment turns and tighten jam nut 13 Turn ignition switch OFF Q Ss BR BRAKE HOSE te BOOM RETRACT N 7 CYLINDER PORT BOANO o ore QN 1 RETRACT sl gt HOSE 9 S g LOWERING PORT LOWERING TEE PUMP SUPPLY HOSE CONNECTOR CJ 9 PRESSURE RELEASE oO o LEVER PRESSURE HOSE HAND PUMP Figure 4 53 Quick Disconnect on Supply Hose 4 59 TM5 3810 305 10 Lower Boom A WARNING A WARNING Everyone must be clear of the area before moving hoist control When lowering boom to a hori lever Failure to follow this zontal position work from side procedure could cause DEATH of upperstructure not under or serious injury boom Failure to follow this procedure could cause DEATH 3 Turn ignition switch ON Push forward on or serious injury boom hoist control lever in cab until boom is lowered to horizontal position 1 With 5 16 in hex allen wrench remove plug from the hold valve cartridge protruding up 4 Turn ignition switch OFF on bottom side of hoist cylinder Figure 4 55 5 Swing boom mechanically over one side refer to 2 With the same wrench back out internal plug counterclockwise until wire retaining ring 6 Tighten internal plug on hold valve cartridge stops it Do not force plug beyond this point until it bottoms out in the o
162. nd 10 Properly maintained wire rope is essential to safe crane operation Consult Operator s Manual for proper maintenance and inspec tion requirements 11 When spin resistant wire is used the allow able rope loading shall be the breaking strength divided by five 5 unless otherwise specified by wire rope manufacturer OPERATION 12 Crane load ratings must not be exceeded DO NOT ATTEMPT TO TIP THE MA CHINE TO DETERMINE ALLOWABLE LOADS 13 Crane load ratings are for lift crane service Applications for other than lift crane clam shell and magnet are permitted Due to significant variations in materials and appli cations consult factory for optimum capabil ity 14 Weight of hooks hook blocks slings and all other load handling devices must be consid ered part of the load to be handled and must be subtracted from the load ratings to obtain the allowable load to be lifted 15 Crane load ratings are based on freely sus pended loads SIDE LOAD ON BOOM OR JIB IS EXTREMELY DANGEROUS 16 Practical working loads depend on the sup porting surface wind velocity pendulum action jerking or sudden stopping of loads hazardous surroundings experience of per sonnel proper operation tire inflation tire condition traveling with loads multiple machine lifts proximity of electrical wires etc Appropriate reduction of load ratings must be made for these and any other condi tions which may affect practical
163. nd impose side loads on boom This will cause damage to boom CAUTION Never pull to the side with a crane boom Crane booms are not designed for excessive side pull and may collapse if sub jected to excessive side loading CAUTION Do not continue to pull block up after contact has been made with boom head This will result in damage to boom head and sheaves The cable may also be broken causing load to drop CAUTION When spotting load it may be necessary to alter boom length or boom angle In making these adjustments the operator must guard against exceeding rated load as determined by the Capac ity Chart Failure to follow this procedure could cause damage to equipment TM5 3810 305 10 CAUTION Insufficient tire pressure reduces the On Tires capacity At tempts to pick rated capacity without properly inflated tires may cause vehicle to tip and or result in damage to tires and rims CAUTION Traveling over uneven terrain with rear axle oscillation locked out can result in instability Excessive boom length can also cause instability depending on terrain and wind pressure Fail ure to follow this procedure could cause damage to equip ment CAUTION Never use a chromate base corrosion inhibitor when coolant contains ethylene glycol Use only nonchromate base inhib itors Chromate base inhibitors reacting with ethylene glycol can produce chromium hydroxide commonly known as g
164. o any new damage during operation 3 Monthly Inspections are recommended with a signed report by an authorized competent in spector The Monthly Reports should include inspection of the following a All functional operation mechanisms for excessive wear of components brake system parts and lubrication b Limit switches TM5 381 305 10 c Crane hooks for excess throat opening or 2 Rope stretch All ropes will stretch when twisting along with a visual for cracks loads are initially applied As rope deterio rates from wear fatigue etc excluding d Wire rope and reeving for conditions accidental damage continued application of causing possible removal a load of constant magnitude will produce varying amounts of rope stretch A stretch e Wire rope slings for excessive wear curve plotted for stretch vs time Figure 4 broken wires kinking twisting and me 41 displays three discrete phases chanical abuse a Initial stretch during the early beginning f All end connections such as hooks shack period of rope service caused by the rope les turnbuckles plate clamps sockets etc adjustments to operating conditions con for excessive wear and distortion structional stretch 4 An Annual Inspection with a signed report b Following break in there is a long period must be made for the following the greatest part of the rope s service life during which a slight increase in stretch a Crane hook for cr
165. o follow these procedures could cause SERIOUS INJURY Compressed air used for cleaning purposes must not exceed 30 psi 207 kPa Safety glasses must be used when cleaning parts Failure to follow this procedure could cause SERIOUS INJURY Before applying lubrication accumulations of dirt or other abrasive material should be removed from the rope Cleaning is accomplished with a stiff wire brush and dry cleaning solvent P D 680 and dried with compressed air Immediately after it is cleaned the rope should be lubricated When it is normal for the rope to operate in dirt rock or other abrasive material the lubricant should be selected with great care to make certain that it will penetrate and at the same time will not pick up any of the material through which the rope must be dragged As a general rule the most efficient and most economical means to do cable lubrication protection is by using some method or system that continuously applies the lubricant while the rope is in motion Many techniques are used including the continu ous bath dripping pouring swabbing painting and where circumstances dictate automatic sys tems can be used to apply lubricants either by a drip or pressure spray method Figure B 1 B 2 TM5 3810 305 10 The arrows in the illustration indicate the direction in which the rope is moving PAINTING PM o CN CONTINUOUS POURIING SWABBING DRIPPING 1 Methods of Appl
166. on To be distributed IAW DA Form 12 25 E Block No 5737 Operator s maintenance require ments for TM 5 3810 305 10 U S GOVERNMENT PRINTING OFFICE 1994 300 421 03207 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS WRENS WTH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADORESS THEN JOT DOWN THE Cdr 1st Inf Bn DOPE ABOUT IT ON THIS ATTN SP4 J Brown FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT Key West FL 33040 IN THE MAIL DATE SENT Date you send 2028 2 PUBLICATION NUMBER PUBLICATION DATE TITLE Operator s Organiza TM 10 3930 65 7 14 amp P Date of TM tional Direct Support General IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD DONE ABOUT IT Page l para 2 figure 6 the paragraph does not relate to the nomenclature Please correct this mistake PLN TED NAME G8ADE OR TITLE AND TELEPHONE NUMBER SIGN MERE SP4 J Brown AUTOVON 721 8331 Ter ome STOW DA ve 2028 2 Sa eee eo ens YOUR OUTFIT WANTS TO KNOW ABCUT YOUR 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY CF THIS ANC G vE 17 TO YOUR HEADQUARTERS RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG wry ms pusrication FROM PRINT YOUR UNIT S COMPLETE AOORESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT PUBLICATION DATE PUBLICATION TITLE Operator s Manual for Crane Whee Mounied Hydraulic Ligh
167. on of cable for use Title Page Hoist Line Reeving 2 2 Installing Wedge Socket On Cable 2 3 UM ie Spooling Cable On Drums Installing Cable On Winch P 2 1 TM5 3810 305 10 Hoist Line Reeving When reeving the machine in preparation for any job it should be kept in mind that hoisting and lowering speeds decrease as the number of parts of line increases For most efficient use of the LRT 110 Crane it is therefore desirable to use minimum required number of parts for lifting Never use less than the number of parts of line called for by the Capacity Chart Failure to follow this procedure could cause DEATH or serious injury To determine the number of parts needed refer to the Capacity Chart HOIST LINE ANTI TWO BLOCK SWITCH ANTI TWO BLOCK COUNTERWEIGHT 1 PART LINE MAX LOAD 2 PART LINE 6 000 LB MAX LOAD 12 0001 Figure 2 1 Hoist Line Reeving 2 2 1 Remove socket and wedge from cable and thread it through the hook block for 2 part and 3 part reeving 2 When required number of parts has been de termined reeve cable as shown 3 Attach a wedge type cable socket to cable dead end and secure it to either the boom head or hook block as required 4 Dead end cable on hook block for an odd number of line parts and on boom peak for an even number of parts The crane has sufficient cable provided to allow hook to reach ground level with any boom length and elevation when reeve
168. onal Direct Support and General Support Maintenance Manual for Lead Acid Storage Bat teries 4HN 24 V MS75047 1 2HN 12 V 6 TN 12 V TM 55 2350 262 14 Technical Manual Transportability Guidance Armored Combat Earthmover M9 Night Vision Equipment TM 11 5855 236 10 Operators Manual for Night Vision Goggles AN PVS 5 and AN PVS 5A TM 11 5855 238 10 HR Hand Receipt Manual Covering End ltem Components of End Item COElI Basic Issue Items BII and Addi tional Authorization List AAL for Night Vision Goggles AN PVS 5 and AN PVS 5A Chemical Biological and Nuclear EM 934 2 cds ted Puce eben NBC Protection EM 335 d eost rettet ed de NBC Decontamination EM 3 61 ete E Field Behavior of NBC Agents Including Smoke and Incendiaries 3 4899 CBR Decontamination Unit Level MCB Proficiency TM 3 4230 214 12 amp Operator s and Organizational Maintenance Manual Includ ing Repair Parts and Special Tools Lists Decontaminating Apparatus Portable DS2 1 1 2 Quart ABC M 11 TM 34240 280 10 Operators Manual Mask Chemical Biological Aircraft ABC M24 and Accessories Mask Chemical Biological Tank M25 and Accessories Mask Chemical Biological Tank M25A1 and Accessories TM 34240 282 L List of Applicable Publications LOAP 12 and 20 CFM Gas Particulate Filter Units TM 36910 227 10 Manual Tra
169. or other abrasive defects 3 Check sheaves and rollers to determine whether each turns freely and whether they are properly aligned with the travel of the rope All bearings must be in good operating condition and furnish adequate support to the sheaves and rollers Sheaves that are permit ted to wobble will create additional forces that accelerate the deterioration rate of the rope 4 If starter filler and riser strips on drums are used check their condition and location Should these be worn improperly located or badly designed they will cause poor winding dog legs and other line damage TM5 3810 305 10 Whenever possible follow the path that the rope will follow through a complete operating cycle Be on the lookout for spots on the equipment that have been worn bright or cut into by the rope as it moves through the system Ordinarily excessive abrasive wear on the rope can be eliminated at these points by means of some type of protector or roller Cable Lubrication Refer to page B 2 for complete information regarding lubrication of the cable 4 55 TM5 3810 305 10 Section VI Operation Under Emergency or Abnormal Conditions Emergency Load Lowering Procedure Swing the Boom Mechanically In the event that lowering a suspended load by l Remove three nuts 1 bolt 2 three washers the normal means is impossible due to engine 3 five bolts 4 washers 5 deck plate 6 failure pump failure or a h
170. ortable hydraulic and mechanical rope cutters are available In remote areas however it may at times be necessary to use less desirable cutting methods Incorrect cable type or size will not function properly and may be dangerous when used Failure to follow this procedure could cause DEATH or serious injury Make certain slings ties and hooks are of sufficient capacity properly set and secure before performing any lift operation Failure to follow this procedure could cause DEATH or serious injury Always use a qualified signalman and observe load while the equipment is in operation When spotting a load it may become necessary to alter the boom angle or length If adjustment is necessary consult the LRT 110 Capacity Chart before performing a lift Failure to follow this procedure could cause DEATH or serious injury Exhaust gases can produce symp toms of headache dizziness and loss of muscular control DEATH permanent brain dam age or other serious injury may be caused by exhaust gases TM5 3810 305 10 If exhaust gases or exposure symptoms are observed ventilate the area immediately and treat affected personnel Administer artificial respiration if required Expose affected personnel to fresh air Keep affected personnel warm Do not permit physical exertion e Refer to FM 21 11 First Aid For Soldiers for a more detailed description of treatment procedures Never operate equipmen
171. ose or broken connectors Report damaged or loose wiring to unit maintenance Hoses and fluid lines Look for wear damage and leaks Make sure clamps and fittings are tight Wet spots show leaks but a stain around a fitting or connector can also mean a leak If leakage comes from a loose fitting or connector tighten the fitting or connector If something is broken or worn out report it to unit maintenance f Vehicle must be on level ground in order to get correct fluid level measurement 9 It is necessary for you to know how fluid leaks affect the status of your equipment The following are definitions of the types classes of leakage you need to know to be able to determine the status of your equipment Learn and be familiar with them and REMEMBER when in doubt notify your supervisor Class I Seepage of fluid as indicated by wetness or discoloration not great enough to form drops Class II Leakage of fluid great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class APPENDIX F TM5 3810 305 10 III Leakage of fluid great enough to form drops and fall from the item being pheckediinsoected CAUTION operation is allowable with minor leakages Class or Il Of course consideration must be given to the fluid capacity in the item system being checked inspected hen operating with Class or Il leaks continue to check
172. ound make certain the work platform is secured before personnel enter or leave When working from a work platform belting off or otherwise attaching a work platform to an adjacent pole structure or other equipment shall not be permitted except when personnel are entering or leaving the work platform e Make certain all movement by personnel on a work platform is done in a slow and controlled manner e Make certain personnel on the work platform wear safety belts with lanyards attached to hook or shackle Lifting a work platform is a single crane operation Never use more than one crane to lift a work platform e Never use a work platform to lift an external load Never allow electrically con nected electrode holders to contact metal components of a work platform Electrode holder contact can cause burning and or melting of work platform suspen sion which could allow the work platform to fall Failure to follow this procedure could cause DEATH or serious injury If a welding operation is to be performed make certain electrode holders do not contact metal components of the work platform When the work platform is suspended from a load line a stabilizing tag line must be attached to the work platform and controlled to minimize any swaying motion TM5 3810 305 10 1 47 1 48 blank TM5 3810 305 10 CHAPTER 2 PREPARATION FOR USE The purpose of this chapter is to familiarize the operator with the preparati
173. out 3 ft 914 mm of cable Insert wedge block between winch cable and winch brace at counterweight side 9 Shut engine off Figure 5 7 Storage Location C 10 Install toggle sheave brackets on top of boom as follows a Remove two right side attaching links 4 and toggle sheave brackets 5 from storage location C Figure 5 7 on right front side of carrier frame b Remove two sheave pins 6 from toggle sheave brackets 5 c Attach two toggle sheave brackets 5 and attaching links 4 Figure 5 8 to studs on top of boom The cable should lay over two toggle sheave brackets 5 between ears Secure two attaching links 4 and toggle sheave brackets 5 with two lynch pins 7 tethered to attaching links 4 d Remove two sheaves 8 from tool box and install on toggle sheave brackets 5 with sheave pins 6 Make sure hex head of sheave pin 6 is aligned with key stock on toggle sheave bracket 5 CAUTION With anti two block safety feature not functional do not apply excessive line pull to cable This can cause serious damage to cable hook block boom head and winch e Start engine Hold on anti two block BY PASS switch Figure 5 9 f Maintain tension on cable and remove wedge block from winch drum Using winch control lever pull hook block and plate up to and in contact with boom head Stop as soon as contact is made TM5 3810 305 10 Figure 5 8 _Installing Sheaves
174. ow lift arm 16 as follows a Remove hoist line from lift arm 16 by re 5 22 moving pin 12 connecting adjustable truss rod 11 to top of mast 3 Figure 5 31 Figure 5 6 Weight of the lift arm is approxi mately 95 Ib 43 kg Use two people to properly support the lift arm Failure to follow this procedure could cause DEATH or serious injury Manually lower lift arm 16 down toward boom Remove sheave 14 from clevis on lift arm 16 This will leave the cable slack Remove adjustable truss rod 11 by re moving pin 12 from top of lift arm 16 Remove bottom pin 17 and lift arm 16 from mast 3 Figure 5 3 1 Restow in storage location B Figure 5 11 on right side of boom Figure 5 31_Assembling the Mast TM5 3810 305 10 f Install sheave 14 back in clevis on lift arm 16 Index sheave pin 13 and lock sheave bracket 15 to side of lift arm 16 g Maintain tension on cable and remove wooden wedge from winch drum h Start engine Hold on anti two block BY PASS switch and use winch to pull loose cable down snug against boom from boom head to winch Stop as soon as all slack is removed from cable i Shut engine off 5 Remove and stow mast 3 as follows a Remove two truss rods 10 from mast 3 Figure 5 11 Storage Locations A and B Figure 5 11A Stow truss rods 10 and adjustable truss rod 11 in storage loca tion A Figure 5 11
175. ow this procedure could cause DEATH or serious injury No operations with a work platform are authorized on tires Always make certain the LRT 110 Crane is on a stable surface with the outriggers fully extended Failure to follow this procedure could cause DEATH or serious injury TM5 3810 305 10 Never use a work platform near energized power lines or ground cables Failure to follow this procedure could cause DEATH or serious injury Never allow electrically con nected electrode holders to contact metal components of a work platform Electrode holder contact can cause burning and or melting of work platform suspen sion which could allow the work platform to fall Failure to follow this procedure could cause DEATH or serious injury Dry cleaning solvent P D 680 used to clean parts is toxic and flammable Use only in well ventilated areas and avoid con tact with eyes skin or clothing Wear the proper protective clothing and equipment goggles or safety glasses face shield and gloves Do not breath vapors Do not use near sparks or open flames and do not smoke while using it Failure to follow this procedure could cause DEATH or serious injury 1 35 TM5 3810 305 10 Compressed air used for cleaning purposes must not exceed 30 psi 207 kPa Safety glasses must be used when cleaning parts Failure to follow this procedure could cause DEATH or serious injury CAUTION Make sure three sheaves and
176. p sand and dust out of the hydraulic system by keeping the reservoir filler cap tight and servicing the hydraulic system filters frequently The fuel system should be kept free of sand and dust by keeping the tank filler cap tight and servicing the fuel filters frequently When lubricating thoroughly clean each grease fitting before attaching the grease gun Pump generous amounts of grease into all lubrication points using the fresh grease to pump out the old grease The increased frequency of lubrication and service noted above should be determined by observations made at work site Inspection will indicate how long it takes for lubricants breathers and filters to accumulate unacceptable amounts of sand or dust The frequency of lubrication and service should be adjusted accordingly The engine and air cleaner should also be serviced frequently to prevent sand and dust from entering the engine The engine oil and oil filter should be changed at shorter than normal intervals to insure a clean oil supply to the engine s moving parts Adequate ground bearing support must be provided for the outrig ger when operating on soft surface Be alert for signs of LRT 110 Crane movement during operations Failure to follow this procedure could cause DEATH or serious injury 2 Insure that the terrain is adequate to support the crane s weight High Humidity or Saltwater In some locations such as coastal areas the LRT 110 Crane may
177. pected temperatures TM5 3810 305 10 Crankcase oil is particularly important be cause it helps dissipate heat Check the oil level frequently and add oil as required to maintain the correct level Low oil will hinder heat dissipation The cooling system is pressur ized Use extreme caution and proper protection when removing radiator cap after operating tem perature is reached When removing cap loosen it slowly to the left then pause a moment Steam and hot gases will be escaping through the radiator cap avoid being burned by these gases Continue to turn cap until it can be removed Failure to follow this procedure could cause SERIOUS INJURY Prevent overheating To insure proper cool ant circulation drain and flush the cooling system Clean any foreign matter from the radiator cooling fins and core air passages Replace defective hoses and tighten hose clamps Eliminate any leaks detected and fill the system with a 5070 solution of ethylene glycol and water A corrosion inhibitor is also recommended Engine overheating due to loss of coolant will most often be corrected by SLOWLY replac ing the lost coolant with engine idling Water containing larger than normal concen trations of salt or minerals should not be used in the cooling system Salt will cause corro sion and mineral deposits will collect on the coolant passage walls Both processes inhibit proper cooling 4 69 TM5 3810 305 10 3 Check the
178. ra service and care when operated under unusual condi tions High or low temperatures long periods of hard use and continued use in sand water mud or snow will break down lubricants Add or change lubricant more often under these condi tions However during long periods when the LRT 110 Crane is not in use the service intervals can be lengthened Cable Inspection All cable in active service should be inspected DAILY along with spooling sheaves wedge sockets and any other cable fittings for damage A thorough cable inspection should be made WEEKLY by a competent inspector Refer to Section V Wire Rope Instructions 4 28 for guidelines covering inspection mainte nance repair and replacement of cable Incorrect cable type or size will not function properly and may be dangerous when used Failure to follow this procedure could cause DEATH or serious injury Before installing a new or replacement cable make certain cable is of the correct type and size Cable Specifications The LRT 110 Crane is equipped with 180 ft 54 86 m of 1 2 in diameter 6x19 IWRC IPS cable Preventive Maintenance Checks and Services PMC The following Preventive Maintenance Checks and Semites PMCS should be followed regu larly to maintain the LRT 110 Crane at peak operating condition Perform PMCS more often to compensate for continuous operation or under abnormal conditions i e extreme cold or heat exposure to moisture or salt
179. rake fluid only DOT 5 MIL B 46176 b Check brake pedal and brakes for proper operation WARNING Wear leather gloves when working with wire rope WIRE ROPE Check wire rope rope sockets and fittings for damage wear corrosion heat damage fatigue and lubrication Refer to the cammrcial operators manual for wire rope inspection Criteria stamdards and descriptions of wire rope damage WARNING Sheave edges may be sharp DO NOT touch the sheave edge Visually check sheaves SHEAVES AND HOOK BLOCK a Visually check sheaves for sharp edges and wear Sharp edges are evident when wire rope shows signs of cuts fraya or wear on the inside of the sheave groove b Check hook block for cracks damage Check safety latch for damage or missing hardware MCCESSORY ITEMS Check heater defroster fan windshield wipers horns and mirrors for damage cracks ard proper operation BODY CAB HOOD AND HULL ASSY a Check hood ferders deck glass and tool box for dame b Check operator s seat for tears M MONTHLY EQUIPMENT 1S NOT READY AVAILABLE IF Reservoirs below Min mark Brakes won t stop vehicle a Six 6 randanly distributed broken wires in one 1 rope lay or three 3 broken wires in 1 rope lay b Loss of 1 3 the Original diameter of Outside wires is detected C The rope is deter iorated from rust or Corrosion d There is severe kinking crushing or pirdcaging e E
180. ration of Remaining Parts Used in Assembly Suspension INDEX 6 EE O23 Ol gt gt gt UR D ERN PE l EE 1 AI un 1 N o2 N rai ir e Swing Gear Swing Lever Swing System Systems Electrical Hydraulic Swing T Tachometer Hour Meter Terminal Efficiencies Approximate for Wire Rope Test Equipment Tools and Time Intervals Unusual Conditions Tires Checks and Inspections Lift Procedure Load Chart Load Rating Tools and Test Equipment Torque Converter Towing Procedure for Emergency Recovery Only TypeI Towing Procedure for Emergency Recovery Only Type II Transmission Transmission Oil Checks and Inspections Transmission Speed Shift Lever Transmission Temperature Gauge Transmission Theory of Operation Transport Preparation of Carrier for Transportability Type I Air Transport A gt 1 1 1 1 1 1 oo cA fg DN 14 IS r3 UN vlla CA ION km Fe 1 CA T N ali 1 enc oN Hr D a A i5 R N N 4 1 Land Transport Marine Transport Rail Transport Towing Transportability Type II Air Transport Helicopter Transport Land Transport Marine Transport Rail Transport Towing Troubleshooting Operator Electrical Circuit Non Functional Engine Cranks but Does Not Start Engine Does Not Cr
181. re are two widely accepted methods of applying seizing l Method A Lay one end of the seizing wire in the groove between two strands wrap the other end tightly in a close helix over a position of the groove using a seizing iron a round bar 1 2 to 5 8 in diameter by 18 in long Figure 4 29 Both ends of the seizing wire should be twisted together tightly and with a finished appearance Seizing widths should not be less than the rope diameter 2 Method B The second of two accepted meth ods for placing seizing on wire rope is illus trated in Figure 4 30 The seizing itself should be a soft or annealed wire or strand The seizing wire diameter and the length of the seize will depend on the diameter of the wire rope But the length of the seizing should never be less than the diameter of the rope being seized For preformed ropes one seizing on each side of the cut is normally sufficient But for those that are not pre formed a minimum of two seizings is recom mended Figure 4 3 1 Seizings should be spaced six rope diameters apart 4 34 SSSSSSS a E um ERRASSE O Se FITTEST a_i mU Figure 4 29 Seizing Wire Rope Method A SS SEI AFTER CUTTING PREFORMED zi IRES Figure 4 31 SeizinG Applied Before Cutting ea AFTER CUTTING TM5 3810 305 10 Table 3 1151 seizing lengths and seizing wire diameters suggest
182. reen slime This substance reduces the heat transfer rate and can cause serious engine overheating CAUTION Water added to battery can freeze before it mixes with electrolyte During very cold weather add water to battery just prior to or during operation of vehicle If vehicle is not to be run connect an external charger to battery if adding water 1 39 TM5 3810 305 10 CAUTION BE ALERT FOR SIGNS OF PUMP CAVITATION The hydraulic oil provides lubrication for pumps When too heavy or stiff it will not flow fast enough to meet pump demand and a vacuum or cavitation will be created A screaming noise indicates inadequate pump lubrication and if allowed to continue for more than a short period will result in serious damage to pumps CAUTION If the LRT 110 Crane is to be towed a distance of more than 1 mile 1 6 km and or at speeds greater than 3 mph 4 8 km h the front driveshaft must be disconnected from the front axle As an alternative to disconnect ing the driveshaft if he engine is operable the engine may be started and allowed to idle during the towing process This will circulate lubricant in the trans mission lubricating the clutches during the towing operation Failure to disconnect the drive shaft or to run the engine will cause internal damage to the transmission as the vehicle is towed CAUTION The tow bar MS500048 is the only tow bar to be used on this vehicl
183. ren 11 710 Ib 5 312 kg 12 520 Ib 5 679 kg 24 230 Ib 10 991 kg TM5 3810 305 10 Outrigger Bore 5 0 in 127 mm Stroke 17 75 in 45 1 mm Rod 3 0 in 76 mm Figure 1 4 General Dimensions 1 12 10 11 NOTE TM5 3810 305 10 All dimensions assume boom fully retracted and crane equipped with standard tires Overall Length Centerline of Rotation to Boom End Boom End to Front of Carrier Tailswing Radius Centerline of Rotation to Boom Pivot Height of Cab Ground Clearance to Transmission Ground Clearance to Outrigger Box Centerline of Rotation to Centerline of Rear Axle Wheelbase Centerline of Front Outrigger Box to Centerline of Rear Outrigger Box Overall Length of Carrier 25 ft 8 16 in 7 83 m 17 ft 8 in 5 39 m 6 ft 6 5 in 1 99 m 7 ft 9 in 2 36 m 4 ft 8 5 in 1 44 m 6 ft 2 in 1 88 m 14 4 in 366 mm 15 in 38 1 mm 4 ft 2 9 in 1 29 m 9 ft 2 74 m 14 ft 4 in 4 37 m 19 ft 1 6 in 5 83 m TM5 3810 305 10 13 15 17 18 20 Overall Travel Width Overall Height Ground Clearance to Lowest Point of Axle Outrigger Extension Below Grade Track Width of Carrier Effective Width of Outriggers Overall Width Over Floats Figure 1 5 General Dimensions 8 ft 2 44 m 7 ft 8 5 in 2 35 m 14 in 356 mm 7 3 in 185 mm 6 ft 10 3 in
184. rier Failure to follow this procedure could cause DEATH or serious injury With one person handling the tether rope raise upperstructure high enough to check bottom of mounting base plate to see if it is clean Remove any foreign material that may have accumulated on mounting base plate Figure 5 24 Attached Tether Rope Figure 5 37 Boom Support Removal 5 33 TM5 3810 305 10 Two personnel are required on Keep hands and arms clear of all the deck next to the upperstruc pinch points while checking the ture one on each side to observe alignment of the upperstructure the upperstructure alignment and the carrier mounting surface Another person is required on the Failure to follow this procedure ground to handle the tether rope could cause SERIOUS INJURY 2 Continue to hoist assembly high enough to clear rotary manifold and electrical collector CAUTION ring cover 1 to 2 in 25 4 to 50 8 mm is sufficient Make sure the base plate opening clears the connections on the 3 By pushing on lift arm and pulling with tether ey Failure to rope manually swing upperstructure into proceda mounting position with boom pointing in a 10 damage to equipment o clock direction on left side of carrier 4 Slowly lower the upperstructure over rotary 5 38 manifold to within 0 5 in 13 mm of rotary manifold FRONT Figure 5 38 Installing Upperstructure Installing Upperstructure on Carrier
185. riginal position It cannot be removed because approximately Replace plug 0 5 in 13 mm of threads remain at stop 7 Swing boom mechanically over cab refer to page 4 56 PLUG WIRE RETAINING RING Figure 4 55 Internal Plug 4 60 Lower the LRT 110 Crane Off the Outriggers Never disconnect hydraulic lines or fittings before venting pres sure Turn dipstick cap 1 4 turn to safety notch to relieve pres sure Failure to follow this TM5 3810 305 10 Remove reducer 6 to 4 and cap 4 from connector tee on pressure hose Figure 4 56 Remove single return hose and adapter from tee and connect connector tee to tee Use reducer 6 to 4 and cap 4 to cap adapter on single return hose removed from tee in step 3 procedure could cause SERIOUS INJURY 1 Turn dipstick 1 4 turn to safety notch relieve pressure EXTEND SIN HOSE PRESSURE HOSE CONNECTOR f TEE cA Remove appropriate extend hose from outrig ger solenoid to GLE RETURN HOSE A EMERGENCY RETURN ma AT Ate PUMP SUPPLY HOSE Y DISCONNECT PORT PRESSURE RELEASE LEVER ane As S umm Figure 4 56 Lowering the LRT Crane off the Outriggers 4 61 TM5 3810 305 10 6 Remove plug and place elbow and female 7 Close pressure release lever on hand pump quick disconnect on one end of emergency Pump to retract outrigger to travel position return hose and connect hose to d
186. rine Transport Helicopter Transport n A oo 5 1 TM5 3810 305 10 Section Sectionalization The LRT 110 Type II Crane is equipped with a nents are stored on the LRT 110 Crane with sectionalization kit complete with all components pinned connections in storage locations A thru E and tools necessary to disassemble it into two Figure 5 1 All tools extension hoses and separate loads for transport and reassemble it on accessories required are stowed in carrier tool another site All of the sectionalization compo box on left side of vehicle TOOL BOX Figure 5 1 Storage Locations Preparation for and Sectionalization of the LRT 110 Type Il Crane for External Air Transport EAT Preparation for Separating Upperstruc ture from Carrier The LRT 110 Crane should be positioned on a suitable unobstructed location for disassembly procedure A WARNING Vehicle must be level to prevent possible loss of control of upper structure when lifting off of carrier DEATH or serious injury may result if upperstruc ture gets out of control 1 Start engine and with boom lowered over cab retracted and in travel position proceed as follows 5 2 a Set outriggers by extending beams and lowering outrigger pads to the ground Lift the LRT 110 Crane off ground and level it using bubble level on right side of console CAUTION When removing hook block from storage bracket pay out cable while raising boom to pr
187. rollably dropping a load Rotate the upperstructure to a safe position Failure to follow this procedure could cause DEATH or serious injury A WARNING Entry of air into lowering port will cause winch motor to cavi tate The winch motor lowering port tee must be capped to pre vent load from free falling when hand pump pressure is applied Failure to follow this procedure could cause DEATH or serious injury A WARNING When working the hand pump clear all personnel from the area Failure to follow this procedure could cause DEATH or serious injury When lowering boom to a hori zontal position work from side of upperstructure not under boom Failure to follow this procedure could cause DEATH or serious injury 1 33 TM5 3810 305 10 Everyone must be clear of the area before moving hoist control lever Failure to follow this procedure could cause DEATH or serious injury Starting fluid is toxic and highly flammable Container is pressur ized to act as an expellent Do not heat container and do not discharge starting fluid in con fined areas or near an open flame Failure to follow this procedure could cause SERIOUS INJURY Adequate ground bearing support must be provided for the outrig ger when operating on soft surface Be alert for signs of LRT 110 Crane movement during operations Failure to follow this procedure couild cause DEATH or serious injury Never use less than the number of parts of
188. rom 2 to 1 at 2 3 mph 3 5 km h 2 to 3 or from 3 to 2 at 3 6 mph 5 10 km h 3 to40 or from 4 to 3 at 6 11 mph 10 18 km h Use four wheel drive only when greater traction is necessary Four wheel drive engagement is accomplished by a mechanical coupling in transmission It may be necessary to creep to get gears to align CAUTION Under emergency or extreme traveling circumstances it is possible to stop the LRT 110 Crane with the parking brake However this results in rapid brake wear After stopping 3 or 4 times by this method parking brake adjustment should be made Failure to follow this procedure could cause damage to equipment Stopping the Engine Before stopping the engine perform the follow ing steps 4 20 1 Put transmission in neutral 2 Engage parking brake 3 Turn off accessories 4 Reduce engine speed 5 Turn ignition switch OFF CAUTION A dirty cab can result in damage to instruments and controls 6 Keep cab clean Lift procedure Outriggers Never allow boom or load to swing into power lines If the crane must be operated in the vi cinity of power lines follow these safety precautions Contact the power company and have all power lines and ground wires turned off Never allow any portion of the equipment including cable hook block lines and load closer to power lines than the distances shown on the Electrical Warning Danger Decal Know the maximum he
189. rs Cable Hook Block List of Items Required Load Chart on Outriggers on Tires Load Lowering Procedure Emergency Load Rating References Definition of Load Rating on Outriggers on Tires Lowering the LRT 110 Crane to the Ground Lubrication Chart Lubrication Instructions Lubrication Points Illustrated Lubrication Cable Lubrication Checks and Inspections Major Components Location Nomenclature Marine Transport Type I Marine Transport Type II Maximum Permissible Hoist Line Load Chart Minimum Safety Requirements for Work Platforms Suspended from Load Line or Rigidly Mounted on Boom Moving the LRT 110 Crane Before Moving to a Job Site INDEX 4 N JJ N ER 1 N Jp 1 N p ui NO fo ON elio 1 N c n iN Fl EE A iE w wo a AEE Un gt o2 m 59 _ I 0 UR 5 UR New Cranes Break In Requirements Nomenclature Major Component Operating Instructions and Functions Initial Adjustments and Control Settings Operation Under Emergency and Abnormal Conditions Operation Under Normal Conditions Shut Down start up Transportability Use of Operator s Controls and Indicators Operations Inspection Wire Rope and Operation Under Emergency and Abnormal Conditions Under Normal Conditions Operator Observations Operator Troubleshooting Outriggers Control
190. s sion temperature Normal operating temperature is 160 to 190 degrees F 71 to 88 degrees C CAUTION Traveling with high transmission temperature above 250 degrees F 121 degrees C can cause damage to vehicle Do not shut engine off when transmission is overheating If transmission temperature rises above 250 degrees F 121 degrees C while traveling the LRT 110 Crane must be stopped and allowed to cool Shift to neutral and run engine at 1 000 to 1 200 rpm The temperature should drop rapidly to 160 to 190 degrees F 71 to 88 degrees C If temperature does not drop trouble is indicated and should be determined before moving again Overheating generally occurs due to working in too high a gear ratio CAUTION Never shift between forward and reverse while the LRT 110 Crane is in motion Failure to follow this procedure could cause damage to equipment Downshifts should not be made when vehicle speed exceeds maximum speed of next lower range Downshifting at excessive speeds will overspeed drive train components and cause damage to drive shafts Full power shifts under load may be made with out endangering transmission or drive train components TM5 3810 305 10 CAUTION Do not operate for extended periods with wide open throttle at speeds below minimums shown Failure to follow this procedure could cause damage to equipment Upshifting and Downshifting Recommendations Shift from 1 to 2 or f
191. sconnect system has been deactivated Functions of raising winch and extending and lowering boom will not operate To use any of these functions for the following procedures turn on anti two block BY PASS switch This is to be done only as required 3 Prepare to raise hook block up to boom head by removing plate 1 Figure 5 3 from tool box and place over dead end bracket on top of hook block The LRT 110 Crane should be reeved with a two part line for this procedure 4 Start engine and swing upperstructure and boom around to right side of carrier to 2 o clock position 5 Shut engine off 5 4 Figure 5 3 Preparation for Raising the Hook Block TM5 3810 305 10 Weight of mast is approximately 98 Ib 44 kg Use two people to properly support and lift mast Failure to follow this procedure could cause DEATH or serious injury 6 Remove two pins 2 and mast 3 from stor age location D Figure 5 4 on left side of up perstructure Lay mast 3 on carrier deck for future assembly and store two pins 2 in tool box for future use 7 Start engine Swing upperstructure to left side of the LRT 110 Crane to an approximate 10 o clock position C 7 z 2 o S xs J v N TA gt X ou Figure 54 Storage Location D 5 5 TM5 3810 305 10 8 Lower hook block to ground positioning it on its side Figure 5 5 Maintain tension on cable and continue to pay
192. ses H 10 and H 11 to connectors on rotary mani a Relieve pressure in extend retract valve fold circuit by turning ignition switch ON holding on anti two block BY PASS d Reconnect wiring harness on collector switch and operating boom extend retract ring The anti two block system is now lever in both directions several times until operable pressure is released Turn ignition switch OFF e Check to make sure the torque arm stop pin hoses and wiring harness are all in b Connect extend retract hoses hooked place and connected to rotary manifold under tabs Figure 5 13 onto rotary manifold Turn hydraulic reservoir cap 1 4 turn clockwise to close reservoir COLLECTOR RING WIRE HARNESS _ STOP PIN TELESCOPE EXTEND HOSE r TELESCOPE RETRACT HOSE BOOM HOIST LOWER HOSE 4 E i BOOM HOIST ROTARY RAISE HOSE MANIFOLD 1 qu e Figure 5 13 Rotary Manifold Hoses 5 41 TM5 3810 305 10 Removal and Stowage of Remaining 2 Remove and stow lift equipment as follows Parts Used in Assembly WARNING 1 Lower boom to horizontal position using the following procedure Weight of lift arm is approxi mately 95 Ib 43 kg Use two a Remove wedge from winch and stow in people to properly support and tool box lift the lift arm Failure to follow this procedure could cause b Start engine Lower boom to a horizontal DEATH or serious injury position while raising hook block a Remove p
193. ses can explode Do not smoke or allow sparks or open flames near batteries Wear safety glasses or goggles when checking the batteries Failure to follow this procedure could cause DEATH or serious injury Sulfuric acid contained in batteries can cause serious bums If battery TM5 3810 305 10 corrosion or electrolyte makes contact take immediate action to stop the burning effects EYES Flush with cold water for no less than 15 minutes and seek medical attention immediately SKIN Flush with large amounts of cold water until all acid is removed Seek medical attention as required INTERNAL If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magnesia beaten egg or vegetable oil Seek medical attention immediately CLOTHING EQUIPMENT Wash area with large amounts of cold water Neutralize acid with baking soda or household ammo nia Failure to follow this procedure could cause DEATH or serious injury The operator must exercise sound judgment in positioning outrig gers The outriggers should not be set near holes on rocky ground or on extremely soft ground Setting outriggers in such locations may result in the vehicle tipping causing DEATH or serious injury 1 29 TM5 3810 305 10 1 30 The LRT 110 Crane must be level prior to extending boom or lifting loads To achieve this condition outriggers should be extended to lift carrier wheels off the gro
194. should be made with a wire rope caliper using the correct method B Figure 4 21 For measuring ropes with an odd number of outer strands special techniques must be employed Design specifications for wire rope are such that the diameter is slightly larger than the nominal size according to the allowable tolerances shown in Table 2 Table 2 Oversize Limits of Wire Rope Diameters Nominal Rope Diameter Allowable Limits Over 1 4 in and larger 6 35 mm and larger 0 5 These limits have been adopted by the Wire Rope Technical Board WRTB and are being considered for inclusion in the forthcoming revised edition of Federal Standard RR W 410 In the case of certain special purpose ropes such as aircraft cables and elevator ropes each has specific requirements In measuring a wire rope correctly always measure the larger dimension The true diameter A lies within the circumscribed circle B Avoid using incorrect measurement position C Figure 4 21 A TRUE DIAMETER B CORRECT Ed C INCORRECT Figure 4 21 How to Measure or caliper a Wire Rope 4 30 Unreeling and Uncoiling Wire rope is shipped in cut lengths either in coils or on reels Great care should be taken when the rope is removed from the shipping package since it can be permanently damaged by improper unreeling or uncoiling Looping the rope over the head of the reel or pulling the rope off a coil while it is lying on the ground will crea
195. should be extended to lift carrier wheels off the ground Use bubble level next to the operator s seat to insure that vehicle is level The bubble must be centered in circle Failure to follow this procedure could cause DEATH or serious injury 1 Set outriggers with boom over front of ve hicle not side When a firm footing or level ground is not otherwise available use sub stantial timbers solid blocking or other structural members for support Distribute load so as not to exceed safe bearing capacity of underlying material and to enable leveling of the LRT 110 Crane While operating the LRT 110 Crane frequently check and level the crane Proper positioning is critically important to both safety and effective ness of craning operations 4 21 TM5 3810 305 10 Hook latch is intended to retain loose slings or devices under slack conditions It is not intended to be an anti fouling device Caution should be used to prevent the latch from supporting any of the load Periodic inspection of latch must be made to insure its proper operating condition Failure to follow this procedure could cause DEATH or serious injury Make certain slings ties and hooks are of sufficient capacity properly set and secure before performing any lift operation Failure to follow this procedure could cause DEATH or serious injury CAUTION When removing hook block from storage bracket pay out cable while raising boom to prev
196. ssure is released Turn ignition switch OFF EXTENSION HOSES Figure 5 15 Quick Disconnect Fittings 5 36 Turn the face during the follow ing procedure to avoid having hydraulic oil splash in face or eyes Failure to follow this procedure could cause SERIOUS INJURY Disconnect winch extension hoses H 10 and 101 Figure 3 15 from both upper structure and underneath carrier Do not connect winch lines to rotary manifold at this time Install dust caps on quick disconnect fittings on valve under carrier Figure 5 14 _Extension Hoses TM5 3810 305 10 c Roll up hoses H a and H 11 and connect 5 Remove toggle sheave brackets 5 and at ends together Figure 5 14 Return them taching links 4 from boom as to tool box follows 3 Relieve pressure in extend retract and boom a Remove two pins 6 and sheaves 8 from hoist circuits by turning ignition switch ON toggle sheave brackets 5 Stow sheaves holding on anti two block BY PASS switch 8 in tool box Remove cable from and operating extend retract and boom hoist bracket 5 and restow pins 6 in brackets levers several times in both directions until 5 pressure is released Turn ignition switch b Remove lynch pins 7 and attaching links 4 from studs on top of boom 4 Push the boom hoist cylinder hoses sticking out through cutout in front of upperstructure c Remove cable from between ears and back inside and attach to fittings on rotary remove
197. st upperstructure off carrier Be sure that while it is raising it is clearing rotary manifold and electrical col lector ring cover It will not be necessary to clear manifold cover by more than to 2 in 25 to51 mm Stop hoisting at this point 3 Swing upperstructure around and lower it to ground as follows Using one person pushing on lift arm and mast assembly one person guiding counterweight end of upperstructure and one person holding the tether rope swing upperstructure around to right side of carrier Figure 5 24 Attached Tether Rope b Align upperstructure parallel to carrier with boom tip to rear and counterweight to front Figure 5 25 Keep arms and hands from under upperstructure Failure to follow this procedure could cause SERIOUS INJURY c Install canvas bag located in tool box around and under base plate of upperstruc ture Pull drawstring tight and tie TM5 3810 305 10 CAUTION Keep all hoses out of the way when lowering upperstructure Make sure the winch extension hoses are not pinched against the outrigger beam as the upperstruc ture is lowered This could result in damage to the extension hoses Lower upperstructure until just short of touching ground Figure 5 25 Lowering the Upperstructure TM5 3810 305 10 e Remove posts 19 20 21 and 22 and six pins 23 from storage locations A D and E 5 27 and 5 28 Two pins 2 and tube 24 are located
198. stallation valley breaks i e where the wire ruptures between strands should be given serious attention When two or more such conditions are found the rope should be replaced immediately It is well to remember that once broken wires appear in a normal rope operating under normal conditions a good many more will show up within a relatively short period Attempting to squeeze to the last measure of service from a rope beyond the allowable number of broken wires will create an intolerably hazardous situation A diagnostic guide to some of the most prevalent rope abuses is given in Table 8 On the following pages these abuses are illus trated and described A wire that has broken under a tensile load in excess of its strength is recognized by the cup and cone configuration at the fracture point A Figure 4 43 The necking down of the wire at point of failure shows that failure occurred while the wire retained its ductility A fatigue break is usually characterized by squared off ends perpendicular to the wire either straight across or Z shaped B and c TM5 3810 305 10 gita AV ut ABRASIO Figure 4 42 Effects of Abrasion and Peening Figure 4 43 Types of Breaks in Wire Rope 4 49 TM5 3810 305 10 Table 8 Diagnostic Guide to Common Wire Rope Abuses Abuse Symptoms Possible Causes Fatigue Wire break is transverse either straight across or Z shaped Broken ends will
199. t TM5 3810 305 10 9 August 1991 71 2 TON Rough Terrain Crane BE BE EXACT PIN POINT WHERE IT 15 PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT 18 WRONG EDI Me AND WHAT SHOULD BE DONE ABOUT IT PAGE NO MARE NO PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER DA FORM 2028 2 PREVIOUS EDITIONS PS IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE 1 TO YOUR HEADQUARTERS REVERSE OF OA FORM 2028 2 FILL IN YOUR UNIT S ADDRESS FOLO BACK DEPARTMENT OF THE ARMY OFFICIAL BUSINESS Commander US Army Tank Automotive Command ATIN AMSTA MB Warren Michigan 48397 5000 3NI11034vu04H34 A LAT ee m o ee 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 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
200. t with personnel on the hook or a load Failure to follow this procedure could cause DEATH or serious injury Crane operators must always be prepared to take emergency action while a load is suspended in the air Never leave the operator s compartment with a load suspended Failure to follow this procedure could cause DEATH or serious injury 1 31 TM5 3810 305 10 Keep all parts of body and tools away from moving cable Fail ure to follow this procedure could cause DEATH or serious injury Never allow boom or load to swing into power lines If the crane must be operated in the vicinity of power lines follow these safety precautions eContact the power company and have all power lines and ground wires turned off e Never allow any portion of the equipment including cable hook block lines and load closer to power lines than the distances shown on the Electrical Warning Danger Decal e Know the maximum height and reach of the crane and erect a suitable barricade around all power sources e Warn all personnel in the work area of the power source and electrocution hazard e If contact with a power source does occur DO NOT STEP OFF THE CRANE Stay on the vehicle until the power is turned off or the equipment is lowered and clear of the power source elf fire or other conditions force the operator to leave the crane jump off and away keeping all parts of the body clear of the equipment Failure to
201. te loops in the line Pulling on a loop will at the very least produce imbalance in the rope and may result in open or closed kinks Figure 4 22 Once a rope is kinked the damage is permanent To correct this condition the kink must be cut out and the shortened pieces used for some other purpose Improper handling will help create open A or closed B kinks The open kink will open the rope lay the closed kink will close it Do not allow the rope to form a small loop If however a loop forms and is removed at the point shown C a kink will be avoided When the looped rope is put under tension D a kink will form The rope is then permanently damaged and is of little value Unwinding wire rope from its reel also requires careful and proper procedure There are three methods to perform this procedure correctly 1 Method A The reel is mounted on a shaft supported by two jacks or a roller payoff Figure 4 23 Since the reel 1s free to rotate the rope is pulled from the reel by a workman holding the rope end and walking away from the reel as it unwinds A braking device should be employed so that the rope is kept taut and the reel is restrained from over running the rope This is necessary particu larly with powered de reeling equipment TM5 3810 305 10 Figure 4 22 Wire Rope Kinking Figure 4 23 Mounted Unreeling 4 31 TM5 3810 305 10 Figure 4 24 On Vertical Unreeling amp Stand Figure 4 25
202. ted by raised fist Travel opposite track in diraction indicated by circular motion of other hst vertically in ieont of body For land cranes only LOWEA With arm extended downward forefinger pointing down move hand in small honzontai circle MOVE SLOWLY Use one hand lo give any motion signal and place other hand motioniess in front of hand giving the mot ion signal Hoist slowly shown as example EMERGENCY STOP Both arms extended paims down move arms back and forth horz ontalty EXTEND BOOM Telescop ing Booms Both fists in front body with thumbs pointing oulward USE MAIN HOIST Tap fist on head then use regular signals RAISE THE BOOM AND LOW ER THE LOAO with arm tended thumb pointing up flex lingers in and out as long as 1028 movement is desired TRAVEL Arm extended lor ward hand open and slightly raised make pushing motion in direction of travel RETRACT BOOM Telescop ing Booms Both lists in front of body with thumbs pointing toward each other USE WHIPLINE Auxiliary Ho ist Tap elbow with one hand then use regular signals LOWER THE BOOM ANO RAISE THE LOAD With arm extended thumb pointed down fingers in and out as long as load movement is desired DOG EVERYTHING hands in front of body Clasp EXTEND BOOM Telescoping Boom One Hand Signal One tisi in front of chest with thumb tapping chest Figure 4 16 Hand Signals for Crane Operation RAISE
203. temperature is reached When removing cap loosen it slowly to the left then pause a moment Steam and hot gases will be escaping through the radiator cap avoid being burned by these gases Continue to turn cap until it can be removed Failure to follow this procedure could cause SERIOUS INJURY Coolant Check to be sure level is near top of radiator tank Check through inspection hole in hood General Condition Inspect vehicle in general for wear leakage and damage Leakage Make a ground check below the vehicle for signs of leaks CAUTION Never operate engine with oil level below the ADD 1 QT mark or above the FULL mark Fail ure to follow this procedure could cause damage to equip ment 4 10 Engine Oil The level should be indicated on the dipstick Figure 4 15 Oil level should be checked when engine is cold Transmission Oil Check transmission oil level dipstick with engine running and transmission in neutral Check at a transmission operating temperature of 160 to 190 degreesF 71 to 88 degrees C Insure that oil is at FULL line indicated on dipstick Hydraulic System Check hoses tubes compo nents reservoir dipstick valves pumps motors connections cylinder mounting bushings and pins The system level with all cylinders re tracted in travel mode should be at FULL mark on dipstick located on reservoir fill cap Lubrication Perform daily lubrications as shown in lubrication chart
204. terials List Type I Rail Transport Materials List Type II Rear Axle Centering Indicator Reeving Hoist Line Removal and Stowage of Parts Used for Assembly of Parts Used for Separation of Remaining Parts Used in Assembly Removing Upperstructure from Carrier Preparation for Replacement of Wire Rope Requirements Environmental Safety Decals Safety Equipment Checks and Inspections Safety Precautions General Cautions General Warnings Introduction Minimum Safety Requirements for Work Platforms Suspended from Load Line or Rigidly Mounted on Boom Safety Decals Saltwater High Humidity or Sandy or Dusty Work Sites TM5 3810 305 10 4A N WN N N 1 4A NIES 4 m E dol 1 eO C 1 1 NIN Lond WO T x INDEX 5 TM5 3810 305 10 Seat Adjust Lever Sectionalization Preparation for and Sectionalization of LRT 110 Crane Type II for External Air Transport EAT Preparation for and Assembly of Sectionalized LRT 110 Crane Type II After External Air Transport EAT Seizing Wire Rope Separating Upperstructure from Carrier Preparation Shut Down Socketing Wire Rope Special Break In Requirements for New Cranes Specifications Equipment Speedometer Spooling Cable on Drums Start up Starter Button Starting the Engine Steering Steering Selector Stopping the Engine Storage Data Stowage of Parts Used for Assembly of Parts Used for Sepa
205. th 1 2 inch diameter I P S I W R C Preformed 1 21 TM5 3810 305 10 DISTANCE ABOVE GROUND LEVEL Q y Sy OG POFFO 35 FT 25 FT 15 FT 5 FT Figure 1 6 Radius from Centerline of Rotation Never lift or swing load directly above operator s compartment or over ground personnel in the work area Failure to follow this procedure could cause DEATH or serious injury TM5 3810 305 10 NOTE Working areas are areas meas ured in a circular arc around centerline or rotation CRANE WORKING POSITIONS ON OUTRIGGERS L 360 BOOM CENTERLINE Zz DN 7 ON TIRES 360 is BOOM CENTERLINE STRAIGHT bv OVER FRONT a ROTATION CENTERLINE RADIUS LINES INDICATE LIMITS OF WORKING POSITIONS CORRESPONDING TO LOAD CHARTS Figure 1 7 Working Area Diagram 1 23 TM5 3810 305 10 Section V Power and Utility Requirements NOT APPLICABLE Section VI Environmental Requirements NOT APPLICABLE Section VII List of Items Furnished Hook Block A 10 ton single sheave hook block is provided with swivel hook and safety latch Sheaves comply with SAE J 881 The weight of the hook block provides adequate overhaul of the cable insuring smooth cable operation of the hy draulic winch Cable A 1 2 inch diameter 6 x 19 class cable of right regular lay having an independent wire rope core and constructed of improved plow steel is provided having a
206. the rope break 2 Frequency of inspection Will it be safe until the next scheduled inspection 3 Maintenance history How rapid is the degradation 4 Consequences of failure Will it present hazards to personnel 5 Historical records of similar equipment To make certain that sufficient information is obtained following are guidelines that should be adhered to The groove size is evaluated on the basis of how the gage leaf fits the groove Daylight under the gage is not tolerable when using the worn groove gage If a full oversize gage is used some daylight may be acceptable but this really must be judged by relating the measurement to the actual size of the rope For new rope extra caution should be observed as to its fit in the groove Characteristically ropes become smaller in diameter immediately after being placed in service As a result they would operate satisfactorily in a worn groove one that was gaged OK by the worn groove gage Nonetheless in some cases a rope may not pull down and if this happens abnormal wear may occur It is important to remember that a tight groove not only pinches and damages the rope but that the pinching prevents the necessary adjustment of the wires and strands On the other hand a groove that is too large will not provide suffi cient support in this case the rope will flatten and thereby restrict the free sliding action of the wires and strands 4 4
207. tifreeze so lution as recommended in the amount and strength appropriate to anticipated tempera tures A corrosion inhibitor is recommended Inspect clamps radiator hoses and radiator Replace or repair any cooling system compo nent found to be defective Condensation in fuel tank contaminates the fuel supply with water This can freeze in fuel lines and block fuel flow to engine To minimize this possibility keep tank as full as possible during cold weather This may entail refilling tank more frequently than usual but the inconvenience is small compared to clearing a blocked fuel line 2 Check and drain the fuel water separator If water is found in fuel tank drain tank and refill it with uncontaminated fuel 3 Lubricate with correct lubricants For tem peratures below 10 degrees F 23 degrees C service the LRT 110 Crane with Arctic diesel fuel in fuel tank and Arctic lubricating oil MIL L 46167 in the engine To aid cold weather start below O degrees F 18 degrees C service hydraulic system and transmission with Arctic lubricating oil MIL L 46167 refer to Lubrication chart Appendix CAUTION Water added to battery can freeze before it mixes with electrolyte During very cold weather add water to battery just prior to or during operation of vehicle If vehicle is not to be run connect an external charger to battery if adding water Battery care is needed The battery is more likely to sustain
208. tightly Ropes with kinks must be removed from service Bird caging Bird caging results from tor sional imbalance that comes about because of mistreatments such as sudden stops the rope being pulled through tight sheaves or wound on too small a drum This is cause for rope replacement unless the affected portion can be removed Localized conditions Particular attention must be paid to wear to the equalizing sheaves During normal operations this wear TM5 3810 305 10 is not visible Excessive vibration or whip can cause abrasion and or fatigue Drum crossover and flange point areas must be care fully evaluated All end fittings including splices should be examined for worn or broken wires loose or damaged strands cracked fittings worn or distorted thimbles and tucks of strands Heat Damage After a fire or the presence of elevated temperatures there may be metal discoloration or an apparent loss of internal lubrication fiber core ropes are particularly vulnerable Under these circumstances the rope should be replaced Protruding Core If for any cause the rope core protrudes from an opening between the strands the rope is unfit for service 10 Damaged End Attachments Cracked bent or broken end fittings must be eliminated The cause should be sought out and cor rected In the case of bent hooks the throat openings measured at the narrowest point should not exceed 15 over normal nor should
209. to take the slack out of cable CAUTION If the LRT 110 Crane is to be towed a distance of more than 1 mile 1 6 km and or at speeds greater than 3 mph 4 8 km h the front drive shaft must be dis connected from the front axle As an alternative to disconnect ing the drive shaft if the engine is operable the engine may be started and allowed to idle during the towing process This will cir culate lubricant in the transmis sion lubricating the clutches during the towing operation Failure to disconnect the drive shaft or to run the engine will cause internal damage to the transmission as the vehicle is towed TM5 3810 305 10 3 Disconnect the drive shaft by removing four 5 Attach tow bar to the lugs on the outrigger capscrews and two caps Figure 4 59 The and to towing vehicle driveshaft must be disconnected from the front axle and secured to a frame crossmem 6 Release the parking brake in the operator s ber to prevent it from contacting the rotating cab by pulling the lever up to release it If the axle input yoke or the ground while the vehicle s electrical power is available turn on vehicle is being towed The spider bearing the emergency four way flashers caps must be taped or wired together to prevent them from falling off and being lost The crane may now be towed at speeds up to 20 mph 32 km h depending on existing 4 Place the two wheel four wheel drive shift conditions for whatever distance is neces
210. toggle sheave brackets 5 manifold Figure 5 19 COLLECTOR RING WIRE HARNESS TELESCOPE TELESCOPE EXTEND HOSE emer HOSE Figure 5 8 Sheaves BOOM HOIST LOWER HOSE Figure 5 1 5 37 TM5 3810 305 10 d Stow toggle sheave brackets 5 with attaching links 4 in storage location C on bracket on right hand front of earner Figure 5 7 Secure with pins 6 con nected to the attaching links 4 Completion of Upperstructure Assembly 1 Install anti two block counterweight as follows a Remove clevis from anti two block switch on boom head Hook the weight chain on clevis and reinstall on anti two block switch b Using a 6 mm hex allen wrench open counterweight halves c Install weight halves around hoist line hanging down over boom head sheave Secure halves with thumbscrews 2 Raise boom and install mounting capscrews inside upperstructure using the following procedure a Swing mast and arm assembly out of the way b Start engine Raise boom to a minimum of 45 degree angle c Shut engine off 5 38 BLOCK ANTI TWO COUNTERWEIGHT BLOCK SWITCH 2 PART HOIST LINE HOOK BLOCK Figure 5 2 Anti Two Block Counterweight Switch and Hook Block TM5 3810 305 10 d Remove stop pin and lockwasher from tool box and install in upperstructure torque arm bracket Make sure end of stop pin goes down through ear on side of rotary manifold Tighten stop pin
211. twisting be greater than 10 4 47 TM5 11 12 13 3810 305 10 Peening Continuous pounding is one of the causes of peening The rope strikes against an object such as some structural part of the machine or it beats against a roller or it hits itself Often this can be avoided by placing protectors between the rope and the object it is striking Another common cause of peen ing is continuous passage under high ten sion over a sheave or drum Where peening action cannot be controlled it is necessary to have more frequent inspections and to be ready for earlier rope replacement The external appearance of two ropes are il lustrated one of which has been abraded and the other peened Figure 4 42 Also shown are the cross section of both wires in these conditions Note that a crack has formed as a result of heavy peening Scrubbing Scrubbing refers to the displace ment of wires and strands as a result of rubbing around or against an object This in turn causes wear and displacement of wires and strands along one side of the rope Corrective measures should be taken as soon as this condition is observed Fatigue Failure Wires that break with square ends and show little surface wear have usually failed as a result of fatigue Such 14 failures can occur on the crown of the strands or in the valleys between the strands where adjacent strand contact exists In almost all cases these failures are related
212. ucture and steering system The LRT 110 Crane design meets all the appli cable requirements of OSHA EPA PCSA Std 4 ANSI B30 5 and the specified SAE Stan dards Major Component Nomenclature NOTE All directional references in this manual right or left front or rear etc correspond to the position of the operator when facing forward in operator s cab Upperstructure The upperstructure includes the counterweight and hydraulic winch Boom Attachment The boom attachment in cludes the crane boom boom lift cylinder and hook block Carrier The carrier includes the chassis frame engine transmission swing bearing planetary axles outriggers operator s cab fuel tank hydraulic reservoir batteries and tool compart ment TM5 3810 305 10 Section Il Capabilities The LRT 110 Crane is capable of Lifting 15 000 pounds at a 10 foot radius or 4 000 pounds at a 30 foot radius throughout a 360 degree rotation on outriggers Lifting 13 600 pounds straight over the front on tires A travel speed of up to 22 miles per hour on a level hard surface A travel speed of up to 2 5 miles per hour carrying a 4 500 pound load at a 20 foot radius straight over the front Rough terrain travel when switched into four wheel drive Continuous operation in temperatures of up to 120 degrees F or altitudes of up to 5 000 feet Fording up to 30 inches of water Operating in ammunition and petroleum dumps Se
213. uipment 1 25 TM5 3810 305 10 The LRT 110 Crane Tool Kit Consists of Tool Wrench 3 4 x 7 8 Wrench 9 16 x 5 8 Wrench 5 8 x 11 16 Wrench 3 4 x 7 8 Wrench 12 inch Adjustable 6 Wrench Lug 7 Handle 8 Adapter 8 to 6 9 Cap 4 10 Reducer 6 to 4 11 Tee 8 12 Plug 4 13 Plug 6 14 Plug lo 15 Plug 12 16 Disconnect Quick Female 17 Adapter 6 to 4 18 Hose 19 Adapter 6 to 6 20 Cap 6 21 Cap 12 22 Adapter 12 to 8 23 Wrench He 5 16 24 Wrench He 5 32 25 Hose 26 Pin 27 Hose 28 Pump Hand 29 Adapter 30 Hose 31 Elbow 32 Plug Pipe 4 33 Plug Cap 34 Adapter Hex Axle Plug 35 Link 1 2 3 4 5 36 Cylinder Ether Use Emergency swing Hose connections Hose connections Hose connections All purpose Wheel nuts Lug wrench Hose adapter Emergency hose Winch brake hose Emergency hose adapter Open hose ends Open hose ends Open hose ends Open hose ends Reservoir tank Hose adapter Outrigger emergency return Hose adapter Hose cap Hose cap Hose adapter Boom hold valve Extend cylinder hold valve Hand pump supply hose Engages handle on hand pump Pressure supply from hand pump Emergency crane operation Hose adapter Test guage connector Hose fitting Hose plug Hose cap Axle check plug removal Hook block to pintle air transport Cold start assist in container eee NO el es LO a a WO ee OCT WO
214. und Use bubble level next to the operator s seat to insure that vehicle is level The bubble must be centered in circle Failure to follow this procedure could cause DEATH or serious injury Hook latch is intended to retain loose slings or devices under slack conditions It is not in tended to be an anti fouling device Caution should be used to prevent the latch from support ing any of the load Periodic in spection of latch must be made to insure its proper operating condition Failure to follow this procedure could cause DEATH or serious injury An operator must be guided by the Capacity Chart mounted on vehicle when considering load weights Rated loads must never be exceeded Failure to follow this procedure could cause DEATH or serious injury The intent of the information is to prevent any possibility of either reverse winding of the rope on the winch drum causing breakage of winch cable or the unseating of cable from winch drum resulting in uncontrolled fall of the hook block and load Failure to follow this procedure could cause DEATH or serious injury Never lift and swing a load directly over operator s compart ment or over ground personnel in the work area Failure to follow this procedure could cause DEATH or serious injury Using an axe or hatchet to cut wire rope may be dangerous If necessary to use proceed with great caution Failure to follow this procedure could cause SERIOUS INJURY P
215. ve 4240 00 252 3776 Pr 2 3 Grease Gun 4930 00 253 2478 Ea 1 4 Adapter Grease Gun Flex 4930 00 288 151 1 Ea 1 5 Bag Pamphlet 7520 00 559 9618 Ea 1 6 Fire Extinguisher 4215 00 555 8837 Ea 1 7 Kit Sign Vehicle 9909 00 565 6267 Ea 1 8 Kit First Aid 6545 00 922 1200 Ea 1 WARNING The pintle hook NSN 2450 00 835 9093 is authorized for use on Aviation Support Unit Cranes only The towing capacity of this pintle hook is 30 000 Ibs This capacity is 10 000 Ibs less than the standard cranes pintle hook capacity of 40 000 Ibs Failure to consider the lower capacity may result in death in jury or damage to equipment NOTE The smaller pintle hook adapter aand capscrews are all required to support the Aviation Support Unit Crane 9 Hook Pintle 2540 00 835 9093 Ea 1 10 Adapter 2540 01 332 0108 Ea 1 11 Capscerws 5305 00 042 6417 Ea 4 1 APPENDIX F OPERATOR CREW TM5 3810 305 10 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS GENERAL Your Preventive Maintenance Checks and Services Table lists the inspections and care of your equipment required to keep it in good operating condition Record all deficiencies and shortcomings along with corrective action taken on DA Form 2404 OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES 1 The number column of your PMCS is the source for the number used on the TM Number Column on DA Form 2404
216. vidence of beat damage exists f Six 6 broken wires in one 1 strand Sheave show evidence of Sharp edces ITEM N 18 19 20 21 22 23 2 25 APPENDIX F TM5 3810 305 10 OPERATOR CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES BEFORE INTERVAL INSTRUMENTS D DURING A AFTER W WEEKLY ITEM 10 BE INSPLCTED PROCEDURE FOR AND HAVE REPAIRED FILLED ADJUSTED AS NEEDED Check for damage to winch or improperly wound cable Check oil level APPENDIX C Fill as required STEERING SYSTEM a Check hoses lines and fittings for cracks leaks and loose fittings b Check steering valve for damage C Check steering valve selector for proper operation HYDRAULIC MANUAL CDNTROLS Operate controls Check boom outriggers hook block and ewing rotation controls for smooth proper operation and leaks from the control valve HYDRAULIC LINES FITTINGS AND CYLINDERS Check for leaks Check cylinders for smooth operation ANTI TWO BLOCK SYSTEM Check the system for proper operation Lift the counterweight to touch the boam tip an audible horn must sound and warning light operate Check the cable and reel for tension and ease of operation and damage BOOM ANGLE INDICATOR Check for proper operation Raise and lower the the indicator must move fram 0 degrees to 75 degrees without binding sticking Check for bent
217. wing procedure a Start engine Raise outrigger beams Lift outrigger pads that are underneath boom just enough to clear ground CAUTION Do not allow outrigger beam located under upperstructure to contact winch hoses Failure to follow this procedure could cause damage to equipment b Using swing lever rotate swing bearing to unlocked position with cam roller on axle lockout valve located at rear bottom of rotary manifold centered in notch Figure 5 20 Location of Boom Hoist Cylinder Hoses After Disconnection TM5 3810 305 10 NOTE This position will permit oscilla tion of rear axle when maneuver ing carrier away from upperstruc ture 2 Use crab steering and short forward reverse movements to move the carrier until it is clear of upperstructure 3 Prepare outriggers for travel using the fol lowing procedure a Raise outrigger beams to travel position b Shut engine off c Remove nuts washers bolts and pads from ends of outrigger beams Reinstall bolts washers and nuts after pads are removed ROTARY MANIFOLD a TORQUE ARM BRACKET Figure 5 32 Rear Axle Oscillation 5 25 TM5 3810 305 10 d Stow pads in hanger brackets on right side of boom toward tip Secure with rod 25 and two cotter pins 26 Figure 5 33 lo cated on boom 4 Clean and stow all remaining items and tools 5 used for sectionalization disassembly in tool box Check fuel t
218. wire diameters of UNITS OF ROPE LIFE discarded ropes Figure 4 41 Stretch vs Time 4 45 TM5 3810 305 10 3 Reduction in rope diameter Any marked reduction in rope diameter indicates degrada tion Such reduction may be attributed to a Excessive external abrasion b Internal or external corrosion c Loosening or tightening of rope lay d Inner wire breakage e Rope stretch f Ironing or milking of strands In the past whether or not a rope was allowed to remain in service depended to a great extent on the rope s diameter at the time of inspection Currently this practice has under gone significant modification Previously a decrease in the rope s diameter was compared with published standards of minimum diameters The amount of change in diameter is of course useful in assessing a rope s condition But comparing this figure with a fixed set of values is for the most part useless These long accepted standards are not in themselves of any serious significance since they do not take into account such factors as a Variations in compressibility between IWRC and Fiber Core b Differences in the amount of reduction in diameter from abrasive wear or from core compression or a combination of both c The actual original diameter of the rope rather than its nominal value As a matter of fact all ropes will show a sig 4 46 nificant reduction in diameter when a load is applied Therefore
219. with a 36 mm socket and breaker bar Figure 5 40 COLLECTOR RING WIRE HARNESS TELESCOPE EXTEND HOSE TELESCOPE P am i ae RETRACT HOSE STOP PIN BOOM HOIST LOWER HOSE BOOM HOIST RAISE HOSE Figure 5 40 Rotary Manifold Hoses TM5 3810 305 10 e Install 10 mounting capscrews and 20 f Tighten all 18 capscrews Refer to Figure 5 40 washers inside of upperstructure Figure 5 41 for torquing sequence and tool re quirements for each mounting capscrew Set the torque wrench to 205 16 278 N Using torque multiplier in conjunc tion with torque wrench the actual torque on the capscrew is 722 lb ft 979 N m 2 FRONT 3 Location TOOLS REQUIRED BY TOOL NUMBER Ref REFER TO PAGE 5 45 6 2 8 4 B L6 12 8 4 5 7 25 5 2p ks Jp 8 4 ds 7 25 EEUU CN TUNE RENT 6 1312 8 4 B 7 25 1 6 13 2 84 149 4 2 6 3 4 2 131712515 Emp Am E QE UNE 9 16 5 2 ee 210 aa 7 25 5 _ ej Js3s ja 7 25 2 16 3 2 7 25 5 i 6 3 2 8 a 7 25 14 6 3 2 8 4 18 7 25 gt 6 o4 qom J7 29 we 216 6 4 2 7 125 5 J ee 33 8 15 i 7 25 Figure 5 41 Tools Used for Tightening of Capscrews oY TM5 3810 305 10 3 Connect hoses and wiring harness to rotary c Remove plugs from winch hoses and stow manifold using the following procedure in tool box Connect winch ho
220. working loads 17 Crane load ratings with an asterisk beside 18 19 20 21 29 23 24 TM5 3810 305 10 them are based on the machine s structural strength All other ratings are based on stability and do not exceed the specified percentage of tipping load as determined by SAE Crane Stability Test Code J765a For all boom lengths between the retracted and extended boom length the rated loads are determined by boom angle only shown in the extended boom column For boom angles not shown use capacity of the next lower boom angle When either radius or boom length or both are between listed values the smaller of the two load ratings shall be used Load ratings are dependent upon the crane being maintained according to manufacturer s specifications The maximum load which may be telescoped is limited by boom angle hydraulic pressure boom lubrication etc It is safe to attempt to extend and retract within the limits of the ca pacity chart It is recommended that load handling de vices including hooks and hook blocks be kept away from boom head at all times The boom angles shown on the capacity chart give an approximation of the operating radius for a specified boom length The boom angle before loading should be greater to account for boom deflection DO NOT LIFT LOAD OVER OPERATOR TM5 3810 305 10 DEFINITIONS 25 Operating Radius The horizontal distance from the axis of rotat
221. y Lubricate swing bearing through the grease fitting on the inside of cab while rotating the upperstructure Cable Lubrication During fabrication ropes receive lubrication the kind and amount depending on the rope s size type and anticipated use This in process treat ment will provide the finished rope with ample protection for a reasonable time if it is stored under proper conditions But when the rope is put into service the initial lubrication may be less than needed for the full useful life of the rope Because of this possibility periodic appli cations of a suitable rope lubricant are necessary The important characteristics of a good wire rope lubricant are as follows 1 It should be free from acids and alkalis 2 It should have sufficient adhesive strength to remain on the ropes 3 It should be of viscosity capable of penetrat ing the interstices between wires and strands 4 It should not be soluble in the medium sur rounding it under the actual operating condi tions 5 It should have a high film strength 6 It should resist oxidation e Dry cleaning solvent P D 680 used to clean parts is toxic and flammable Use only in well ventilated areas and avoid contact with eyes skin or clothing Do not breath vapors Wear the proper protective clothing and equipment goggles or safety glasses face shield and gloves Do not use near sparks or open flames and do not smoke while using it Failure t
222. y the updates is indicated by a vertical line in the outer margins of the page Updates to wiring diagrams are indicated by shaded areas Dates of issue for original and updated pages work packages are Original 0 09Aug 91 Change 1 01Nov 00 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 16 AND TOTAL NUMBER OF WORK PACKAGES IS 876 CONSISTING OF THE FOLLOWING Page WP Revision Page WP Revision Page WP Revision No No No No No No Cover 1 1 34 4 15 Cover 2 1 35 4 16 a LOEP 1 1 36 4 17 b LOEP 1 1 37 4 18 i 1 1 38 4 19 ii 1 1 39 4 20 1 1 1 40 4 21 1 2 1 41 4 22 1 3 1 42 4 23 1 4 1 43 4 24 1 5 1 44 4 25 1 6 1 45 4 26 1 7 1 1 46 4 27 1 8 1 1 47 4 28 1 9 1 48 4 29 1 10 2 1 4 30 1 11 2 2 4 31 1 12 2 3 4 32 1 13 2 4 4 33 1 14 2 5 4 34 1 15 2 6 4 35 1 16 3 1 4 36 1 17 3 2 4 37 1 18 3 3 4 38 1 19 1 3 4 4 39 1 20 1 4 1 4 40 1 21 4 2 4 41 1 22 4 3 4 42 1 23 4 4 4 43 4 5 4 44 4 45 4 46 4 47 4 48 TM 5 3810 305 10 INSERT LATEST UPDATED PAGES WORK PACKAGES DESTROY SUPERSEDED DATA Page WP Revision Page WP Revision Page WP Revision No No No No No No 4 49 5 21 F 4 4 50 5 22 F 5 4 51 5 23 6 4 52 5 24 7 4 53 5 25 8 4 54 5 26 INDEX 1 4 55 5 27 INDEX 2 4 56 5 28 INDEX 3 4 57 5 29 INDEX 4 4 58 5 30 INDEX 5 4 59 5 31 INDEX 6 4 60 5 32 INDEX 7 4 61 5 33 INDEX 8 4 62 5 34 Authentication 4 63 5 35 Sample 2028 Front 4 64 5 36 Sample 2028
223. ydraulic line failure a and pinion cover 7 Figure 4 52 hydraulic hand pump is provided The following procedures will restore the vehicle to a normal NOTE traveling or towing attitude Move swing lever in same swing A WARNING direction to relieve oil pressure as the upperstructure is being During the execution of this turned procedure the danger exists of uncontrollably dropping a load 2 Attach a wrench to the protruding shaft of the Rotate the upperstructure to a swing box drive Turn swing box drive shaft safe position Failure to follow clockwise to swing boom to the right and this procedure could cause counterclockwise to swing boom to the left DEATH or serious injury 3 Rotate the upperstructure and the load to a NOTE safe area Two men are required to perform this task 3 Figure 4 52 Swing Drive Box 4 56 TM5 3810 305 10 Prepare Equipment The hand pump is mounted in the left side tool box The pump supply and pressure hose with a connec tor tee is also located in this box The pump is used from this location by inserting the pin in the pump handle Attach Supply Hose Attach the quick disconnect on the pump supply hose to the nipple on the reservoir side of the filter manifold Figure 4 53 QUICK DISCONNECT RESERVOIR SUPPLY PORT BRAKE HOSE BOOM RETRACT CYLINDER PORT RETRACT HOSE LJ E se LOWERING PORT LOWERING TEE PRESSURE RE
224. ying Lubrication Figure B B 3 t a uomngponqm c g 10811 ur 3l ex Ho vU V REFER TO MAINTENANCE MANUAL FOR DRAIN REFILL INCREASE LUBRICATION FREQUENCY UNOER SEVERE 19 18 PROCEDURES AND FOR ADDITIONAL LUBRICATION INFORMATION OPERATING CONDITIONS 12400 278 O O CHK CHECK DA DRAN amp REFILL LUB LUBRICATE OWPSTICK CHANGE FILTER TEMPERATUR LUBRICANT ANGE ANTI FREEZE A 46153 MIXTURE 50 BASE S0 WATER 1007 MIL L 2104 GRADE 15W 40 10 F AND ABOVE 2 ENGINE amp FICTER 1 QT FILTER BELOW 10 F COOLING SYSTEM CH E 34 F AND ABOVE P 10 46167 CHK 1 2104 GRADE 10W 10 F ANO ABOVE e p 1 CHK HYORAULIC RESERVOIR 238 GAL TOTAL SYSTEM 45 GAL CHK 5 MASTER Brake cyumpers AS REC D SLE XI WZ MS HN N iT i 1 2104 GRADE 10W 0 AND ABOVE MIL L 46167 TO 65 F 46176 BRAKE FLUID 55 F TO 131 F ABLE GEAT rd as neo MIL G 10924 GAEASE 4 2105 GRADE 80W90 65 F AND ABOVE SWING REDUCTION UNIT 3 0T EE L2 TURNTABLE RACE LUBE MiL G 10924 GREASE FROM BACK OF OPERATOR 20 SHOTS SWING UPPER UNIT WHILE GREASING gi CONSULT OPERATOR S MANUAL B5 F TO 250 F els ai TOP BEARING 10 STEERING CYLINDER PINS a 9 10924 GREASE 65 F TD 250 F _ MIL L 2104 GRADE 15 40 10 F AND ABOVE fel

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